Valves for Harsh Environments

Challenges and Considerations of Designing Solenoid Valves for Harsh Environments

While the operation of solenoid valves in controlled environments is generally straightforward, designing these valves for harsh conditions — including high vibration, extreme temperatures, fluctuating climates, and dirty environments — presents significant challenges. We outline of few of these challenges and discuss key considerations below. 

Vibration Challenges
High-vibration environments, such as those found in heavy machinery, transportation, or oil and gas industries, can cause numerous issues for solenoid valves. The constant shaking can lead to wear and tear, eventually leading to mechanical failure. Additionally, vibrations can cause valves to open or close unintentionally, leading to flow control inaccuracies.
Designing for high vibration environments involves using robust materials and structures to withstand the mechanical stress. Dampening mechanisms may also be incorporated to absorb and minimize the impact of vibrations. Securing the solenoid's coil and armature to prevent movement and using vibration-resistant electrical connections are other crucial design considerations.

Extreme Temperature Issues
Solenoid valves operating in extremely cold or hot environments face real issues related to material contraction/expansion and changes in fluid properties. In frigid climates, components can contract and become brittle, leading to failure. Conversely, in hot conditions, materials may expand, causing leaks or valve malfunctions. Moreover, the fluid or gas being controlled may become more viscous in cold temperatures or more volatile in hot temperatures, complicating flow control. To cope with temperature extremes, designers must select materials that maintain their properties over a wide temperature range. Additionally, they might use insulation or heating elements for cold environments or cooling mechanisms for hot environments. Special considerations may also be required for the fluid or gas being controlled to ensure reliable operation despite temperature-induced changes in its properties.

Climate Concerns
Variable climates can expose solenoid valves to a range of concerns, from corrosion due to high humidity to damage from UV radiation in sunny environments. In rainy or high-humidity settings, moisture ingress can lead to corrosion or electrical shorts. To design valves that can withstand diverse climates, materials resistant to corrosion and UV radiation should be used. Additionally, proper sealing techniques are essential to prevent moisture ingress, and electrical components should be designed with safeguards against short-circuits.

Dirty Environments
In dirty or dusty conditions, like those found in construction, mining, or certain manufacturing processes, particles can enter the valve, causing clogging, wear, and degradation of performance over time. To overcome these challenges, solenoid valves can be designed with dust-tight housings and advanced sealing technologies to prevent ingress of particles. Self-cleaning designs or easy-to-clean structures can also be advantageous in these environments. Moreover, robust materials can be used to resist wear and tear from particulate matter.

Designing solenoid valves for harsh environments is a challenging but crucial task. We design these types of valves to continue to function reliably under demanding conditions. By understanding the challenges posed by high vibration, extreme temperatures, varied climates, and dirty conditions, our design team can make informed choices regarding materials, structures, and protective measures. 

Don’t let the operating environment hold you back, contact the Pros at Solenoid Solutions for an engineered solution!