Application example 4 – On-off solenoid

Twin solenoid for mining

The times when coal seams were mined with a pickaxe are long gone. Likewise, the use of wood and  iron girders for supporting the galleries – called a longwall – are also a thing of the past. Today, miners are protected by hydraulically operated shields.

This so-called shield assembly forms a type of bow, which is hydraulically pressed against the rock and tensioned. This is enabled by a master cylinder between runner and cap, as well as additional cylinders which extend the cap or press it back against the rock. This shield is also advanced by cylinders when the machines operating under its protection have removed another section of the seam and the shield must follow the coal.

The hydraulic system must naturally fulfill numerous safety requirements. Shut-off valves prevent the pressure in a cylinder from suddenly dropping, for example. The actuating solenoids also have a correspondingly sophisticated design. Two single-acting solenoids, operating independently of each other, are always in use: one to extend the cylinder – the other to retract it.

These are located together with the control electronics in a shared rectangular solenoid housing of around 40 millimeters by 80 millimeters. This has the advantage that only one connector is required, and simplifies handling for the user. Finally, around six to eight twin solenoids are used per shield. With around 150 shields per longwall, this gives a total of 800 to 1200 twin solenoids that must be supplied with electric power.

The main hazard in coal mining is still caused by the fact that the coal releases combustible gases, which can explode in so-called fire damp. The ignition of very fine coal dust has also cost many lives. Since it only requires the emission of a small spark, all electrical equipment must be designed to ensure that no sparking occurs (intrinsically safe equipment).

The control electronics of the twin solenoids is particularly clever, as the system is designed to save energy: while the armature is initially attracted with a rated current of 100 milliamps and a force of ten newtons, it reduces the current to around 50 percent of the initial value in a time-controlled manner when the armature has reached the pole. It thus utilizes the specified effect that the magnetic force, on account of the air gap between armature and pole, increases to approx. 40 newtons at rated current in the stroke end position, and can also reliably hold the hydraulic valve in the end position with 20 newtons at reduced current.

Application example 1

On-off solenoid for active steering
This is a lifting/holding solenoid, which overexcites when the car engine starts ...

 

 

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Application example 2

On-off solenoid for brake assistant and ESP
Many drivers do not use the maximum braking effect in dangerous situations...

 

 


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Application example 3

On-off solenoid for transfer case
This on-off solenoid is a constituent of a transfer case drive, in addition to the DC motor ...

 

 

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