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Solenoid valves are important electromagnetic devices which are used widely in various fields. Considering the uncertainty of failure mechanisms in practical operation, a thermal-structure coupled model of a direct action solenoid valve is constructed by using the finite element method. The coupled model provides useful information such as temperature distribution and stress distribution for failure mechanism study of the solenoid valve. The model results predict that the failure of the solenoid valve is closely related to the thermal expansion inside the coil, which means the high temperature generated by thermal expansion melts the insulation layers. Under the combined action of high temperature and coupled stress, the shorting of coils occurs and the resistance decreases which may cause the eventual failure of the solenoid valve. To verify the prediction of the finite element model, a degradation experiment is designed. The results suggest that the failure of the solenoid valve is a gradual degradation process, and there are several mutations of coil temperature and resistance. The high temperature melts the insulation layers and causes the shorting of coils, which further decreases the resistance and increases the current. Later more heat is generated to rise coil temperature and melt insulation layers, which will short out the coils and drop the resistance. With such a relationship, as the temperature rises alternately, the resistance decreases alternately until the solenoid valve completely fails. The model provides a reference for failure mechanism study and life prolonging research of solenoid valves.

Failure Mechanism Study of Direct Action Solenoid Valve Based on Thermal-Structure Finite Element Model