The utilisation of compressed air as a primary power source in pneumatic systems is integral to the operations of various industries. One key component that aids in the precise control of compressed air flow is the solenoid valve. This device, with its robust open-and-shut mechanism, allows industries to regulate the flow of compressed air with accuracy and efficiency, ensuring optimal performance of their pneumatic systems.
To introduce the solenoid valve for air compressors more comprehensively, we have curated this blog post. In this blog, we will explore the basics, types, working, functions and maintenance tips of solenoid valves.
A] What Are Compressed Air Solenoid Valves?
The air compressor solenoid valve is an electromechanical device utilised to control the airflow in the air compressor system. The air compressor solenoid valve converts electrical energy into mechanical energy with the help of electromagnetic force. Depending upon the capacity, pressure, and internal mechanism, it comes in a variety of shapes and sizes. It is used in diverse applications such as HVAC systems, automobiles, and industrial automation systems. Its exclusive diaphragmatic design offers a high flow rate, lower energy consumption, and optimal air regulations.
B] Types of Solenoid Valves For Compressor
1. Direct-acting Valves
Direct-acting valves, also known as zero-rated solenoid valves, are solenoid valves that utilise a specialised plunger to open and close the air media by creating a magnetic field around the plunger. With minimal operating pressure and fast startups, it allows industries to control their media flow remotely. It consists of a coil, a plunger, and a valve seat. When electricity is produced, the coil induces an electromagnetic field to shift the plunger away from the valve seat and gates the media flow.
2. Pilot-operated Valves
Pilot-operated valves, also known as indirect-acting valves, are used to control the valve’s orifice. It has a built-in mechanism that controls the magnitude of the electromagnetic force, facilitating precise controls of media flow. It consists of three components: the main valve, the pilot valve, and the sensing line. The pilot valve adjusts its position by sensing the command for position changes. This allows the pilot-operated valve to open and close seamlessly. It is widely used in various industries where precise and accurate media flow control is needed.
Want to learn about which types of tools are powered by compressed air? Our comprehensive guide explains in detail the types of tools that need compressed air to operate.
C] How Compressed Air Solenoid Valves Work?
The solenoid valve for the air compressor comprises a coil, plunger (armature), diaphragm, central orifice, hanger spring, disk, and seat. When electricity is produced in the coil, it creates an electromagnetic field around the plunger and forces the plunger to alter its position. Further, the plunger movement opens and closes the central orifice as per operational requirements, providing seamless control of compressed air.
In the open orifice, compressed air flows through the piping system. On the contrary, a closed orifice restricts the airflow going into the piping system. The air compressor solenoid valve can be controlled through computerised commands, allowing industries to control compressed air flow remotely. In addition, It aids in safeguarding the air receiver tank by managing and maintaining the air pressure produced by the compressor.
D] Functions Of Solenoid Valve In Air Compressor
1. Startup & Shutdown Controls
Due to its robust open and shut mechanism, the solenoid valve offers precise startup and shutdown of compressed air flow with minimal pressure fluctuation. It allows or restricts the flow of air by opening or closing the central orifice of the valve. Also, the solenoid valve for the compressor plays a pivotal role in prolonging the service of the screw air compressor.
2. Pressure Control
Responding to pressure sensors or controllers, it accurately adjusts the air pressure and mitigates the manifestation of over or under-pressure situations in the pneumatic systems. With a faster response time, the solenoid valve is known for maintaining constant air pressure throughout the system.
3. System Safety
The solenoid valve in the air compressor plays a crucial role in safeguarding the compressor units by swiftly cutting off the airflow. Doing so saves the systems from unnecessary pressure-building, safeguarding compressor units from potential damage. Whether it is normal or reciprocating air compressors, a solenoid valve plays a pivotal role in system safety and prolonging the life of compressors.
4. Power Efficient
A Solenoid valve for compressed air consumes minimal power while controlling the compressed air flow. Its low power consumption with swift performance allows industries to save costs on energy investment while maintaining operational efficiency.
5. High Flow Rate
The Solenoid valve is made in such a way that it allows the passage of maximum air with a high flow rate. It aids in offering maximum throughput without lowering the air pressure. It permits industries to achieve maximum efficiency with precise control over compressed air.
E] Benefits Of Using Solenoid Valves In Compressed Air Systems
1. Fast Response Time
The Solenoid valve in the compressor has a built-in mechanism that swiftly responds to controlling sensors and performs open or shut operations as per requirement. Its robust open-and-close mechanism makes it perfect for applications where precise and accurate control is essential.
2. Remote Operation
With solenoid valves, industries can operate or give computerised commands to solenoid valves remotely. It eliminates the need to go to the physical location for turning on or shutting down the valve manually. Operators can give on/off instructions remotely.
3. Compact & Lightweight
Solenoid valves are compact and made from very light materials. The compact and lightweight properties of the solenoid valves facilitate seamless installation even in tighter or more dense spaces. Also, these properties offer extreme suitability for mobile compressors due to their lightweight and small design.
4. Cost Effective
Its low-maintenance design, system safety property, and automation solution benefit industries and provide cost-effective solutions for the long term. These contribute to a more sustainable and reliable operational environment.
F] Maintenance Best Practices
When it comes to maintaining the solenoid valve, it is vital to clean it frequently to function well. Proper cleaning and frequent maintenance eliminate the chances of air compressor solenoid valve leakage.
The maintenance best practices are:
- Frequent solenoid valve filter change
- Checking for leaks regularly
- Testing its operating conditions to ensure optimal performance
- Checking for clogs
- Referring manufacturer’s guide to ensure best maintenance practices
Conclusion
Solenoid valves are vital equipment for compressors, offering robust mechanisms for controlling the compressed air flow. Its precise open-and-shut controls allow industries to obtain the desired control over compressed air. From fast response time to remote operation, it offers numerous benefits. Consider shared maintenance best practices to prolong the life of your solenoid valve.
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