The Design and Analysis of a Proportional Solenoid with Experimental Validation of Static and Dynamic Behavior.

Featured Application: Magnetic FEM analysis results for quasi-static cases can be used in dynamic simulations through Look-Up Tables, which reduce the computation time. This study presents the design and analysis of a proportional solenoid used in electro-pneumatic brake systems for heavy vehicles. The solenoid was designed using a traditional method, and its static and dynamic characteristics were investigated both theoretically and experimentally. ANSYS 2024 R1 Maxwell was employed for theoretical static analysis, focusing on the effects of the geometric dimension parameters in the fixed and moving pole contact regions on the force–displacement characteristics. The optimal dimensions for proportionality were determined under constraint parameters. The static analysis results provided the magnetization curve data, which were used to create Look-Up Tables for a dynamic model in MATLAB R2024b-Simulink, and this method reduced the simulation time and increased the dynamic simulation accuracy. Following static analysis, a prototype electromagnet was manufactured and tested. The solenoid achieved a constant magnetic force of 45 ± 3 N with a current of 1.3 A over a working range of 1–3 mm. The dynamic model, incorporating data from ANSYS, yielded results that closely matched the experimental findings. [ABSTRACT FROM AUTHOR]