Why DC Solenoids Underperform in Practice - EMWorks Webinars

Описание: A Simulation-Based Electro-Thermal Analysis

Many DC solenoids are designed using simplified assumptions: fixed current, constant resistance, and negligible thermal effects. In real operating conditions, however, most solenoids are voltage-driven, and coil resistance increases significantly as temperature rises.

This webinar examines why solenoids that perform well in cold-coil calculations often underdeliver in prototypes and real systems.

Using a simulation-based approach, we analyze voltage-driven DC solenoids with identical geometries and supply voltage, while varying key coil parameters such as:

Wire gauge
Number of turns
Copper losses
Temperature rise over time

The results clearly show how electro-thermal effects reduce steady-state current and force, and why ignoring thermal coupling leads to overly optimistic performance predictions.

What you’ll learn

Why voltage-driven solenoids behave differently from constant-current assumptions
How temperature rise impacts coil resistance, current, and force
The trade-offs between wire gauge, turn count, and thermal performance
Why electro-thermal coupling must be considered early in solenoid design
How simulation helps explain prototype underperformance before physical testing

This session is intended for engineers and designers working on electromechanical systems, actuators, and DC solenoid applications who want more reliable performance predictions and fewer surprises during prototyping.