Fast Development and Rapid Prototyping of a Compact Fast 3/2 Way Switching Valve

A fast 3/2 way solenoid actuated spool type switching valve and its fast development and rapid prototyping are presented. The valve features a very compact design for ease of integration, a nominal flow rate of 10 l/min @ 5 bar pressure loss, a switching time of approximately 1 ms, a powerful yet compact solenoid, and an integrated wave spring for spool actuation. The valve’s switching performance, in particular the magnetic force characteristics, were studied by extensive simulations. For a first feasibility check of the design, the valve was manufactured in ABS (Acrylnitril-Butadien-Styrol) by a 3D printer. To check the achievable switching time, the spool was manufactured in steel and the magnet as a laminated stack with a copper winding. The other valve components, however, were taken from the 3D printer plastic realization. First tests confirmed the concept, but showed that a somewhat larger magnet is required to achieve the intended short switching times.