This research presents a theoretical and experimental study of the dynamic response of a 2602 Texas Remcor solenoid valve. The dynamic response is characterized by a physical model. The model identifies the effective parameters on the valve performance. It has been found that current, pressure, flow rate, spring force, and plunger mass have some effect on the valve performance. Based on the dynamic model analysis, some operational conditions, like pressure and voltage, have been varied. Also some modifications have been applied to the original valve. The valve has been operated at 30, 40, and 50 psi and at 12, 24, and 36 volt. The valve modifications include the weight and the shape of the plunger and the volume of the cavity after the outlet orifice.
In order to track any sign of improvement, the valve response has been divided into four phases:
- Plunger- opening time.
- Flow- opening time.
- Plunger- closing time.
- Flow - shutting off time.
For each phase, the performance of original and modified valve has been tested. For the first phase, a significant improvement has been achieved in which the time delay
has been reduced from the average of 17.8 and 25.1ms to 4.6 and 4.8 ms for original and modified valve respectively. Furthermore, it was observed that the valve required more voltage as the fluid pressure increased. Reducing the volume of the valve had helped in reducing the time for the flow to reach its maximum value into half (from3.95 to 2.15 ms). The plunger - closing time was found to independent to the flow rate, pressure, and voltage. It depended only on the spring force; thus, by reducing plunger’s weight significantly reduced the closing time. The average closing time for the original plunger is 13.5 ms where it is equal to 2.9 ms for the modified valve. The time delay in the final phase depends on the ability of the nozzle to drain the remaining fluid in the valve after closing the plunger. The time is varied from 62 ms at the lowest flow rate to 1.6 ms highest flow rate. Reducing the volume of the valve cavity significantly decreased this time delay. The valve performance in general has been measured for the original and the modified valve in terms of area under the response curve. The modifications reduced the application error and brought the performance closer to the ideal situation.
Several springs were tested for performance, the time delay of opening and closing the plunger was improved by 34% when using the NN – 47 spring. However, the optimum spring constant K in which the opening and closing time of the plunger were the shortest was found experimentally to be 200 N/mm.