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Electromagnet - function & explanation

A current-carrying coil creates a magnetic field in its immediate vicinity. An iron core made of ferromagnetic material serves to strengthen the magnetic field. The magnetic north pole is where the magnetic field lines leave the iron core. At the magnetic south pole, the field lines re-enter the iron core.

This functional principle is utilised to either pick up or hold ferromagnetic objects by means of a holding solenoid or to move mechanisms by means of a lifting solenoid.

The magnetic fields of electromagnets can be individually adjusted via voltage regulation. This is particularly important for thin sheets in order to prevent the field lines from affecting the underlying materials. Conversely, the magnetic force decreases as the air gap increases. This can be counteracted by briefly overexciting the coils.

Electromagnets - overview of typical variants

  • Electro holding magnets

  • Electro-permanent holding magnets

  • Single-stroke solenoid

  • Single-acting bistable solenoid

  • bistable solenoid as double solenoid

  • Linear solenoids as alternating current solenoids

  • Brake solenoid

  • Magnetic coupling

 

Holding magnets round/rectangular

Linear and actuating solenoids

Areas of application for electromagnets in industry

Overview of the areas of application

Electromagnets are usually used wherever parts or components need to be held, controlled or moved. The principle of a current-carrying coil can also be used in metal detection for separation technology, or to remove any remanence in individual workpieces using a demagnetiser.

Examples of technical applications

There are numerous industrial applications for electromagnets in general. The following are just a few examples from the large overall field

  • Electro holding magnets for pick & place applications in robotics

  • Electric holding magnets in holding brakes

  • Electric holding magnets in component handling

  • Electromagnetically switchable clutches

  • Electromagnetically switchable brakes

  • Linear solenoid as vibration solenoid

  • Lifting magnets in the scrap industry for handling scrap iron

  • Lifting magnets in steel production

  • Lifting magnets in the steel trade

  • Lifting magnets for door locking

  • Lifting magnets for locking the steps

  • Linear solenoids in access systems

  • Linear solenoids as locking solenoids

  • Linear solenoids as pinch valves

  • Linear solenoids in dosing technology

  • Linear solenoids in ejection systems

  • Linear solenoids for moving flaps

Selection and procurement of industrial electromagnets

Selection criteria for electromagnets

In order for us to be able to offer you the right solution, we need as comprehensive an application description as possible. This is used to create a requirements profile which serves as the basis for the design of the solenoids. It can be roughly outlined as follows:

In component handling, the component to be lifted must be described in terms of its dimensions, weight, material and surface properties. In addition, the work cycle must be known.

For linear solenoids, in addition to the overall application, the stroke distance must also be known, as well as the required force, the installation position, are there any transverse forces that must be absorbed by the armature, etc....

Electrical requirements such as the desired voltage or required cables or plugs can be customised. As we at magnet.works wind our coils ourselves, a wide variety of winding wires can be specified. This ensures that exactly the wire that your application requires is used.

Tips for procurement and integration into existing systems

Our competent sales team will be happy to arrange an on-site appointment to discuss the best possible solution for your application.

Selection and procurement of industrial electromagnets

In addition to the customised production of your required electromagnet, holding solenoid or linear solenoid, we can also offer a wide range of innovative additional options such as

  • Digital nameplatesso that, for example, your technicians can read out the number of switching cycles using a readout device or contact us immediately in the event of a replacement.

  • Monitoring of the condition: Switching times and current consumption can give an indication of the state of wear.

  • DC/DC converter to ensure that the solenoid always receives the required voltage in the event of large voltage fluctuations.

  • PWM modules

  • Rectifier plug

  • generally can Customised solutions to control your solenoid, holding solenoid or linear solenoid can be developed together with you. We can also offer all the necessary tests for control hardware and software.

All about Holding magnets

Electro holding magnets consist of a Coil, which is located in a soft magnetic housing. Energising the coil produces a Open magnetic field, which exits via the pole surfaces of the housing. The magnetic field is closed via a ferromagnetic component. In the permanent electromagnet, there is a coil next to the coil. an additional permanent magnet in the housing.

Overview

The customisable design of the magnets enables seamless integration into a wide range of applications.

The holding forces of the magnets are adjustable to ensure optimum performance depending on requirements.

The magnetic field can be set up and dismantled quickly, which makes these magnets ideal for dynamic pick & place applications.

Permanent electromagnets offer currentless holding, which increases safety in critical applications.

Remanence, i.e. residual magnetism in the workpiece, can be effectively reduced by a pole reversal control unit in order to guarantee product quality.

Magnetic holder with position sensing in plastic housing and bellows

Example of a customised version of a linear solenoid. A special feature is the plastic housing on the back to protect the electronics. Do you have a special requirement for a linear solenoid? Talk to us, we will find a solution.

Round electromagnet, designed as a ring magnet

Example of a customised version of a round electromagnet. The ring-shaped design should be mentioned as a special feature. Do you have a special requirement for a holding magnet? Talk to us, we will find a solution.

Electro holding magnet in rectangular design with 2-piece centre pole

Example of a customised version of a rectangular electromagnet. The two-part centre pole and the special casting are worth mentioning as special features. Do you have a special requirement for a holding magnet? Talk to us, we will find a solution.

Electro holding magnet with rounded holding surface as excavating magnet

The rounded holding surface makes this version of an electromagnet particularly suitable as a lifting magnet for magnetisable small parts such as screws or nails. Available in different diameters.

Linear solenoid in painted housing

Solenoid with cube plug and bellows on both sides. A special feature of this solenoid is the housing painted to automotive standards. Simply tell us the desired colour and the required paint structure and we will provide a professional paint finish.

Linear solenoid in moulded frame housing and with angled plug

Linear solenoid with angled plug. The moulded housing and the bellows on both sides prevent the ingress of dirt, which means that this linear solenoid can be used in unclean environments. The thread on the armature allows it to be attached to a lever mechanism or similar, for example.

Linear solenoid as locking solenoid on mounting plate

Locking solenoid for door locking, for example. The robust bearing allows high lateral forces to be applied without deforming the inside of the locking solenoid and preventing it from moving. It can be mounted on the side of the housing or at the bottom via the mounting plate.

Solenoid with emergency release

Solenoid in rectangular housing with side mounting options and mechanical emergency release. The bellows prevent the ingress of dirt.

Lifting magnet round with mounting flange and bellows on both sides

Linear solenoid with cube plug. The bellows on both sides prevent the ingress of dirt, which means that this linear solenoid can also be operated in environments where there is a risk of dirt.

Linear solenoid as vibration solenoid

Vibrating solenoid in round housing with angled plug. This vibration solenoid is operated with 230VAC and vibrates at 50Hz. Different frequencies are possible, as are different vibration stroke lengths.

Linear solenoid in cost-effective design in frame housing with cable outlet on the side

Lifting magnet designed as a frame magnet. It is attached via an internal thread on the long side. The thread on the armature allows connection to a lever mechanism, for example, so that the lifting magnet can be used as an actuating element.

Rectangular holding rod with through hole

Rectangular electromagnet with special pole shape and through-hole. The housing is milled from a block instead of a U-profile.

The electromagnet at a glance

electromagnets, which are based on the principle of the Electromagnetism based, utilise current flowing through a wire coil to generate a magnetic field. These Dependence on the power supply This distinguishes them fundamentally from permanent magnets.

A key feature of electro-holding magnets is the controllability of their magnetic field:

  • The strength of the magnetic field can be changed simply by adjusting the voltage.
  • This property offers a High flexibility and enables the use in various applications, from the industrial production up to medical devices.

Properties of electromagnets

While electro holding magnets have a certain energy consumption, the focus of their use is on their Adaptability and precision orientated. These properties are crucial for their role in a variety of technological applications.

The ability to control the magnetic field Fast and precise makes electromagnets particularly useful in situations that require Rapid reactions and flexible adjustments require. Such applications benefit from the continuous adaptability of the solenoids, which makes it possible to respond to immediate changes in the operating environment or process requirements.

Your Flexibility and precise controllability make electromagnets an indispensable tool in many areas of technology. From the Production technology, where they are used for moving and positioning parts, through to scientific applications, Electromagnets show their versatility and importance in modern technology by being used to influence particle flows.

All about Linear solenoids

Linear solenoids are specialised electromagnets that can be Utilising the magnetic field, to perform mechanical movements. They are available in a variety of designs tailored to the specific needs of different industries. Due to their ability to interact with external forces, they offer a Flexible and efficient solution for mechanical drive tasks.

Overview

Solenoids generate a magnetic field by energising a coil, which pulls or pushes the armature. In some versions, a permanent magnet holds the armature in position without current.

Designs range from simple, robust single solenoids with or without return springs to bistable solenoids.

Fast switching times, long service life and maintenance-free use. They require little energy and are flexible to install.

Used in locking systems, mechanical actuators, as valve solenoids and in safety technology, especially in the transport and manufacturing sectors.

Magnetic holder with position sensing in plastic housing and bellows

Example of a customised version of a linear solenoid. A special feature is the plastic housing on the back to protect the electronics. Do you have a special requirement for a linear solenoid? Talk to us, we will find a solution.

Round electromagnet, designed as a ring magnet

Example of a customised version of a round electromagnet. The ring-shaped design should be mentioned as a special feature. Do you have a special requirement for a holding magnet? Talk to us, we will find a solution.

Electro holding magnet in rectangular design with 2-piece centre pole

Example of a customised version of a rectangular electromagnet. The two-part centre pole and the special casting are worth mentioning as special features. Do you have a special requirement for a holding magnet? Talk to us, we will find a solution.

Electro holding magnet with rounded holding surface as excavating magnet

The rounded holding surface makes this version of an electromagnet particularly suitable as a lifting magnet for magnetisable small parts such as screws or nails. Available in different diameters.

Linear solenoid in painted housing

Solenoid with cube plug and bellows on both sides. A special feature of this solenoid is the housing painted to automotive standards. Simply tell us the desired colour and the required paint structure and we will provide a professional paint finish.

Linear solenoid in moulded frame housing and with angled plug

Linear solenoid with angled plug. The moulded housing and the bellows on both sides prevent the ingress of dirt, which means that this linear solenoid can be used in unclean environments. The thread on the armature allows it to be attached to a lever mechanism or similar, for example.

Linear solenoid as locking solenoid on mounting plate

Locking solenoid for door locking, for example. The robust bearing allows high lateral forces to be applied without deforming the inside of the locking solenoid and preventing it from moving. It can be mounted on the side of the housing or at the bottom via the mounting plate.

Solenoid with emergency release

Solenoid in rectangular housing with side mounting options and mechanical emergency release. The bellows prevent the ingress of dirt.

Lifting magnet round with mounting flange and bellows on both sides

Linear solenoid with cube plug. The bellows on both sides prevent the ingress of dirt, which means that this linear solenoid can also be operated in environments where there is a risk of dirt.

Linear solenoid as vibration solenoid

Vibrating solenoid in round housing with angled plug. This vibration solenoid is operated with 230VAC and vibrates at 50Hz. Different frequencies are possible, as are different vibration stroke lengths.

Linear solenoid in cost-effective design in frame housing with cable outlet on the side

Lifting magnet designed as a frame magnet. It is attached via an internal thread on the long side. The thread on the armature allows connection to a lever mechanism, for example, so that the lifting magnet can be used as an actuating element.

Rectangular holding rod with through hole

Rectangular electromagnet with special pole shape and through-hole. The housing is milled from a block instead of a U-profile.

How does a linear solenoid work?

The linear solenoid is a Shape of the electromagnets, in which an electromagnetic force is applied to a coil to move the armature of the solenoid from the stroke start position to the stroke end position.

Resetting can be carried out by means of an integrated return spring or by external force.

A special form is the bistable linear solenoid represent:

  • Its anchor is without further energy supply held in an end position by external forces using a permanent magnet.
  • By a current pulse in reverse polarity, or by Energising a second coil, the armature is moved to the other end position, where it is also held in position by a permanent magnet.

Types and properties of linear solenoids

We at magnet.works see ourselves as Special magnet maker. As we develop and produce our own products, we can fulfil all possible customer requirements.

The following standard designs are typically available:

  • Single lifting magnets as sheet metal stirrup magnets without potting: Simple and cost-effective, suitable for basic applications.
  • Single lifting magnets moulded as sheet metal stirrup magnets: These magnets achieve a protection class of at least IP40, which makes them resistant to dust and splash water.
  • Single solenoids in solid material housing: Developed for higher forces, with precisely guided anchors to extend service life. Customisable with different connector types and customer-specific fastening solutions.
  • Bistable solenoid, single-acting: Available in open frame or solid housing, maintains end position without power, ideal for interlocking systems. Offers a compact design and low energy consumption, ideal for battery operation.
  • Bistable solenoid as double solenoid: Enables control in both lifting directions and is designed for high forces and long lifting distances.