Solenoid valves for automotive air suspension pumps are primarily used to regulate air pressure in the suspension system, allowing for adjustment of suspension firmness to enhance driving comfort and stability. As the core actuating component of the solenoid valve, the performance of the coil directly determines the valve’s response speed, sealing reliability, and service life; therefore, it imposes high requirements on both material selection and winding processes.
Video of Coil Winding for Automotive Air Suspension Pump | WIRESUN
Characteristics
High heat resistance rating. Solenoid valves are typically installed in the engine compartment or near the chassis, where they are continuously exposed to high temperatures ranging from 60 to 150°C. The coil form and enameled wire must be made of Class H (180°C) or higher insulation materials to prevent inter-turn short circuits caused by high-temperature aging.
Vibration and fatigue resistance. Continuous vibration and shock occur while the vehicle is in motion; the coil windings must be tight and uniform, combined with potting or varnish curing processes, to prevent wire loosening or breakage caused by long-term vibration.
Strong waterproofing, dustproofing, and sealing. Since air suspension systems are often exposed to the damp and dusty environment of the undercarriage, the coil assembly requires a robust sealing structure (such as injection-molded encapsulation) to achieve an IP67 or higher protection rating, preventing short circuits and failures caused by moisture intrusion.
Fast response speed and low power consumption. Air suspension systems require frequent and rapid on-off cycling to precisely control air pressure. The coil’s inductance and number of turns must be optimally designed to ensure sufficient electromagnetic pulling force while reducing power consumption and heat generation, thereby enhancing response sensitivity.
Service life must meet vehicle requirements. Generally, the coil must operate stably for over 100,000 kilometers and withstand hundreds of thousands of on-off cycles, which places high demands on wire material, insulation grade, and winding consistency.
Winding Precautions
Wire Selection: Prioritize high-temperature-resistant polyurethane or polyimide enameled wire to ensure the insulation layer does not soften or peel off at high temperatures.
Tension Control: Tension must be uniform and consistent during the winding process. If the tension is too loose, vibration may cause the windings to loosen; if too tight, it may damage the enameled wire insulation, creating a short-circuit hazard.
Inter-turn Insulation: An insulating layer should be added between multi-layer windings, or self-adhesive enameled wire should be used, to prevent inter-layer discharge or short circuits.
Winding Neatness: The wire arrangement must be neat and tight to prevent crossing or overlapping, which can cause uneven local heating and adversely affect heat dissipation and service life.
Lead Wire Securing: The coil lead wire connections are vulnerable points and must be securely tied and fixed with adhesive to prevent wire breakage due to vibration fatigue.
Vacuum Impregnation and Curing: After winding is complete, the coil must undergo vacuum impregnation followed by thorough drying and curing to enhance overall moisture resistance, vibration resistance, and insulation performance.
Turn Count and Resistance Consistency: During mass production, tolerances for turn count and wire diameter must be strictly controlled to ensure stable coil resistance values and guarantee consistent electromagnetic pulling force and response characteristics.
About WIRESUN
Founded by a management team with over 30 years of hands-on expertise in coil winding, WIRESUN has grown into one of Dongguan's trusted precision coil manufacturers. We provide OEM and ODM custom coil winding services, producing air core coils, bobbin coils, and special-shaped coils, along with coil winding machines and wire tensioners.
Contact us:
tech@wiresun.com ｜ +86-186 2185 7689 (Bi Danfeng)