A proportional control valve is a valve used to control fluid flow rate by varying the size of the flow passage via a restrictor. The regulated flow rate subsequently adjusts parameters affecting a process in a system, mainly level, pressure and temperature. The other minor parameters include: weight, thickness, humidity, density, Ph, color and viscosity.

In an automatic control valve, the restrictor is directed by a signal from a controller called an actuator. A proportional control solenoid valve utilizes a solenoid as an actuator for variable valve positioning.

A direct-operated 2-way standard proportional solenoid valve operates very similar to a direct-operated solenoid valve with the difference that the former operates through a range of valve positioning while the later only provides two switching states (i.e. on/off), Figure 1. In a direct-operated proportional solenoid valve, the plunger is the restrictor.

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Operating Principle

In principle it is possible to proportionally control the plunger with variable DC voltage, however in practice static friction on the guide points of the plunger impairs the sensitivity of the valve, which results in greater hysteresis effects (the phenomenon in which the value of a physical property lags behind changes in the effect causing it). To prevent static friction, the normal inlet signal can be converted into a pulse width modulated voltage signal (PWM) using special control electronics.

Pulse-width modulation (PWM) is a technique often used to allow the control of the power supplied to electrical devices. The average value of voltage (and current) fed to the solenoid is controlled by turning the power switch on and off at a fast rate (Figure 2). This kind of control puts the plunger into a very fast but weak amplitude oscillation. The oscillation puts the plunger in a balanced state which maintains its constant sliding friction. The plunger’s oscillation motion has no effect on the fluid’s flow behavior.

The longer the switch is on compared to the off periods, the higher the total power supplied to the solenoid. The term duty cycle describes the proportion of on time, t1, to the cycle duration, T. A low duty cycle corresponds to low power, because the power is off for most of the time. Duty cycle is expressed in percent, 100% being fully on.

Selection Criteria

In Continuous flow applications, the choice of appropriate valve size is much more important than with on/off valves. With a high orifice setting the valve can already reach full flow rate at a very small opening (stroke). The remaining stroke is then useless, which impairs resolution and the general control quality of the valve. With an orifice size that is too small on the other hand, the valve won’t reach full flow rate. It is recommended that the pressure drop over the valve should be around 30 % of the total pressure drop within the system.

Typical Applications

Here are some common applications of Proportional Solenoid Control Valve.

Burner/Flame Control: Two gases must be controlled in a burner control system; both are in a desired ratio with one another. The ratio of combustion gas to oxidant gas, e. g., air or oxygen, is determined by the flame that is required for the respective process.

Level Control with Pressurization (Flow Pressure Control): Atmospheric pressure control is one possible type of level control. Via two solenoid control valves, a PID controller supplies enough air or nitrogen so that there is always the same pressure pressing against the fluid that changes when the fluid pressure drops through removing a portion of the fluid.

Mixture of Cold and Warm Water: A Pt100 temperature sensor measures the temperature of the mixed water. The temperature controller brings this temperature to the given reference value by controlling two solenoid control valves accordingly.

Temperature Control: A solenoid control valve can set the cold water supply to a heat exchanger in accordance with the measured process water temperature. If this is higher than the reference value, more cold water is required. If it is lower than the reference value, less cooling is required. A heating circuit works in a similar way.

Flow Control: A solenoid control valve can be used directly as a control valve, for direct flow control, for example.
Actuator Control (Static Pressure Control): Two solenoid control valves can control the air for pneumatic drive (piston valve, cylinder, etc.). A PID controller determines which of the two valves must open. The control electronics set the drive via the solenoid control valves so that the process value corresponds with the set point given.

Ejectors/Pressure Control: A solenoid control valve can control the propellant gas flow rate. More propellant gas creates greater suction power and a deeper vacuum in the suction line. The controller sets the valve according to the vacuum pressure.

You are looking for proportional solenoids as drive for your solenoid valve or a pilot or pressure reducing valve for oil or other fluid and gaseous media?