One Piece Electromagnet / Solenoid Housings


Indimet Inc. has developed an innovative forging process where we have successfully integrated multiple parts of a solenoid into a single piece design.

Followed by a single setting machining, we are able achieve superior functionality and performance.

Traditional Method of Manufacturing

• Form the solenoid can / tube
• Machine the center pole
• Machine / stamp flux collector
• Stamp out flange
• Assemble - threading/interference fit and rivet if necessary

Indimet’s Innovative Method of Manufacturing

• Combines the can, pole, flux collector, and flange into one piece
• Eliminates substantial amount of machining in the component manufacturing
• Eliminates assembly costs because the process produces a single piece
• Reduces total cost of assembly and manufacturing
• Is capable of accommodating a wide rangeof pole sizes and combinations with can/housing and flux collector sizes.

Materials Used

• Low carbon steels, such as SAE 1010, 1008

Note: In addition, we have developed technologies to further improve the magnetic performance

---

Advantages

Single Setting Machining

Indimet-Single piece housing
Tolerances: After forging, we are able to machine these solenoids in a single setting. Unlike the multi-piece design, tolerances do not stack up.

1. With greater precision in concentricity, alignment tubes and other
   expensive parts are no longer needed
2. Better fit with various other complementary parts
3. Improved side loading performance on sliding piston

The concentricity tolerances for concentric bores, and longitudinal tolerances can be as strict as 10 microns.

Grain Flow

Indimet-Single Piece Housing
Our technology has all the grain lines in the direction of the magnetic flux, improving the total magnetic performance, allowing for less copper usage.

Deep Drawn Part
Grain flow is in the direction that the metal sheet was originally rolled in. This may not be the optimal direction when formed into a housing.

Base vs. Wall Thickness

Indimet-Single Piece Housing
Our capabilities allow for a varying wall and base thickness in net forging shape for optimal magnetic circuit characteristics

Deep Drawn Part
Must have the same wall and base thickness after extrusion

In traditional solenoids with the same base and wall thickness, magnetic saturation occurs fastest in the base. To optimize for magnetic performance and design, a thicker base is preferred.

No Air Gap
Indimet-Single piece housing
Because of its one piece design, there are no air gaps between the pole, can, and flux collector.

Deep Drawn parts
Will have complex assembly operations with multiple parts, each providing its own air gap.

Hysterisis Curve

Multi-Piece Design	Indimet Technology

Piston/ Sliding Armature
Our pioneering processes of manufacturing improves magnetic hysteresis by up to 10% and improves the linear behavior.

Yoke/Pole Piece
New process of manufacturing to total lower cost compared to traditional bar-fed CNC methods of manufacturing.

Other Innovative Technologies

Piston/ Sliding Armature
Our pioneering processes of manufacturing improves magnetic hysteresis by up to 10% and improves the linear behavior.

Yoke/Pole Piece
New process of manufacturing to total lower cost compared to traditional bar-fed CNC methods of manufacturing.