Simulation and Modeling of a Controlled Solenoid

A design solution for a solenoid coil’s control system is presented in this engineering EDUblog. The electrical component of the solenoid is used in conjunction with a traditional proportional, integral, and derivative (PID) controller unit in this control model to examine the effectiveness of the control system.


The Solenoid, Controller of Magnetic Fields and Electromagnet All-In-One

The solenoid has been used as an electrodynamic device for numerous electrical and mechanical components in recent years.  (Often in tandem with Actuators).  Replicating the impact of electricity upon motion, it acts like a magnet.

So a coil carrying a current coiled to the right size and form to enclose an iron core known as a plunger or armature, which provides rectilinear motion, can be thought of as a solenoid.

Solenoids are utilized as actuator devices and employed as a control element for speedy and safe execution of switching jobs inside fluid in a variety of applications, such as fluid systems. They also offer low electrical power consumption and compact controller design.






Solenoid Application in Control Systems













The productivity of classic manufacturing processes, such the manufacture of steel and coal, has increased significantly as a result of process automation. On the other side, factory automation facilitated the development of novel tools, methods, and techniques, as seen in the cases of materials engineering for nanofabrication and solid state electronics.  Sophisticated modeling of a controlled solenoid has aided much to development.

But as history has demonstrated, early optimism and hopes that all facets of the production process, starting with a design and the isolated automated manufacturing cells, could be united into one coherent integrated system, frequently fell short of expectations. There are instances of businesses that invested a significant amount of time, money, and resources in automation yet failed to successfully integrate it into reliable, functional systems.






The creation of semiconductor devices, nanofabrication, non-contact technologies for material surface processing, and fast prototyping are just a few of the high-tech projects that several local enterprises are working on in the field of materials science and engineering.

Here, the production procedures are mostly based on job shop and cell activities, with very little assembly line work.

In order to monitor and manage the fabrication processes, which include lithography, film deposition and growth, annealing and diffusion, metrology, etching, baking, and curing, clean room technologies and materials engineering require integrated computer-based automated equipment.

A high-tech Pittsburgh company called Advantech US creates technology for the production of thin film electrical microcircuits. Vacuum deposition equipment is used in the operations to create prototype thin-film circuits and create microcircuit patterns using photolithography.

Plextronics Inc. (acquired by Solvay in 2014), another Pittsburgh-based business engaged in materials engineering, develops and produces conductive polymers used for printed electronics, which includes next-generation products for light, power, and circuitry, such as flexible displays, plastic solar cells, and organic RFID tags.

Extrude Hone, a division of Kennametal, provides cutting-edge material solutions based on automated, non-contact material processing. The facility uses abrasive flow machining (AFM), micro-flow machining (AMF), thermal energy machining (TEM), and electrolytic machining as technological methods (ECM).

Powerex, Inc., a manufacturer of high power solid state devices, is another example of a company that makes semiconductors.

The technologies utilized there include clean room technologies, automated production based on cell manufacturing with materials engineering connected to diffusion processes, and software design tools.

For the automotive, alternative energy, aerospace, medical equipment, electrical equipment, communication, and other industrial domains, the firm is a leading supplier of discrete, modular, and integrated high power semiconductor devices and solutions. IGBT assemblies, thyristors & diode modules, MOSFET modules, etc. are a few examples of the items.







Electronic & EM Consulting

Industries & Applications



Motors and Generators

Modern motors and generators require optimal use of materials to produce the maximum possible torque in the smallest size increments to lower manufacturing costs, and maximize ROI.

Electric Machines

Various parameters of the EM base design can be studied to find their effect on the overall performance including sensitivity analysis, tuning augmentation, radiation gain, impedance matching losses, etc.

Touch Sensors

Touch sensors are ubiquitous in modern technology. Understanding the mutual capacitance of your screen with an outside dielectric is crucial in determining when a “touch” is recorded.

Wireless Integration

Wireless Integration Testing is a crucial component in determining the performance readiness of antennas in the presence of interference from each platform and neighboring antennas.

PCB Analysis

Many PCB-related problems require alterations via component placement, trace routing, or the plane metallization itself, all of which prove difficult to manage on the bench.

Signal Integrity

From layout of PCBs supporting high-speed lanes, cable assemblies, high-density connectors, and other interfaces, we capture existing design performance and identify core areas for improvement.


By leveraging advanced EM-field simulators dynamically linked to powerful harmonic-balance and transient circuit simulation, our engineers can break the cycle of repeated design iterations.

Electromagnetic Compatibility and EMI

Dynamically link advanced EM field solvers to power circuit simulators, predicting EMI/EMC performance of electrical devices through integrated workflows.

Electronics Cooling

Investigate the maximum temperature locations of EM systems, ensure incorporation of sufficient cooling schemes, and prevent over-heating of electronic parts and components.

Industry and Military Standards

Through simulation, ensure compliance with one (or more) industry and/or military technical standards such as IEC 60601-1 for medical electrical equipment.


Be it non-linear material properties, transient excitation, eddy current effect, proximity effect, or hysteresis, our engineers can determine the estimated core loss and thermal winding loss.

Sensitivity Analysis

Several consideration of the EM base design can be analyzed to determine their influence on the overall performance within a sensitivity analysis, including radiation gain and impedance matching losses.

Failure Analysis

Determine if an interaction between operating equipment and the supporting structure has a statistical likelihood to create a destructive resonant operating condition resulting in equipment failure.