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Views: 2 Author: Site Editor Publish Time: 2026-01-12 Origin: Site
In precision fluid control systems, the miniature solenoid valve is a critical component. Whether it is controlling the airflow in a medical ventilator or managing the chemical reagents in a laboratory analyzer, the reliability of the valve determines the reliability of the entire machine.
When a solenoid valve fails, it can lead to costly downtime, inaccurate dosing, or even safety hazards. Understanding why these failures happen—and how to prevent them—is essential for any product designer or maintenance engineer. Here are the five most common causes of 3 ways solenoid valve failure and the best practices to keep your systems running smoothly.
The most frequent cause of mini solenoid valve failure is contamination. Small particles, such as dust, metal shavings from piping, or crystallized chemicals, can lodge between the valve seat and the seal.
The Symptom: The valve fails to close completely (leading to leaks) or gets stuck in the open position.
The Prevention: Always install a filtration system upstream of the valve. For micro-valves, a fine mesh filter is usually sufficient to trap particulates. Additionally, ensure that all tubing is flushed and cleaned during the initial assembly of your device.
Not all rubbers and plastics are created equal. If the fluid passing through the valve is aggressive (like certain medical reagents or cleaning alcohols) and the seal material isn't rated for it, the seal will eventually swell, crack, or dissolve.
The Symptom: Internal leaking, a "sticky" valve response, or total loss of pressure.
The Prevention: Verify the chemical compatibility of your medium with the valve materials. At Pincheng Motor, we offer various seal options, including EPDM, FKM (Viton), and Silicone. Matching the right elastomer to your fluid is the best way to ensure long-term performance.
The solenoid coil is the electromagnetic heart of the valve. If it receives the wrong voltage or is kept energized for too long without proper heat dissipation, it can overheat and "burn out."
The Symptom: The valve makes no sound (no "click") when power is applied, and the coil may feel excessively hot or smell of burnt plastic.
The Prevention: Always operate the valve within its rated voltage (e.g., DC 12V or 24V). If your application requires the valve to be open for long periods, consider using a Low-Power Solenoid Valve or a PWM (Pulse Width Modulation) circuit to reduce the holding current once the valve has shifted.
Every 2 way micro solenoid valve has a specific operating pressure range. Pushing a valve beyond its maximum rated pressure can physically prevent the plunger from moving or damage the internal diaphragm.
The Symptom: The valve fails to open even when energized, or you hear a "humming" sound as the coil struggles to overcome the pressure.
The Prevention: Carefully review your system’s peak pressures. If your system involves high-pressure spikes, choose a valve with a higher Maximum Operating Pressure (MOPD). Our technical team can help you select a valve that provides a safety margin for your specific pressure requirements.
Even the best valves have a limited mechanical lifespan. In applications like high-speed sorting or precision dosing, a valve may cycle millions of times. Over time, the internal plunger or spring can fatigue.
The Symptom: Gradual loss of response time or inconsistent flow rates.
The Prevention: For high-cycle applications, look for valves rated for long-life performance (e.g., 10 million+ cycles). Using a high-quality stainless steel plunger and specialized spring coatings can significantly extend the interval between maintenance.
Preventing solenoid valve failure isn't just about maintenance—it's about choosing the right component from the start. By considering filtration, material compatibility, and electrical limits during the design phase, you can eliminate 90% of potential failures.
At Shenzhen Pincheng Motor, we specialize in manufacturing high-precision mini 3 way solenoid valve designed to withstand rigorous industrial and medical standards. Our valves are tested for durability and precision, ensuring that your devices perform flawlessly in the field.
Are you experiencing valve issues in your current design?Contact our engineering experts today for a free technical review. We can help you identify the root cause of your failures and provide a customized, high-reliability valve solution.
