Abstract: The present disclosure provides a method and system for measuring an increase in wattage to detect a potential winding failure. The increase in watts in the winding occurs when a time-varying magnetic field from active turns of the winding induces a time-varying current on shorted turns of the winding. The resistance through the shorted turns and the induced current result in power usage and increased watts. The wattage increase is much greater than a resistance decrease in the winding by the shorted turns. Measuring the watts results in detecting a shorting winding with greater sensitivity than measuring the resistance. In one embodiment, the winding can be tested offline with a wattmeter and power supply. In another embodiment, the winding in use and its wattage can be monitored continuously or periodically locally or remotely, with an optional sensor to initiate a signal upon reaching a certain percentage increase in watts.

Abstract: A method of sealing coil leads during encapsulation by placing a lead of a coil in a tube, such that there remains a gap between the lead and the tube; placing the coil in a mold such that the gap remains open to an environment surrounding the mold; and injecting encapsulation material into the closed mold in a liquid state under pressure, thereby causing the material to flow through the gap toward the environment. Injecting encapsulation material into the mold may be done at a rate, temperature, and/or environmental temperature to cause the material to solidify before passing through the gap into the environment. In any case, there is no need to seal the mold to the leads. Each lead of the coil may be placed into an individual tube and/or the tubes may be is formed within a single sleeve.

Abstract: A process control valve with a spring rate adjustment and a spring force adjustment, thereby accommodating tight spring tolerances, such as those encountered in low power and proportional applications. The spring rate and spring force may both be adjusted after the valve has been fully assembled, thereby reducing manufacturing costs.

Abstract: A method of sealing coil leads during encapsulation by placing a lead of a coil in a tube, such that there remains a gap between the lead and the tube; placing the coil in a mold such that the gap remains open to an environment surrounding the mold; and injecting encapsulation material into the closed mold in a liquid state under pressure, thereby causing the material to flow through the gap toward the environment. Injecting encapsulation material into the mold may be done at a rate, temperature, and/or environmental temperature to cause the material to solidify before passing through the gap into the environment. In any case, there is no need to seal the mold to the leads. Each lead of the coil may be placed into an individual tube and/or the tubes may be is formed within a single sleeve.

Abstract: A low-noise solenoid has an armature with a projecting ridge receivable within a groove in a pole piece. As the ridge enters the groove, the magnetic force which opposes a return spring decreases until there is equilibrium whereat the armature remains suspended without impacting upon the pole piece.