Last Updated on 2026-01-23 by SolenoidFactory
Introduction to Long Stroke Solenoid Technology
A long stroke solenoid is a type of electromagnetic actuator designed to deliver extended linear motion compared to standard short-stroke solenoids. While traditional solenoids typically operate within strokes of 2–10 mm, a long stroke solenoid can achieve strokes ranging from 15 mm to over 50 mm, depending on design and force requirements.
This extended motion capability makes the long stroke solenoid an ideal solution for applications requiring significant mechanical travel, smooth actuation, and precise positional control. As industries demand smarter and more compact motion control solutions, the long stroke solenoid has become a preferred alternative to motors and pneumatic systems in many scenarios.
This article explores long stroke solenoid applications across industries, as well as design principles, advantages, and real-world case studies.
1. Long Stroke Solenoid Applications in Industrial Automation
In industrial automation, the long stroke solenoid plays a key role in systems that require linear motion with fast response and repeatability.
Typical Industrial Automation Uses
Mechanical latching and unlocking mechanisms
Conveyor sorting gates
Automated material handling stops
Packaging machinery pushers
A long stroke solenoid provides quick actuation without the complexity of a motor-driven system. Because the stroke length is extended, it can directly replace small pneumatic cylinders in compact automation systems.
Case Example
A packaging equipment manufacturer integrated a long stroke solenoid to control a carton diverter arm. The solenoid delivered a 30 mm stroke to redirect packages on a conveyor line. Compared to the previous pneumatic system, the long stroke solenoid reduced maintenance costs and eliminated air supply requirements.
2. Long Stroke Solenoid Applications in Smart Home and Security Devices
Smart home technology increasingly relies on electromagnetic actuators. A long stroke solenoid is commonly used in:
Smart lock internal bolt control
Motorized cabinet locking systems
Automated door latches
Because a long stroke solenoid can provide extended linear travel, it allows secure bolt engagement without mechanical gear assemblies.
Case Example
A smart security system manufacturer replaced a small DC motor with a long stroke solenoid in a digital lock design. The solenoid offered faster locking response, lower power consumption in pulse mode, and improved reliability over millions of cycles.
3. Long Stroke Solenoid Applications in Medical Equipment
Medical devices often require compact, reliable actuation systems. A long stroke solenoid is used in:
Drug dispensing systems
Sample collection devices
Diagnostic analyzers
The controlled motion of a long stroke solenoid ensures precise dosing and repeatability.
Case Example
A laboratory automation company used a long stroke solenoid to drive a reagent dispensing plunger. The long stroke ensured consistent fluid delivery, while the electromagnetic actuation allowed silent operation in clinical environments.
4. Long Stroke Solenoid Applications in Consumer Appliances
In home appliances, a long stroke solenoid supports mechanisms that require controlled motion in compact spaces.
Common applications include:
Coffee machine brewing units
Washing machine door locks
Refrigerator ice dispensers
Rice cooker lid locks
Case Example
A coffee machine manufacturer integrated a long stroke solenoid to control the brewing chamber lock. The extended stroke allowed the mechanism to engage securely while maintaining a compact design. The long stroke solenoid operated in a high-humidity environment without performance degradation.
5. Long Stroke Solenoid Applications in Automotive Systems
The automotive industry benefits from the long stroke solenoid in applications that require reliable motion under harsh conditions.
Examples include:
Electronic door latch systems
Fuel system control mechanisms
Adjustable airflow vents
EV charging port locks
Case Example
An automotive OEM implemented a long stroke solenoid to control a charge port locking pin in an electric vehicle. The extended travel ensured reliable engagement even with alignment tolerances and temperature variations.
6. Long Stroke Solenoid Applications in Vending and Payment Systems
Vending machines and automated kiosks rely on compact actuators. A long stroke solenoid is used for:
Coin lock mechanisms
Product dispensing gates
Anti-theft locking devices
The fast response of a long stroke solenoid ensures reliable operation in high-cycle commercial environments.
7. Long Stroke Solenoid Applications in Industrial Safety Systems
Safety interlock systems often require actuators capable of longer travel distances. A long stroke solenoid is used in:
Machine guard locking
Emergency stop mechanical releases
Access control barriers
The reliability of a long stroke solenoid in high-cycle conditions makes it ideal for safety-critical designs.
8. Engineering Considerations for Long Stroke Solenoid Design
Designing a long stroke solenoid requires balancing stroke length, force output, and thermal performance.
Key Design Parameters
| Parameter | Importance in Long Stroke Solenoid |
|---|---|
| Stroke Length | Determines total travel distance |
| Pull Force Curve | Must remain sufficient across stroke |
| Coil Power | Affects temperature rise |
| Duty Cycle | Continuous vs intermittent use |
| Mechanical Return | Spring or gravity-assisted |
Because magnetic force decreases over distance, a long stroke solenoid often requires optimized magnetic circuits and longer coils to maintain force output.
9. Advantages of Long Stroke Solenoid Compared to Alternatives
A long stroke solenoid offers multiple advantages over motors and pneumatic cylinders:
Faster response time
Lower system complexity
No compressed air requirement
Lower maintenance
Compact structure
For many OEM designs, replacing small motors with a long stroke solenoid reduces system cost and increases reliability.
10. Custom Long Stroke Solenoid Solutions from SF
SF specializes in designing custom long stroke solenoid solutions for OEM applications. With more than 10 years of electromagnet manufacturing experience, SF provides:
Custom stroke lengths up to 50 mm+
Optimized force curves
Low-noise structural designs
High-temperature coil options
Long-life cycle performance
SF engineering teams work closely with customers to tailor each long stroke solenoid to the mechanical and electrical requirements of the application.
Why Long Stroke Solenoid Technology Is Expanding Across Industries
The long stroke solenoid has become an increasingly important actuator across industries due to its ability to provide extended linear motion in a compact, efficient design. From industrial automation to smart home devices and medical systems, the versatility of the long stroke solenoid continues to drive innovation.
As OEMs seek reliable, low-maintenance alternatives to motors and pneumatic systems, the long stroke solenoid stands out as a high-performance electromagnetic solution.
Manufacturers like SF, with deep expertise in custom electromagnet engineering, are helping companies integrate long stroke solenoid technology into next-generation products with improved reliability, efficiency, and design flexibility.
Custom all kinds of electromagnet, contact SF electromagnet factory whatsapp +86 189 0261 1680
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