Using Solenoids to Increase Safety in Hybrid Cars

A manufacturer sought a solution for disconnecting the battery of a hybrid car during an accident, without the possibility of the battery connecting again. TLX designed a custom latching solenoid that used residual magnetism instead of a permanent magnet; meaning once the solenoid unlatched, it would not re-latch without applying power.

Customer Problem

If a hybrid car is in a serious accident, passengers and emergency personnel risk coming in contact with the automobile’s high voltage battery. In order to eliminate the danger, a manufacturer sought a solution for disconnecting the battery during an accident, without the possibility of the battery connecting again.

The TLX Solution

TLX designed a custom latching solenoid that used residual magnetism instead of a permanent magnet; meaning once the solenoid unlatched, it would not re-latch without applying power. A pulse of power in either polarity would provide exceptional latching force without permanent magnets. The residual magnetism latching design is suitable for use in vehicle locks, latches, disconnects and safety cutout applications.

View Design Solution

Residual Magnetism Latching Solenoid

Stroke: 2.5 mm

Latching force (approx. for size shown): 40 N

Response time: < 10 ms

Release current: 1 amp

Release response: 3 ms

Release voltage: 12 Vdc

Durability: > 500K cycles

Connector type: As required

All TLX components are customized to fit system requirements, meaning technical specifications are unique to each customer and design. Examples given on our website are for illustration purposes only.

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Our Process

Step 1 / Initial Review

Our engineering team works directly with you to determine the viability of your program and identify the best solution based on your specifications.

Step 2 / Quote

Quotes include all costs related to your project - tooling, prototype, piece part, production and project specific costs.

Step 3 / Design Review & Prototypes

Our engineering team reviews the design with you and makes any adjustments needed. Prototypes are built according to design specifications for testing.

Step 4 / Testing

Prototypes are tested according to your specifications, with all relevant test data provided to you for evaluation.

Step 5 / APQP

DFMEA’s, PFMEA’s, control plans and process flow diagrams are started to drive the product intent design.

Step 6 / Pre-Production

Working drawings are developed for production. A second prototype build and a set of production parts are made from tooling and thoroughly tested.

Step 7 / PPAP/Production

The final design along with the PPAP (Production Part Approval Process) is developed and the new product enters production.

Step 8 / Ongoing Improvements

Our team collaborates with you to continue making improvements to the product to best meet your needs, increasing efficiency and reducing cost.

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