Design and Optimization of a Pneumatic Microvalve with Symmetric Magnetic Yoke and Permanent Magnet Assistance

Electromagnetic pneumatic microvalves, widely used in knitting machines, typically operate based on a spring-return mechanism. When the coil is energized, the electromagnetic force overcomes the spring force to attract the armature, opening the valve. Upon de-energization, the armature returns to its original position under the restoring force of the spring, closing the valve. However, most existing electromagnetic microvalves adopt a radially asymmetric magnetic yoke design, which generates additional radial forces during operation, leading to armature misalignment or even sticking. Additionally, the inductance effect of the coil causes a significant delay in the armature release response, making it difficult to meet the knitting machine’s requirements for rapid response and high reliability. To address these issues, this paper proposes an improved electromagnetic microvalve design. First, the magnetic yoke structure is modified to be radially symmetric, eliminating unnecessary radial forces and preventing armature sticking during operation. Second, a permanent magnet assist mechanism is introduced at the armature release end to enhance release speed and reduce delays caused by the inductance effect. The effectiveness of the proposed design is validated through electromagnetic numerical simulations, and a multi-objective genetic algorithm is further employed to optimize the geometric dimensions of the electromagnet. The optimization results indicate that, while maintaining the fundamental power supply principle of conventional designs, the new microvalve structure achieves a pull-in time comparable to traditional designs during engagement but significantly reduces the release response time by approximately 80.2%, effectively preventing armature sticking due to radial forces. The findings of this study provide a feasible and efficient technical solution for the design of electromagnetic microvalves in textile machinery applications.