Hydraulic solenoid is the actuator of different types of hydraulic valves, and the solenoid coil assembly is the main part of the complete hydraulic solenoid. Even though there are different types of hydraulic solenoids for different hydraulic valves, the solenoid coil assemblies for different hydraulic solenoids are exactly the same.
A complete solenoid coil assembly includes bobbin with terminals, copper wires, coil can and the over molded materials. When we discuss the price of solenoid coils, it includes the solenoid coil cost and profits. Solenoid coil cost is determined by three basic factors, raw material cost, energy cost, and labor cost.
Solenoid Coil Materials Cost
Different solenoid coil parts are made of different types of raw materials. The cost of solenoid coil raw materials can help us get a better understanding of solenoid coil price.
Solenoid Coil Bobbin Assembly Cost
Solenoid bobbin with terminals consists of two parts, the solenoid bobbin, and terminals. To make a complete solenoid bobbin with terminals includes four steps: molding, assembly, stamping, and tool making. Solenoid bobbin is made of plastics, in the molding process, the molding machines will mold plastics into formed bobbins. In the assembly process, with the help of terminal assembly machines, we can insert terminals in the solenoid bobbins. In the following processes, the solenoid bobbin assembly will be completed. The cost of solenoid bobbin assembly is determined by the cost of plastic materials, and the performance of molding machines and assembly machines.
Solenoid bobbin can be manufactured in different sizes and shapes. There are many solenoid bobbin manufacturers around the world. Solenoid bobbin assembly normally is sold in large quantity, the price of single solenoid bobbin assembly is low, take Chinese solenoid bobbin price as an example, the cost of solenoid bobbin assembly is normally between $0.01 – 0.5.
Solenoid Copper Wires Cost
The copper wires used for hydraulic solenoid is the most common copper wires in the market. Among all types of wire conductor materials, copper wire is the most widely used conductor material, which has large output and much cheaper price. Despite the cheap price, copper wires also maintain the advantages of low resistivity, easy manufacture, and full frequency conduction balance, etc.
Even though the price of solenoid copper wire is low, it does not mean that all the copper wires have the same price. In fact, copper wires have different grades, such as class f, class h, and class n. Different grades represent different melting temperatures, and lower melting temperature makes the copper wire easier to burn. But, as the copper wire grades escalated, the price of copper wires increases, too.
The diameters of solenoid copper wires can be customized. Normally, the solenoid copper wire diameter range is between 0.04-4.5mm. The copper winding magnet wire mainly supplied industrial factories, so it is also sold in large quantity. Normally, the copper wire supply range begins with 100 kilograms. The price of class f and class h copper wire is between $5.5-9.2 per kilogram. As the copper wire grades and the purchase quantity changes, the price of solenoid copper wire changes, too.
Solenoid Coil Can Assembly Cost
Solenoid coil cans are made of different types of materials. Some types of hydraulic solenoid coils use plastic coil cans, some use iron coil cans. The cost of solenoid coil can is not expensive. The main cost of solenoid coil can assembly is the over-mold process. During the over-mold process, the injection molding machine is needed.
Talking about the injection molding cost, in my personal opinion, it also contains the three basic factors, the raw material cost, energy cost, and labor cost. Here is all about the raw material costs. The raw materials can be used for over mold process are various, and the raw material cost can be various, too. There are many different plastic raw materials can be used for solenoid coil during mold process, such as PET, PPE, etc. But we have to admit that there are some small solenoid coil manufacturers use cheap PE or PP materials so that their solenoid coil molding cost is lower than others. The price of engineering plastics raw material PET and PPE is between $850-1200 per ton.
Energy Cost & Labor Cost
The energy cost and labor cost of solenoid coils must not generalize. There are solenoid coil manufacturers all over the world, different solenoid coil manufacturers have different energy and labor cost.
During solenoid coil manufacturing process, the operation of different equipment needs stable power support. The electricity consumption cost is also a part of the solenoid coil cost. The electricity prices of different countries are different, so the calculation of solenoid coil energy cost must consider your own production capacity. For example, the energy consumption of the machines is 100 kilowatt per hour, and your solenoid coil capacity is 100 pieces, which mean a solenoid coil needs 1kilowatt energy consumption. Then you can add the energy cost of each solenoid coil.
The calculation of labor cost nearly the same. You have to calculate the average production capacity, and your total labor cost, then you can get your average labor cost of each solenoid coil.
