FAIST Control Systems is proud to announce a major milestone in the development of its new pneumatic actuator with an integrated solenoid valve, designed to redefine compactness, durability, and efficiency in EGR (Exhaust Gas Recirculation) systems.
A compact and robust solution for modern challenges
The development, which leverages FAIST’s extensive expertise in pneumatic actuation, responds to the increasing demand for systems that combine structural robustness, controllability, and space efficiency. Traditional EGR system bypasses rely on separate solenoid valves and actuators, requiring significant space and robust fixing mechanisms to endure high-vibration environments. FAIST’s innovative solution integrates the solenoid valve directly into the pneumatic actuator, achieving remarkable improvements, with the main ones listed below.
- Space optimization: the integrated design eliminates the need for additional fixing points and connecting pipes, reducing the overall packaging size by 40% compared to existing solutions.
- Enhanced durability: positioning the solenoid core in the physical center of the actuator improves stability and extends the lifespan under vibrational loads.
- Cost and efficiency gains: by eliminating external connections and optimizing material selection, the new actuator reduces production costs while maintaining high performances.
A global team effort
The development of this actuator has been developed collaboratively by FAIST’s engineering teams from Italy and China. Led by Chief of Product Development Officer Tina Cortese, Senior Application Engineer Vincent Guo, and Application Engineer Giacomo Biavati, the project utilized FAIST’s integrated development systems to meet the diverse needs of customers worldwide. The collaboration resulted in a product that balances design, regulatory, and cost requirements across different markets.
Senior Engineer Vincent Guo shares with us valuable insights into the development process, highlighting the innovative features and engineering challenges of this groundbreaking actuator:
“The primary goal of the actuator is precise and rapid movement to a calibrated position based on input signals,” says Eng. Guo. “While FAIST’s experience ensures reliability in pneumatic actuation, integrating the solenoid valve was the main challenge. FAIST’s design integrates the solenoid valve within the actuator housing, achieving a 40% reduction of space in comparison with the actual available products, while also enhancing durability. By aligning the solenoid’s axis with the pneumatic rod, the design reduces wear and improves balance under high-vibration conditions.”
Prototypes are currently in development and will be available by the first quarter of the current year, with design verification planned later in 2025. Serial production is targeted for 2026.
Material and design excellence
FAIST’s extensive experience with plastic materials in automotive applications played a critical role in this project. Key features include:
- Material selection - high-performance plastics were chosen based on load, environment, cost, and safety considerations.
- Temperature and pressure resistance - rigorous endurance and environmental tests ensure performance under extreme conditions.
- Deformation and wear prevention - simulations and ribbed designs minimize deformation, while early testing suggest no need for self-lubricating additives in the material. Avoiding additives not only lowers costs but also supports the design's robustness by eliminating potential chemical incompatibilities or aging effects that could compromise performance over time.
Comprehensive testing and validation
FAIST’s state-of-the-art Validation and Testing laboratory in Italy ensures comprehensive evaluation of the actuator’s performance. Testing includes:
- Environmental simulations, where thermal chambers and vibration tests replicate harsh conditions.
- Electrical and mechanical validations, with leakage tests, flow checks, and dielectric strength assessments part of the standard testing process.
- Durability tests, during which endurance testing under operational loads guarantees reliability.
The future of EGR applications
FAIST’s new actuator stands out in the market due to its unique integration of the solenoid valve into the pneumatic cover assembly, a design that is unmatched in compactness and efficiency. Plans for future enhancements include introducing PWM (Pulse Width Modulation) control for modulated operation, further expanding the actuator’s capabilities.
“Lightweight and compact designs like this are the future of EGR systems,” concludes Eng. Guo. With the use of advanced simulation tools like Catia and FEA, paired with the Company’s global leverage and collaborative approach, FAIST has once again demonstrated its commitment to innovation and excellence.
Stay tuned for more updates as FAIST Control Systems team continues to push the boundaries of engineering in the automotive sector.