Method and apparatus for assembling magnets utilizing Halbach array magnetic fields

Abstract

This invention provides a magnet assembly method and apparatus that utilizes a Halbach array magnetic field. [Solution] The method includes the steps of: assembling the alignment jig 110 around the axis of rotation (c) of the alignment jig 110 which forms a Halbach array in a cylindrical shape; connecting a pin structure 130 in which a plurality of guide pins 131 are arranged in an arrangement groove 121 between the alignment jig and the alignment jig; preferentially assembling a 3-piece magnet 21, excluding the circumferential magnet, in a first assembly space (P1) partitioned by the plurality of guide pins on the arrangement groove; assembling the circumferential magnet in a second assembly space (P2) secured by separating the guide pins of the pin structure; pressurizing the upper ends of all magnets assembled in the Halbach array to final align them to match the height of the rotor hub; and curing the bond applied between the final aligned Halbach array magnets all at once and separating them from the alignment jig.

Description

Technical Field

[0001] The present invention relates to a magnet assembly method and apparatus utilizing a Halbach array magnetic field, and more particularly, to a magnet assembly method and apparatus utilizing a Halbach array magnetic field applicable to the production of a rotor of an electric vehicle drive motor.

Background Art

[0002] Generally, a drive motor for an armature (EVx) includes a stator that receives electrical energy from a battery and generates a rotating magnetic field, and a rotor that rotates by the rotating magnetic field generated by the stator.

[0003] Among these, the rotor (Rotor) converts the rotating magnetic field generated by the stator by receiving power supply into drive energy, and for this purpose, has a structure in which a plurality of magnets (Magnetic substance) are arranged around a cylindrical rotating body (rotor hub). At this time, the plurality of magnets can be assembled in a circular Halbach array form in order to amplify the magnetic field in the direction where the stator is located.

[0004] Such a Halbach array method has the advantage of being able to strengthen the magnetic field of the magnet, but has the disadvantage that it is difficult to assemble when assembling the magnetized magnets on the rotating body due to the repulsive force that pushes each other out in terms of production.

[0005] For example, the prior art Halbach array methods include a magnetized permanent magnet assembly method and an unmagnetized permanent magnet assembly method.

[0006] The former magnetized permanent magnet assembly method (also referred to as the pre-magnetization method) is an assembly method in which magnetized permanent magnets, which are difficult to arrange due to the magnetized magnetic force and difficult to implement automation, are bonded manually one by one to the rotating body.

[0007] However, in the former case, since each magnetized permanent magnet is bonded individually, it takes a long time for the bond to harden, which has the disadvantage of reducing the productivity of rotor production. Another disadvantage is that the permanent magnets move freely due to repulsive forces until the bond hardens, making it difficult to optimize the magnetic direction. Furthermore, bonding between permanent magnets alone does not easily solve the problem of scattering during rotation, and separate covering (carbon fiber reinforced plastic, aramid fiber, metal sleeve, etc.) is required, which presents the problem of difficulty in automating the process.

[0008] The latter method for assembling unmagnetized permanent magnets (also called the post-magnetization method) involves first assembling the unmagnetized magnet material onto a rotating body, and then applying an external magnetic field to magnetize it.

[0009] However, in the latter case, after assembly, the magnetization level drops in areas where the position of the magnetic field and the magnet material do not coincide during magnetization (for example, in the tangential direction of the rotating body), resulting in a disadvantage that the magnetization rate of the permanent magnet is lower compared to the method of assembling the magnetized permanent magnet. In other words, a characteristic of the Halbach array is that there are magnets oriented tangentially to the rotation axis of the rotor, and since this direction is perpendicular to the direction in which the magnetic flux is applied through the external electromagnet (yoke), it has the problem that it cannot be 100% saturated.

[0010] Furthermore, in the latter case, unmagnetized magnetic materials cannot be distinguished through Gauss or Flux measurements. This leads to increased costs for the magnet supplier, such as having to apply epoxy coatings of different colors to distinguish them. Additionally, if the wrong color coating is applied upon delivery, it can lead to assembly errors, and if the problem is discovered after bonding following magnetization, it is irreversible, resulting in increased sunk costs.

[0011] The information contained in this background section is intended to enhance understanding of the background of the invention and may include information that is not prior art already known to a person with ordinary skill in the art to which this art belongs. [Overview of the project] [Problems that the invention aims to solve]

[0012] The object of the embodiments of the present invention is to provide a magnet assembly method and apparatus that utilizes a Halbach array magnetic field, which automates the assembly of magnets in a specific order in a stabilized state by utilizing the Halbach array magnetic field characteristics formed on a cylindrical alignment jig and the physical properties of the magnets. [Means for solving the problem]

[0013] According to one aspect of the present invention, a magnet assembly method utilizing a Halbach array magnetic field includes the steps of: assembling an array jig around the axis of rotation (c) of an alignment jig that forms a Halbach array magnetic field in a cylindrical shape; joining a pin structure in which a plurality of guide pins are arranged in an arrangement groove between the alignment jig and the array jig; preferentially assembling a three-piece magnet, excluding the circumferential magnet, in a first assembly space (P1) partitioned by the plurality of guide pins on the arrangement groove; assembling the circumferential magnet in a second assembly space (P2) secured by separating the guide pins of the pin structure; pressurizing the upper ends of all magnets assembled in the Halbach array to final align them to match the height of the rotor hub; and curing the bond applied between the final aligned Halbach array magnets all at once and separating them from the alignment jig.

[0014] Furthermore, the steps of joining the pin structure may include: aligning a magnet assembly unit for assembling three magnets on one side of the arrangement groove; and joining the pin structure so that the first assembly space (P1) is aligned to match the three magnet assembly positions of the magnet assembly unit.

[0015] Furthermore, the steps for preferentially assembling the three-piece magnets may include: pushing the three-piece magnets aligned in the magnet assembly unit through a pusher to slide and assemble them into the first assembly space (P1) of the arrangement groove; and, once the assembly of the three-piece magnets is complete, the pusher is moved backward and the pin structure rotates to align the next first assembly space (P1).

[0016] Furthermore, the pin structure is rotatably connected by a rotor-shaped alignment jig or arrangement jig, and is characterized by rotating with respect to the rotation axis (c) to the extent that it can align the next first assembly space (P1).

[0017] Furthermore, the process may include a step in which, after the step in which the three-piece magnet is preferentially assembled, adhesive is applied between the assembled three-piece magnet.

[0018] Furthermore, the steps for assembling the circumferential magnets include: a step of first assembling all the circumferential magnets that are magnetized on the outside according to a specific assembly order; and a step of post-assembling all the circumferential magnets that are magnetized on the inside once the first assembly is complete.

[0019] Furthermore, the final alignment step may include: assembling support blocks to the bottom of the magnets assembled in a Halbach array by the alignment jig; bonding and assembling rotor hubs inside the magnets assembled in a Halbach array; and pressurizing the upper ends of all the magnets through a pressurizing block.

[0020] Furthermore, the separation step may include the step of placing the magnets and rotor hubs, which have been assembled on the alignment jig and whose final alignment is complete, into an oven to cure them together; and the step of separating the Halbach array magnet assembly, which has been integrally manufactured by crossing the alignment jig, which has been cooled after curing, with the pressure block.

[0021] On the other hand, a magnet assembly device utilizing a Halbach array magnetic field according to one aspect of the present invention includes an alignment jig that forms a Halbach array magnetic field through a large number of permanent magnets fixedly arranged in a cylindrical shape; and an array jig coupled to the alignment jig around a rotation axis (c), which is capable of assembling a plurality of magnetized magnets to match the Halbach array using the properties of the Halbach array magnetic field.

[0022] Furthermore, the large number of permanent magnets arranged in the alignment jig form a Halbach array magnetic field using one of the 8-segment, 6-segment, or 4-segment construction methods, and the multiple magnets assembled in the alignment jig are assembled in a specified assembly order that takes into account the interaction between the magnets and the magnetic field characteristics using one of the 8-segment, 6-segment, or 4-segment construction methods.

[0023] Furthermore, the alignment jig may consist of an outer diameter (OD) alignment jig that forms a magnetic field concentrated inward by an inner rotor or an outer rotor, or an inner diameter (ID) alignment jig that forms a magnetic field concentrated outward.

[0024] Furthermore, the alignment jig is made of iron (Fe) material and is characterized by generating an attractive force that fixes the position of the magnets during assembly.

[0025] Furthermore, the magnet assembly apparatus utilizing the Halbach array magnetic field may further include: a pin structure coupled to the arrangement groove between the alignment jig and the array jig when assembling the magnets; a magnet assembly unit that presses and assembles three pieces of magnets, excluding the magnet oriented in the circumferential direction a, into the arrangement groove partitioned through the pin structure; a support block assembled at the bottom of the alignment jig and the array jig with all the magnets assembled in the arrangement groove after the pin structure has been separated; and a pressure block that pressurizes the upper ends of all the magnets with the support block assembled to perform final alignment to match the height of the rotor hub.

[0026] Further, the magnet assembly unit may include an assembly hole formed by coupling a lower block and an upper block; and a pusher that pushes the three-piece magnet assembled in the assembly hole and slides it into the placement groove for sliding assembly.

[0027] Further, the lower block forms a placement groove for assembling the three-piece magnet on its upper surface, the upper block forms a guide groove on the lower surface at a position corresponding to the placement groove, and the assembly hole may be formed through the combination of the placement groove and the guide groove.

[0028] Further, the assembly order of a specific three-piece magnet in the assembly hole is characterized in that the tangential magnet is preferentially assembled in the center, and after bonds are applied to both ends of the assembled tangential magnet, the diagonal magnets are assembled in order on the left and right sides of the tangential magnet.

[0029] Further, in the magnet assembly unit, the lower block is made of iron (Fe) for the assembly of the three-piece magnet in the assembly hole, and the upper block and the pusher may be made of aluminum.

[0030] Further, the pin structure may have a structure in which a plurality of guide pins are arranged in a circular shape with respect to the rotation axis (c).

[0031] Further, when the pin structure is coupled to the placement groove, it guides the insertion position of the three-piece magnet through a first assembly space (P1) secured between the plurality of guide pins, and when separated, it secures a second assembly space (P2) for the circumferential magnet assembled through the diameter size of the guide pins.

[0032] Further, the pin structure is rotatably coupled to the alignment jig around the rotation axis (c), and can rotate at a certain angle with the alignment jig to maintain a fixed insertion point of the three-piece magnet with respect to the magnet assembly unit.

Advantages of the Invention

[0033] According to embodiments of the present invention, by assembling magnets in a stabilized state using the Halbach array magnetic field characteristics formed on a cylindrical alignment jig and the physical properties of the magnets, it is possible to easily manufacture a Halbach array magnet assembly without interference between magnets.

[0034] Furthermore, automating the magnet assembly process using pin structures and magnet assembly units, as well as the final alignment and bond curing processes of the assembled magnets, has the effect of improving productivity by reducing manufacturing time.

[0035] Furthermore, by specifying an assembly sequence that takes into account the interaction between magnets and the characteristics of the magnetic field for each of the 8-part, 6-part, and 4-part Halbach array construction methods, it is possible to stably assemble the magnets without deformation of their shape. [Brief explanation of the drawing]

[0036] [Figure 1] This document shows a magnet assembly device utilizing a Halbach array magnetic field according to an embodiment of the present invention. [Figure 2] This shows an example of the configuration of a 3-piece magnet defined when applying an 8-part Halbach array according to an embodiment of the present invention. [Figure 3] This shows a magnet assembly unit for assembling a three-piece magnet according to an embodiment of the present invention. [Figure 4] This shows a pin structure that guides the assembly position of a three-piece magnet according to an embodiment of the present invention. [Figure 5] This is a cross-sectional view taken along line A-A' showing the final alignment state of magnets assembled in a magnet assembly device according to an embodiment of the present invention. [Figure 6] This flowchart schematically illustrates a magnet assembly method utilizing a Halbach array magnetic field according to an embodiment of the present invention. [Figure 7] This diagram illustrates the process of assembling a three-piece magnet using a pin structure and a magnet assembly unit according to an embodiment of the present invention. [Figure 8]This diagram shows the process in which the circumferential magnet is assembled after the three-piece magnet according to an embodiment of the present invention is preferentially assembled. [Figure 9] This shows the final alignment and curing process of magnets assembled in a Halbach array according to an embodiment of the present invention. [Figure 10] The Halbach array assembly sequence when divided into four parts according to the first additional embodiment of the present invention is shown. [Figure 11] The Halbach array assembly sequence when divided into 6 sections according to the second additional embodiment of the present invention is shown. [Modes for carrying out the invention]

[0037] Hereinafter, embodiments of the present invention will be described in detail with reference to the attached drawings, so that they can be easily implemented by a person with ordinary skill in the art to which the present invention belongs.

[0038] The terms used herein are for the purpose of describing specific embodiments and are not intended to limit the invention. As used herein, singular forms are intended to include plural forms unless otherwise clearly indicated in the context. The terms “including” and / or “containing” as used herein identify the presence of the mentioned features, integers, stages, operations, components and / or parts, but will not be understood to exclude the presence or addition of one or more other features, integers, stages, operations, components and / or groups thereof. As used herein, the terms “and / or” include any one or all combinations of the items enumerated in relation.

[0039] Throughout the specification, terms such as 1, 2, A, B, (a), (b), etc., may be used to describe various components, but such components should not be limited by such terms. Such terms are merely for distinguishing a component from other components, and do not limit the nature, order, or sequence of the component.

[0040] Throughout the specification, when a component is referred to as being “linked” or “connected” to another component, it should be understood that it may be directly linked or connected to the other component, but there may also be other components in between. Conversely, when a component is referred to as being “directly linked” or “directly connected” to another component, it should be understood that there are no other components in between.

[0041] Throughout this specification, the terminology used is solely for the purpose of describing specific embodiments and is not intended to limit the invention. Singular expressions include plural expressions unless otherwise clearly indicated in the context.

[0042] In addition, it is understood that one or more of the methods or aspects thereof described below may be performed by at least one controller. The term “controller” may refer to a hardware device including memory and a processor. The memory is configured to store program instructions, and the processor is specifically programmed to execute program instructions to perform one or more processes, which are described in more detail below. A controller can control the operation of a unit, module, component, device, or similar, as described herein. It is also understood that the methods described below may be performed by a device including a controller together with one or more other components, as will be recognized by those skilled in the art.

[0043] Next, a magnet assembly method and apparatus utilizing a Halbach array magnetic field according to an embodiment of the present invention will be described in detail with reference to the drawings.

[0044] Figure 1 shows a magnet assembly device utilizing a Halbach array magnetic field according to an embodiment of the present invention.

[0045] Referring to Figure 1, the magnet assembly device 100 utilizing a Halbach array magnetic field according to an embodiment of the present invention includes an alignment jig 110 that forms a Halbach array magnetic field through a large number of permanent magnets 10 fixedly arranged in a cylindrical shape, and an array jig 120 that is coupled to the alignment jig 110 around a rotation axis c and capable of assembling a plurality of assembly magnets (hereinafter referred to as "magnets" for convenience) 20, which are magnetized using the properties of the Halbach array magnetic field, to match the Halbach array.

[0046] The large number of permanent magnets 10 arranged in the alignment jig 110 form a Halbach array magnetic field using one of the 8-segment, 6-segment, or 4-segment construction methods. The multiple magnets 20 assembled in the alignment jig 120 are assembled in a specified assembly order that takes into account the interaction between the magnets and the magnetic field characteristics using one of the 8-segment, 6-segment, or 4-segment construction methods.

[0047] Here, the alignment jig 110 may consist of an outer diameter (OD) alignment jig or an inner diameter (ID) alignment jig that forms a magnetic field concentrated inward by an inner rotor or an outer rotor.

[0048] The OD alignment jig and the ID alignment jig are similar in that they have a similar structure in which a large number of permanent magnets 10 are arranged.

[0049] However, as shown in Figure 1, the OD alignment jig forms a Halbach array magnetic field that is concentrated (enhanced) in the inward / rotation axis c direction, and the alignment jig 120 is assembled on its inner diameter. Conversely, the ID alignment jig forms a Halbach array magnetic field that is concentrated in the outward direction, and the alignment jig 120 is assembled on its outer diameter.

[0050] The following description will focus on a magnet assembly method in which the alignment jig 110, according to an embodiment of the present invention, is applied using an inner rotor. However, as mentioned above, the embodiments of the present invention are not limited thereto, and an ID alignment jig can also be applied.

[0051] The magnets 20 assembled in the array jig 120 are pre-magnetized permanent magnets.

[0052] The alignment jig 110 is made of iron (Fe) material and generates an attractive force to fix the position of the magnets 20 during assembly.

[0053] The array jig 120 can be made from a non-magnetic metal such as iron (Fe) or aluminum (Al).

[0054] The Halbach array is a technique that maximizes the strength of magnetism in one direction and has the characteristic of concentrating the magnetic field in the outward (outer diameter) or inward (inner diameter) direction of the alignment jig 110, depending on the arrangement of the permanent magnets 10.

[0055] For example, in the case of an inner rotor, the magnetic strength must be maximized outward through the Halbach array. Therefore, in the case of the OD alignment jig 110 applied to this, the Halbach array magnetic field is concentrated in the inward (inner diameter) direction. Consequently, even if the alignment jig 120 is made of the same iron as the OD alignment jig 110, the assembled magnets 20 will have the characteristic of being more strongly attracted to the outer diameter (OD) side than to the inner diameter side.

[0056] In embodiments of the present invention, a magnet assembly method utilizing a Halbach array magnetic field is realized by taking advantage of the aforementioned characteristics, and this magnet assembly method is automated. For example, the magnet assembly apparatus 100 utilizing a Halbach array magnetic field can automate operations such as coupling, separation, assembly, and transport by utilizing an automated equipment 200 including a multi-joint robot, cylinders, and actuators.

[0057] Figure 2 shows an example of the configuration of a 3-piece magnet defined when applying an 8-part Halbach array according to an embodiment of the present invention.

[0058] JPEG2026084059000002.jpg24170

[0059] JPEG2026084059000003.jpg51170

[0060] At this time, the tangential magnet 20b, which is magnetized in the tangential direction b of the rotation axis c, is attracted to iron (Fe) and adheres tightly to the OD alignment jig 110. In addition, the diagonal magnets 20c, which are magnetized at a 45-degree angle on both sides of the tangential magnet 20b, create a stronger magnetic field and adhere even more tightly to the OD alignment jig 110. Here, the height H of the OD alignment jig 110 is formed to be longer than the length L of the magnet 10, in order for the magnets to generate an attractive force to iron (Fe).

[0061] When the three pieces of magnet 21 are joined, bond 40 is applied between the magnets, and after all three pieces of magnet 21 are assembled, the remaining circumferential magnets 20a (e.g., up and down) are assembled. The curing of the bond 40 is carried out all at once in the final aligned state after all the magnets 10 have been assembled.

[0062] Figure 3 shows a magnet assembly unit for assembling a three-piece magnet according to an embodiment of the present invention.

[0063] Figure 4 shows a pin structure that guides the assembly position of a three-piece magnet according to an embodiment of the present invention.

[0064] Figure 5 is a cross-sectional view taken along line A-A' showing the final alignment state of magnets assembled in a magnet assembly device according to an embodiment of the present invention.

[0065] Referring to Figures 3 to 5, the magnet assembly apparatus 100 utilizing a Halbach array magnetic field according to an embodiment of the present invention may further include: a pin structure 130 coupled to the arrangement groove 121 between the alignment jig 110 and the array jig 120 when assembling the magnets 20; a magnet assembly unit 140 that presses and assembles the three-piece magnets 21, excluding the magnet 20a oriented in the circumferential direction a, into the arrangement groove 121 partitioned through the pin structure 130; a support block 150 assembled at the bottom of the alignment jig 110 and the array jig 120 after the pin structure 130 has been separated and all the magnets 20 have been assembled in the arrangement groove 121; and a pressure block 160 that, with the support block 150 assembled, pressurizes the upper ends of all the magnets 20 to perform final alignment to match the height of the rotor hub 170.

[0066] The magnet assembly unit 140 is a jig structure for preferentially assembling a specific set of magnet assemblies (e.g., a 3-piece magnet) into the placement groove 121 according to the guide of the pin structure 130.

[0067] The magnet assembly unit 140 includes an assembly hole 144 formed by joining a lower block 141 and an upper block 142, and a pusher 143 that pushes the three-piece magnet 21 assembled in the assembly hole 144 into the arrangement groove 121 for sliding assembly.

[0068] The lower block 141 has a mounting groove 144a on its upper surface for assembling the three magnets 21.

[0069] The upper block 142 has a guide groove 144b formed on its lower surface at a position corresponding to the previously described groove 144a.

[0070] The assembly hole 144 is formed through the connection of the previously described mounting groove 144a and guide groove 144b.

[0071] JPEG2026084059000004.jpg34170

[0072] The magnet assembly unit 140 is constructed such that the lower block 141 is made of iron (Fe) for ease of assembly of the three magnets 21 in the assembly hole 144, and the upper block 142 and pusher 143 are made of aluminum.

[0073] The pusher 143 can push or reverse the three-piece magnet 21 through automated equipment 200 such as a cylinder / actuator, enabling its forward / reverse movement to be automated.

[0074] The pin structure 130 has a structure in which multiple guide pins 131 are arranged in a circle with respect to the rotation axis c.

[0075] When the pin structure 130 is connected to the placement groove 121, it guides the insertion position (point) of the three-piece magnet 21 through a first assembly space P1 secured between the multiple guide pins 131. When separated, it secures a second assembly space P2 for the circumferential magnet 20a (e.g., ↑↓) which is assembled through the diameter size (thickness) of the guide pins 131. The diameter size of the guide pins 131 is manufactured to match the width length of the circumferential magnet 20a (e.g., ↑↓) and a gap (g:gap) of 0.05 mm or less, so that the circumferential magnet 20a can be assembled smoothly.

[0076] The pin structure 130 is rotatably coupled to the alignment jig 110 around the rotation axis c. It then rotates at a constant angle relative to the alignment jig 110 via a servo motor (not shown), maintaining a constant insertion point for the three magnets 21 into the magnet assembly unit 140. This ensures uniform assembly quality.

[0077] On the other hand, based on the configuration of the magnet assembly device 100 utilizing the Halbach array magnetic field described above, a magnet assembly method utilizing the Halbach array magnetic field according to an embodiment of the present invention will be described.

[0078] Figure 6 is a flowchart illustrating a method for assembling magnets using a Halbach array magnetic field according to an embodiment of the present invention.

[0079] Referring to Figure 6, the magnet assembly method utilizing a Halbach array magnetic field according to an embodiment of the present invention is as follows: (S10) an array jig 120 is assembled around the rotation axis c of an OD alignment jig 110 that forms a Halbach array magnetic field through a large number of permanent magnets 10 fixedly arranged in a cylindrical shape; (S20) a pin structure 130 having a plurality of guide pins 131 arranged in an arrangement groove 121 between the OD alignment jig 110 and the array jig 120 is coupled; (S30) a three-piece magnet 21, excluding the circumferential magnet 20a, is preferentially assembled in a first assembly space P1 partitioned by the plurality of guide pins 131 on the arrangement groove 121; The process includes the steps of: assembling the circumferential magnets 20a in a second assembly space P2 secured by separating the guide pins 131 of the pin structure 130 (S40); pressurizing the upper ends of all the magnets 20 assembled in a Halbach arrangement to final align them to match the height of the rotor hub 170 (S50); and curing the bond 40 applied between the final aligned Halbach arrangement magnets all at once and separating them from the OD alignment jig 110 (S60).

[0080] After the bond 40 is applied between the assembled three-piece magnet 21, the circumferential magnet 20a is assembled.

[0081] Figure 7 shows the process of assembling a three-piece magnet using a pin structure and magnet assembly unit according to an embodiment of the present invention.

[0082] Referring to Figure 7, the flow leading to the aforementioned steps S20 and S30 is illustrated in diagrammatic form.

[0083] First, step S20 includes the step (S21) of aligning a magnet assembly unit 140 for assembling a three-piece magnet 21 on one side of the arrangement groove 121, and the step (S22) of coupling a pin structure 130 so that the first assembly space P1 is aligned to match the assembly positions of the three-piece magnet 21 of the magnet assembly unit 140. In other words, the pin structure 130 can be coupled such that a guide pin 131 is positioned in the second assembly space P2 where the circumferential magnet 20a is assembled with reference to the Halbach array magnetic field formed in the OD alignment jig 110.

[0084] Next, step S30 may include the step (S31) in which, once the pin structure 130 is coupled, the pusher 143 pushes the three-piece magnet 21 aligned in the magnet assembly unit 140 to slide and assemble into the first assembly space P1 of the arrangement groove 121, and the step (S32) in which, once the assembly of the three-piece magnet 21 is complete, the pusher 143 is reversed and the pin structure 130 rotates through the OD alignment jig 110 to align the next first assembly space P1.

[0085] At this time, the pin structure 130 is rotatably connected by a rotor-shaped OD alignment jig 110 or alignment jig 120, and rotates as far as possible to align the next first assembly space P1 with respect to the rotation axis c. For example, the rotation can be operated through automated equipment 200 such as a servo motor.

[0086] Furthermore, the magnet assembly unit 140 is used to assemble the three-piece magnet 21 for the next assembly. By repeating this three-piece magnet assembly process, all three-piece magnets 21 can be assembled in all of the first assembly spaces P1 partitioned through the pin structure 130.

[0087] On the other hand, Figure 8 shows the process in which the circumferential magnet is assembled after the three-piece magnet according to the embodiment of the present invention has been preferentially assembled.

[0088] JPEG2026084059000005.jpg23170

[0089] Therefore, step S40 of the present invention is characterized by including a step (S41) in which all of the circumferential magnets 20a that are magnetized on the outside (↑) according to a specific assembly order are pre-assembled, and a step (S42) in which all of the circumferential magnets 20a that are magnetized on the inside (↓) are post-assembled once the pre-assembly is complete.

[0090] According to the features of the present invention, in the case of a circumferential magnet 20a magnetized on the outside (↑: outside is the N pole), it can be positioned upright due to the magnetic field characteristics formed in the OD alignment jig 110, the physical characteristics corresponding to the inverted trapezoidal cross-sectional shape of the magnet 20, and the restraining force (magnetism) provided by the OD alignment jig 110 made of iron (Fe). In the case of a circumferential magnet 20a magnetized on the inside (↓: inside is the N pole), the force due to the magnetic field characteristics is canceled out by the pressing force, and it can be positioned upright due to the physical characteristics and the restraining force provided by the OD alignment jig 110 made of iron (Fe). Here, the physical characteristics refer to the characteristics of the hardware side of the magnet 20. That is, the cylindrically arranged magnets 20 have an inverted trapezoidal cross-sectional shape in which the lower end length is shorter than the upper end length that contacts the OD alignment jig 110. Due to this shape (structure), the circumferential magnet 20a can be inserted and coupled between the three-piece magnets 21 which are preferentially assembled on both sides, and its upper part can be physically fixed.

[0091] On the other hand, Figure 9 shows the final alignment and curing process of magnets assembled in a Halbach array according to an embodiment of the present invention.

[0092] Referring to Figure 9, the flow leading to the aforementioned steps S50 and S60 is illustrated in diagrammatic form.

[0093] First, step S50 includes the steps of assembling a support block 150 at the bottom of the magnets 20 assembled in a Halbach array using an OD alignment jig 110 (S51), bonding and assembling a rotor hub 170 inside the magnets 20 assembled in a Halbach array (S52), and applying pressure to the upper end of the magnets 20 assembled in a Halbach array through a pressure block 160 (S53). At this time, the pressure from the support block 150 assembled at the lower end of the assembled magnets 20 and the pressure block 160 assembled at the upper end causes all the magnets 20 to be finally aligned so that their heights match those of the rotor hub 170.

[0094] The rotor hub 170 can be assembled in its position after all the magnets 20 have been assembled by the OD alignment jig 110 and the array jig 120 has been separated. However, the embodiments of the present invention are not limited thereto, and the array jig 120 can be provided with the rotor hub 170 from the beginning. Therefore, the process of assembly after separation can be omitted.

[0095] The support block 150 and the pressure block 160 are removed after the final alignment is completed.

[0096] Next, step S60 includes the step of placing the magnets 20 and rotor hub 170, which have been assembled on the OD alignment jig 110 and have undergone the final alignment, into the oven 300 to cure them together (S61), and the step of separating the Halbach array magnet assembly 30, which has been manufactured integrally with the pressure block 160 by crossing the cooled OD alignment jig 110 after curing (S62).

[0097] The oven 30 cures the bond 40 bonded between the magnet 20 and the rotor hub 170, which are fixed by the magnetic field of the OD alignment jig 110. For example, the bond 40 is made of resin and can be cured by set resin curing conditions (e.g., UV conditions).

[0098] The Halbach array magnet assembly 30 is manufactured in a ring structure, similar to the rotor hub 170 attached to the inside, and can be used in the manufacture of drive motors for electric vehicles and various other motors.

[0099] Although embodiments of the present invention have been described above, the present invention is not limited to the embodiments described above, and a variety of other modifications are possible.

[0100] For example, the embodiments of the present invention described above were explained assuming an OD alignment jig 110 applied to an inner rotor. However, embodiments of the present invention are not limited thereto and can also be explained assuming an ID alignment jig 110 applied to an outer rotor.

[0101] In the case of an outer rotor, the magnetic strength must be maximized outward through the Halbach array. Therefore, in the ID alignment jig 110 applied to this, the Halbach array magnetic field is concentrated in the outward (outer diameter) direction. With the cylindrical alignment jig 120 coupled to the outside of the ID alignment jig 110, multiple magnets 20 can be assembled to match their orientation.

[0102] Furthermore, the embodiments of the present invention described above assumed an 8-part Halbach arrangement and, after preferentially assembling the 3-piece magnets, assembled the circumferential magnet 20a, specifying the order in which the magnets magnetized on the outside (↑) were assembled first, followed by the magnets magnetized on the inside (↓).

[0103] However, the embodiments of the present invention are not limited to the eight divisions, and the assembly can be performed by specifying an assembly sequence that takes into account the interaction between magnets and the characteristics of the magnetic field, which are applicable to the four-division and six-division Halbach array construction methods.

[0104] Since the additional embodiments of the present invention described below can be implemented based on the magnet assembly device 100 utilizing a Halbach array magnetic field, redundant explanations will be omitted, and the focus will be on the differences.

[0105] First, Figure 10 shows the Halbach array assembly sequence when divided into four parts according to the first additional embodiment of the present invention.

[0106] Referring to Figure 10, the four-part Halbach array according to the first additional embodiment of the present invention includes first to fourth polarity magnets 22a to 22d having different magnetization directions.

[0107] JPEG2026084059000006.jpg24170

[0108] Bond 40 is applied to the space between the first and second piece magnets 22-1 from which the guide pin 131 has been removed.

[0109] JPEG2026084059000007.jpg18170

[0110] Here, the guide pin 131 can be manufactured with an arrangement spacing and diameter size to secure assembly space for the 1_2 piece magnet 22-1 and the 2_2 piece magnet 22-2.

[0111] Next, Figure 11 shows the Halbach array assembly sequence when divided into 6 parts according to the second additional embodiment of the present invention.

[0112] Referring to Figure 11, the six-part Halbach array according to the second additional embodiment of the present invention includes first to sixth polarity magnets 23a to 23f having different magnetization directions.

[0113] JPEG2026084059000008.jpg24169

[0114] Bond 40 is applied to the space between the two magnets 23 from which the guide pin 131 has been removed.

[0115] Subsequently, two magnets 23e and 23f with different tangential directions can be assembled in the space between the two pieces of magnet 23.

[0116] Here, the guide pin 131 can be manufactured with an arrangement spacing and diameter size to secure assembly space for the two-piece magnet 23 and the tangential b magnets 23e and 23f.

[0117] Thus, according to the embodiments of the present invention, by assembling the magnets in a stabilized state due to the characteristics of the Halbach array magnetic field formed in the cylindrical alignment jig and the physical properties of the magnets, it is possible to easily manufacture a Halbach array magnet assembly without interference between the magnets.

[0118] Furthermore, automating the magnet assembly process using pin structures and magnet assembly units, as well as the final alignment of the assembled magnets and the bond curing process, has the effect of improving productivity by reducing manufacturing time.

[0119] Furthermore, by specifying an assembly sequence that takes into account the interaction between magnets and the characteristics of the magnetic field for each of the 8-part, 6-part, and 4-part Halbach array construction methods, it is possible to stably assemble the magnets without deformation of their shape.

[0120] Embodiments of the present invention are not limited to the apparatus and / or methods described above, but can also be realized through programs for realizing functions corresponding to the configuration of embodiments of the present invention, recording media on which such programs are recorded, and such realization can be easily achieved by experts in the art to which the present invention belongs based on the above description of embodiments.

[0121] Although embodiments of the present invention have been described in detail above, the scope of the present invention is not limited thereto. Various modifications and improvements by those skilled in the art, utilizing the basic concepts of the present invention as defined in the following claims, also fall within the scope of the present invention. [Explanation of Symbols]

[0122] 10: Permanent magnets 20: Magnets (for assembly) 20a: Circumferential magnet 20b:Tangential magnet 20c: Diagonal direction magnet 21:3 Piece Magnets 100: Magnet assembly device 110: Alignment Jig 120: Array Jig 121: Placement groove 130: Pin structure 131: Guide pin 140: Magnet Assembly Unit 141: Lower block 142: Upper block 143: Pusher 144: Assembly Hall 144a: Mounting groove 144b: Guide groove 150: Support Block 160: Pressurized block 170: Rotor Hub 200: Automation equipment 300: Oven

Claims

1. The stage in which the alignment jig is assembled around the axis of rotation (c) of the alignment jig that forms a cylindrical Halbach array magnetic field; A pin structure having multiple guide pins arranged in the arrangement groove between the alignment jig and the array jig is connected; In the first assembly space (P1) partitioned by the plurality of guide pins on the arrangement groove, the three-piece magnets, excluding the circumferential magnet, are preferentially assembled; The circumferential magnet is assembled in a second assembly space (P2) that is secured by separating the guide pins of the aforementioned pin structure; The stage of pressurizing the upper ends of all magnets assembled in a Halbach array to final align them to the height of the rotor hub; and The step of curing the bond applied between the final aligned Halbach array magnets in one piece and separating them from the alignment jig; A magnet assembly method that utilizes a Halbach array magnetic field, including the Halbach array.

2. The step in which the aforementioned pin structure is joined is: The step in which a magnet assembly unit for assembling three-piece magnets is aligned on one side of the aforementioned arrangement groove; and The pin structure is joined such that the first assembly space (P1) is aligned to match the three-piece magnet assembly position of the magnet assembly unit; A method for assembling magnets utilizing the Halbach array magnetic field described in claim 1, including the method described in claim 1.

3. The stage in which the three magnet pieces are preferentially assembled is: The steps of pushing the three magnets aligned in the magnet assembly unit through a pusher to slide them into the first assembly space (P1) of the arrangement groove; and Once the assembly of the three-piece magnet is complete, the pusher is moved backward, and the pin structure rotates to align the next first assembly space (P1); A magnet assembly method utilizing the Halbach array magnetic field described in claim 2, including the method described in claim 2.

4. The aforementioned pin structure is rotatably connected by a rotor-shaped alignment jig or array jig. A magnet assembly method utilizing a Halbach array magnetic field according to claim 3, characterized in that the next first assembly space (P1) is rotated as far as possible with respect to the rotation axis (c).

5. After the stage in which the three magnet pieces are preferentially assembled, A magnet assembly method utilizing a Halbach array magnetic field according to claim 1, further comprising the step of applying a bond between the three assembled magnet pieces.

6. The step in which the aforementioned circumferential magnet is assembled is: The step of pre-assembling all the circumferential magnets that are magnetized on the outside according to a specific assembly order; and Once the aforementioned pre-assembly is complete, the next step is to reassemble all the circumferentially magnetized parts on the inside; A magnet assembly method utilizing a Halbach array magnetic field as described in claim 1, characterized by including the following:

7. The aforementioned final alignment step is, The step of assembling a support block at the bottom of the magnets assembled in a Halbach array using the aforementioned alignment jig; The step of bonding and assembling the rotor hub inside the magnets assembled in the Halbach array; and A step of applying pressure to the upper ends of all the magnets through the pressure block; A method for assembling magnets utilizing the Halbach array magnetic field described in claim 1, including the method described in claim 1.

8. The aforementioned separation step is, The step of placing the magnets and rotor hubs, which have been assembled in the alignment jig and whose final alignment is complete, into an oven to cure them together; and The step of separating the Halbach array magnet assembly, which is manufactured integrally with the pressure block, by crossing the alignment jig, which has been cooled after curing; A method for assembling magnets utilizing the Halbach array magnetic field described in claim 1, including the method described in claim 1.

9. Alignment jig that forms a Halbach array magnetic field through a large number of permanent magnets fixedly arranged in a cylindrical shape; and An alignment jig that is coupled to the alignment jig around a rotation axis (c) and capable of assembling multiple magnets, which have been magnetized using the properties of the Halbach array magnetic field, to match the Halbach array; A magnet assembly device that utilizes a Halbach array magnetic field, including the Halbach array magnetic field.

10. The large number of permanent magnets arranged in the alignment jig form a Halbach array magnetic field using one of the following methods: 8-segment, 6-segment, or 4-segment construction. The magnet assembly device utilizing a Halbach array magnetic field according to claim 9, characterized in that the plurality of magnets assembled in the array jig are assembled in a specified assembly order that takes into account the interaction between the magnets and the magnetic field characteristics using one of the eight-part, six-part, and four-part construction methods.

11. The aforementioned alignment jig is, A magnet assembly device utilizing a Halbach array magnetic field as described in claim 9, comprising an outer diameter (OD) alignment jig that forms an inwardly concentrated magnetic field by an inner rotor or an outer rotor, or an inner diameter (ID) alignment jig that forms an outwardly concentrated magnetic field.

12. The aforementioned alignment jig is, A magnet assembly device utilizing a Halbach array magnetic field, as described in claim 9, characterized in that it is made of iron (Fe) material and generates an attractive force to fix the position of the magnets during assembly.

13. A pin structure that, when the magnet is assembled, is coupled to the alignment groove between the alignment jig and the arrangement jig; A magnet assembly unit assembled by pressing three magnets, excluding the magnet oriented in the circumferential direction a, into an arrangement groove partitioned through the aforementioned pin structure; After separating the pin structure, with all the magnets assembled in the arrangement groove, a support block is assembled at the bottom of the alignment jig and the arrangement jig, A pressure block that, with the support block assembled, pressurizes the upper ends of all the magnets to finalize them so that they match the height of the rotor hub; A magnet assembly device utilizing a Halbach array magnetic field, further comprising the Halbach array magnetic field according to claim 9.

14. The aforementioned magnet assembly unit is Assembly holes formed by joining the lower block and the upper block; and A pusher that pushes the three-piece magnet assembled in the assembly hole and slides it into the arrangement groove; A magnet assembly device utilizing a Halbach array magnetic field as described in claim 13, including the above.

15. The lower block has a mounting groove formed on its upper surface for assembling the three magnets. The upper block has a guide groove formed on its lower surface at a position corresponding to the previously described groove. The assembly hole is formed through the connection of the aforementioned mounting groove and guide groove, wherein the magnet assembly device utilizing the Halbach array magnetic field is as described in claim 14.

16. The assembly order of the three specific magnets in the aforementioned assembly hole is: A magnet assembly device utilizing a Halbach array magnetic field according to claim 14, characterized in that a tangential magnet is preferentially assembled in the center, and after adhesive is applied to both ends of the assembled tangential magnet, diagonal magnets are assembled in the order of left and right of the tangential magnet.

17. The aforementioned magnet assembly unit is A magnet assembly device utilizing a Halbach array magnetic field according to claim 14, wherein the lower block is made of iron (Fe) for the purpose of assembling the three-piece magnets within the assembly hole, and the upper block and pusher are made of aluminum.

18. The aforementioned pin structure is A magnet assembly device utilizing a Halbach array magnetic field according to claim 13, having a structure in which a plurality of guide pins are arranged in a circular pattern with respect to the rotation axis (c).

19. The aforementioned pin structure is A magnet assembly device utilizing a Halbach array magnetic field according to claim 18, characterized in that when coupled to the arrangement groove, the insertion position of the three-piece magnet is guided through a first assembly space (P1) secured between a plurality of guide pins, and when separated, a second assembly space (P2) for the circumferential magnet assembled through the diameter size of the guide pins is secured.

20. The aforementioned pin structure is A magnet assembly device utilizing a Halbach array magnetic field according to claim 13, wherein the device is rotatably coupled to the alignment jig about the rotation axis (c), and rotates at a constant angle with the alignment jig to maintain a constant insertion point for the three-piece magnets into the magnet assembly unit.

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