Halbach array assembly method and apparatus utilizing permanent magnet jig device

Abstract

This invention provides a Halbach array assembly method and jig utilizing a permanent magnet jig device that can ensure quality balance. [Solution] The Halbach array assembly method includes the steps of: inserting a magnet array jig 130 between an ID alignment jig 120 paired with an OD alignment jig 110, which has multiple permanent magnets 10 arranged in a cylindrical shape and forms a magnetic field in the radial direction a and the tangential direction b; assembling multiple assembly magnets 20 in accordance with their orientation into an array groove formed along the outer surface of the magnet array jig; separating the magnet array jig from the OD alignment jig and the ID alignment jig once all of the assembly magnets have been assembled into the array groove; and performing a bonding operation to fix the multiple assembly magnets arranged in the array groove to produce an integrated ring-shaped Halbach array permanent magnet.

Description

Technical Field

[0001] The disclosed content relates to a Halbach array assembly method and apparatus using a permanent magnet jig device, and more particularly, to a Halbach array assembly method and apparatus using a permanent magnet jig device applied 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] The rotor receives power supply, converts the rotating magnetic field generated by the stator into driving energy, and thus has a structure in which a plurality of magnets (magnetic substances) 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 to amplify the magnetic field in a certain direction of the stator.

[0004] Such a Halbach array method has the advantage of strengthening the magnetic field of the magnet, but in terms of manufacturing, there is a disadvantage that it is difficult to assemble due to the back force that mutually extrudes when assembling the magnetized magnet onto the rotating body.

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

[0006] The method of assembling magnetized permanent magnets of electrons is an assembly method in which magnetized permanent magnets that are difficult to arrange due to the magnetized magnetic force and difficult to automate are bonded to the rotating body one by one by hand.

[0007] However, the former method involves bonding each magnetized permanent magnet individually, which has the disadvantage of requiring a long time for the bond to harden, thus reducing the productivity of rotor manufacturing. Another disadvantage is that the permanent magnets move due to back forces before 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, so a separate covering (such as carbon fiber reinforced plastic, aramid fiber, or metal sleeve) is required, which is another disadvantage.

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

[0009] However, the latter method has the disadvantage that, after assembly, the magnetization decreases in areas where the magnetic field and the position of the magnet material do not coincide (for example, in the tangential direction of the rotating body), resulting in a lower permanent magnetization rate compared to the method of assembling the magnetized permanent magnets. Furthermore, in the latter method, it is impossible to distinguish unmagnetized magnet material through Gauss or flux measurements. This leads to increased costs, such as the magnet supplier having to apply epoxy coatings of different colors to distinguish them. Moreover, if the wrong color is applied at the time of delivery, it can lead to incorrect assembly, and once bonding has occurred after magnetization, it is too late to correct the problem, resulting in increased sunk costs.

[0010] The information described in the background art is provided to facilitate understanding of the background of the present invention and may include information that is not prior art and is already known to those with ordinary skill in the art to which this art belongs. [Overview of the project]

[0011] One embodiment provides a Halbach array assembly method and jig utilizing a permanent magnet jig device that uses a cylindrical, two-tiered permanent magnet assembly jig to assemble a large number of assembly magnets in the magnet arrangement jig according to their orientation, and then proceed with bonding work in the assembled state, thereby dramatically shortening the manufacturing time for motor rotors and ensuring quality balance by eliminating the problem of incorrect assembly.

[0012] In one aspect, a Halbach array assembly method utilizing a permanent magnet jig device includes the steps of: inserting a magnet array jig between an ID alignment jig and an OD alignment jig, which are paired with an OD alignment jig and which have multiple permanent magnets arranged in a cylindrical shape and form magnetic fields in the radial direction a and tangential direction b; assembling multiple assembly magnets in alignment grooves formed along the outer circumferential surface of the magnet array jig according to their orientation; separating the magnet array jig from the OD alignment jig and the ID alignment jig once all of the multiple assembly magnets have been assembled in the alignment grooves; and performing a bonding operation to fix the multiple assembly magnets arranged in the alignment grooves to produce an integrated ring-shaped Halbach array permanent magnet.

[0013] Furthermore, the step of assembling the assembly magnets according to their orientation is characterized in that it can be performed using either magnetized assembly magnets or unmagnetized assembly magnets.

[0014] Furthermore, the step of assembling the assembly magnets according to their orientation may include a step of detecting a magnet that fails to align with the magnetic field direction and orientation during assembly, and thus fails to be positioned correctly.

[0015] Furthermore, the step of detecting the magnet that failed to be positioned correctly may include the step of positioning the assembly magnet on a reference magnet provided for distinguishing polarity and proceeding with error proofing to confirm the magnetized direction or orientation.

[0016] Furthermore, the step in which the assembly magnets are assembled according to their orientation is characterized by being assembled using one of three arrangement methods: eight divisions, six divisions, or four divisions, depending on their polarity.

[0017] Furthermore, the step of assembling the assembly magnets according to their orientation is characterized in that the assembly magnets are sequentially assembled according to priority groups formed on the magnet arrangement jig, which take into account the direction of the magnetic field.

[0018] Furthermore, the step of assembling the assembly magnets according to their orientation may include: a step of preferentially assembling a plurality of assembly magnets having the same first polarity with respect to the magnetic field in the radial direction a in the magnet arrangement jig; a step of assembling a plurality of assembly magnets having a second polarity opposite to the first polarity with respect to the magnetic field in the radial direction a; a step of assembling a plurality of assembly magnets having a magnetic field in the tangential direction b; and a step of assembling a plurality of assembly magnets that are not oriented in the radial direction a or the tangential direction b.

[0019] Furthermore, the step of assembling the plurality of assembly magnets may include a step in which the assembly magnets having the same polarity are assembled first, followed by the assembly of the assembly magnets having the opposite polarity.

[0020] Furthermore, the step of assembling multiple assembly magnets that are not oriented in the radial direction a and the tangential direction b is characterized in that assembly magnets having diagonal polarity formed by adjacent magnetic fields in the radial direction a and the tangential direction b are assembled.

[0021] Furthermore, the bonding operation is characterized by including the steps of: injecting resin onto the assembly magnets arranged in the arrangement groove using a dispenser; attaching an upper cover to the magnet arrangement jig after the resin injection is complete, placing it in a vacuum chamber, and carrying out a degassing operation under constant pressure conditions; and placing the magnet arrangement jig after the degassing operation is complete in an oven and curing it according to set resin curing conditions (e.g., UV conditions).

[0022] On the other hand, a permanent magnet jig apparatus for assembling a Halbach array, relating to one aspect, includes an outside diameter (OD) alignment jig in which a plurality of permanent magnets are arranged cylindrically to form magnetic fields in the radial direction a and the tangential direction b; an inside diameter (ID) alignment jig paired with the OD alignment jig in which a plurality of permanent magnets are arranged cylindrically; and a magnet alignment jig inserted cylindrically between the OD alignment jig and the ID alignment jig, which generates a ring-shaped Halbach array permanent magnet through a bonding operation in which a plurality of assembly magnets are assembled in orientation in an alignment groove formed on the outer surface with respect to a rotation axis c.

[0023] Furthermore, the OD alignment jig is characterized by making it possible to check whether there is any incorrect assembly where the orientation does not match the magnetic field direction when assembling multiple assembly magnets in the magnet arrangement jig, and fixing the assembly magnets in a fixed position.

[0024] Furthermore, the ID alignment jig is characterized by forming a magnetic field in the same direction as the OD alignment jig, assisting in the alignment of the assembly magnets assembled in the magnet arrangement jig into their fixed positions, and increasing the fixing force.

[0025] Furthermore, the assembly magnets are characterized in that they are assembled using magnetized or unmagnetized magnets, with one of three arrangement methods (8 divisions, 6 divisions, or 4 divisions) depending on the polarity.

[0026] Furthermore, it further includes a base that forms an insertion groove for inserting the magnet array jig on the upper surface, and the OD alignment jig and the ID alignment jig have a structure provided side by side on the upper surface of the base with reference to the rotation axis c.

[0027] Also, the magnet array jig can include an upper cover that fixes a plurality of assembly magnets assembled in the array groove during the bonding operation.

[0028] Also, the upper cover is located above the assembly magnet assembled in the array groove, and can form a flow space portion so as to fill the empty space during the bonding operation and allow the remaining resin to overflow.

[0029] Also, the flow space portion is manufactured in a tapered shape and has a structure that assists upward separation even if there is resin that has overflowed after curing in an oven.

[0030] Also, the magnet array jig can include a support block that is located at the lower end of the assembly magnet assembled in the array groove and forms a flow channel for the resin injected during the bonding operation.

[0031] According to one embodiment, by utilizing a two-stage permanent magnet jig device provided on the outer diameter (OD) and inner diameter (ID) sides of the magnet array jig, it is possible to assemble in accordance with the orientation direction without distinction between magnetized magnets and unmagnetized magnets. By performing bonding using the state assembled in the magnet array jig as it is, there is an effect that it is possible to manufacture a Halbach array permanent magnet with an integrated ring structure having shortened assembly time and uniform quality.

[0032] Also, when assembling the assembly magnet in the magnet array jig, by checking the magnetic direction or orientation using a reference magnet by an error-proof method and fundamentally eliminating incorrect assembly problems, the uniformity of product quality can be ensured.

[0033] Furthermore, by strengthening the bonding force and reducing the problem of magnets scattering during assembly, it is possible to reduce costs and processes by eliminating the need for separate sleeves (coverings).

[0034] Furthermore, by using modularized Halbach array permanent magnets in an integrated ring structure, it will be possible to easily assemble rotors for electric vehicle motors around the rotation axis c during manufacturing, which is expected to improve product yield and productivity. [Brief explanation of the drawing]

[0035] [Figure 1] This is a perspective view showing the configuration of a permanent magnet jig device according to one embodiment. [Figure 2] This is a plan view showing the configuration of a permanent magnet jig device according to one embodiment. [Figure 3] Figure 2 shows a magnified view of section "A". [Figure 4] A cross-sectional view of a permanent magnet jig device according to one embodiment is shown. [Figure 5] This shows the arrangement space realized according to the permanent magnet shape used in one embodiment. [Figure 6] This flowchart schematically illustrates a Halbach array assembly method utilizing a permanent magnet jig device according to one embodiment. [Figure 7] This shows the process by which multiple assembly magnets according to one embodiment are assembled in accordance with their orientation. [Figure 8] This is a diagram illustrating the concept of error proofing according to one embodiment. [Figure 9] This is a cross-sectional view showing the flow of the bonding process for a permanent magnet according to one embodiment. [Figure 10] This shows a structure in which the upper cover is attached to the magnet arrangement jig during bonding work according to one embodiment. [Figure 11] The following shows an example of the arrangement of the outer / inner diameter permanent magnets in a permanent magnet jig device according to another embodiment. [Modes for carrying out the invention]

[0036] Hereinafter, an embodiment will be described in detail with reference to the attached drawings, so that it can be easily implemented by a person with ordinary skill in the art to which the present invention pertains.

[0037] The terms used herein are for the purpose of describing specific embodiments and are not intended to limit the invention. As used herein, the singular form is intended to also include the plural form unless otherwise clearly indicated in the context. The terms “including,” and / or “including,” as used herein, identify the presence of the mentioned features, integers, steps, actions, components, and / or parts, but will not be understood to exclude the presence or addition of one or more other features, integers, steps, actions, components, and / or groups thereof. As used herein, the terms “and / or” include any one or all of the related items listed.

[0038] Throughout the specification, terms such as 1, 2, A, B, (a), (b), etc., may be used to describe various components, but the components should not be limited by these terms. These terms are used to distinguish a component from other components, and they do not limit the nature, order, or sequence of the component.

[0039] Throughout this specification, when a component is referred to as being "linked" or "connected" to another component, it should be understood that the other component may be directly linked or connected, or there may be other components in between. On the other hand, 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.

[0040] Throughout this specification, terms used are for the purpose of describing specific embodiments and are not intended to limit the invention. Singular expressions include plural expressions unless otherwise clearly defined in the context.

[0041] Next, a Halbach array assembly method and jig utilizing a permanent magnet jig device according to one embodiment will be described in detail with reference to the drawings.

[0042] Figure 1 is a perspective view showing the configuration of a permanent magnet jig device according to one embodiment. Figure 2 is a plan view showing the configuration of a permanent magnet jig device according to one embodiment, and Figure 3 is an enlarged view of portion "A" in Figure 2. Finally, Figure 4 shows a cross-sectional view of a permanent magnet jig device according to one embodiment.

[0043] Referring to Figures 1 to 4, the permanent magnet jig device 100 according to one embodiment includes an outside diameter (OD) alignment jig 110 in which a plurality of permanent magnets 10 are arranged in a cylindrical shape to form a magnetic field in the radial direction a and the tangential direction b; an inside diameter (ID) alignment jig 120 in which a plurality of permanent magnets 10 are arranged in a cylindrical shape in a pair with the OD alignment jig 110; and a magnet alignment jig 130 which is inserted cylindrically between the OD alignment jig 110 and the ID alignment jig 120, and in which a plurality of assembly magnets 20 are assembled in accordance with the orientation of a Halbach arrangement in an arrangement groove 131 formed on the outer circumferential surface with respect to a rotation axis (or central axis) c, and a ring-shaped Halbach arrangement permanent magnet 20 is generated by bonding work.

[0044] The permanent magnet jig device 100 of the present invention has the characteristic that the OD alignment jig and ID alignment jig 110 and 120 are configured on the outer diameter (OD) and inner diameter (ID) sides of the magnet arrangement jig 130, respectively. Therefore, it may be named a "two-stage (or double) structured permanent magnet jig device". In other words, the present invention makes it possible to manufacture a Halbach array permanent magnet 20 by utilizing the two-stage structured permanent magnet jig device 100 to assemble and bond multiple assembly magnets 20 in accordance with the orientation of a Halbach array.

[0045] The OD alignment jig 110 plays a role in confirming whether there are any incorrectly assembled assembly magnets 20 where the orientation of the assembly magnets does not match the direction of the magnetic field when assembling multiple assembly magnets 20 on the magnet arrangement jig 130, and in positioning (or fixing) the assembly magnets 20 in their designated (or reference) positions.

[0046] The ID alignment jig 120 forms a magnetic field in the same direction (a and b directions) as the OD alignment jig 110, aligning the assembly magnets 20 assembled in the magnet arrangement jig 130 to their designated positions (or reference positions), and plays a role in working in cooperation with the OD alignment jig to increase the fixing force of the assembly magnets 20.

[0047] The OD alignment jig 110 and the ID alignment jig 120 are mounted side by side on the upper surface of the base 140 with respect to the rotation axis c.

[0048] The base 140 has an insertion groove 142 formed on its upper surface 141 for inserting the magnet arrangement jig 130.

[0049] Referring to Figure 3, an 8-part arrangement state is shown in the Halbach arrangement method according to one embodiment.

[0050] The permanent magnets 10 arranged inside the OD alignment jig 110 and the ID alignment jig 120 respectively include a first magnet 10a that forms a magnetic field in the radial direction a and a second magnet 10b that forms a magnetic field in the tangential direction b.

[0051] In terms of placement space, the second magnet 10b is formed to be smaller than the first magnet 10a.

[0052] The assembly magnets 20 can be magnetized or unmagnetized.

[0053] The assembly magnets 20 are assembled sequentially using the OD alignment jig 110 and the ID alignment jig 120, according to priority groups that take into account the magnetic field direction formed on the magnet arrangement jig 130 (see Figure 7).

[0054] The first magnet 10a is arranged in pairs at opposing (corresponding) positions on the OD alignment jig 110 and the ID alignment jig 120, and is arranged in a symmetrical structure such that the polarities N and S of the outer diameter (OD) and inner diameter (ID) are opposite. Therefore, the outer diameter (OD) and inner diameter (ID) are paired, and a magnetic field in the radial direction a can be effectively formed.

[0055] Similarly, the second magnet 10b is positioned in pairs at opposing (corresponding) positions on the OD alignment jig 110 and the ID alignment jig 120, effectively forming a magnetic field in the tangential direction b. Although the second magnet 10b has spatial constraints and its magnetic field is smaller compared to the radial direction a, it is sufficient to hold the assembly magnet 20, which is oriented and / or magnetized in the tangential direction b, in place and prevent incorrect assembly.

[0056] Furthermore, the first magnet 10a and the second magnet 10b may form a pair with the magnetization positions of each assembly magnet 20 as a single unit, and adjacent magnets 10a, 10b, 10a, ... on both sides may be arranged with a spacing g of the aforementioned single unit (i.e., one assembly magnet).

[0057] Such OD alignment jigs 110 and ID alignment jigs 120 include placement structures 111, 121 for arranging the permanent magnets 10, and fixing parts 112, 122 for preventing the arranged permanent magnets 10 from coming loose.

[0058] In this case, the arrangement structures 111 and 121 may be implemented as structures that can use at least one of the cylindrical magnets 10-1 and the rectangular bar magnets 10-2, depending on the shape of the permanent magnet 10.

[0059] For example, Figure 5 shows the arrangement space realized according to the permanent magnet shape used in one embodiment.

[0060] Referring to Figure 5(A), the first arrangement structures 111a and 121a corresponding to the cylindrical magnet 10-1 and the cross-sectional views of their first fixing parts 112a and 122a are shown.

[0061] The first arrangement structures 111a and 121a form a multilayer structure partitioned to arrange multiple cylindrical magnets 10-1 vertically. While such cylindrical magnets 10-1 have the advantage of being less expensive than rectangular bar magnets 10-2, they cannot be completely attached to each other by magnetic force.

[0062] Referring to Figure 5(B), the second arrangement structures 111b and 121b corresponding to the rectangular bar magnet 10-2, and the cross-sectional views of their second fixing parts 112b and 122b are shown.

[0063] The second arrangement structures 111b and 121b for fixing the rectangular bar magnets 10-2 have a space capable of receiving one rectangular bar magnet 10-2 vertically. Such rectangular bar magnets 10-2 can accommodate more magnetic material in the same volume. Therefore, they can be used or modified to enhance the magnetic force.

[0064] With the magnet alignment jig 130 inserted between the OD alignment jig 110 and the ID alignment jig 120, the assembly magnets 20 are assembled to match the orientation of the magnetic field formed in the alignment groove 131.

[0065] The magnet arrangement jig 130 includes an upper cover 132 that secures the assembly magnets 20 assembled in the arrangement groove 131. The upper cover 132 is attached to the top of the magnet arrangement jig 130 and can secure the assembly magnets 20 assembled in the arrangement groove 131 so that they do not come loose or move.

[0066] In the above description, the permanent magnet jig device 100 can automate the assembly process using automation equipment 400, which includes process-specific articulated robots and actuator devices. For example, the magnet array jig 130 may be inserted, separated, and transported via the automation equipment 400, and the assembly magnets 20, gripped by the robot / actuator's gripper, may be transported to the array groove 131 for assembly.

[0067] On the other hand, based on the configuration of the permanent magnet jig device 100 described above, a permanent magnet Halbach array assembly method according to one embodiment will be explained.

[0068] Figure 6 is a flowchart illustrating a Halbach array assembly method utilizing a permanent magnet jig according to one embodiment.

[0069] Referring to Figure 6, the Halbach array assembly method utilizing a permanent magnet jig device according to one embodiment includes the following steps.

[0070] A magnet alignment jig 130 is inserted by an automated device 400 between an OD alignment jig 110, which has multiple permanent magnets 10 arranged in a cylindrical shape and forms magnetic fields in the radial direction a and the tangential direction b, and an ID alignment jig 120 which is paired with the OD alignment jig 110 (S10).

[0071] Multiple assembly magnets 20 are assembled in the arrangement grooves 131 formed on the outer surface of the magnet arrangement jig 130 by the automated equipment 4000 in accordance with the orientation of the Halbach arrangement (S20).

[0072] Once all of the assembly magnets 20 are assembled in the arrangement groove 131, the magnet arrangement jig 130 is separated from the OD alignment jig 110 and the ID alignment jig 120 by the automated equipment 400 (S30).

[0073] The automated equipment 400 performs a bonding operation to fix the multiple assembly magnets 20 arranged in the arrangement groove 131, thereby producing an integrated ring-shaped Halbach array permanent magnet 20 (S40).

[0074] This Halbach array assembly method, utilizing such a permanent magnet jig device 100, dramatically reduces manufacturing time by assembling the assembly magnets 20 in the magnet array jig 130 according to a set orientation, and then bonding (and / or potting) the assembly magnets 20 assembled according to the set orientation using the magnet array jig 130. Furthermore, by fundamentally eliminating problems caused by incorrect assembly during the process of assembling the assembly magnets 20 in the magnet array jig 130, uniformity of product quality can be ensured. In addition, by strengthening the bonding force and reducing the problem of the assembly magnets 20 scattering, costs and the number of processes can be reduced by eliminating the need for separate sleeves (coverings).

[0075] Figure 7 shows the process by which multiple assembly magnets according to one embodiment are assembled in accordance with the orientation of the Halbach array.

[0076] Referring to Figure 7, the assembly magnets 20 are assembled sequentially according to a priority order that takes into account the polarity of the permanent magnets 10 placed in the OD alignment jig 110 and the ID alignment jig 120, and the direction of the magnetic field formed in the magnet arrangement jig 130. At this time, the assembly magnets 20 are assumed to be magnetized magnets.

[0077] First, multiple assembly magnets 20 having the same first polarity (↑) are preferentially assembled in the magnet arrangement jig 130 by the automated equipment 400, based on the magnetic field in the radial direction a (S21).

[0078] Next, a plurality of assembly magnets 20 having a second polarity (↓) opposite to the first polarity (↑) with respect to the magnetic field in the radial direction a are assembled in the magnet arrangement jig 130 by the automated equipment 400 (S22).

[0079] Next, a plurality of assembly magnets 20 having a magnetic field (→←) in the tangential direction b are assembled in the magnet arrangement jig 130 by the automated equipment 400 (S23). At this time, as in S21 to S22, the assembly magnets 20 having polarity in the same direction in the tangential direction b (for example, to the left or counterclockwise) may be assembled first, and then the assembly magnets 20 having polarity in the opposite direction in the tangential direction b (for example, to the right or clockwise) may be assembled.

[0080] In the assembly process of such assembly magnets 20, if an assembly magnet 20 is assembled that does not align with the direction of the external magnetic field, the assembly magnet 20 will not be able to be properly positioned (in other words, the assembly magnet 20 will not be able to be positioned at the reference position according to the Halbach array). Therefore, when the assembly magnets 20 are assembled according to the orientation of the Halbach array, an assembly magnet 20 that fails to be positioned at the correct position due to a mismatch between the magnetic field direction of the permanent magnet and the orientation of the assembly magnet can be detected, thereby preventing incorrect assembly of the assembly magnets 20. Furthermore, if the assembly magnets 20 are unmagnetized magnets, there is no need to consider the orientation of the Halbach array, and it is possible to prevent incorrect assembly of the assembly magnets 20.

[0081] JPEG2026084073000002.jpg41163

[0082] At this time, in the case of the assembly magnet 20 having diagonal polarity in step S24, error proofing proceeds to prevent incorrect assembly.

[0083] Figure 8 is a diagram illustrating the concept of error proof according to one embodiment.

[0084] Referring to Figure 8(A), error proofing is a method of confirming the magnetization direction or orientation by positioning the assembly magnet 20 on a reference magnet 25 provided to distinguish the polarity of the assembly magnet 20.

[0085] The reference magnet 25 does not necessarily have to be a permanent magnet; a ferrite magnet is sufficient. Using a reference magnet with a strong magnetic field may cause a decrease in the magnetic susceptibility of the unmagnetized assembly magnet 20. Error proofing is a method that minimizes the contact area with the reference magnet 25 and allows for accurate identification of the polarity of the assembly magnet 20.

[0086] Referring to Figure 8(B), the assembly magnets 20 rotate around the north and south poles of the reference magnet 25, allowing us to determine the magnetized direction or orientation of the assembly magnets 20. In particular, in the case of unmagnetized assembly magnets 20 that are only oriented, the orientation can be determined even with a weak magnetic field, and this does not affect the decrease in magnetic susceptibility during magnetization after assembly is complete.

[0087] For example, the assembly magnet 20 tends to align with the direction of the magnetic field formed by the reference magnet 25. Therefore, when the assembly magnet 20 is rotated by the automated equipment 400 around the north and south poles of the reference magnet 25, the assembly magnet 20 tends to rotate so that its orientation aligns with the direction of the magnetic field formed by the reference magnet 25.

[0088] Taking these characteristics into consideration, by using a vision sensor, image sensor, or contact sensor, the orientation of the assembly magnet 20 can be determined, and incorrect assembly of the assembly magnet 20 (misalignment of magnetic direction or orientation) can be prevented.

[0089] Furthermore, while the orientation does not need to be considered in the case of unmagnetized magnets, even in this case, if magnets with incorrect orientation are assembled, proper alignment will not be possible, thus preventing incorrect assembly.

[0090] On the other hand, Figure 9 is a cross-sectional view showing the flow of the bonding process for a permanent magnet according to one embodiment.

[0091] Referring to Figure 9, the bonding process according to one embodiment is performed after the magnet arrangement jig 130, in which all of the assembly magnets 20 have been assembled, has been separated from the OD alignment jig 110 and the ID alignment jig 120 (S30). When the magnet arrangement jig 130 is separated from the OD alignment jig 110 and the ID alignment jig 120, the magnet arrangement jig 130 may experience fluidity of the assembly magnets 20 as the external magnetic field from the permanent magnets disappears. Therefore, care must be taken to prevent the assembly magnets 200 from being disturbed by impacts or other factors.

[0092] Using the dispenser 40, resin 45 is injected onto the assembly magnets 20 arranged in the arrangement groove 131 (S41). At this time, the magnet arrangement jig 130 may be preheated according to the properties of the resin 45.

[0093] The upper cover 132 is attached to the magnet arrangement jig 130, in which the resin 45 has been injected, by the automated equipment 400. The assembly magnets 20 are then placed into the vacuum chamber 200 by the automated equipment 400, and the assembly magnets 20 are degassed according to a constant pressure condition (e.g., -90 to -100 kPa) (S42). Through this degassing process, the resin 45 is evenly diffused into the empty spaces between and around the arranged assembly magnets 20, and any remaining air bubbles inside are expelled.

[0094] The magnet arrangement jig 130, after the degassing process is complete, is placed into the oven 300 by the automated equipment 400 and cured according to the set resin curing conditions (e.g., UV conditions) (S43).

[0095] After the resin 45 has hardened, the ring-shaped, integrated Halbach array permanent magnet 20 is separated from the array jig 130 by the automated equipment 400 (S44).

[0096] Because the Halbach array permanent magnet 20 has a modular structure with an integrated ring structure, it has the advantage of being easily assembled around the rotation axis c when manufacturing a rotor for an electric vehicle motor.

[0097] On the other hand, Figure 10 shows a structure in which the upper cover is attached to the magnet arrangement jig during bonding work according to one embodiment.

[0098] Referring to Figure 10, the upper cover 132 is coupled to the top of the assembly magnets 20 arranged in the arrangement groove 131, blocking vertical flow, and is also used as a device for expanding and degassing the resin during bonding (potting) work.

[0099] The upper cover 132 is located above the assembly magnets 20 and fills the empty space between the assembly magnets 20 during the bonding process, forming a fluid space 133 that allows any remaining resin 45 to overflow.

[0100] The fluid space section 133 is manufactured in a tapered shape (hood shape), which allows the resin 45 that overflows onto the top of the assembly magnet 20 after the resin has hardened in the oven to be easily separated.

[0101] The magnet arrangement jig 130 is located at the lower end of the assembly magnets 20 assembled in the arrangement groove 131 and includes a support block 135 in which a flow channel 134 for the resin 45 injected during the bonding process is formed.

[0102] The fluid channel 134 within the magnet arrangement jig 130 refers to the empty space remaining between the arrangement groove 131 and the assembly magnets 20 arranged therein. It is a very narrow space, but it will eventually be filled with resin 45.

[0103] Therefore, the fluid channel 134 forms a passage connecting the assembly magnets 20, which are arranged so that the injected resin 45 fills all of the empty spaces, and helps to spread the resin 45 evenly. It can also serve as an air discharge channel during degassing. In addition, the resin filling the fluid channel 134 makes surface contact with the bonded assembly magnets 20, minimizing damage due to localized forces.

[0104] Although one embodiment has been described above, the present invention is not limited to the above embodiment, and various other modifications are possible.

[0105] For example, in one embodiment shown in Figure 3, the explanation focused on a two-stage permanent magnet jig device 100 in which a magnetic field is formed by corresponding permanent magnets 10 on the outer diameter (OD) and inner diameter (ID) sides of the magnet arrangement jig 130, and the assembly magnets 20 are arranged therein.

[0106] However, the embodiments of the present invention are not limited thereto, and a method can be applied in which a magnetic field is formed by permanent magnets 10 placed on either the outer diameter (OD) or inner diameter (ID) side, and assembly magnets 20 are arranged therein.

[0107] Figure 11 shows an example of the arrangement of permanent magnets in the outer and inner diameters of a permanent magnet jig device according to another embodiment.

[0108] Referring to Figure 11(A), an example of a construction method in which the assembly magnets 20 are arranged in units of four sections is shown.

[0109] When the assembly magnets 20 are arranged in four-part units, permanent magnets 10 are placed on only one of the outer diameter (OD) or inner diameter (ID) sides of the magnet arrangement jig 130 to form a magnetic field in the radial direction a, and permanent magnets 10 in the tangential direction b are not placed (removed). At this time, multiple assembly magnets 20 having the same first polarity are preferentially assembled in the magnet arrangement jig 130 based on the magnetic field in the radial direction a, and thereafter, multiple assembly magnets 20 having a second polarity opposite to the first polarity can be assembled.

[0110] JPEG2026084073000003.jpg24163

[0111] Referring to Figure 11(B), an example of a construction method in which the assembly magnets 20 are arranged in units of six sections is shown.

[0112] When the assembly magnets 20 are arranged in units of six, the permanent magnets 10 are placed on only one of the outer diameter (OD) or inner diameter (ID) sides of the magnet arrangement jig 130, forming a magnetic field in the radial direction a. Two assembly magnets 20 with symmetrical diagonal polarities are assembled between the permanent magnets 10. The assembly magnets 20 can then be assembled in a position that forms a magnetic field in the tangential direction b, with the magnets positioned in pairs on the outer diameter (OD) and inner diameter (ID). The assembly magnets 20 assembled in the tangential direction b magnetic field are assembled between two symmetrical diagonal assembly magnets 20.

[0113] Other aspects are the same as those described in the embodiments of the present invention above, so redundant explanations will be omitted.

[0114] Thus, according to one embodiment, by utilizing a two-stage permanent magnet jig device provided on the outer diameter (OD) and inner diameter (ID) sides of the magnet arrangement jig, the assembly magnets 20 can be assembled in accordance with the orientation direction of the Halbach arrangement without distinguishing between magnetized and unmagnetized magnets. Furthermore, by performing the bonding work while the magnets are assembled in the magnet arrangement jig, the assembly time of the assembly magnets 20 can be shortened, and a Halbach arrangement permanent magnet with a uniform quality integrated ring structure can be manufactured.

[0115] Furthermore, when assembling the magnets into the magnet arrangement jig, the magnetic direction or orientation can be confirmed using an error-proof method that utilizes a reference magnet, thereby fundamentally eliminating the problem of incorrect assembly of the magnets and ensuring uniformity of product quality.

[0116] Furthermore, by strengthening the bonding force and reducing the problem of magnets scattering during assembly, a separate sleeve (or covering) can be eliminated, thereby reducing assembly costs and the number of steps involved.

[0117] Furthermore, when manufacturing rotors for electric vehicle motors using modularized Halbach array permanent magnets in an integrated ring structure, the ease of assembly around the rotation axis c is a significant advantage, leading to improved product yield and productivity.

[0118] Although the embodiments 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]

[0119] 10: Permanent magnets 20: Assembly magnets 25: Reference Magnet 30: Halbach array permanent magnets 40: Dispenser 45: Resin 100: Permanent magnet jig device 110: Outer diameter (OD) alignment jig 120: Internal diameter alignment jig 130: Magnet arrangement jig 131: Arrangement grooves 132: Top cover 133: Fluid space section 134: Flow channel 135: Support Block 140: Bass 141:Top surface 142: Insertion groove 200: Vacuum Chamber 300: Oven

Claims

1. A magnet alignment jig is inserted between an OD alignment jig, which has multiple permanent magnets arranged in a cylindrical shape and forms magnetic fields in the circumferential and tangential directions, and an ID alignment jig that is paired with the OD alignment jig; A step in which multiple assembly magnets are assembled in alignment grooves formed along the outer surface of the magnet arrangement jig in accordance with the orientation of a Halbach arrangement; Once all of the assembly magnets have been assembled in the arrangement groove, the magnet arrangement jig is separated from the OD arrangement jig and the ID arrangement jig; and A step of performing a bonding operation to fix a plurality of assembly magnets arranged in the aforementioned arrangement groove; A Halbach array assembly method utilizing a permanent magnet jig device, including the above.

2. The step of assembling the aforementioned assembly magnets in accordance with the orientation of the Halbach array is as follows: A Halbach array assembly method utilizing a permanent magnet jig device according to claim 1, wherein the assembly magnets are assembled using either magnetized assembly magnets or unmagnetized assembly magnets.

3. The step of assembling the aforementioned assembly magnets in accordance with the orientation of the Halbach array is as follows: A Halbach array assembly method utilizing a permanent magnet jig device according to claim 1, comprising the step of detecting an assembly magnet that has failed to be positioned in the correct location because the magnetic field direction of the permanent magnet does not match the orientation of the assembly magnet.

4. The step of detecting a magnet that has failed to be positioned in the designated location is: A Halbach array assembly method utilizing a permanent magnet jig device according to claim 3, comprising the step of positioning the assembly magnets on a reference magnet and confirming the magnetized direction or orientation of the assembly magnets.

5. The step of assembling the aforementioned assembly magnets in accordance with the orientation of the Halbach array is as follows: A Halbach array assembly method utilizing the permanent magnet jig device according to claim 1, wherein the assembly magnets are assembled in one of the following arrangement methods: eight-part, six-part, or four-part units.

6. The step of assembling the aforementioned assembly magnets in accordance with the orientation of the Halbach array is as follows: A Halbach array assembly method utilizing a permanent magnet jig device according to claim 1, wherein the assembly magnets are sequentially assembled according to priority groups formed on the magnet arrangement jig, taking into account the direction of the magnetic field.

7. The step of assembling the aforementioned assembly magnets in accordance with the orientation of the Halbach array is as follows: The step involves assembling a plurality of assembly magnets having the same first polarity with respect to the circumferential magnetic field into the magnet arrangement jig; A step in which a plurality of assembly magnets having a second polarity opposite to the first polarity are assembled with reference to the circumferential magnetic field; Steps include assembling a plurality of assembly magnets having the tangential magnetic field; and A step in which multiple assembly magnets having orientations other than the circumferential and tangential directions are assembled; A Halbach array assembly method utilizing the permanent magnet jig device described in claim 6, including the method described in claim 6.

8. The step of assembling the aforementioned multiple assembly magnets is: A Halbach array assembly method utilizing the permanent magnet jig device according to claim 7, comprising the step of assembling assembly magnets having opposite polarity after assembling assembly magnets having the same polarity in the same direction.

9. The step of assembling multiple assembly magnets having orientations other than the circumferential and tangential directions is as follows: A Halbach array assembly method utilizing the permanent magnet jig device according to claim 7, wherein assembly magnets having diagonal polarity formed by adjacent circumferential and tangential magnetic fields are assembled.

10. The aforementioned bonding process is A step in which resin is injected into the assembly magnets arranged in the aforementioned arrangement groove; The upper cover is attached to the magnet arrangement jig after the resin injection is completed, the assembly magnets are placed in a vacuum chamber, and the assembly magnets are subjected to a degassing process under constant pressure conditions; and The magnet arrangement jig, after the degassing process is completed, is placed in an oven and cured according to the set resin curing conditions; A Halbach array assembly method utilizing the permanent magnet jig device according to claim 1, characterized in that it includes the following:

11. A permanent magnet jig device for assembling a Halbach array, An OD alignment jig in which multiple permanent magnets are arranged in a cylindrical shape to form magnetic fields in the circumferential and tangential directions; An ID alignment jig paired with the OD alignment jig, having multiple permanent magnets arranged in a cylindrical shape; and A magnet alignment jig inserted between the OD alignment jig and the ID alignment jig, in which multiple assembly magnets are assembled in alignment grooves formed on the outer circumference in accordance with the orientation of the Halbach arrangement, and which generates a ring-shaped Halbach arrangement permanent magnet by bonding work; A permanent magnet jig and device including a magnet.

12. The aforementioned OD alignment jig is The permanent magnet jig device according to claim 11, wherein when assembling a plurality of assembly magnets in the magnet arrangement jig, the assembly magnets are positioned in a fixed position.

13. The aforementioned ID alignment jig is The permanent magnet jig device according to claim 12, which forms a magnetic field in the same direction as the OD alignment jig, aligns the assembly magnets assembled in the magnet arrangement jig to their fixed positions, and increases the fixing force of the assembly magnets in cooperation with the OD alignment jig.

14. The aforementioned assembly magnets are The permanent magnet jig device according to claim 11, which is assembled using magnetized or unmagnetized magnets in one of eight-part, six-part, or four-part arrangement methods.

15. A base on which an insertion groove for inserting the magnet arrangement jig is formed on the upper surface; It further includes, The permanent magnet jig device according to claim 11, wherein the OD alignment jig and the ID alignment jig are provided side by side on the upper surface of the base with respect to the rotation axis.

16. The aforementioned magnet arrangement jig is The permanent magnet jig device according to claim 11, further comprising an upper cover for fixing a plurality of assembly magnets assembled in the arrangement groove during the bonding operation.

17. The top cover is The permanent magnet jig device according to claim 16, which is located above the assembly magnets assembled in the aforementioned arrangement grooves, fills the empty space during the bonding operation, and forms a fluid space portion so that any remaining resin overflows.

18. The aforementioned fluid space section is The permanent magnet jig device according to claim 17, wherein the resin is tapered after curing in an oven so that any overflowing resin separates.

19. The aforementioned magnet arrangement jig is The permanent magnet jig device according to claim 11, comprising a support block located at the lower end of the assembly magnets assembled in the aforementioned arrangement groove, and having a flow channel formed for the resin injected during the bonding operation.

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