Halbach Magnet Assembly Curved Pulse Magnetization
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Solution Overview
Problem
Conventional methods for manufacturing Halbach magnets are low in productivity and face challenges in achieving precise assembly due to magnetic repulsions and attractions, making it difficult to produce magnets with desired characteristics.
Innovation Solution
A method involving the preparation of unmagnetized magnet materials with predetermined magnetization easy axes, adhering them to form an assembly, and applying a curved pulse magnetic field to magnetize the assembly, where the angle between adjacent magnet blocks' magnetization directions ranges from 30 to 120 degrees.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pre-magnetized permanent magnet blocks are bonded together to form a Halbach magnet, then the magnetic characteristics can be improved, but the productivity is low and mass production is difficult due to repulsions and attractions during assembly
Solution Approach 1:
The magnetization step is performed after assembly rather than before, which is a reversal of the conventional sequence. By assembling unmagnetized blocks first and then magnetizing the entire assembly, the patent eliminates the repulsion/attraction problems during assembly while achieving the desired Halbach magnetic characteristics in the final product
Solution Approach 2:
Multiple unmagnetized magnet blocks are assembled into a single assembly unit before magnetization. This merging approach allows all blocks to be positioned without magnetic interference, and then the entire assembly is magnetized simultaneously to create the Halbach array with precise magnetic characteristics
2Reliability
If pre-magnetized permanent magnet blocks are bonded together, then the magnetic characteristics can be improved, but the assembly precision is deteriorated due to repulsions and attractions
Solution Approach 1:
The assembly of magnet blocks is performed in the unmagnetized state before magnetization, eliminating magnetic repulsion and attraction forces that would otherwise interfere with precise positioning. After assembly is complete with high precision, the entire assembly is then magnetized to achieve the desired Halbach magnetic characteristics without compromising assembly accuracy
3Productivity
If a magnetic field is applied to adjacently arranged unmagnetized magnet blocks with different orientation directions, then magnetization can be achieved, but conventional methods report that magnetization cannot be performed when magnetization directions differ by 90 degrees between adjacent blocks
Solution Approach 1:
A curved magnetic field trajectory is applied during magnetization, allowing the magnetic field to smoothly transition between different orientation directions of adjacent magnet blocks. This curved field approach enables magnetization of blocks with various orientation angles (30-120 degrees) that would be impossible with conventional straight magnetic field lines
Solution Approach 2:
The patent changes the parameters of the magnetic field from conventional straight/uniform fields to curved pulse magnetic fields with specific trajectory characteristics. This parameter change enables the magnetic field to effectively magnetize adjacent blocks with different orientation directions, achieving both high productivity and reliable magnetization results
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly increases productivity in manufacturing Halbach magnets and allows for higher productivity in magnetization, avoiding the precision issues associated with traditional methods and enabling the production of magnets with desired characteristics.
Implementation Method 1
a step of applying a curved pulse magnetic field to the assembly to magnetize the assembly
Data Source
AI summary
A method for manufacturing a magnet includes (1) a step of preparing three or more unmagnetized magnet materials of which magnetization easy axes are oriented in predetermined directions, and adhering the unmagnetized magnet materials with each other to make an assembly, and (2) a step of applying a curved pulse magnetic field to the assembly to magnetize the assembly, wherein in the step (2), the unmagnetized magnet materials are magnetized into magnet blocks, and an angle θ (where 0≤θ≤180 degrees holds) formed by magnetization directions of at least a pair of magnet blocks adjacent to each other is in a range of 30 degrees to 120 degrees.