Permanent Magnet Compression Molding With Synchronized Pulse Coils
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Solution Overview
Problem
Conventional compression-molding processes for permanent magnets result in large manufacturing structures and limited magnetic properties due to the size of electromagnets and the inability to increase magnetic field intensity beyond saturation.
Innovation Solution
A method using electromagnetic coils to generate both compression force and orientation magnetic fields, allowing for adjustable waveform and intensity through transient currents, enabling higher orientation degrees and densities in permanent magnets, while reducing the size of the compression structure and power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If an electromagnet is used to generate the orientation magnetic field, then the magnetic field intensity can be increased, but the size of the compression device becomes large and the structure becomes complicated
Solution Approach 1:
The patent replaces the conventional electromagnet system with a pulsed magnetic field generation system using coil assemblies that generate both compression force and orientation magnetic field through controlled current pulses. This substitution eliminates the need for large, complex electromagnet structures while achieving the required magnetic field intensity through transient electromagnetic forces.
Solution Approach 2:
The patent changes the operational parameters from continuous electromagnetic field generation to pulsed transient fields. By controlling the duration, amplitude, and timing of current pulses, the system achieves high magnetic field intensity only when needed, reducing overall system size and complexity while maintaining effective magnetic properties.
2Force
If the electromagnet size is increased to achieve higher magnetic field intensity, then the orientation magnetic field intensity can be increased, but the overall size of the compression device increases
Solution Approach 1:
The patent employs periodic pulsed action where coil assemblies generate intense magnetic fields in short bursts during the compression process. The pulsed current application creates high-intensity orientation magnetic fields only during the critical molding phase, eliminating the need for continuously large electromagnets and reducing overall device dimensions.
Solution Approach 2:
The system transitions from static, continuously-powered electromagnets to dynamic, transiently-activated coil assemblies. The magnetic field intensity is dynamically controlled through pulse timing and amplitude, allowing high field strength during compression while maintaining a compact overall structure that is not constrained by continuous field generation requirements.
3Force
If a large electromagnet is used to generate the orientation magnetic field, then the magnetic field intensity can be increased, but the power consumption increases
Solution Approach 1:
The patent uses periodic pulsed current application to generate magnetic fields only during the brief compression window. This transient operation mode consumes power only when magnetic field intensity is required, dramatically reducing overall power consumption compared to continuously-operating electromagnets while maintaining peak field intensity during the molding process.
Solution Approach 2:
The system rushes through the magnetic field generation phase by applying intense current pulses only for the duration necessary to establish orientation during compression. By skipping continuous field maintenance and generating fields only when needed, the system achieves high magnetic field intensity with minimal energy expenditure.
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 enhances the magnetic properties of permanent magnets by increasing orientation degrees and densities, reduces the size of the compression structure, and lowers power consumption, addressing the limitations of conventional methods.
Implementation Method 1
providing a drive coil to generate an electromagnetic force when a transient current is passed into the drive coil, so as to apply a molding compression force to magnetic powder under compression
Implementation Method 2
providing an orientation coil to generate an orientation magnetic field when a current is passed into the orientation coil, thereby providing the magnetic powder under compression with an anisotropic property
Data Source
AI summary
A compression-molding method for a permanent includes: providing a drive coil to generate an electromagnetic force when a transient current is passed into the drive coil, so as to apply a molding compression force to magnetic powder under compression, and providing an orientation coil to generate an orientation magnetic field when a transient current is passed into the orientation coil, thereby providing the magnetic powder under compression with an anisotropic property; and synchronously passing the transient currents to the drive coil and the orientation coil to synchronously generate the electromagnetic force and the orientation magnetic field, thereby completing compression-molding of the permanent magnet, wherein a magnitude of the electromagnetic force and an intensity of the orientation magnetic field are respectively changed by changing peak values of the transient currents.