Magnetizing Array Ring for Annealed Magnet Grain Alignment
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Solution Overview
Problem
The manufacturing of conventional permanent magnet arrays is challenging and expensive due to the need for complex processing steps and material waste, as they require gradual variation in magnetization direction, which is difficult to achieve with unidirectional bulk permanent magnets.
Innovation Solution
A method involving the use of magnetizing array rings to orient and align grains of bulk magnetic material during annealing, allowing for the formation of annealed magnets with controlled grain alignment and flux distribution, potentially reducing material waste and processing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional bulk permanent magnets are cut into smaller pieces to create varying magnetization directions, then the desired flux distribution can be achieved, but material waste increases and manufacturing complexity increases
Solution Approach 1:
The magnetizing array is segmented into multiple discrete magnets arranged in a specific pattern, allowing independent control of magnetization directions while avoiding the need to cut the bulk magnetic material. This segmentation applies to the magnetizing tools rather than the workpiece, achieving flux distribution control without material waste.
Solution Approach 2:
The magnetizing array is positioned and configured before the actual magnetizing process. By pre-arranging the magnetizing magnets in specific orientations and positions, the desired varying magnetization directions are established beforehand, enabling precise flux distribution control during the magnetizing process without requiring subsequent cutting or assembly operations.
2Manufacturing precision
If conventional bulk permanent magnets are cut and assembled into arrays with varying magnetization directions, then the desired magnetic field distribution can be achieved, but device complexity increases
Solution Approach 1:
The magnetizing array combines multiple magnetizing magnets with different orientations into a single integrated tool assembly. This merged structure allows simultaneous application of multiple magnetization directions to different regions of the bulk magnetic material in one operation, achieving complex flux distribution control without multiple processing steps or assembly operations.
Solution Approach 2:
The magnetizing array acts as an intermediary tool that transfers the desired magnetization pattern from the tool design to the bulk magnetic material. By embedding the magnetization direction information in the magnetizing array itself rather than requiring complex cutting and assembly processes, the system simplifies the manufacturing workflow while maintaining precise magnetization direction control.
3Manufacturing precision
If magnetizing array rings are used to orient grains during annealing, then grain alignment and flux distribution are improved, but the manufacturing process requires additional equipment
Solution Approach 1:
The magnetizing array rings utilize changes in magnetic field parameters (strength, direction, distribution) during the annealing process to control grain orientation. By varying the magnetic field parameters applied during annealing, precise grain alignment is achieved without requiring complex mechanical positioning or multiple processing steps, as the field parameters themselves carry the orientation information.
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 method enables the efficient formation of annealed magnets with optimized performance by aligning grains in a single step, improving flux density and coercivity, and reducing manufacturing costs compared to traditional cutting and assembly methods.
Implementation Method 1
the magnetizing array ring having a magnetic field defining directions for orienting grains of the ring of bulk magnetic material
Implementation Method 2
operating the furnace to anneal the ring of bulk magnetic material and grow the grains in the directions
Implementation Method 3
placing the assembly in a furnace, and operating the furnace to anneal the ring of bulk magnetic material
Data Source
AI summary
A method of forming an annealed magnet includes positioning a magnetizing array ring concentrically with a ring of bulk magnetic material to form an assembly, the magnetizing array ring having a magnetic field defining directions for orienting grains of the ring of bulk magnetic material, placing the assembly in a furnace, and operating the furnace to anneal the ring of bulk magnetic material and grow the grains in the directions. A magnetic array assembly includes a furnace; and an assembly including (i) a ring of bulk magnetic material having grains and (ii) a magnetizing array ring concentric with the ring of bulk magnetic material, and having a magnetic field defining directions for orienting the grains during growth thereof in a presence of heat from the furnace.