Moulding System with Separator for Permanent Magnet Manufacturing
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Solution Overview
Problem
Conventional manufacturing methods for permanent magnets are costly and require multiple shaping steps, resulting in significant waste of expensive magnet material.
Innovation Solution
A method involving a moulding system with a separator to create distinct compartments within the mould, where the first material is compacted to the desired shape without the need for additional shaping processes, using a cheaper dummy material that does not significantly affect the magnetic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional manufacturing methods are used to produce rectangular magnets and then grind/cut them into desired shapes, then the target shape can be achieved, but expensive magnet material is wasted significantly
Solution Approach 1:
The mould volume is segmented into a first compartment and a second compartment using a separator. The first compartment is shaped to match the target magnet geometry, while the second compartment accepts cheaper dummy material. This segmentation allows the expensive magnet material to be placed only where needed in the final product, eliminating waste from subsequent grinding or cutting operations.
2Shape
If multiple shaping steps are used to achieve the target magnet shape, then the desired geometry is obtained, but the manufacturing process becomes complex and costly
Solution Approach 1:
The separator is pre-configured in the mould with the exact target shape of the magnet before the magnet material is introduced. This preliminary action defines the final magnet geometry in advance, eliminating the need for subsequent shaping steps such as grinding, cutting, or machining. The magnet material is compacted directly into the predetermined shape during the initial moulding process.
3Reliability
If expensive magnet material is used throughout the entire magnet volume, then high magnetic properties are achieved, but manufacturing cost increases
Solution Approach 1:
Different material qualities are assigned to different regions of the magnet. The first compartment contains expensive magnet material with high magnetic properties where the field is needed, while the second compartment contains cheaper dummy material in regions where magnetic properties are less critical. This local differentiation maintains the necessary magnetic performance while significantly reducing overall material cost.
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 simplifies the manufacturing process, reduces material waste, and produces magnets with high coercivity and saturation magnetization suitable for applications like wind turbine generators, without the need for grinding or machining.
Implementation Method 1
separating, by a separator, a mould volume into a first compartment and a second compartment; filling a first material into the first compartment
Implementation Method 2
compacting the first material and the second material
Data Source
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AI summary
It is described a method for manufacturing a permanent magnet, the method comprising: separating, by a separator (107, 207), a mould volume into a first compartment (109, 209) and a second compartment (111, 211); filling a first material (119, 219) into the first compartment (109, 209); filling a second material (121, 221) into the second compartment (111, 211); compacting the first material and the second material, wherein the separator is shaped such that a shape of the first compartment corresponds to a target shape of the magnet.