Radially Anisotropic Multipolar Magnet Production Without Mold Core
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Solution Overview
Problem
The existing methods face challenges in producing radially anisotropic multipolar magnets with an inner diameter less than 3 mm and in creating magnets that can provide magnetic fields with varying waveform widths, which are essential for high-precision micro-motors with different design requirements.
Innovation Solution
A method and device for producing radially anisotropic multipolar solid cylindrical magnets by arranging outer oriented poles outside a mold without a core, adjusting the sum of their widths or arc lengths, and applying staged magnetic fields to align magnetic particles effectively, allowing for the production of magnets with adjustable waveform widths and small diameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a mold core is used to produce radially anisotropic multipolar magnet rings, then the manufacturing process is established and reliable, but the inner diameter cannot be reduced below 3 mm and waveform width cannot be adjusted
Solution Approach 1:
The patent removes the mold core from the traditional molding structure, extracting the problematic component that prevented small inner diameter production. By eliminating the core, the patent enables production of magnets with inner diameters less than 3 mm and allows waveform width adjustment without being constrained by core geometry.
Solution Approach 2:
Instead of using a central core to define the inner diameter, the patent inverts the approach by using outer oriented poles arranged around the mold to define the magnetic field geometry. This inversion allows the inner diameter to be determined by the mold cavity rather than a core, enabling small inner diameters and adjustable waveform widths.
2Manufacturing precision
If outer oriented poles are arranged outside the mold without a core, then small inner diameters and adjustable waveform widths are achieved, but the magnetic field alignment becomes more difficult
Solution Approach 1:
The patent applies preliminary magnetization treatment to the magnetic particles before final molding. By pre-aligning the magnetic particles using an external magnetic field before the particles are fully positioned in the mold, the patent simplifies the subsequent alignment process and ensures proper radial orientation even without a central core.
Solution Approach 2:
The patent introduces an external magnetic field as an intermediary to facilitate magnetic particle alignment. This external field acts as a mediator that temporarily guides the magnetic particles into the correct radial orientation during the molding process, making alignment easier without requiring a complex core structure.
3Manufacturing precision
If the sum of widths of outer oriented poles is less than 0.9πD, then magnetic particles rotate with the mold during magnetization improving orientation, but the magnetic field intensity distribution becomes more complex
Solution Approach 1:
The patent employs dynamic rotation of the mold during magnetization, allowing magnetic particles to rotate together with the mold. This dynamic approach enables the particles to continuously adjust their orientation in response to the changing magnetic field direction, achieving superior radial alignment. The sum of pole widths being less than 0.9πD creates sufficient magnetic field variation during rotation to drive this alignment effect.
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 enables the large-scale production of high-precision radially anisotropic multipolar magnets with improved magnetic performance, increased magnetic energy product, and controllable waveform widths, suitable for micro-motors with various parameters, while reducing production costs and energy consumption.
Implementation Method 1
applying a first magnetic field to fully magnetize the magnetic particles in the mold cavity
Implementation Method 2
the magnetic particles in the mold cavity are aligned along the oriented magnetic field
Implementation Method 3
the mold and the magnetic particles in the mold cavity are rotated during magnetization
Implementation Method 4
applying an increased stress to the magnetic particles in the mold cavity by an upper ram and a lower ram
Implementation Method 5
applying a fourth magnetic field to demagnetize the molded blank
Data Source
AI summary
A method and device for producing a radially anisotropic multipolar solid magnet adapted to different waveform widths are provided. A mold core is removed from a mold for molding the magnet, and outer oriented poles, the number of which is the same as that of poles of the radially anisotropic multipolar solid cylindrical magnet, are arranged outside the mold. The width of a front end of a single outer oriented pole is determined according to the desired width of a single waveform of the radially anisotropic multipolar solid cylindrical magnet after being magnetized. The sum L of widths or arc lengths of front ends of all the outer oriented poles is less than 0.9πD, particularly less than 0.7πD, where D is the outer diameter of a mold sleeve. Magnetic particles in a mold cavity are rotated with the mold only during magnetization.