Split Non-Magnetized Permanent Magnet Manufacturing
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Solution Overview
Problem
Conventional methods for manufacturing non-magnetized permanent magnets using grain boundary diffusion face challenges in mass production due to adhesive deterioration during heating and increased processing time, leading to high eddy current losses in permanent magnet motors.
Innovation Solution
A manufacturing method involving the creation of anisotropic blocks with uniformly aligned magnetization, followed by sequential cutting operations to form split blocks, applying grain boundary diffusion, and re-adhering cut surfaces, while maintaining a thin thickness in the magnetization direction to prevent adhesive deterioration and optimize diffusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a permanent magnet is split into multiple pieces to reduce eddy current loss, then eddy current loss is reduced, but the adhesive property deteriorates during subsequent heating processes
Solution Approach 1:
The patent applies preliminary action by performing the grain boundary diffusion treatment on the entire permanent magnet block before splitting it into multiple pieces. This sequence ensures that the adhesive property is not exposed to high-temperature heating that would cause deterioration, while still achieving the desired diffusion effect. The magnet is divided into first and second permanent magnet pieces after the diffusion treatment, maintaining adhesive integrity.
2Reliability
If grain boundary diffusion is performed after splitting and re-adhering the magnet block, then magnetic property is enhanced, but processing time increases due to multiple steps
Solution Approach 1:
The patent performs the grain boundary diffusion treatment as a preliminary step before splitting the magnet block. By conducting the diffusion treatment on the intact block first, then splitting it into pieces with the desired magnetic properties, the process eliminates the need for multiple heating and adhering cycles that would otherwise be required to achieve the same diffusion effect on split pieces.
3Reliability
If the magnet block is cut into thin sections to optimize diffusion, then diffusion property is improved, but the number of pieces increases requiring more adhering operations
Solution Approach 1:
The patent performs the grain boundary diffusion treatment on the entire magnet block before splitting it into a minimal number of pieces (first and second permanent magnet pieces). This approach optimizes diffusion by applying the treatment to the full block structure, then dividing it only where necessary to achieve the desired magnetic properties, avoiding the need to cut the block into numerous thin sections.
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 reduces eddy current losses, enhances motor efficiency, and facilitates mass production by preventing adhesive deterioration and optimizing grain boundary diffusion, thus improving the manufacturing efficiency of split type non-magnetized permanent magnets.
Implementation Method 1
performing a grain boundary diffusion on the plurality of split blocks
Data Source
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AI summary
A manufacturing method of split type non-magnetized permanent magnet may include manufacturing an anisotropic block having a uniformly aligned magnetization determining direction. A first cutting operation of cutting the anisotropic block in a direction which is perpendicular to the magnetization determining direction is performed. A grain boundary diffusion is performed on the plurality of slit blocks. Adhering surfaces of the plurality of split blocks to each other which are cut by the first cutting operation is performed. A second cutting operation of cutting the block in a direction is performed which is perpendicular to the magnetization determining direction and the first cutting direction.