V-Shaped Permanent Magnet Module Post-Magnetization
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Permanent magnet modules with V-shape configurations face challenges in magnetization due to attracting and repelling forces during pre-magnetization, requiring high energy and incomplete magnetization, especially in applications like offshore wind turbines where magnets can detach due to adhesive failure.
Innovation Solution
A method and system for post-magnetization of permanent magnet modules with V-shaped magnets, applying a first magnetic field perpendicular to one leg and then a second field perpendicular to the other leg, using a fixture with upper and bottom magnetizing coils arranged perpendicularly to efficiently magnetize the module with reduced energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pre-magnetization is applied to V-shape permanent magnet modules, then magnets can be magnetized before assembly, but high energy consumption and incomplete magnetization occur due to attracting and repelling forces
Solution Approach 1:
The patent applies preliminary action by performing magnetization after assembly rather than before assembly. The magnets are first assembled in their final V-shape configuration on the rotor, and then magnetized in situ using a specialized magnetizing device with multiple coils that can overcome the attracting and repelling forces between adjacent magnets. This resolves the contradiction by achieving complete magnetization (improving manufacturing quality) while providing a controlled process that manages energy consumption more effectively than conventional pre-magnetization methods.
2Ease of manufacture
If pre-magnetization is applied to V-shape permanent magnet modules, then magnets can be magnetized before assembly, but magnetization is incomplete due to attracting and repelling forces
Solution Approach 1:
The patent performs magnetization as a preliminary action after assembly, using a dedicated magnetizing device with multiple coils (first coil, second coil, third coil) that are positioned to magnetize each magnet individually or in groups. This sequential magnetization approach overcomes the attracting and repelling forces that prevent complete magnetization in conventional methods, ensuring that all V-shape magnets achieve their full magnetic potential while maintaining the benefits of pre-assembly configuration.
Solution Approach 2:
The magnetization process is segmented into multiple stages using different coils for different magnet groups. The first coil magnetizes a first group of magnets, the second coil magnetizes a second group, and the third coil magnetizes a third group. This segmentation allows each magnet or group to be magnetized independently without interference from adjacent magnets, achieving complete magnetization while maintaining the V-shape configuration assembled beforehand.
3Ease of operation
If V-shape permanent magnet modules are assembled and transported before magnetization, then assembly and transport are simplified, but magnetization becomes more complex and energy-intensive
Solution Approach 1:
The patent performs assembly and transport as preliminary actions before magnetization. The V-shape magnets are assembled on the rotor and transported to the magnetization station in their final configuration. The magnetization system, while complex with multiple coils and control mechanisms, is designed to handle this pre-assembled module efficiently. This approach simplifies assembly and transport operations while concentrating the complexity only in the magnetization stage, where it is necessary to achieve complete magnetization of the V-shape configuration.
4Manufacturing precision
If high energy is applied for magnetization of V-shape magnets, then magnetization can be achieved, but the process becomes less efficient and more costly
Solution Approach 1:
The magnetization process is divided into segments using multiple coils that target different groups of magnets sequentially. The first coil magnetizes a first group of magnets with optimized energy input, the second coil magnetizes a second group, and the third coil magnetizes a third group. This segmentation allows each magnet or group to receive precisely the energy needed for complete magnetization without wasting energy on already-magnetized magnets or attempting to overcome excessive opposing forces simultaneously, thereby achieving manufacturing precision with improved energy efficiency.
Solution Approach 2:
The magnetization process uses periodic action by applying magnetic fields in sequential pulses through different coils rather than applying continuous high energy. Each coil is activated in turn to magnetize its target group of magnets, allowing the system to achieve complete magnetization through repeated, controlled energy applications rather than a single high-energy pulse, thus improving overall energy efficiency while maintaining magnetization effectiveness.
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
Enables complete and energy-efficient magnetization of permanent magnet modules with V-shaped magnets, reducing the complexity of assembly and transport, and minimizing the risk of magnet detachment by focusing on each leg separately during magnetization.
Implementation Method 1
applying a first magnetic field such that magnetic flux lines are substantially perpendicular to a first leg of the V-shape... applying a second magnetic field such that magnetic flux lines are substantially perpendicular to a second leg of the V-shape
Data Source
AI summary
A method for magnetizing a section of one or more permanent magnets arranged substantially in a V-shape, comprising: applying a first magnetic field such that magnetic flux lines are substantially perpendicular to a first leg of the V-shape, and removing the first magnetic field. Then the method comprises applying a second magnetic field such that magnetic flux lines are substantially perpendicular to a second leg of the V-shape, and removing the second magnetic field. Systems and methods for magnetizing sections of permanent magnet modules are also provided.