Adhesive robot automatically assembles rotors
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Adhesive robot automatically assembles rotors

New robot automatically assembles rotors of permanent magnet synchronous motors

Magnetic Innovations is the expert in the field of permanent magnet synchronous motors. These motors are typically used for Direct drive Torque motor application which consists of a stator assembly and a rotor assembly. For the stator, there are several automated manufacturing solutions on the market that apply the copper windings fully automated onto the stator. But for the rotors, in order to assemble magnets, mostly customer-specific automation solutions are required, as there is no standard equipment available. Or, it is done by hand. In order to improve the quality of our production line, Magnetic Innovations has developed a robot cell. This robot assembles the rotors automatically and checks the end result for its specified magnetic properties.

Improved position accuracy of the rotors

over the course of the past 2 years the robot has been developed in close collaboration with an external automation and robotization specialist. And, the end result is impressive!

The robot makes a lot of manual work unnecessary and helps to improve our product. The Robot cell is equipped with internal component Storage. Here the rotor parts and magnets are stored until they are picked up by the robot, to be assembled into the magnetic rotor.

The storage space is suitable for processing rotors for our frameless PMSM motors of the MI-F Series from size 110mm up to and including 485mm.

Ensuring the quality of permanent magnet motors

Thanks to years of experience with permanent magnet motors, we know how to ensure the quality of these motors. Magnetic Innovations assesses the quality of a magnetic rotor based upon:

  • The accuracy of the starting materials used.
  • The magnetic field strength across position.
  • The adhesive process mount the magnets to the rotor.

First, an input check takes place, which determines whether the starting materials have been supplied in accordance with specifications. In addition, the machine checks each magnet individually, to see if it is within a specified bandwidth in terms of magnetic properties. If not, it is registered and rejected and the next magnet is used.

By implementing this quality check, we are able to obtain a very homogeneous magnetic field in the rotor. Which provides very good properties in terms of low torque constant ripple and cogging.

Adhesive bonding

The permanent magnets are attached to the rotor by means of adhesive bonding. Adhesive bonding has proven itself for many years within the high-tech and aviation industry. It is very reliable, provided the right conditions are used. The choice in terms of adhesive, dosage, and the connection process determine the quality.

The type of adhesive has been chosen based on our experience and expertise in bonding permanent magnets and rotors. The adhesive we have selected has been extensively tested and found to be suitable for all motor and environmental specifications as they apply to our motors.

To achieve good adhesion of the adhesive and thus a good adhesive connection, it is very important to clean the surface and make it suitable for adhesion. This step in the process is also fully automated.

After the magnets are placed in the storage chamber of the robot cell. The robot, by means of atmospheric plasma, cleans and activates the adhesive surface of both, the rotor part and the magnet, so that an optimal adhesive connection can be obtained.

High position accuracy enhances the magnetic field of the pm motors

In order to avoid a build-up of position tolerances, we have devised a unique solution with which we can pick-up and position the magnets. This makes it possible to achieve a high position accuracy, which contributes to a very homogeneous magnetic field in the rotor. Homogeneity of the magnetic field in a rotor provides very good properties in terms of low cogging and low torque constant ripple. And a generally smooth running motor.

After applying all magnets, the entire magnetic field is scanned and specifications are verified to the specification requirement. Based on a unique serial number, a fingerprint of the particular rotor is stored for future reference and traceability.

This new robot takes away the need for manual labor in rotor manufacturing, increases our manufacturing capacity and helps to improve the performance of our product. Magnetic Innovations has taken a major leap forward when it comes to the efficiency and positioning accuracy of our rotors thanks to this new robot.

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Happy Holidays 2020
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Happy Holidays 2020

Happy Holidays and a succesful new year

The ongoing pandemic affected the entire world and tested our ability to adjust to a changing landscape. We are happy to say that we have had a good year. We have been working on some ground breaking projects with our customers and have been on-track with growing our busines

The launch of new products in 2021

We are excited about 2021 and are getting ready to launch some exciting new products. We are going to release several new Moving Magnet Voice Coil Actuators and will be launching a new controller to drive our actuators. We will also expand our  Frameless High Torque Motor Family. You will hear more about this in the new year. 

Holiday wishes

For now, the team at Magnetic Innovations wishes you happy holidays and peace, health and prosperity throughout the coming year. Thank you for your continued support and partnership. We look forward to working with you in the years to come.

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Photo in header by Kevin Bidwell via Pexels

Top 5 industries for direct drive torque motor
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Top 5 industries for direct drive torque motor

Top 5 industries for direct drive torque motor

Magnetic Innovations is a solid global partner for the development and supply of direct drive torque motors. Their international customers come from a wide range of industries. Next to their customers, they also receive daily quote requests for their torque motor. This information was gathered and used to create a list with the top five industries for torque motors. See which industries are leading, when it comes to using direct drive motor technology for their applications.

Direct drive torque and linear motors are alternatives to the more traditional motors with a gearboxes and ball screws. Direct drive motors are seen as a technological step up from standard transmission motors. Although the basic design of the direct drive motors have been around for a long time, it is still considered new technology.

What is a direct drive torque motor?

High torque motors are permanent magnet synchronous motors (PMSM). They are suitable in a variety of applications where high torque and a high efficiency is required. The high torque frameless motors consist of two parts. The armature assembly (stator) with windings and the rotor assembly carrying the magnets. Torque motors have many size options, they are variable when it comes to their diameter, length and power. The low cogging design makes the motors also suitable for servo control applications.

Top 5 industries torque motors

Nowadays, engineers have a lot options when deciding which type of motor to use. Companies large and small really understand they have a lot to gain by using high torque pm-motors. Most companies and engineers switch to torque motors because they are looking for ways to increase overall performance and quality.

  1. Machine Tool Industry 
    Machine tools are used at the starting point of almost every manufacturing activity. A significant reduction of costs can be achieved by installing direct drive motors in various machines and systems. Torque motors are also a good match because they offer more size options than traditional motors with a gear system. This and low maintenance operations are often the motivations for industry leaders to choose a direct drive torque motor.

  2. Robotics & Semicon Industry
    Robotics have long been an important part of the electronics and semiconductor industry. Manufacturers need speed, accuracy and flexibility to profitably tap into the market. The torque motors from magnetic innovations are characterized by low cogging values, high torque and a high accuracy. This results in smooth operations where errors are minimized. This is why they are also suitable for medical technology applications.

  3. Industrial HVLS Fans
    A quiet environment and high efficiency operation is essential in many fan applications. Multiple industries depend on standard asynchronous (ac) motors for their fans, but the landscape is changing. Driving the fan blades directly with a direct drive fan motor instead of an induction motor with a gear or belt, will assure high efficiency, quiet operation and longer operational life in addition to a reduced motor size by a factor of 2 to 3.

  4. Energy Industry
    The ongoing trend towards sustainability leads many industries to use permanent magnet synchronous motors. Thanks to the increasing customer demand, the renewable (green) energy industry is growing. This growth drives companies to look for solutions that are more cost competitive, innovative and efficient. That is why companies within this industry look towards the direct drive technology, to offer them a more efficient system. Nowadays, torque motors are used in various green energy applications such as wind-and water turbine generators.

  5. Production Industry
    In industries where space is limited, hygiene is important and maintenance cost are high, direct drive torque motors offer an opportunity. Magnetic Innovations developed belt drive motors and drum motors especially for those industries. Combining these motors with a smart infeed conveyor system, will result in high dynamic applications that will help to boost productivity. Several production plants invested in these direct drive motors, to lower maintenance and save on cost.

Icons used in the infographic are made by Smashicons, smalllikeart, DinosoftLabs and xnimrodx from www.flaticon.com

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