Automated magnet assembly for large PM synchronous machines with integrated permanent magnets

Joseph, Eric; Tremel, Jan; Hofmann, Benjamin; Meyer, Alexander; Franke, Jörg; Eschrich, Sebastian

doi:10.1109/edpc.2013.6689727

Cited by 14 publications

(7 citation statements)

References 2 publications

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“…Using industrial robots brings high flexibility to the robot cell compared to using some of the existing stiffer equipment for PM surface mounting [6]. Different robot models, more robots or, e.g., a rotational table can be used to achieve sufficient reach for other translator geometries.…”

Section: Discussionmentioning

confidence: 99%

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Robotized Surface Mounting of Permanent Magnets

2014

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Using permanent magnets on a rotor can both simplify the design and increase the efficiency of electric machines compared to using electromagnets. A drawback, however, is the lack of existing automated assembly methods for large machines. This paper presents and motivates a method for robotized surface mounting of permanent magnets on electric machine rotors. The translator of the Uppsala University Wave Energy Converter generator is used as an example of a rotor. The robot cell layout, equipment design and assembly process are presented and validated through computer simulations and experiments with prototype equipment. A comparison with manual assembly indicates substantial cost savings and an improved work environment. By using the flexibility of industrial robots and a scalable equipment design, it is possible for this assembly method to be adjusted for other rotor geometries and sizes. Finally, there is a discussion on the work that remains to be done on improving and integrating the robot cell into a production line.

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Section: Discussionmentioning

confidence: 99%

“…Despite the growing market for PM machines, the PM assembly processes for such machines are often still manual. There are some examples though of recent developments in this field [5][6][7]. An often referred to model for successful production planning is the Toyota production system [8].…”

Section: Introductionmentioning

confidence: 99%

Robotized Surface Mounting of Permanent Magnets

2014

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“…In the original process this is done manually by deforming the cavity with a chisel impact. For the automation of this step a concept for a mechanical magnet fixation process was developed and integrated in an existing technology [2]. The whole demonstrator including the fixation device is shown in Figure 9.…”

Section: Automation Concept For a Mechanical Magnet Fixation Processmentioning

confidence: 99%

“…To reach this goal, flexible manufacturing solutions are needed. At the FAPS institute, several approaches matching the named demand are investigated considering the whole manufacturing process chain for electric drives production with the focus on automation with the maximum flexibility [2]- [8]. To mention here are advanced cutting techniques, robot based highly flexible stator winding, energy efficient insulation and contacting processes as well as motor recycling and magnet processing such as handling, fixation and magnetization.…”

Section: Introductionmentioning

confidence: 99%

Innovative developments for automated assembly and fixation of integrated permanent magnets in rotors of synchronous machines

Mahr

Meyer

Hofmann

et al. 2015

2015 5th International Electric Drives Production Conference (EDPC)

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Automation in the field of magnet handling and rotor assembly for permanent magnet synchronous motors is growing constantly, due to rising market share of high output motors. In the past, especially at the institute FAPS, large efforts have been made to reduce the amount of manual processes for maintaining market expansion and the increase of efficiency of the electric machine. Current research work has the aim of increasing the grade of automation even for large numbers of variants with low investment. In this paper two different demonstrators one for handling and one for the fixation of magnetized high coercive magnets are presented. The handling device inserts magnets of different dimensions in cavities vertically. For demonstrating an integrated fixation process an existing magnet assembly unit has been modified to enhanced functionality. Both devices offer fully automated operation ability within a wide portfolio of different rotor types and magnet dimensions.

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“…Furthermore, the assembly process of pre-magnetised PMs into the final SPM rotor design can require specialised fixtures to handle PM elements with appropriate care and locate them precisely on the rotor, preventing them from being damaged in the process and ensuring personnel safety from potentially strong attractive or repulsive magnetic forces. Despite PMSMs being widely used today, the PM rotor production processes are still largely manually driven due to different rotor sizes, complexities and motor designs [5].…”

Section: Introductionmentioning

confidence: 99%

3D-Printed rapid prototype rigs for surface mounted PM rotor controlled segment magnetisation and assembly

Melecio

Mohammed

Schofield

et al. 2019

2019 IEEE International Electric Machines &Amp; Drives Conference (IEMDC)

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This paper examines the feasibility of dedicated 3-D printed rigs use for enabling effective build and magnetisation of PM segments and controlled PM rotor assembly of a surface mounted PM rotor design. To this end a commercial surface mounted PM rotor design has been rebuilt and modified to allow for representation of a range of different PM magnetisation conditions. It is shown that suitable geometry assembly rigs made of electrically and magnetically passive material can be rapidly prototyped using 3D printing and applied to enable efficient PM segment build and magnetisation in a desired layout, as well as controlled surface mounted PM rotor assembly.

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Automated magnet assembly for large PM synchronous machines with integrated permanent magnets

Cited by 14 publications

References 2 publications

Robotized Surface Mounting of Permanent Magnets

Robotized Surface Mounting of Permanent Magnets

Innovative developments for automated assembly and fixation of integrated permanent magnets in rotors of synchronous machines

3D-Printed rapid prototype rigs for surface mounted PM rotor controlled segment magnetisation and assembly

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