Abstract
Due to lower magnetic properties of polymer-bonded magnets compared to sintered magnets, a complete redesign of the multipolar soft magnetic flux barriers in rotors with alignment guidelines was carried out to eliminate the frequently used rare-earth magnets, causing a new influence of the outer magnetic field on the cavity by using soft magnetic inserts. Within this new process, the main influencing factors on the magnetic flux density such as filler content, tool temperature, holding pressure and injection velocity were analysed and correlated. The studies were based on the compound of Polyamide 12 and up to a 60 vol.-% of the hard magnetic filler, strontium ferrite. Based on the study, the injection moulding of multipolar-bonded magnets into soft magnetic inserts for rotors and, in turn, into complex geometries can be optimized in terms of the orientation of the filler, the microstructure and the magnetic flux density. The investigations show no significant influence of the process parameters known from the literature such as the mass temperature Tm, which affects the magnetic flux density, as well as the orientation and the microstructure similar to tool temperature Tt, but is less efficient. The main influencing factors identified during the investigations are the tool temperature Tt, the injection velocity vin and the holding pressure ph. As known influencing factors are only based on simple geometries such as ring structures or plates, new factors were determined for complex rotor geometries.
Highlights
Polymer-bonded permanent magnets are mainly used in the field of sensor technology as signal transmitters, which help to drive this technology
Thermoplastic-based matrix materials allow the fabrication of permanent magnets by injection moulding, and the utilization of the advantages in the area of geometry freedom and the accuracy of the components, especially in small and thin geometries due to a reduced shrinkage [2]
The polymer-bonded permanent magnets are composite materials consisting of a polymer matrix with embedded, hard, magnetic filler particles
Summary
Polymer-bonded permanent magnets are mainly used in the field of sensor technology as signal transmitters, which help to drive this technology. Recent investigations aimed to enable the integration of polymer-bonded permanent magnets into electric plate packages in the drive motors of the electromobility using full geometry freedom As a result, these new concepts can be applied, among others, in the field of separate, excited, asynchronous machines, which held a market share of 83% among the engine types in Germany in 2008 [7]. A raise in the output density and the efficiency could be shown as simulative and experimental [11] In this investigation, the influence and the correlation between the process parameters, the material and the viscosity, as well as the magnetic properties regarding the fabrication of polymer-bonded, permanent, magnetic flux barriers within the rotors, are presented for a synchronous reluctance motor. Tithheinntehwe rreoatloizrsa,tiaonnds tphruessetnhteedopinpothrtius nwiotyrkto aallpopwlythteheopntiemwizraottioorn coofntcheepftabforircaatisoynnochf rpoonloyumserr-ebluonctdaendce, pmeromtoarnewnitt,hmaagcnometimc eflrucxial bcaorrniteerxstw. ithin the rotors, and the opportunity to apply the new rotor concept for a synchronous reluctance motor with a commercial context
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