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DE-102025127048-A1 - METHOD FOR MOUNTING MAGNETS USING HALBACH ARRAY MAGNETIC FIELDS AND DEVICES FOR THEM

DE102025127048A1DE 102025127048 A1DE102025127048 A1DE 102025127048A1DE-102025127048-A1

Abstract

One embodiment may include a method for mounting magnets: assembling (S10) an arrangement device (120) and an alignment device (110), wherein the alignment device (110) has a cylindrical shape with a rotation axis (c), placing (S20) a plurality of guide pins (131) in a placement recess (121) formed between the alignment device (110) and the arrangement device (120), wherein the plurality of guide pins (131) form a pin structure (130), placing (S20) a plurality of magnets (20) at first mounting spaces (P1) between the plurality of guide pins (131) in the placement recess (121), removing the plurality of guide pins (131) from the placement recess (121), wherein second mounting spaces (P2) are provided, placing (S40) circumferential magnets (20a) at the second assembly rooms (P2), pressing (S50) upper ends of the majority of magnets (20) and the circumferential magnets (20a) to align all array magnets according to a certain height, curing (S60) of a bonding material (40) between the aligned array magnets, and releasing (S60) the alignment device (110) from the array magnets.

Inventors

  • Seongjun Park

Assignees

  • HYUNDAI MOTOR COMPANY
  • KIA CORPORATION

Dates

Publication Date
20260513
Application Date
20250710
Priority Date
20241108

Claims (20)

  1. A method for mounting magnets, comprising: Assembling (S10) an arrangement device (120) and an alignment device (110), wherein the alignment device (110) has a cylindrical shape with a rotation axis (c), Place (S20) a plurality of guide pins (131) in a placement recess (121) formed between the alignment device (110) and the arrangement device (120), wherein the plurality of guide pins (131) form a pin structure (130), Place (S20) a plurality of magnets (20) at first mounting spaces (P1) between the plurality of guide pins (131) in the placement recess (121), Removing the plurality of guide pins (131) from the placement recess (121), wherein second mounting spaces (P2) are provided, Place (S40) circumferential magnets (20a) at the second assembly spaces (P2), Pressing (S50) the upper ends of the majority of magnets (20) and the circumferential magnets (20a) to align all array magnets according to a specific height, Curing (S60) a bonding material (40) between the aligned array magnets, and Releasing (S60) the alignment device (110) from the array magnets.
  2. Procedure according to Claim 1 , further comprising: aligning (S21) a magnetic mounting unit (140) onto a surface of the placement recess (121), and aligning (S22) the magnetic mounting unit (140) with the pin structure (130), such that the magnetic mounting unit (140) places a set of magnets (21) in a first of the first mounting spaces (P1) which is located between two adjacent pins (131) of the pin structure (130).
  3. Procedure according to Claim 2 , wherein placing the plurality of magnets (20) at first mounting spaces (P1) in the placement recess (121) comprises: moving (S31) by means of a pusher (143) of the magnet mounting unit (140) the set of magnets (21) to the first of the first mounting spaces (P1) in the placement recess (121), after completion of the placement of the set of magnets (21) in the first of the first mounting spaces (P1), (S32) retracting the pusher (143), rotating the pin structure (130), and aligning the magnet mounting unit (140) with a second of the first mounting spaces (P1).
  4. Procedure according to Claim 3 , wherein the pin structure (130) is rotatably connected by a rotor-shaped alignment device (110) or a rotor-shaped arrangement device (120), and wherein the pin structure (130) is rotated with respect to the axis of rotation (c).
  5. Procedure according to one of the Claims 1 until 4 , further comprising, after placing a first set of magnets (21) in a first assembly space (P1), applying the connecting material (40) between the first set of magnets (21).
  6. Procedure according to one of the Claims 1 until 5 , wherein the placement of the circumferential magnets (20a) in the second assembly spaces (P2) comprises: first placement (S41) of circumferential magnets (20a) which are magnetized outwards, according to a predetermined assembly sequence, and after completion of the first placement, second placement (S42) of all circumferential magnets (20a) which are magnetized inwards.
  7. Procedure according to one of the Claims 1 until 6 , wherein pressing the upper ends of the plurality of magnets (20) and the circumferential magnets (20a) comprises: placing (S51) a support block (150) on a lower section of the array magnets, connecting (S52) a rotor hub (170) to an inside of the array magnets, and pressing (S53) the upper ends of array magnets by means of a pressing block (160).
  8. Procedure according to Claim 7 , wherein the process of releasing the alignment device (110) from the array magnets comprises: placing (S61) the aligned array magnets and the rotor hub (170) in an oven (300), curing the aligned array magnets and the rotor hub (170) together, and releasing (S62) the alignment device (110).
  9. System comprising: an alignment device (110) configured to form a Halbach array magnetic field by means of a plurality of permanent magnets (10) arranged in a cylindrical shape, an arrangement device (120) connected to the alignment device (110) with respect to a rotation axis (c) of the alignment device (110), and a plurality of magnets (20) corresponding are magnetized in the Halbach array magnetic field in a Halbach array.
  10. System according Claim 9 , wherein the majority of permanent magnets (10) configured to form the Halbach array magnetic field are based on an 8-division method, a 6-division method or a 4-division method, and wherein the majority of magnets (20) have an assembly sequence based on an intermagnetic interaction and a property of the magnetic field according to one of the 8-division, 6-division or 4-division methods.
  11. System according Claim 9 or 10 , wherein the alignment device (110) is an outside diameter alignment device, or OD alignment device, which is configured to generate magnetic fields concentrated on an inside direction according to an inside rotor, or wherein the alignment device (110) is an inside diameter alignment device, or ID alignment device, which is configured to generate magnetic fields concentrated on an outside direction according to an outside rotor.
  12. system according to one of the Claims 9 until 11 , wherein the alignment device (110) comprises an iron material (Fe).
  13. system according to one of the Claims 9 until 12 , further comprising: a pin structure (1310) which, when mounting the magnet, is connected to a placement recess (121) between the alignment device (110) and the arrangement device (120), a magnet mounting unit (140) which presses and mounts three magnet pieces (21), without magnets (20a) aligned in the circumferential direction (a), into the placement recess (121) subdivided by the pin structure (130), a support block (150) which is mounted on lower sections of the alignment device (110) and the arrangement device (120) in a state in which all magnets are mounted on the placement recess (121) after the pin structure (130) has been released, and a pressing block (160) which presses the upper ends of all magnets in a state in which the support block (150) is mounted, in order to position all magnets according to the height of a rotor hub (170) to align finally.
  14. System according Claim 13 , wherein the magnet mounting unit (140) comprises: a mounting hole (144) formed between a lower block (141) and an upper block (142), and a pusher (143) designed to push a set of magnets (21) through the mounting hole (144) and into the placement recess (121).
  15. System according Claim 14 , wherein the lower block (141) has a receiving groove (144a) for mounting the set of magnets (21) on an upper surface, wherein the upper block (142) has a guide groove (144b) on a lower surface at a position which corresponds to the receiving groove (144a), and wherein the mounting hole (144) is formed by connecting the receiving groove (144a) and the guide groove (144b).
  16. System according Claim 14 or 15 , wherein the set of magnets (21) comprises three magnet pieces (21), wherein a tangential direction magnet (20b) is arranged in a center, wherein a connecting material (40) is applied to both ends of the tangential direction magnet (20c), and wherein diagonal magnets (20c) are arranged on a left side and a right side of the tangential direction magnet (20b).
  17. System according to Claim 14 , 15 or 16 , wherein the lower block (141) is made of iron (Fe) and the upper block (142) and the push button (143) are made of aluminium.
  18. system according to one of the Claims 13 until 17 , wherein the pin structure (130) has a plurality of guide pins (131) which are arranged in a circular shape around the axis of rotation (c).
  19. System according Claim 18 , wherein the pin structure (130) guides insertion positions of three magnet pieces (21) by means of a first mounting space (P1), which, when connected with the placement recess (121), is ensured between the plurality of guide pins (131), and ensures a second mounting space (P2) of the circumferential magnet (20a) to be mounted by a diameter size of the guide pin (131) when released.
  20. system according to one of the Claims 13 until 19 , wherein the pin structure (130) is rotatably connected to the alignment device (110) about the axis of rotation (c) and is rotatable about a predetermined angle with the alignment device (110), to provide insertion points for a set of magnets (21) for the magnet mounting unit (140).

Description

Technical field The present disclosure relates to a method for mounting magnets using Halbach array magnetic fields and a device therefor, and in particular a method for mounting magnets using Halbach array magnetic fields and a device therefor for a rotor of an electric motor of an electric vehicle. background In general, a drive electric motor of an electric vehicle EVx has a stator, which receives electrical energy from a battery and generates a rotating magnetic field, and a rotor, which rotates due to the rotating magnetic field generated by the stator. The rotor receives power and converts the rotating magnetic field generated by the stator into driving energy. For this purpose, it has a structure in which a plurality of magnetic materials are arranged around the circumference of a cylindrical rotor (rotor hub). In this case, the plurality of magnets can be assembled in a circular Halbach array configuration to amplify a magnetic field in the direction oriented by the stator. Such an arrangement in the form of a Halbach array has the advantage that the magnetic field of the magnetic substance can be amplified, but has the disadvantage that when assembling a magnetized magnetic substance with the rotor, assembly is difficult due to mutual repulsion with regard to manufacturing. The arrangement in the form of a Halbach array of a related technique, for example, includes a mounting method with magnetized permanent magnets and a mounting method with non-magnetized permanent magnets. A magnetized permanent magnet assembly method (also known as premagnetization method) is an assembly method of manually connecting a permanent magnet, where an arrangement by a magnetized magnetic force and an automation implementation on the rotor one after the other is difficult. However, since the first method involves individually bonding the magnetized permanent magnets one by one, it has the disadvantage of requiring considerable time for the bonding material to cure, thus reducing rotor manufacturing productivity. Another drawback is that the permanent magnet creeps due to repulsion until the bonding material has cured, making it difficult to optimize the magnetic direction. Furthermore, it is difficult to solve a stray magnet problem during rotation solely through the bonding of the permanent magnets, and a separate cover (carbon fiber reinforced plastic, aramid fiber, metal sleeve, etc.) is required, making automation of the process challenging. The assembly method with non-magnetized permanent magnets (also referred to as the latter method) is a method in which a non-magnetized magnetic material is first assembled with the rotor and then the non-magnetized magnetic material is magnetized by applying an external magnetic field. The latter method, however, has the disadvantage that the degree of magnetization of a part (e.g., a tangential direction of the rotor), where the positions of the magnetic field and the magnetic material do not coincide, deteriorates during magnetization after assembly. Consequently, the magnetization rate of the permanent magnet is lower than with the method of assembling the magnetized permanent magnet. That is to say, a characteristic of the Halbach array is that a magnet is aligned in a tangential direction on a rotational axis of the rotor, and this direction is perpendicular to the magnetic flux application direction by an external electromagnet (yoke), which is why 100% saturation cannot be achieved. Furthermore, in the latter method, it is impossible to distinguish the non-magnetized magnetic material using Gaussian or flux measurements. This leads to increased costs, for example, due to the need for a different colored epoxy coating for differentiation by the magnet supplier. Additionally, if the coating is incorrect upon delivery, it can cause incorrect assembly. Furthermore, even if a problem is confirmed after magnetization, the connection cannot be repaired during assembly, resulting in increased scrap costs. The foregoing information disclosed in this background section is provided solely for a better understanding of the background of the present disclosure, and therefore cannot be considered information. contain information which is not part of the state of the art as it is known to a person skilled in the art in this country. Brief explanation Embodiments provide a method for mounting or assembling (hereinafter referred to as mounting) magnets using Halbach array magnetic fields and a device for this purpose, which automates the mounting of magnets in a specific sequence in a stabilized state using the properties of a Halbach array magnetic field formed in a cylindrical alignment device and the physical properties of a magnet. Further embodiments provide a method for mounting or assembling magnets using Halbach magnetic fields, comprising: a step in which an arrangement device is arranged (e.g., mounted) about a rotational axis c of an alignment device, which forms a Halbach a