Search

DE-102025137327-A1 - METHOD AND DEVICE FOR ASSEMBLING A HALBACH ARRAY USING A PERMANENT MAGNET MOUNTING DEVICE

DE102025137327A1DE 102025137327 A1DE102025137327 A1DE 102025137327A1DE-102025137327-A1

Abstract

A method for assembling a Halbach array using a permanent magnet assembly device (100) may comprise: inserting (S10) a magnet arrangement device (130) between an outer diameter alignment device, hereinafter referred to as OD alignment device, (110) which has a plurality of permanent magnets arranged in a cylindrical shape and forming a magnetic field in a radial direction (a) and a tangential direction (b), and an inner diameter alignment device, hereinafter referred to as ID alignment device (120) which is formed as a pair with the OD alignment device (110); arranging (S20) a plurality of arrangement magnets (20) in an arrangement groove (131) which is formed along an outer circumference of the magnet arrangement device (130) according to an orientation of a Halbach array; separating (S30) the magnet arrangement device (130) from the OD alignment device (120); and the ID alignment device (110) when all of the plurality of arrangement magnets (20) are arranged in the arrangement groove (131), and performing (S40) a joining operation to fix the plurality of arrangement magnets (20) arranged in the arrangement groove (131).

Inventors

  • Seongjun Park

Assignees

  • HYUNDAI MOTOR COMPANY
  • KIA CORPORATION

Dates

Publication Date
20260513
Application Date
20250916
Priority Date
20241108

Claims (20)

  1. Method for assembling a Halbach array using a permanent magnet assembly device (100), comprising: Introducing (S10) a magnet arrangement device (130) between an outer diameter alignment device, hereinafter referred to as OD alignment device, (110) which comprises: a plurality of permanent magnets arranged in a cylindrical shape and forming a magnetic field in a radial direction (a) and a tangential direction (b), and an inner diameter alignment device, hereinafter referred to as ID alignment device (120), which is formed as a pair with the OD alignment device (110), Arranging (S20) a plurality of arrangement magnets (20) in an arrangement groove (131) which is formed along an outer circumference of the magnet arrangement device (130) according to an orientation of a Halbach array, Separating (S30) the magnet arrangement device (130) from the OD alignment device (120) and the ID alignment device (110) when all of the plurality of arrangement magnets (20) are arranged in the arrangement groove (131), and performing (S40) a joining operation to fix the plurality of arrangement magnets (20) arranged in the arrangement groove (131).
  2. Procedure according to Claim 1 , wherein, when arranging the plurality of arrangement magnets (20) according to the orientation of the Halbach array, each arrangement magnet (20) of the plurality of arrangement magnets is arranged using a magnetized arrangement magnet (20) or a non-magnetized arrangement magnet.
  3. Procedure according to Claim 1 or 2 , wherein the arrangement of the plurality of arrangement magnets (20) according to the orientation of the Halbach array comprises: detecting an arrangement magnet from the plurality of arrangement magnets (20) which has not been positioned in a correct position, based on a mismatch between a magnetic field direction of a permanent magnet and an orientation of the arrangement magnet (20).
  4. Procedure according to Claim 3 , wherein detecting the arrangement magnet (20) which has not been positioned in a correct position comprises: checking a magnetization direction or the orientation of the arrangement magnet (20) by arranging the arrangement magnet (20) on a reference magnet (25).
  5. Procedure according to one of the Claims 1 until 4 , wherein, when arranging the plurality of arrangement magnets (20) according to the orientation of the Halbach array, the plurality of arrangement magnets (20) are arranged as an 8-piece unit, a 6-piece unit or a 4-piece unit.
  6. Procedure according to one of the Claims 1 until 5 , wherein the arrangement of the plurality of arrangement magnets (20) according to the orientation of the Halbach array comprises: sequential arrangement of plurality of arrangement magnets (20) according to a priority group which takes into account a magnetic field direction formed on the magnet arrangement device (130).
  7. Procedure according to Claim 6 , wherein the arrangement of the plurality of arrangement magnets (20) according to the orientation of the Halbach array comprises: arranging a first part of the plurality of arrangement magnets (20) with a first polarity which is the same as that of the magnetic field in the radial direction (a) in the magnet arrangement device (130), arranging a second part of the plurality of arrangement magnets (20) with a second polarity which is opposite to the first polarity based on the magnetic field in the radial direction (a), arranging a third part of the plurality of arrangement magnets (20) with the magnetic field in the tangential direction (b), and arranging a fourth part of the plurality of arrangement magnets (20) with an orientation which differs from the orientations of the radial direction (a) and the tangential direction (b).
  8. Procedure according to Claim 7 , wherein the arrangement of the plurality of arrangement magnets (20) comprises: first arranging a first subset of the plurality of arrangement magnets (20) with a polarity of the same direction and then arranging a second subset of the plurality of arrangement magnets (20) with a polarity of an opposite direction.
  9. Procedure according to Claim 7 or 8 , wherein, when arranging the plurality of arrangement magnets (20) with an orientation which differs from the orientations of the radial direction (a) and the tangential direction (b), a fifth part of the plurality of arrangement magnets (20) is arranged with a polarity of a diagonal direction which is formed from a magnetic field of an adjacent radial direction (a) and tangential direction (b).
  10. Procedure according to one of the Claims 1 until 9 , wherein the joining process comprises: injecting resin (56) into the plurality of arrangement magnets (20) arranged in the arrangement groove (131), connecting an upper cover (132) to the magnet arrangement device (130) on which the injection of the resin (45) is completed, placing the plurality of arrangement magnets (20) into a vacuum chamber (200), performing a bubble removal process on the plurality of arrangement magnets (20) under a predetermined pressure condition, and placing the magnet arrangement device (130) for which the bubble removal process is completed into an oven (300), and performing a curing process according to a predetermined resin curing condition.
  11. Permanent magnet mounting device (100) for a Halbach array mounting, the permanent magnet mounting device (100) comprising: an outer diameter alignment device, hereinafter referred to as OD alignment device, (110) in which a plurality of permanent magnets (10) are arranged in a cylindrical shape to form a magnetic field in a radial direction (a) and a tangential direction (b), an inner diameter alignment device, hereinafter referred to as ID alignment device, (120) which is configured as a pair with the OD alignment device and in which the plurality of permanent magnets (10) are arranged in a cylindrical shape, and a magnet arrangement device (130) which is inserted between the OD alignment device (110) and the ID alignment device (120) and is configured to produce a Halbach array permanent magnet in a ring shape by a joining process, while a plurality of arrangement magnets (20) is arranged in an arrangement groove (131) which is formed on an outer circumference, according to an orientation of the Halbach array.
  12. Permanent magnet mounting device (100) according to Claim 11 , wherein the OD alignment device (110) is configured to position one arrangement magnet from the plurality of arrangement magnets (20) in a correct position when the plurality of arrangement magnets (20) are arranged in the magnet arrangement device (120).
  13. Permanent magnet mounting device (100) according to Claim 12 , wherein the ID alignment device (120) is configured to: form a magnetic field in the same direction as the OD alignment device (110), align the arrangement magnet (20) arranged in the magnet arrangement device (130) in the correct position, and increase a fixing force of the arrangement magnet (20) in conjunction with the OD alignment device (110).
  14. Permanent magnet mounting device (100) according to one of the Claims 11 until 13 , wherein each arrangement magnet of the plurality of arrangement magnets (20) uses a magnetized magnet or a non-magnetized magnet and the plurality of arrangement magnets (20) is arranged as an 8-piece unit, a 6-piece unit or a 4-piece unit.
  15. Permanent magnet mounting device (100) according to one of the Claims 11 until 14 , further comprising a base (140) which is formed with an insertion groove for inserting the magnet arrangement device (130) onto an upper surface, wherein the OD alignment device (110) and the ID alignment device (120) are installed parallel to the upper surface of the base (140) based on a rotation axis (c).
  16. Permanent magnet mounting device (100) according to one of the Claims 11 until 15 , wherein the magnet arrangement device (130) comprises: an upper cover (132) which is configured to fix the plurality of arrangement magnets (20) which are arranged in the arrangement groove (131) when the joining process is carried out.
  17. Permanent magnet mounting device (100) according to Claim 16 , wherein the upper cover (132) is on a top side of the plurality of arrangement magnets (20), which are arranged in the The joint groove (131) is arranged to form a flowable space (133) so that resin (45) remaining after filling an empty space can rise when the joining process is carried out.
  18. Permanent magnet mounting device (100) according to Claim 17 , wherein the flowable space (133) is formed in a tapered shape so that the resin (45) hardened in an oven (300) can be separated.
  19. Permanent magnet mounting device (100) according to one of the Claims 11 until 18 , wherein the magnet arrangement device (130) has a support block (135) which is arranged at the lower end of the arrangement magnets (20) arranged in the arrangement groove.
  20. Permanent magnet mounting device (100) according to Claim 19 , wherein the support block (135) has a fluid passage (134) for a resin (45) injected during the joining process.

Description

Technical field The present disclosure relates to a method and a device for assembling a Halbach array using a permanent magnet assembly device, and in particular to a method and a device for assembling a Halbach array using a permanent magnet assembly device, which is applicable to the manufacture of a rotor of a drive electric motor of an electric vehicle. background Typically, an electric vehicle (EV) drive motor may have a stator, which is designed to receive electrical energy from a battery and generate a rotating magnetic field, and a rotor, which rotates due to the rotating magnetic field generated by the stator. The rotor receives energy and converts the rotating magnetic field generated by the stator into driving energy. For this purpose, it has a structure in which magnets are arranged around the circumference of a cylindrical rotor (rotor hub). In this case, the majority of magnets can be arranged in a circular Halbach array to amplify a magnetic field in the direction in which the stator is located. Such a method using a Halbach array has the advantage that the magnetic field of the magnets can be amplified, but from a manufacturing point of view, it has the disadvantage that it is difficult to assemble due to the mutual repulsion force when assembling the magnetized magnets with the rotating element. The conventional Halbach array method includes, for example, a method of assembly using magnetized permanent magnets and a method of assembly using non-magnetized permanent magnets. The assembly process using magnetized permanent magnets is a mounting or assembly method of connecting (e.g., gluing) the permanent magnets, whose arrangement is difficult due to the magnetized magnetic force, which also makes the implementation of automation difficult, using the rotating element, one after the other and manually. However, since in the first case the magnetized permanent magnets are connected individually, one after the other (e.g., glued), a considerable amount of time is required for the bond to cure, which has the disadvantage of reducing rotor manufacturing productivity. Furthermore, the permanent magnets can shift or creep due to repulsion before the bond has cured, making it difficult to optimize the magnet orientation. Additionally, it is difficult to solve a stray magnet problem during rotation using only the connection between the permanent magnets, necessitating a separate cover ring (e.g., made of carbon fiber reinforced plastic, aramid fiber, a metal sleeve, or similar material). The assembly process using non-magnetized permanent magnets is a process in which the non-magnetized magnetic material is first mounted on a rotating element and then magnetized by applying an external magnetic field. However, a disadvantage of this method is that magnetization after assembly reduces the magnetization level of sections where the position of the magnetic material and the magnetic field do not align (e.g., a tangential direction of the rotating element). This results in a lower magnetization rate for the permanent magnet compared to assembly using pre-magnetized permanent magnets. Furthermore, in the latter case, the unmagnetized magnetic material is indistinguishable by gaussian or flux measurement. Therefore, magnet manufacturers often apply different colored epoxy coatings for differentiation, which increases costs. If the coating is applied in the wrong color, incorrect assembly becomes a problem, and this cannot be rectified after magnetization, even if the issue is confirmed, thus increasing scrap costs. The above information disclosed in this background section is intended only to improve the understanding of the general background of the present disclosure and may therefore contain information that does not represent the prior art already known to a person skilled in the art in this field in this country. Brief explanation The present disclosure or invention (hereinafter also referred to as: disclosure) aims to provide a method for assembling a Halbach array using a permanent magnet assembly device and an assembly device used therein, which are capable of significantly reducing the manufacturing time of a rotor for an electric motor and ensuring a balance of quality by preventing the problem of faulty assembly, by assembling a large number of array magnets in a magnet arrangement device according to their orientation using a permanent magnet assembly device arranged in a cylindrical two-stage structure, and by performing a joining operation in the assembled state. A method for assembling (hereinafter referred to as "assembling") a Halbach array using a permanent magnet assembly device may comprise: inserting a magnet arrangement jig (e.g., magnet arrangement jig) between an OD alignment jig (e.g., OD alignment jig), which comprises a plurality of permanent magnets arranged in a cylindrical shape and forming a magnetic field in a radial and a tangential direction, and an ID alignment jig (e.g.,