Prototyping: The case history of the neodymium magnets actuator for textile loom
A leader in the production of textile machines has partnered with Rd Europe Group to improve automation and loom productivity. The needs were several and the R&D Europe Group staff was responsible for the design, prototyping and production of a special assembly shaped rod / magnetic actuator, which could improve the performance of the machinery perfectly adapting to the existing one. The solution was the realization of a magnetic linear actuator with Halbach axial field, formed by a stem on which are applied 20 neodymium rings with axial Halbach magnetization (and not radial). The assembly is a special product, designed to also respond to the implementation requirements. The magnetic rings are in fact mounted on the stem, simplifying the production. Another critical problem of the project was the fact that the magnetic field had to be external to the stem to ensure speed and predetermined dimensions.
The solution designed by Rd Europe Group has also guaranteed to the customer the elimination of a part of mechanical processing, simplifying the production process but also improving the machine performance in terms of reliability and maintenance requirements.
The magnet produced by Rd Europe Group is a plastonedoymium BM17T with Br of 1.2 T coated and protected by a stainless steel tube. Thanks to the work of RD Europe designers, the client company was able to present the solution as an absolute novelty of the field, to a prestigious international event held in Shanghai in China.
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RD EUROPE GROUP AND UNIVERSITY OF PISA TOGETHER TO DEVELOP AN INNOVATIVE ENGINE
The Department of Electrical Engineering of the University of Pisa has recently contacted RD Europe Group to work on the prototype of an axial flow engine model to be used for university planning. Basically the request was to create a full-size motor, with a structure of transparent plastic material: a kind of functioning model to show students the operation of the apparatus. The model designed works in both directions, thanks to the magnetic disc structure with axial rotation movement. It can generate current or power, depending on how it rotates. In addition, variating the distance of the magnetic disks, is possible to study how the torque generates changes depending on the distance of the magnetic walls.
The University of Pisa has chosen RD Europe Group to design and implement a complex prototype for the university education because we are able to design and produce many kinds of prototypes also for the industry, in a very short time, but with the highest technical professionalism.
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The rotor for evolved powertool has a magnetic heart!
By partnering with large and small companies of powertool, RD Europe Group is able to produce highly advanced magnetic rotors. Thanks to the magnetic heart, in fact, the rotors RD Europe are more powerful and longer endurance because are brushless, the weakest part and subject to usury. For a big Italian company with over 60 years of history in the production of drills, grinding machine and industrial powertool, we have produced a new evolved rotor to improve the vehicle refinishing grinding machine on which the rotor was installed. Basing on customer’s drawing, RD Europe Group studied the needs and found the best solution for the performance required. Primarily about the magnetic material of the rotor for a very high torque ripple. The RD Europe staff has done verification and testing to ensure the couple in relation to thickness, mass and diameter of the plate, by producing some prototypes for tests. The solution was a ring in sintered neodymium, 8 poles with Br 12.5 KGs, nickel-copper-nickel coated and black epoxy. The assembly built by RD Europe Group overcome continuous tests and exceeded expectations by ensuring an improvement of the performance of the grinding machine, which is today on the market in a more advanced version than the previous.
Contact us to innovate your product thanks to the magnetic solution!
Magnetic joints: the high performance solution for most powerful rotors
More and more often the companies contact RD Europe Group to improve parts of their motors and magnetic couplings for more performance thanks to the magnet. It's the case of a latest-generation magnetic joint applied to a hydraulic gear pump. Customer needs were many so the design was complex: first to increase the drive torque with neodymium Nyomag NM-52 and then a coupling without contact between rotor and stator. The transmission of motion in magnetic coupling occurs in fact between the outer and the inner rotor without any contact between mechanical parts but with the same precision of the traditional systems. RD Europe Group has developed 2 different versions of the joint for different motors: a neodymium one with a resistance up to 180 °C of temperature, the other one in samarium cobalt with a resistance up to 300 ° C. Secondly, the magnetic joint has been studied in order to make easier the bonding and the corrosion resistance thanks to an epoxy resin coating on the neodymium magnet. The result? A better performing rotor, powerful and durable which reduces the maintenance costs.
Contact RD Europe Group to improve the performance of your products thanks to a personalized magnet!
Automotive field prototypes: RD Europe together with European big companies
RD Europe is cooperating with a manufacturer leader of automotive water pumps for European market. The aim of this customer is to study a new model that will be launched on the market starting from 2020 and that will be built on over 500.000 motors/year.
The purpose is project and realize a more compact, performant and lighter new water pump in order to improve the motor efficiency. RD Europe’s team is developing a tailored solution to answer to customer needs. First, we focused on realization of a more powerful magnet, with the same obstruction, working on its shape. No more trapezoidal, but lightly curved, in that way we could take advantage of a wider magnetic surface, increasing the mass.
Secondly, improving the last of the piece, which working in water, is subject to typical corrosion trouble. Today magnet coating is realized with stainless steel: a very resistant material but also very expensive, noisy, and complicated to be produced, as must be welded on the rotor in order to guarantee endurance. RD Europe has studied a coating solution with a special injected plastic, that make the assembly lighter, less noisy and easier to be realized and assembled. It simplify considerably the production. The new piece, today in test phase, bring performance and economics advantages. Find out how you can innovate your product together with RD Europe Group!
The sensor ring for automotive
An automotive distributor company has involved RD Europe for the production of 10,000 rings with magnetic sensor for ABS. Customer's requirement was to include in its product range this piece, no longer provided by the mother company. To ensure an adequate post sales service was necessary a supply of sensors rings identical to the original ones that could compensate the lack of the market. RD Europe has created a new project, starting from the existing item, and produced it quickly with little costs; exactly what required the company. The assembly has been realized in plastoferrite, injected directly on a metal sheet support: a complex production process for the realization of a piece granting great reliability and performances equal to the original. The sensor ring has medium-size: diameter 93 mm, height 8.5 mm and two models of 96 and 88 poles. Thanks to RD Europe the company ensure a good post sales service, purchasing the amount of pieces required (without straining the stock). Do you need a complex assembly? Call us to find out what RD Europe can do for your company!
Prototyping easy: the case of the magnetic power steering
Increasingly we collaborate with companies to innovate their products by developing revolutionary solutions for their target market. Often their need is to check the options to understand the feasibility, including economic, of a project. It’s the case of a prototype for the world of motors that RD Europe Group team has developed for a customer, starting from his needs: greater efficiency, reduced size, better performance and lower maintenance requirements (magnetic rotor brushless). The challenge was complex: to create a magnetic rotor skewed 28 poles ring able to withstand 180° C. Normally, to do that, it is needed an important investment for the necessary tooling. RD Europe Group has instead reasoned with the customer in order to cooperate and realizing a pilot structure through which to test this solution on the motor, before proceeding with the investment. The sample produced was then subjected to all the approval processes and testing to confirm its performance. The magnetic rotor made by Rd Europe Group has a length of 50 mm, an outer diameter of 70 mm, an inner diameter of 30 mm and is designed to work with axis inclined by 36 ° (skew effect) to reduce the cogging effect. The solution is modular for other needs, and allows to work in a range from 4 to 32 poles on various types of motors, ensuring better performance and better efficiency of the motor class.
ABS for professional e-bikes: Precision made in RD Europe Group
RD Europe Group team has developed an evolved magnetic system for ABS e-bike to reduce production and assembly costs. The challenge was not simple: produce a magnetic ring for brake devices smaller than traditional ones, lighter and thinner but able to ensure the most precise braking performance. RD Europe has worked on a brake on which are molded the single magnet: the unique piece provides to the e-bike manufacturer lower costs of brake assembly. The ring, which has a diameter of 90 mm, contains 96 poles (each thickness is less than a millimeter in size) thanks to which it guarantees a high precision in braking: the number of poles also identifies the amplitude of the braking, reacting according to the pressure on the brake with a much more accurately precision than the traditional systems. RD Europe system replaces and overcomes the traditional concept of braking on the hub and disc, making the ABS system more fluid, precise and safe. The target is put on market, in a year, 30,000 braking systems equipped with this innovative solution, which will be fitted on a high level of e-bike range.
Find out how to innovate your products with RD Europe!
More power in less space: RD Europe Group rotor for power tools
Another interesting challenge for RD Europe Group commissioned by a power tools sector customer: a magnetic rotor molded directly on the shaft, that grant higher torque at same rpm. RD Europe’s rotor substituted the classic one composed by a magnetic part glued on the rotor. It has been used by the company manufacturer of drills and electric screwdrivers.
To reduce assembling costs and rotor dimensions, RD Europe has projected a magnetic rotor molded directly on the shaft: the new one is a unique piece safer and lighter, with an important and competitive advantage. Concerning the power request, RD Europe has met the perfect solution with BM36T, a material with high residual induction (1.20 T comparing to classic 0.8 T of neodymium, it means 50% more) on a very little rotor (28 mm, 8 poles magnetized). At the moment this project is in Test phase… waiting for being launched on the market. Do you want to develop new solutions to improve your power tools motors?
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Solarium fan: improve efficiency with out-runner motor
RD Europe Group works together with companies all over the world to improve motor efficiency thanks to magnetic technology implementation. It is what we have done for a fan motors manufacturer company, German leader in the field of ventilation. The challenge consisted in reducing energetic consumption of a cooling fan inside a solar shower. Customer’s intention was launch on market a solarium with high performance. It had to grant lower consumption for end clients (aesthetic centers with different machinery, so high levels of energy consumption). In order to do that, we designed the inner fan, converting the traditional inrunner system (which is the heart of the motor that runs) with an outrunner system (which is the external part that runs): RD Europe Group worked with the German manufacturer on a new motor – smaller and more efficient comparing with the previous – the magnetic part has one ring assembled on motor body (instead of lot of magnets, assembled on inner rotor) using the concept of external rotor for wind turbine. Made in bonded neodymium 4 poles, quality BM13L, magnet has a diameter of 53 mm, length of 30 mm and 4 mm of thickness.
Thanks to the innovation of the fan, our customer could launch on market a better product in A+++ class of efficiency, positioning on marketplace in a winning way for power and consumption.
Improve your product: work with RD Europe Group !