Significant Technical Challenges of Conventional Processes

Modern Neodymium magnet(https://www.topmag.in/neodymium-magnets/) wind turbine rotors are devices of exquisite engineering, with a diameter of more than 4.3 meters and a highest point of 1.5 meters, like 84 magnetic poles arranged in a circular motion. Each pole has about 20 magnet blocks made of high-performance material, revealing significant problems when it comes to the production process. The pre-magnetizing technique is used where the process requires that every block should be manually put together, which is an operation that comes with a lot of problems. Due to the strong magnetic repulsion between magnetized blocks (up to a few tons), the assembly process is comparable to handling a "magnetic explosive." The workers must wear special protective equipment and use the magnetic balancer to make millimeter-level positioning, where even a tiny mistake could be as dangerous as high-speed moving objects. The data indicates that this traditional method is of low productivity; for example, a single pole is assembled in over four hours, and the wastage is 15-20%, which is uncompetitive with the mass production of large permanent magnet motors.

Revolutionary Breakthrough in Post-Assembly Magnetization Technology

In the implementation process, there are the following steps: Early on, the technicians, i.e., those responsible for the pre-assembly task, will be able to position the magnet blocks in such a way that they become as easy to secure as regular metal parts, the efficiency of the assembly operation is improved by over 10 times through the new method. Then, the magnetization is performed, the integrated 50T-class pulsed magnetic field generator being the one that manages to magnetize the entire pole in less than a second, the implemented uniformity of ±1.5% being the most consistent in the industry. Thus, the advantages of our solution in comparison with the industry leader's approach, which is the segmented multi-step magnetization technology developed by Siemens Corporation, are multiple: The single-step operation of a Full-pole magnetization method is much better, as it not only eliminates the necessity of repeating the process up to 12 times but also it overcomes the problem of magnetic fluxes, which would otherwise occur at the contact points of the segments resulting in the fluctuation of the flux density from ±8% to ±2%, and it reduces the energy cost by 60%. Field data indicate that this technology increases permanent magnet motor production efficiency by 8 times, ensures 5 times more production precision, and reduces manufacturing costs by 30%, which means it could be the most robust technical support to the mass production of large permanent magnet motors.

Technical Superiority and Industry Impact

This proposal has surpassed all the stringent benchmarks of the global leadership parameters in multiple technical dimensions. To elaborate on efficiency in magnetic field control, the designed multi-stage energy system can easily fully pole magnetize in 10 milliseconds. This is three times faster than an equivalent piece of equipment from VAC, the German manufacturer. Concerning magnetic field control, the unprecedented magnetic circuit design has formed a magnetizing effective zone of φ4.5m × 1.8m, an unparalleled large scale in the world so far. Of course, 100% magnet recovery is also guaranteed. Twenty-three brand-new international invention patents have been issued, and the National Metrology Institute of China has fully verified their technologies. The effects of such technologies are well beyond the limits of IEC 60034-30-1 standards. Apart from the fact that this technology can be widespread, it will also fundamentally redefine the permanent magnet motor manufacturing supply chain because it could pave the way for 5MW+ permanent magnet wind turbines with costs reduced by 25%.