ewec 2010

Proprietary Information of Metis Confidential

Automated Magnetizing Solutions for Permanent Magnet Generators (PMG)

Metis Instruments & Equipment NV

EWEC 2010


Content

• Magnetizing: what, why and when

• ‘Metis Instruments & Equipment’ in a nutshell

• Automated solution for Permanent Magnet Generator (high speed)

• Solutions for Direct Drive• Prototyping solutions


Magnetizing: What?

Apply a strong magnetic field during a short time to allign the magnetic domains.

• Short: milliseconds

• Strong: 3 to 6 Tesla

• Using discharge of the energy of a capacitor bank to drive the windings in dedicated yoke


Magnetizing: Not why, when!

• Single magnets by the supplier• Single magnets prior to glueing• In sub-assembly after glueing• On rotor after mounting• In generator after complete assembly

The later, the better!


Magnetizing a PM:chooze your moment

Magnet supplier

Single magnet storage

Subcomponent Assembly

Issues:TransportationHandling

Storage spaceDirt accumulationHandlingSafetyGlueing time

Solutions:Larger magnetizer

Axial coil fixture

Solutions:Small magnetizerAxial coil fixture

Handling !SafetyHandling errorsMounting time


Magnetizing:chooze your moment

Rotor assembly

Generator assembly

Handling !!SafetyDirt accumulation

...

Solution:Larger magnetizerDedicated yokeFully automated systemOr docking / slave system

Solution:Limited due to access


• Faster Production– Reduced mounting time of magnets– Reduced total production time

• Safer production– Avoid difficult handling of pre-magnetized magnets– Avoid storage of large amounts of pre-magnetized material and components– Magnets are activated at later stage of production process

• Controlled production– In-line inspection of product performance parameters– Automated magnetizing process avoid magnet orientation errors

• Improve product quality– Better tolerances on magnet positioning– Ability to influence field profile

• Opens design opportunities

Advantages of‘late’ magnetization


Metis in a nutshell

Metis is a fast growing high-tech company that specialises in industrial magnetism

• History– Founded in 1998 – Based in Leuven, Belgium.– Spin-off of the University of Leuven, Belgium

• Product lines– Industrial magnetizing technology– Magnetic properties testers for the industry– Turn-key pulsed field installations for research centres


Metis in a nutshell

Metis designs and manufactures all its products in house

• Metis design– FE design of magnetizing fixtures and magnetic assemblies– CAD design of mechanics– CAE design of electronics

• Metis manufacturing– Metis final assembly and testing of its products in its work-shop in Leuven.– Metis production facilities contain:

• Lathes, milling machine, ...• Vacuum installation• Electronics lab

– Metis works together with a variety of specialized suppliers


• Metis delivers totally integrated production solutions• Automation mechanics are designed for the forces of pulsed magnetizing• Solutions are equipped with process & quality control systems• Metis has a vast experience in magnetizing large rotors for electrical machines

Magnetizing EquipmentComplete production units


Magnetizing Equipment Wind Power Industry Solution


Magnetizing EquipmentProviding the solution

• Material properties

• Modelling– Magnetizing yoke– Magnetizing sequence

• Proces sequence

• Quality control


Permanent Magnet SaturationMagnetizing field strength Map

• Based on our experience and measurements

• 2.5 T 99 %• 3.0 T 99.9 %• Magnetizing field only

required for < 1 ms98.0%

98.2%

98.4%

98.6%

98.8%

99.0%

99.2%

99.4%

99.6%

99.8%

100.0%

100.2%

0 1 2 3 4 5

Ba1 Ba2 Ba3 Fit


Magnetizing EquipmentMagnetizing calculations

Calculation and optimization of:

• Magnetizing energy, depending on saturation levels and rotor layout

• Mechanical forces during magnetizing process

• Cooling requirements for desired rep-rates

• Coil parameters and electric steel sheet layout


Magnetizing principle

• Rotor too large for full magnetization in one shot: – Impractical manipulation– Magnetizing energy too high

• Therefore: – Stepwise magnetization– Automated process


Metis Case Study 600 mm rotor – 10 poles


Metis Case Study Axially traveling yoke


Wind Power Industry Solution Process monitoring

• Measurement of magnetizing current:– Standard on every CDM magnetizer– Measures magnetizing current– Compares against minimal value: OK / NOK

• Real-time Feedback of magnetic field characteristics– Measurement of magnetic flux via flux coil in magnetizing fixture– Global measurement– Magnetic flux relates direct to generator performance– Integrated in fixture


Quality control

• Feedback– Gauss meter

• Local, subject to air gap > not suited

– Flux meter via search coil• Global measurement• Measures related to performance• Integrated in yoke


Quality controlFlux measurement

Flux

Scan afterwards much easier

Axial distance


MagnetizingGeared PM generators


Gearless PM Generators

“Direct Drives”


Industrial Magnetizing solutionfor an inside rotor


Direct Drive PMGIntegrated solution

• Put a docking station in the production street

– Rotation provided by production street– Magnetizing head travels over the pole– Mechanically self-supporting– Mostly a compact system


Direct Drive PMGIntegrated solution

• Access the rotor in the stator housing

– Either by opening up a small part of the stator– Provide a traveling head in the stator segment

– Or use the stator winding• They are not designed for • -> mechanical / magnetic issues


Schematics of the Yokeoutside rotor


A solution for aDirect Drive system

• Magnetizing Yoke– 1-2 active poles (symmetric)– Mechanically supported against surface– active axial length 100-200 mm

• Optionally skewed

– Energy requirements ~60 kJ

– Rep-rate: 1-3 minutes per shot


Prototype Service

For small series

Incorporate magnetizing in the validation proces


Prototype Service


Prototype Serviceavailable summer 2010

• Available installation

– Mounting frame• 2 m diameter• 2-10 ton rotor

– Automation– Yoke support– Magnetizer cabinet

• 100+100 kJ

• Variable cost

– Magnetizing yoke– Mounting adapters– Handling


Automated Magnetizing Solutions for Permanent Magnet Generators (PMG)

Summary


SummaryProduction Advantages

• Faster– Reduced mounting time of magnets– Magnetization time typically 1-2 hours/rotor

• Flexible – Different rotor lengths & types

• Safer– No handling of pre-magnetized material– Magnets are activated after assembly

• Controlled– In-line inspection– No human errors

• Improved product quality– Better magnet positioning tolerances– Influence neutral zone & skewness


• Industry innovator: – Design of energy efficient fixtures with FEM and proprietary software– Energy efficient magnetizing makes process economical– Mechanical design of automations suited for pulsed field magnetizing forces

• Vast experience in large rotor magnetization– First system successfully delivered into wind power industry– Experience in rotating machines industry

• Vast experience in magnet materials & measurement of magnetic properties– HyMPulse customers include leading companies– HyMAC customers include leading wind power companies

• Providing combined solutions of magnetization and magnetic measurement• Providing industrially proven turn-key production units• High-level of technical service and support

Magnetizing Equipment Why Metis as your partner?


Feasibility analysis & OfferRequired information

• To asses the feasibility of a magnetizing solution and to prepare a detailed offer, Metis needs the following information:

• 2D model of range of generators to be magnetized• Dimensions and axes lengths• Dimensional tolerances on diameter• Magnet dimensions• Properties of magnetic material• Desired process time per unit (rep.rate)


Wind Power Industry Solution Budget drivers

• Typical system containing:– Automation structure with rotational and linear axis– 100 kJ Magnetizer (required magnetizing energy

depends on rotor layout and desired process time)– One Fixture : can be exchanged for different rotor

types (within limits of automation dimensions) – On-line quality control with flux coil– Panel PC with steering software– Industrial enclosure and CE certification


Your partner for magnetism Contact Metis

Metis Instruments & Equipment

Kapeldreef 60

3001 Leuven

Belgium

Voice: +32 16 298 344

Fax: +32 16 298 319

E-Mail: [email protected]

Web: www.metis.be

ewec 2010

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