Magnet Business Development in Italy with Garnet SRL

“Our distributors are the key to our export success,” said Dave Hills, our Head of Sales, “and Garnet SRL has been the face of magnets for Bunting Magnetics in Italy for over twenty-five years.”

Dave Hills was talking about Garnet SRL after a sales trip to Italy in early March 2019.  The Bunting Europe team regularly visit their distributors to provide support (including attending exhibitions), offer training, and meet customers.

Garnet SRL

Garnet SRL
Dave Hills with Leo Lurino of Garnet SRL

Garnet SRL was founded by Leo Lurino in 1997.  However, his association with Magnet Applications, a Bunting subsidiary, began in 1994.  The company exclusively represents high-profile manufacturers of components for automation, robotics and the automotive industry.  This includes providing magnet and magnetic assembly solutions, designed and manufactured by Bunting Magnetics in the UK.

Garnet SRL is based in Concorezzo in the northern Italian region of Lombardy.  As well as Bunting, the company represents Canon, Arcus Technology, Fastech and others.

Their Magnet and Magnetic Assembly product portfolio is extensive and includes:

Developing Business In Italy

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“The visit proved very useful,” explained Dave.  “It gave me the opportunity to hear about developments in the local Italian market.  We can then adapt our strategies accordingly.  It also provided an opportune time to provide product training and sample the wonderful local Italian food.”

“Developing long-standing relationships with our distributors is key,” said Dave.  “Despite the concerns of BREXIT, we continue to see growth in export sales.  We will need to adapt to manage the new relationship with Europe, but this will not affect our association with our distributors.”

Bespoke Magnets and Magnetic Assemblies

Bunting design and manufacture a wide range of magnets and magnetic assemblies.  Many are bespoke for specific applications.  For further information on bespoke magnet assemblies or magnet designs, please contact us via:

Phone:  +44 (0) 114 276 2264

Email:  sales@buntingeurope.com

Via the Bunting Europe website for specialist magnets and magnetic assemblies

Via eMagnets for online purchase of Magnets and Magnetic Technology

“Our distributors are the key to our export success,” said Dave Hills, our Head of Sales, “and Garnet SRL has been the face of magnets for Bunting Magnetics in Italy for over twenty-five years.” Dave Hills was talking about Garnet SRL after a sales trip to Italy in early March 2019.  The Bunting Europe team […]

https://blog.e-magnetsuk.com/2019/03/18/magnet-business-development-in-italy-with-garnet-srl/

Sensing Magnets at Magnetic Measurement and Sensors Event

Bunting Magnetics Sponsoring UK Magnetics Society Event at LEGO in Denmark

Bunting is sponsoring and exhibiting at a two-day event entitled ‘Magnetic Measurement and Sensors‘ organised by the UK Magnetics Society (21 – 22 March 2019).  The conference is being held at LEGO House in Billund, Denmark.

This two-day event will focus on measurements in the field of magnetics.  New techniques exploiting the ability to pick up low level signals have been turned into robust sensors and systems and introduced in many different industrial settings performing on-line quality assessment of processes and materials.  Secondly, the magnetic materials themselves need to be quality tested using both conventional and new methods. Science in the area keeps on developing, yielding new opportunities for in-sight and products.

Sensor
NXT Sensor – LEGO Engineering

Included in the extensive list of speakers are Henning Kirk and Henning Mikkelsen of LEGO who will talk about ‘Magnets and Sensors for Fun – Applied in Advanced LEGO Toy Products’.

Magnets and Sensors

Magnetic position sensing using Hall Effect devices or Anisotropic Magneto Restrictive sensors is a well-established method of contactless positional location of rotational or linearly moving components.  Multiple sensors offer very accurate resolution and are used extensively in many electronic and mechanical control systems.  Position and rotational sensors can be position inside secondary complex components and utilise a bespoke magnetising fixture, also designed and built by Bunting Magnetics to maximise or set the capabilities of the magnet..

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The Bunting design and engineering team work closely with companies manufacturing and using sensors to develop magnetic assemblies with a focus on weight reduction, minimising false triggers, and performance.

A sensing application may range from a simple proximity switch (e.g. reed switch on a door or window security alarm) to encoder technology for motor control in automotive or aerospace applications.  The Bunting design team has worked on projects where sensors are required for detecting rotor positions, providing measurements (e.g. distances, speed or angle proximity), detecting fluid levels, and triggering switches.  These include magnets used to measure the level of fuel, contactless position sensing magnets, and magnets to sense speed.  A sensing application may range from a simple proximity switch (e.g. reed switch on a door or window security alarm) to encoder technology for motor control in automotive or aerospace applications.  Understanding the technical requirements of a magnetically contactless solution ensures the best design of Magnetic Assembly.

Different Types of Magnets

Many of the bespoke magnetising fixtures designed and manufactured by the Bunting team utilise a Bunting range of compression or plastic bonded Neodymium called BREMAG and BREMAG10N.  Plastic bonded magnets are often used due to their magnetic isotropy and advantage of being able to produce multipole (fine pole) magnetisation patterns for accurate position sensing.

Sensor Magnets
BREMAG Permanent Magnets

Both the BREMAG and BREMAG10N Magnet materials are manufactured in the UK and offer the highest energy (10, 10.5 and a World Leading 11MGOe) of all types of bonded magnets.  With the higher magnetic energy, this type of Neodymium Magnet is ideal for use in brushless DC motors, actuators and sensors.

Bunting also has a range of sintered and bonded neodymium magnets with direction of magnetism controlled to +/- 0.5 degrees.  This range of Magnets has been developed to provide integrators of Magnetostrictive position sensing offer more accurate and more compact systems.  When a typically linear position sensing has an accuracy proportionally to the angular error in an axially aligned ring magnet, magnets with a tighter specification significantly improve the performance.

For further information on magnets used in sensors applications, please contact us on

Phone:  +44(0)114 276 2264

Email:  sales@buntingeurope.com

Via the Bunting Europe website for specialist magnets and magnetic assemblies

Via the eMagnets online Magnet Shop

Bunting Magnetics Sponsoring UK Magnetics Society Event at LEGO in Denmark Bunting is sponsoring and exhibiting at a two-day event entitled ‘Magnetic Measurement and Sensors‘ organised by the UK Magnetics Society (21 – 22 March 2019).  The conference is being held at LEGO House in Billund, Denmark. This two-day event will focus on measurements in […]

https://blog.e-magnetsuk.com/2019/03/11/sensing-magnets-at-magnetic-measurement-and-sensors-event/

HYPED Hyperloop Team Sponsored by Bunting

Supporting The Advancement of Hyperloop Technology

Bunting Magnetics is sponsoring the HYPED Hyperloop team from the University of Edinburgh.  The team is dedicated to accelerating the development of Hyperloop and implementing the technology in the UK.  They will also be competing in the SpaceX Hyperloop Pod Competition in the Summer of 2019.

What Is A Hyperloop?

A Hyperloop is a conceptually revolutionary mode of transportation.  The Hyperloop is a near-vacuum sealed tube or system of tubes through which a pod may travel free of air resistance or friction.  It is exceptionally energy-efficient and can allow the pod to travel at very high speeds.

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Elon Musk congratulating the winners of the Hyperloop Pod Competition II at SpaceX’s Hyperloop track in Hawthorne, Calif., Sunday, Aug. 27, 2017.

In 2012, entrepreneur and engineer Elon Musk introduced his version of the concept.  The Hyperloop Alpha concept was published in August 2013, with proposals for a route between the Los Angeles region to the San Francisco Bay Area.  Many transport experts remain skeptical, citing build costs as a significant limiting factor and even claiming that the idea is “completely impractical”.  However, this has not stopped Elon Musk’s SpaceX further developing the concept.

To speed up the development of the Hyperloop concept, SpaceX launched the Hyperloop Pod Competition in 2015.  The competition’s goal is to support the development of functional prototypes and encourage innovation by challenging student teams to design and build the best high-speed Pod.

The HYPED Hyperloop Team

HYPED Hyperloop Team
HYPED Hyperloop Team

The HYPED team at the University of Edinburgh was founded in 2015 and has grown to over 200 registered student team members in 2019. The members’ wide range of skills and experience allows HYPED to excel in developing the Hyperloop.  Since 2015, the HYPED team has achieved several key milestones including:

HYPED Hyperloop Poddy II (2018)
Design overview of HYPED’s Poddy II (2018)

In 2019, HYPED will build their 3rd Pod.  The focus will be on a more integrated, feasible, and scale-able design, with a greater top speed.  Additionally, the team aims to build a test rail to fully integrate and test the design before shipment and launch.

The Magnet Component

As with many new environment initiatives (e.g. wind turbines and electric vehicles), high-powered Rare Earth Magnets play an important role in the Hyperloop pod design.

A Halbach Module is used to produce contactless propulsion.  A Halbach array is a specific arrangement of a series of permanent magnets. The array has a spatially rotating pattern of magnetism which cancels the field on one side, but boosts it on the other. The major advantages of Halbach arrays are that they can produce strong magnetic fields on one side whilst creating a very small stray field on the opposite side. This effect is best understood by observing the magnetic flux distribution.

A permanent magnetic assembly with high-powered Neodymium Rare Earth Magnets is used as levitation skies and emergency brakes.

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“The Hyperloop concept has the potential of revolutionising transportation,” explained Matthew Swallow, one of Bunting’s Magnet Design Engineers.  “Magnets and magnetic principles are an important part of the Pod design.  Subsequently, we wanted to show our support by sponsoring the HYPED team.”

Bunting design and manufacture a wide range of magnets magnetic assemblies.  Many are bespoke for specific applications.  For further information on bespoke magnet assemblies or magnet designs, please contact us via:

Phone:  +44 (0) 1442 875081

Email:  sales@buntingeurope.com

Via the Bunting Europe website for specialist magnets and magnetic assemblies

Via eMagnets for online purchase of Magnets and Magnetic Technology

Supporting The Advancement of Hyperloop Technology Bunting Magnetics is sponsoring the HYPED Hyperloop team from the University of Edinburgh.  The team is dedicated to accelerating the development of Hyperloop and implementing the technology in the UK.  They will also be competing in the SpaceX Hyperloop Pod Competition in the Summer of 2019. What Is A […]

https://blog.e-magnetsuk.com/2019/03/06/hyped-hyperloop-team-sponsored-by-bunting/

1200 Alnico Magnet Assemblies

Manufacturing Magnetic Assemblies for Sensors

Magnets and Magnetic Assemblies are a key component in many industrial sensing applications.  Typical Magnetic Sensor applications include contactless current sensing, linear and angular position, and rotation sensing.

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Alnico Magnetic Assemblies

The Magnetic Assembly

The Bunting engineering team designed the bespoke magnetic assembly for a specific customer application.  The magnetic assembly consists of:

The Alnico ring magnet is designed to have a tight fit around the steel core.  Once assembled, the magnetic assembly is magnetised using a Bunting designed magnetiser.  The finished magnetic assembly has four magnetic poles.

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Four poles of the Alnico Magnetic Assembly

The magnetic assembly used Alnico magnets due to the ability to maintain a magnetic field at high temperatures.  Other magnet materials, such as Neodymium, would significantly lose magnetic performance with rising temperatures.

This particular order was for 1200 Alnico magnetic assemblies.

Sensor Applications

Magnetic Sensors are used in a wide variety of applications including:

Bespoke Magnets and Magnetic Assemblies

Bunting design and manufacture a wide range of magnets magnetic assemblies.  Many are bespoke for specific applications.  For further information on bespoke magnet assemblies or magnet designs, please contact us via:

Phone:  +44 (0) 114 276 2264

Email:  sales@buntingeurope.com

Via the Bunting Europe website for specialist magnets and magnetic assemblies

Via eMagnets for online purchase of Magnets and Magnetic Technology

All photographs taken by Paul Fears Photography

alnico_magnetic_assembly-2313

 

Manufacturing Magnetic Assemblies for Sensors Magnets and Magnetic Assemblies are a key component in many industrial sensing applications.  Typical Magnetic Sensor applications include contactless current sensing, linear and angular position, and rotation sensing. The Magnetic Assembly The Bunting engineering team designed the bespoke magnetic assembly for a specific customer application.  The magnetic assembly consists of: Alnico […]

https://blog.e-magnetsuk.com/2019/01/29/1200-alnico-magnet-assemblies/

Magnets and Magnetic Assemblies at Southern Manufacturing 2019

Bunting Magnetics Europe Attract Visitors to Stand P225

Magnets, Magnetic Assemblies and Factory Magnetic Solutions will be on show on stand P225 at this year’s Southern Manufacturing & Electronics (5-7 February 2019, Farnborough International Exhibition and Conference Centre, UK).

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Southern Manufacturing and Electronics is promoted as the most comprehensive annual industrial exhibition in the UK.  On display at the show is new technology in machinery, production equipment, electronic production and assembly, tooling and components.  The exhibitors also include subcontract services across an impressively wide range of industries.

Magnet and Magnetic Solutions

Bunting Magnetics, along with their eMagnets UK brand, has exhibited at Southern Manufacturing & Electronics for several years.

“Southern Manufacturing brings together engineers from a wide range of sectors,” explained Dave Hills, Bunting Magnetics’ Head of Sales.  “At every show we have had an enquiry that has developed into an important project.”

On stand P225 Bunting Magnetics will be displaying:

As well as the displayed magnets and magnetic equipment, Bunting’s technical engineers will be available to discuss specific projects such as:

Bunting at Engineering Design Show 2018
Magnetiser fixture

2018 has been an exceptionally successful year for Bunting Magnetics,” said Dave.  “Southern Manufacturing is our second show of the year.  Exhibitions are an important part of our marketing plan as they provide the perfect opportunity to meet potential customers.  We are sure that this year’s exhibition will be a great success.”

For further information on permanent magnets, bespoke magnet designs, and magnetiser assemblies, please contact us:

Phone:  +44 (0) 114 276 2264

Email:  sales@buntingeurope.com

Via the Bunting Europe website for specialist magnets and magnetic assemblies

Via eMagnets for online purchase of Magnets and Magnetic Technology

Bunting Magnetics Europe Attract Visitors to Stand P225 Magnets, Magnetic Assemblies and Factory Magnetic Solutions will be on show on stand P225 at this year’s Southern Manufacturing & Electronics (5-7 February 2019, Farnborough International Exhibition and Conference Centre, UK). Southern Manufacturing and Electronics is promoted as the most comprehensive annual industrial exhibition in the UK.  […]

https://blog.e-magnetsuk.com/2019/01/14/magnets-and-magnetic-assemblies-at-southern-manufacturing-2019/

Magnet Technology Success in 2018

Bunting Magnetics Europe and eMagnets UK Report Growth in 2018

The demand for magnets, magnetic assemblies and magnetising equipment reached new heights in 2018.  The European operation’s sales were 25% higher than in 2017.

bunting magnetics europe simon ayling managing director-
Managing Director, Simon Ayling, outside the Berkhamsted facility

“As an engineering and manufacturing company, we are very proud of our achievements in 2018,” said our Managing Director, Simon Ayling.  “We have invested in our people and manufacturing capabilities.  That has been the foundation of this substantial growth.”

The European operation of Bunting Magnetics includes Bunting Magnetics Europe, Master Magnets, and eMagnets UK.

The Importance of People

In October, Bunting Magnetics Europe successfully achieved the ISO45001 International Standard for occupational health and safety (OH&S).  The implementation of new apprenticeship and trainee programmes will develop the next generation of engineers and skilled people.  New employees have joined the Berkhamsted and Redditch teams boosting staffing levels by approximately 15%.

Bunting Europe Health and Safety Committee
The Bunting Health and Safety Committee

“Our employees are a fundamental part of our success,” explained Simon.

Modernising Manufacturing

The reconfigured manufacturing area at Berkhamsted, including the installation of new manufacturing plant, will improve efficiency and quality.  The new plant includes a high capacity lathe and additional equipment to manufacture high intensity magnet assemblies.

There are plans for further investment in both manufacturing plants in 2019.

Sales Success

Sales of magnets continued to grow in 2018.  Magnets are sold online via eMagnets UK and through the Berkhamsted manufacturing facility.  The vast bulk of sales are for the highest strength Neodymium Rare Earth Magnets.  These are used in motors, sensors, wind turbines and many other commonly used equipment.

Bunting Magnetiser
Bespoke magnetiser

In 2018, there was an increase in the number of Magnetiser projects.  Magnetisers are designed to magnetically charge magnets or magnetic components.  The Bunting engineering team developed a new modular design, with a drive towards reduced manufacturing cost and lower maintenance.  This new magnetiser design proved very popular and resulted in global contracts for bespoke magnetisers.  The forecast for 2019 is very positive.

“Our whole business is based on the science of magnets,” explained Simon, “and our team includes experts in the industry.  Companies contact us with an application and we develop a magnet, magnetic assembly or magnetiser to suit.  This sets us apart from other companies.”

The 2019 outlook remains positive despite political uncertainty with Brexit and other global events.

“This is a very exciting time for the whole Bunting Magnetics Europe group,” said Simon.  “Our aim is to continually improve.  We are blessed with a fantastic workforce who are the foundation of our success.”

For further information on magnets, magnetic assemblies, and magnetisers, please contact us:

Phone:  +44 (0) 114 276 2264

Email:  sales@buntingeurope.com

Via the Bunting Europe website for specialist magnets and magnetic assemblies

Via eMagnets for online purchase of Magnets and Magnetic Technology

Bunting Magnetics Europe and eMagnets UK Report Growth in 2018 The demand for magnets, magnetic assemblies and magnetising equipment reached new heights in 2018.  The European operation’s sales were 25% higher than in 2017. “As an engineering and manufacturing company, we are very proud of our achievements in 2018,” said our Managing Director, Simon Ayling.  […]

https://blog.e-magnetsuk.com/2019/01/10/magnet-technology-success-in-2018/

2018 Review of Magnet News and Blogs

News and Technical Articles on Magnets and Magnetic Assemblies in 2018

2018 has been another exciting year for eMagnets and Bunting Magnetics.  Magnetic technology has never been more important.  Advances in environmental technology such as electric vehicles and wind turbines would not be possible without the simple magnet.  Throughout the year we reviewed some really novel and inspiring ways in which magnetic technology is applied.

February

In 2017, the UK government announced that 2018 will be the Year of Engineering, a national campaign to increase awareness and understanding of engineering among young people aged 7-16, their parents and their teachers.  This is part of a year-long campaign to tackle the engineering skills gap and widen the pool of young people who join the profession.  We wanted to show our support for such an important issue.

March

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Within the magnet industry, there are growing concerns that cutting edge technology could start driving up the price of rare earth minerals.  The Rare Earth mineral Neodymium is used in the manufacture of batteries for electric vehicles and for magnets used in wind turbines and computer hard drives.  Our article assessed the implications of the expected increased demand for rare earth minerals.

May

We featured an article about Tidi-Cable.  We had supplied bespoke Ferrite Magnets to Tidi-Cable for their newly released Tidi-Patch ® Magnetic.  Tidi-Patches instantly lift dangerous trailing cables off the ground and remove potential trip hazards.

Tidi Patch Magnetic Blog

They are used on construction sites, at festivals/events, in factories, in film studios, in mining operations, on oil/gas production sites, shipping yards, and railways.  A simple but innovative product.

August

We asked if offices could continue to function without the simple magnet.  The article focused on three vital pieces of technology that would cease to exist without a Magnet.

Our magnet technical team provided us an update on new magnet developments.  Using Grain Boundary Diffusion Technology, we are now producing Neodymium Magnets that are able to work in the harshest of environments.

September

In September, we exhibited at the Cenex-LCV 2018 event held in Millbrook, Bedfordshire, UK.  Cenex-LCV is the UK’s premier low carbon vehicle event.  There was an exhibition area as well as an extensive seminar programme.  In our post-event review we reviewed the gradual move to electric vehicles.

October

Bunting Europe Health and Safety Committee

The Bunting Health and Safety committee was thrilled to announce being awarded the ISO45001 international standard for occupational health and safety (OH&S).

Bunting at Engineering Design Show 2018

The depth of British engineering and manufacturing expertise was apparent at the Engineering Design Show (Ricoh Arena, Coventry, UK, 17-18 October 2018).  At the show, our UK-based design engineers were available to talk about bespoke magnet and magnetic assembly designs.

At the end of the month, we announced sponsorship of the UK Magnetics Society’s 31st Ewing Event.  The annual event focused on the future, assessing what magnet developments may occur in the next 30 years.

November

Bunting Magnetiser

The first of two case history technical articles in November reviewed a recent project for a bespoke Magnetiser.  High strength magnets (eg Neodymium Rare Earth) are a vital part in many everyday electric appliances.  Charging those small magnets for use in electronics applications often requires a high degree of accuracy.  One typical example is where the magnet interacts with a sensor to confirm that a component is correctly in place.

The second article discussed how we helped a customer reduce the manufacturing cost of a magnetic assembly by 90%.  This was achieved by developing a plastic-coated magnetic assembly that could be magnetised after the injection moulding process.

Bunting at Engineering Design Show 2018

December

At the UK Magnetics Society’s Ewing Event at the end of November 18, the future was very much described as being ‘magnetic’.  Industry experts predicted that magnetic engineering would be fundamental in the development of environmental technology.  An exciting future lies ahead!

Thank you for reading our news and blogs in 2018.  It has been an exciting year and we hope to have helped increase your magnet knowledge.  If you need any information on magnets or magnetic assemblies please contact us on:

Phone:  +44(0)114 276 2264

Email:  sales@buntingeurope.com

Via the Bunting Europe website

Via the eMagnets online Magnet Shop

 

News and Technical Articles on Magnets and Magnetic Assemblies in 2018 2018 has been another exciting year for eMagnets and Bunting Magnetics.  Magnetic technology has never been more important.  Advances in environmental technology such as electric vehicles and wind turbines would not be possible without the simple magnet.  Throughout the year we reviewed some really […]

https://blog.e-magnetsuk.com/2018/12/18/2018-review-of-magnet-news-and-blogs/

The Future Is Magnetic

A Review of the UK Magnetics Society’s Ewing Event 2018

This year’s 31st Ewing Event, organised by the UK Magnetics Society and sponsored by Bunting Magnetics, focused on the important role of ‘magnets’ in the future.  Indeed, it is widely recognised that magnetic fields are the ideal, low-energy way for creating motion.

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At the event, there were a series of talks from industry experts.  They covered a wide range of topics, but the overriding message highlighted the growing importance of magnetic technology.  Here are some predictions made by the speakers:

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Bunting’s Matthew Swallow with Robert Llewellyn

The keynote Ewing Lecture was given by Robert Llewellyn, an electric transport enthusiast.  Robert is widely know for producing and presenting Fully Charged on YouTube, front lining Scrapheap Challenge on Channel 4, and playing the character Kryten in Red Dwarf.

As the conference drew to a close, there was no doubt of the important role magnets and magnetic technology would make in the future.  This is an exciting time to be involved in the industry.

Bunting Magnetics specialises in providing magnetic solutions.  They also sell a wide range of magnets and magnetic components online via their eMagnets UK brand.

For further information on bespoke magnet designs and magnetiser assemblies, please contact us:

Phone:  +44 (0) 114 276 2264

Email:  sales@buntingeurope.com

Via the Bunting Europe website for specialist magnets and magnetic assemblies

Via eMagnets for online purchase of Magnets and Magnetic Technology

A Review of the UK Magnetics Society’s Ewing Event 2018 This year’s 31st Ewing Event, organised by the UK Magnetics Society and sponsored by Bunting Magnetics, focused on the important role of ‘magnets’ in the future.  Indeed, it is widely recognised that magnetic fields are the ideal, low-energy way for creating motion. At the event, there […]

https://blog.e-magnetsuk.com/2018/12/06/the-future-is-magnetic/

Injection Moulded Plastic Magnet Assembly

Changing Manufacturing Techniques To Reduce Cost

Bunting’s engineering design team was asked by a customer to reduce the cost of a magnet assembly.  The magnet assembly formed part of a magnetic coupling with a specific torque ratio.  However, due to the manufacturing process, the cost of assembly was high.

Bunting at Engineering Design Show 2018
The finished Magnetic Assembly

The Magnet Assembly Development Project

The major challenge was that the magnet assembly was going to be coated in plastic using an injection moulding process.  The existing process involved the over-moulding of a Neodymium magnetised assembly.  This was proving the be difficult and costly.  Handling strong magnetised materials was difficult in the moulding process.

Additionally, the magnetised assembly was being exposed to excessive heat.  This would reduce the magnetic performance.

The Bunting engineering design team developed a magnetic assembly that could be magnetised after the injection moulding process. Two unique radially orientated sintered neodymium ring magnets were bonded together to make a long enough magnet to produce the required torque and would then create a 6-pole radial magnetic field when magnetised.

The ‘plastic’ component was then magnetised producing the strongest magnetic field possible for a magnet of this shape and size in an outer 6 pole configuration.

This has been achieved without any compromise in the operational characteristics and torque ratio as the Neodymium grade was increased to compensate for the increased air gap and the loss of the coupling back iron.

Bunting at Engineering Design Show 2018
The Radial Magnetic Field

New Design Benefits

The manufacturing cost has been reduced by 90%.  This has been achieved without any compromise in the operational characteristics and torque ratio.

Tooling costs, which were over £10,000, have also been significantly reduced.

Bunting Magnetics specialises in designing magnetic solutions.  They also sell a wide range of magnets and magnetic components online via their eMagnets UK brand.

For further information on bespoke magnet assemblies or magnet designs, please contact us via:

Phone:  +44 (0) 114 276 2264

Email:  sales@buntingeurope.com

Via the Bunting Europe website for specialist magnets and magnetic assemblies

Via eMagnets for online purchase of Magnets and Magnetic Technology

All photographs taken by Paul Fears Photography

The radial magnetic field of the new magnetic assembly

Changing Manufacturing Techniques To Reduce Cost Bunting’s engineering design team was asked by a customer to reduce the cost of a magnet assembly.  The magnet assembly formed part of a magnetic coupling with a specific torque ratio.  However, due to the manufacturing process, the cost of assembly was high. The Magnet Assembly Development Project The […]

https://blog.e-magnetsuk.com/2018/11/22/injection-moulded-plastic-magnet-assembly/

Bespoke Magnetiser for Electronics Application

Magnetiser Designed For Precision Charging of Small Magnets

High strength magnets (eg Neodymium Rare Earth) are a vital part in many everyday electric appliances.  Charging those small magnets for use in electronics applications often requires a high degree of accuracy.  One typical example is where the magnet interacts with a sensor to confirm that a component is correctly in place.

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Dual magnetiser being tested

At their European headquarters in Berkhamsted, United Kingdom, Bunting’s engineering team design bespoke magnetisers for use in the electronics and commercial appliance markets.

The Magnetiser Design Project

In a recent project, the Bunting design team were faced with a challenging application.  In the electric appliance, the small magnet talks to a sensor to confirm when a key part is correctly positioned.  Normally permanent magnets are supplied magnetised, but this was not possible because:

Subsequently, the magnet part would initially be assembled and over-moulded prior to magnetisation.

Operation Criteria

As in many electronics applications, the numbers of magnetic parts needing to be magnetised were substantial.  The specification stipulated that one part would be magnetised every three (3) seconds.  The production process would run for 24 hours, 6 days a week.  Even with the intense workload, the magnetiser was expected to have a minimum of a 5-year life.

The Design

The normal magnetising firing frequency is every four (4) seconds.  To fire every three (3) seconds, the Bunting design team introduced two base units.  These operated in parallel, magnetising two fixtures every six (6) seconds.  This equates to the magnetiser firing 4,320,000 every year.

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The design team developed the hardware and software to enable the two base units to talk to each other.  This ensured that magnetisation occurred at exactly the same time.

Initial design calculations indicated that the act of magnetisation could generate 8kj of heat 6 seconds.  With the aim of using the least energy possible, the fixture was designed to run at 1400V instead of the maximum 3000V.  This used less than 4kj per firing.  The reduced energy loading meant that the components within the charger were only at 50% stress, extending their expected life.

Additionally, each time a magnetic component is charged, the magnetising coil has to dissipate that 4kj of heat.  To keep the coil operating at an optimum level, a closed loop chiller is used.  This keeps the coils at below 75 degrees centigrade, extracting 1 kW of energy across the two fixtures.

Bunting Magnetiser

Magnetiser Designs

This is one of many projects where the Bunting engineering team has designed a bespoke magnetiser.  Whereas this project was a manual operation, other magnetisers are integrated into automated systems.  Additionally, for overseas operations remote access can be provided via ethernet connections.

Bunting Magnetics specialises in providing magnetic solutions.  They also sell a wide range of magnets and magnetic components online via their eMagnets UK brand.

For further information on bespoke magnetiser designs and magnetic assemblies, please contact us:

Phone:  +44 (0) 114 276 2264

Email:  sales@buntingeurope.com

Via the Bunting Europe website for specialist magnets and magnetic assemblies

Via eMagnets for online purchase of Magnets and Magnetic Technology

 

Magnetiser Designed For Precision Charging of Small Magnets High strength magnets (eg Neodymium Rare Earth) are a vital part in many everyday electric appliances.  Charging those small magnets for use in electronics applications often requires a high degree of accuracy.  One typical example is where the magnet interacts with a sensor to confirm that a […]

https://blog.e-magnetsuk.com/2018/11/06/bespoke-magnetiser-for-electronics-application/