New magnet design from BOMATEC with significant reduction of eddy current losses
The future of magnet technology
In the course of the energy transition, magnets are emerging as a crucial component for the operation of high-speed and high-performance applications. This is due to the trend toward providing applications with a high power density. At the same time, however, this development poses a major challenge for manufacturers: eddy current losses! The generation of eddy currents in the magnetic mass is – as is common in all high-speed designs – a source of significant heat generation and heat dissipation.
Cost-effective solution
Significant improvements in efficiency and performance
Bomatec AG has developed and patented a new design for high-performance motors. SNAKELINE magnets improve eddy current losses and were designed as a means of handling eddy currents compared to conventionally laminated magnets. One of the main challenges associated with laminated magnets is cost. Due to the losses of set width when cutting the magnetic wafers, laminated magnets have a very low material yield, meaning that less than 30% of the material used in the process is delivered as a finished magnet. This is compounded by high process costs due to the handling required by skilled workers to produce the magnetic lamination packages. Snakeline magnets rise to these challenges.
Innovative magnet design
Efficient production and cost savings
Snakeline magnets are notable for their efficient production: Unlike a traditional monolithic magnet, they only require two automated steps – cutting and filling. With this technology, the magnet is not physically broken down into individual magnet segments; instead, paths are cut in a serpentine form by wire erosion.
Another advantage of Snakeline magnets is the ability to create flexible magnet designs and significantly reduce assembly time. In the assembly of rotor packages with magnets, the steps can be drastically reduced compared to segmented magnets. Since the cut in the Snakeline is applied to a finished magnet, the process is easily applicable across designs, and there is no need for a complete redesign of the process to efficiently produce the parts. Bomatec relies on close research and development partnerships to investigate eddy current losses in permanent magnets with complex geometries and special measures to reduce losses. Specially developed analysis tools are used for this purpose, enabling comprehensive 3D simulations to be carried out and the optimum number and shape of segmentation to be determined depending on customer applications.
By using permanent magnets with Bomatec’s Snakeline technology, Fischer Elektromotoren has succeeded in improving its high-performance saw motors. By reducing the losses in the permanent magnet, it was possible to achieve a more stable temperature development even in the event of an overload.
Johannes Söhner, Fischer Elektromotoren GmbH, Billigheim
Sustainability through magnet recycling
SNAKELINE technology as part of a circular economy
The Snakeline innovation not only promises a cost-optimized manufacturing process and a reduction in eddy current losses. Bomatec AG's research work also extends to environmentally friendly and energy-efficient products. Against the backdrop of the Critical Raw Material Act, which was passed by the EU Commission, the Snakeline technology can make an important contribution to a green circular economy. The law provides, among other things, that a larger proportion of raw materials classified as critical, particularly the rare earth metals neodymium and dysprosium, will come from EU recycling in the future. In this context, a consortium of industrial partners and research institutions is focusing on establishing a circular economy for rare earth magnets. The members are using patented hydrogen processing, known as HPMS (Hydrogen Processing of Magnet Scrap). Current analyses by Pforzheim University show that segmentation does not guarantee sufficient quality of the recycled material, as organic residues of the segmentation adhesive have a strong negative influence on the magnetic properties of the recycled magnet. Unfilled Snakeline magnets could meet these challenges by Bomatec designing magnets that are both customer-specific and suitable for recycling as early as the design phase.
flexible magnet designs and significantly reduce assembly time
Diversifying magnetic technology
New supply chains to optimize customer needs
As Bomatec continues to expand its leadership in magnetic technology, it is also pursuing a strategy of diversification to strengthen its presence in Asia, particularly Malaysia. Malaysia has become an emerging center for technology and innovation in recent years. With a growing talent pool of engineers and technicians, as well as a favorable business environment, the country has become an attractive destination for companies looking to expand their presence in the region. In addition to this diversification strategy in Malaysia, Bomatec AG boasts extensive expertise in magnet assembly, particularly specializing in plastic-injected magnets. With years of experience and specialized knowledge in magnet technology, the company is capable of offering high-quality and customized solutions for magnet assembly. From conceptualization to implementation, the company collaborates closely with customers to meet their specific requirements and develop innovative solutions. This expertise in magnet assembly complements the company’s diversification strategy in Malaysia and reinforces its position as a leading provider of magnet technology solutions globally. In summary, Bomatec is not only aiming for a revolution in various industries with its innovative patent in magnet technology, but also providing a great opportunity for strategic expansion into Malaysia to offer customized solutions for assemblies. With this combination of breakthrough technology and dynamic business strategy into new markets, Bomatec AG is striving to shape the future of the magnet industry.
Snakeline as part of a circular economy
Sustainability through magnet recycling
The Snakeline innovation not only promises a cost-optimized manufacturing process and a reduction in eddy current losses. Bomatec AG's research work also extends to environmentally friendly and energy-efficient products. Against the backdrop of the Critical Raw Material Act, which was passed by the EU Commission, the Snakeline technology can make an important contribution to a green circular economy. The law provides, among other things, that a larger proportion of raw materials classified as critical, particularly the rare earth metals neodymium and dysprosium, will come from EU recycling in the future. In this context, a consortium of industrial partners and research institutions is focusing on establishing a circular economy for rare earth magnets. The members are using patented hydrogen processing, known as HPMS (Hydrogen Processing of Magnet Scrap). Current analyses by Pforzheim University show that segmentation does not guarantee sufficient quality of the recycled material, as organic residues of the segmentation adhesive have a strong negative influence on the magnetic properties of the recycled magnet. Unfilled Snakeline magnets could meet these challenges by Bomatec designing magnets that are both customer-specific and suitable for recycling as early as the design phase.
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