Joining technologies for sintered and plastic bonded magnets

Transcription

1 Joining technologies for sintered and plastic bonded magnets

2 Agenda - Company presentation of MS-Schramberg - Products - Joining technologies for sintered and plastic bonded magnets Overmoulding with magnet compound Overmoulding with technical plastic Multi-component injection mould technology Gluing technology Ultrasonic Welding Other joining technologies

3 Company presentation: MS-Schramberg Products Our range of products: Hard ferrite magnets Rare earth magnets Plastic bonded magnets Plastic and Plastic Composite Parts Magnet assemblies

4 Company presentation: Company development Construction of new plastics and magnet assembly production plant 2008 Renaming into MS-Schramberg GmbH & Co. KG Launch of production of micro-injection moulded pieces; Opening of representation office in Shanghai Launch of production of technical plastic parts Start of own Automation technology -department The product line of magnet assemblies was expanded by other joining technologies The Tool and die construction department was expanded The multi-component injection-mould technology was added for the production line Launch of production of magnet assemblies: Adhesive technology Launch of production of rare earth magnets Launch of production of plastic bonded magnets Removing into new building in the industrial area of Schramberg-Sulgen Renaming into Magnetfabrik Schramberg GmbH & Co. KG 1963 Foundation of Herbert Braun GmbH ; start of production of hard ferrite magnets

5 Products: Hard ferrite magnets (barium-/strontium-ferrite) Hard ferrite magnets have the following advantages: economical raw materials very good resistance against corrosion and chemicals easy to magnetise

6 Products: Hard ferrite magnets (barium-/strontium-ferrite) Applications: (1) Linear sensor (2) Permanentelectromagnetic brakes (3) Disc coupling (4) Motive power engineering (5) Pumps (6) Stepper motor (7) Bicycle dynamo (8) Separation magnets (9) Magnet rollers (10) Sensor technology (3) (1) (2) (4) (5) (8) (10) (7) (6) (9)

7 Products: Rare earth magnets (samarium cobalt/neodymium iron boron) Rare earth magnets have the following advantages: high energy density possibilities of miniaturization low temperature coefficient high magnetic stability

8 Products: Rare earth magnets (samarium cobalt/neodymium iron boron) Applications: (1) Medical technology (2) - (6) Diverse engines (7) Sensor technology (1) (2) (5) (4) (3) (7) (6)

9 Products: Plastic bonded magnets (pressed magnets) Applications: (1) Sensor technology (2) Clamping system (3) Swing angle sensor (4) Hysteresis brakes (5) Motive power engineering (6) Position identification (7) Motive power engineering (3) (4) (5) (2) (1) (7) (2) (6)

10 Products: Plastic bonded magnets (injection moulded magnets) Applications: (1) - (2) Rotational speed measurement (3) Angle measurement (9) (1) (2) (4) Flow measurement (5) Yarn tension device (8) (3) (4) (6) Angle measurement (7) - (8) Position identification (11) (9) - (11) Rotational speed measurement (10) (5) (7) (6)

11 Products: Plastic and Plastic Composite Parts (Technical plastic parts) Applications: (1) Analog switch (Automotive) (2) Start-stopp-switch (Automotive) (2) (1) (2)

12 Products: Plastic and Plastic Composite Parts (Micro injection mould parts) Applications: (1) small motors (2) blood clamp (medical engineering) (3) connectors (4) drive wheel (5) catches (clock technology) (6) optical lenses (1) (4) (3) (5) (1) (2) (6) (3) (5)

13 Overmoulding with magnet compound Applications: (1) Small motors (2) Rotational speed measurement (3) Stepper motor (4) Dynamo (5) Fans (6) Flow measurement (4) (2) (5) (6) (3) (5) (1) (2)

14 Joining technologies for sintered and palstic bonded magnets Overmoulding with magnet compound Design parameters: - Shafts and bushings must have a positive fit (e.g. knurl) - Magnet dimensions must be adjusted to bushings or shaft diameters or wall thicknesses. Or in other words the magnet must be in the right proportion with regard to its diameter, the bushing and the shaft - The insert pieces must be high precision pieces in order to minimize overinjections and in order to allow for an automised production process

15 Overmoulding with technical plastic Applications: (1) magnetic coupling for gas meters (5) (2) magnetic coupling for water meters (3) pumps (4) volume flow rate measurement (3) (4) (1) (5) motor management (2)

16 Overmoulding with technical plastic Gear systems to satisfy the highest demands: Applications: (1) angle measurement motor management (2) steering angle detection (3) stepper motor (1) (2) (3)

17 Example for an automised placement process of insert pieces automation

18 Multi-Component Injection Moulding Technique for Plastic Bonded Magnets

19 Multi-component injection mould technology Overview: Two-component Injection Moulding Technique 1.Internal movement within the mould 2.Transfer of the pre-moulded part into a second cavity: 2.1 Rotation of one mould half 2.2 Turning of an index plate/insert 2.3 Transfer from the first station into the second station manually or using handling equipment

20 Multi-component injection mould technology 1. Internal movement within the mould:

21 Multi-component injection mould technology 1. Internal movement within the mould: example

22 Multi-component injection mould technology Two-component Injection Moulding Technique: Second moulding concept 2. Transfer of the pre-moulded part into a second cavity: - Component 1 injected into the cavity (= pre-moulded part). - The pre-moulded part is transferred into another cavity. Variation : 2.1 Rotation of one mould half 2.2 Turning of an index-plate/insert 2.3 Transfer from the first station into the second station manually or using handling equipment - Component 2 injected.

23 Multi-component injection mould technology 2.1 Rotation of one mould half:

24 Multi-component injection mould technology 2.1 Rotation of one mould half: example: Rotor for speedometer drive gears Ø 4,46 ±0,03 mm

25 Multi-component injection mould technology positive fit through additional raising and lowering of plunchers: Component 1 Component example: 1 Pluncher raised 2 Pluncher lowered (A riveted joint is made)

26 Multi-component injection mould technology 2.2 Turning of an index plate/insert: Component 1 injected 2 Component 2 injected 3 Rotation and index plate

27 Multi-component injection mould technology 2.2 Turning of an index plate/insert: example: Wheel of a radiator fan

28 Multi-component injection mould technology 2.3 Transfer from the first station into the second station manually or using handling equipment: 2 1 Concrete example: 1 - Station Station 2

29 Multi-component injection mould technology Samples: Applications: (1) Identification of position (2) Stepper motor (3) Measurement of turning speed (4) Steering angle detection (5) Angle measurement Motor management (4) (3) (1) (5) (5) (2) (4)

30 Multi-component injection mould technology Advantages: High level of precision The ability to combine various performance characteristics in one element A vast range of possible designs (e.g. miniaturising) A better quality of joints by fusion of various individual components Savings on materials A reduction of the number of processing steps The same processing conditions in every cycle Elimination of expensive handling The production of high quantities of complicated assemblies at very reasonable prices

31 Gluing Technology Criterias for a good choice of a suitable glue: Occupational & environmental safety Process management Parts to be joined availability Suitable glue Quality assurance Stresses and loads costs resistance

32 Gluing Technology Joining Pieces - Chemical properties of the surface e.g. contaminations - Physical properties of the surface e.g. surface tension - Mechanical properties: e.g. stability, rigidity - Temperature resistance - Resistances against physical and chemical stress - Size and geometries of the gluing surfaces

33 Gluing Technology Occupational and Environmental Protection - Possible glue substitutes with lower health risks - Measures of protection - Prevention of reject and recycling - Legal regulations

34 Gluing Technology Process Management - Process integration, cycle time - Treatment of surfaces - Required rheological studies (flow properties) - Process parameters: time, temperature, pressure, - Fixation, hybrid joining -Curing - Tolerances

35 Gluing Technology Quality Assurance - Incoming material inspection - Storage conditions - In line inspections - Inspection of components

36 Gluing Technology Loads and Stresses - Mechanical and static stress, creeping - Mechanical and cyclical stress, vibration - Impact / shock - Chemical stress: moisture, salt, grease, oil, - Physical stress: temperature, radiation

37 Gluing Technology Resistance against stress on a long term basis - Required life time of the bonding with regard to the applied stress - Considered test methods

38 Gluing Technology Types of glues being used with MS-Schramberg - 1K epoxid resins - 2K epoxid resins - 2K PUR - Cyanarcrylate - anaerobic types of glue - Methylmethacrylate - Radiation curing glues

39 Gluing Technology Samples: Applications: (1) Linear position identification (2) Clamping system (3) Linear motive power (4) Rotational speed measurement (5) Linear position identification (6) Engine (7) Clamping system (1) (2) (3) (5) (4) (7) (6)

40 Ultrasonic Welding Materials which can be welded: Amorphous and semi-crystalline thermoplastic plastic materials (e.g. ABS, PA 6, PMMA, POM, PP, PS except PTFE) Conditional TPE (thermoplastic elastomere) combine the properties of cross-linked elastomeres with the advantage of a thermoplastic processability Steel Copper Aluminium

41 Ultrasonic Welding Overview on ultrasonic welding joining technology: 1. Seam welding 2. Spot welding 3. embedding 4. riveting 5. flanging

42 Ultrasonic Welding Seam Welding: Preferred design of seams Stepped seam Groove and tongue seam Pinched seam Thin wall seam

43 Ultrasonic Welding Seam Welding: Example for a thin wall seam Example for a pinched seam

44 Ultrasonic Welding Spot Welding: Moulding parts are butt-jointed tightly without creating a seam. A specially shaped sonotrode pinpoint penetrates the upper moulding part up until the middle of the lower moulding part while the plastified material would be pressed firmly in a welding spot. Part of the molten mass flows to the top and is then being integrated annularly by the sonotrode. Spot welding allows a homogeneous welding process of similar and different thermoplastics (heterogeneous mixture/embedding).

45 Ultrasonic Welding Embedding: Definition: While the process of embedding the bore hole wall is being plastified through the metal piece. The plastic flows into an undercut in order to obtain a positive locking. Options for embedding: Threaded bushings Metal grids (loud speaker) Metallic screen tissue (shower head)

46 Ultrasonic Welding Riveting: Riveting allows a positive locking of thermoplastics with different materials, like metals, printed circuit boards,... Possibility of efficient multiple riveting at each welding stroke

47 Ultrasonic Welding Flanging: Joining technology through positive locking the insert piece is being embedded into the plastic piece Positive locking is achieved through a profiled sonotrode

48 Other Joining Technologies - Press-fitting - Shrink wrapping - Clipsing

49 Your requirements and wishes mean for us: Chances The realisation of your dreams Challenge us! Your partner for permanent magnets and plastic parts! MS-Schramberg GmbH & Co. KG Telefon: Max-Planck-Straße 15 Telefax: D Schramberg-Sulgen Internet: 06/2008