ECS Magnet Engineering GmbH - ABM
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ECS Magnet Engineering GmbH - ABM

ECS Magnet Engineering GmbH - ABM ECS Magnet Engineering GmbH - ABM

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Plastic Bonded Magnets for Automotive ApplicationsJuly 2008PresentationPlastic Bonded Magnets for Automotive Applicationsheld on occasion of the ABM workshopMagnetic Materials for Automotive Applicationsand perspectives for Hybrid carson July 2nd, 2008ECS Magnet Engineering GmbHHarkortstrasse 60D - 45145 Essen© ECS Magnet Engineering GmbH

Plastic Bonded <strong>Magnet</strong>s for Automotive ApplicationsJuly 2008PresentationPlastic Bonded <strong>Magnet</strong>s for Automotive Applicationsheld on occasion of the <strong>ABM</strong> workshop<strong>Magnet</strong>ic Materials for Automotive Applicationsand perspectives for Hybrid carson July 2nd, 2008<strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>Harkortstrasse 60D - 45145 Essen© <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>

Table of ContentsJuly 2008• <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>, Essen, Germany• <strong>Magnet</strong> Material Portfolio of <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>• Plastic Bonded <strong>Magnet</strong>s – overview- NEOMAG C, compression molded NdFeB- NEOMAG I, injection molded NdFeB- KOEROX I, injection molded Ferrite- KOEROX HI, injection molded Ferrite + NdFeB• Applications & Examples• sintered NdFeB for Hybrid Electrical Machines<strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>Harkortstrasse 60D - 45145 Essen© <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>

<strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>July 2008<strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>A COMPANY WITH TRADITION AND HISTORY<strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>Harkortstrasse 60D - 45145 Essen© <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>

Historical Background of <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>, Essen(formerly WIDIA <strong>Magnet</strong>technik)July 2008<strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>, Essen, has almost 60 years of experiencein the field of magnetic materials and components:1949 Krupp Widia began to use its knowledge of powder metallurgicaltechnology to produce permanent magnets1950 Introduced sintered AlNiCo = KOERZIT S TM1953 Introduced sintered hard-ferrite magnets = KOEROX S TM1975 Introduced sintered SmCo magnets = KOERMAX S TM1980 Introduced injection molded ferrite = KOEROX I TM1984 Introduced sintered NdFeB magnets = NEOMAG S TM1985/86 Developed and introduced injection molded and compression moldedNdFeB magnets = NEOMAG I & C TM1987/88 Developed and introduced injection moldedferrite/NdFeB magnets = KOEROX HI TM1994 Granted DIN EN ISO 9001 certification1999 Granted ISO / TS 16949 certification2000 Owned by MAGNEQUENCH, Inc. to become MAGNEQUENCH <strong>GmbH</strong>2004 Ownership changed to KANE MAGNETICS INTERNATIONAL to becomeKANE MAGNETICS GMBH2005 Merger with <strong>ECS</strong> to become <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong><strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>Harkortstrasse 60D - 45145 Essen© <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>

Production Location of <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>, EssenJuly 2008<strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>Harkortstrasse 60D - 45145 Essen© <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>

<strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>July 2008The name <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong> (formerly WIDIA <strong>Magnet</strong>technik)stands for a company with• almost 60 years of experience in magnetic materials and components• intensive, ongoing development and cost-effective manufacturing techniquesbased on a broad range of advanced permanent magnets• comprehensive quality assurance based on DIN ISO 9001 and ISO/TS 16949• for quality in customer support• developing application-oriented solutions together with our customers<strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>Harkortstrasse 60D - 45145 Essen© <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>

<strong>Magnet</strong> Material Portfolio of <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>July 2008Production• Bonded Neo & Ferrite• Sintered AlNiCo• Precision assembliesManufacturing and TradeTrade• Sintered Neo(San Huan cooperation)• Sintered Hard – Ferrite• Sintered SmCo<strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>Harkortstrasse 60D - 45145 Essen© <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>

Plastic Bonded <strong>Magnet</strong>s of <strong>ECS</strong>July 2008• NEOMAG C, compression molded NdFeB• NEOMAG I, injection molded NdFeB• KOEROX I, injection molded Ferrite• KOEROX HI, injection molded Ferrite + NdFeB<strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>Harkortstrasse 60D - 45145 Essen© <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>

Plastic Bonded <strong>Magnet</strong>s - OverviewJuly 2008Plastic Bonded <strong>Magnet</strong>s are formed froma mixture of a magnet material and a binding material<strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>Harkortstrasse 60D - 45145 Essen© <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>

Manufacturing Methodes at <strong>ECS</strong>July 2008<strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>Harkortstrasse 60D - 45145 Essen© <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>

Isotropic and Anisotropic Plastic Bonded <strong>Magnet</strong>sJuly 2008Isotropic:Compression and injection molded NdFeB(NEOMAG C, NEOMAG I)<strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>Harkortstrasse 60D - 45145 Essen© <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>

Isotropic and Anisotropic Plastic Bonded <strong>Magnet</strong>sJuly 2008Anisotropic:Injection molded Ferrite and Hybrid (partially oriented)(KOEROX I, KOEROX HI)Anisotropy can be applied by magnetic fields or mechanical force<strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>Harkortstrasse 60D - 45145 Essen© <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>

Orientation of Plastic Bonded <strong>Magnet</strong>sJuly 2008Geometrical orientation (and magnetization) of single ferrite grains<strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>Harkortstrasse 60D - 45145 Essen© <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>

<strong>Magnet</strong>ization of Plastic Bonded <strong>Magnet</strong>sJuly 2008• <strong>Magnet</strong>ization during molding process- REM-structures- electromagnetic devices• <strong>Magnet</strong>ization after molding- electromagetic devices<strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>Harkortstrasse 60D - 45145 Essen© <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>

Filling Rates of Plastic Bonded <strong>Magnet</strong>sJuly 2008ProductionmethodInjectionmoldingInjectionmoldingCompressionmoldingMaterial Vol.% Weight %HF 45 - 65 80 - 90MQ 45 - 65 86 - 93MQ 75 - 85 95 - 98<strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>Harkortstrasse 60D - 45145 Essen© <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>

Maximum Application Temperature of Plastic Bonded <strong>Magnet</strong>sJuly 2008• HF / PA 12 120 - 140°C• HF / PPS 180 - 200°C• MQ1 / PA 12 120 - 140°C• MQ1 / Epoxy 100 - 200°C• Hybrid / PA 12 100 - 120°C<strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>Harkortstrasse 60D - 45145 Essen© <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>

Temperature Behavior of Plastic Bonded <strong>Magnet</strong>sJuly 2008• HF / PA 12 and HF / PPSTK J s -0.2 %/KTK H cJ +0.35 %/K• MQ1 / PA 12TK J s -0.07 down to -0.12 %/KTK H cJ -0.4 %/K• MQ1 / EpoxyTK J s -0.07 down to -0.13 %/KTK H cJ -0.4 %/K• Hybrid / PA 12*TK J s -0.12 down to -0.2 %/KTK H cJ +0.35 down to -0.4 %/K*depending of used NdFeB grade and composition<strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>Harkortstrasse 60D - 45145 Essen© <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>

Example: Temperature Behavior of Plastic Bonded NdFeBJuly 2008Neomag C 63 EP demagnetisation curvesat RT and 150°C and back spring curvesRT150 °CB=0J, B [mT]6005004003002001000-1100-1000-900-800-700-600-500-400-300-200-1000H [kA/m]<strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>Harkortstrasse 60D - 45145 Essen© <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>

Molding MachinesJuly 2008<strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>Harkortstrasse 60D - 45145 Essen© <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>

NEOMAG C – Compression molded NdFeBJuly 2008Examples, all values typicalTradenameBHmax Br Hcb Hcj[kJ/m³] [mT] [kA/m] [kA/m]Neomag C 60EP 64 620 420 1200Neomag C 63EP 69 650 440 980Neomag C 68EP 76 670 460 930Neomag C 80EP 83 710 450 730additional grades are available upon requestand can be taylor-made regarding specific projects<strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>Harkortstrasse 60D - 45145 Essen© <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>

NEOMAG C – Sample PicturesJuly 2008<strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>Harkortstrasse 60D - 45145 Essen© <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>

NEOMAG C - ApplicationsJuly 2008• Motors (e.g. DC-, BLDC-, stepper-)• Generators• Sensors<strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>Harkortstrasse 60D - 45145 Essen© <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>

NEOMAG I – Injection molded NdFeBJuly 2008Examples, all values typicalTradenameBHmax Br Hcb Hcj[kJ/m³] [mT] [kA/m] [kA/m]Neomag I 35 PA 35 480 300 650Neomag I 42 PA 42 520 320 650Neomag I 47 PA 47 550 330 550Neomag I 38 PS 38 475 300 920Neomag I 42 PS 42 510 310 600additional grades are available upon requestand can be taylor-made regarding specific projects<strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>Harkortstrasse 60D - 45145 Essen© <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>

NEOMAG I – AdvantagesJuly 2008• Shape and magnetization flexibility• Small tolerances without additional re-working• Automation of complete production process• Insert technique / combination with plastic parts• Automation of further processing at customer line<strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>Harkortstrasse 60D - 45145 Essen© <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>

NEOMAG I – Sample PicturesJuly 2008<strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>Harkortstrasse 60D - 45145 Essen© <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>

NEOMAG I - ApplicationsJuly 2008• Motors (e.g. DC-, BLDC-, stepper-)• Dashboard instrumentation• Generators• Sensors• Bearings<strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>Harkortstrasse 60D - 45145 Essen© <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>

KOEROX I – Injection molded FerriteJuly 2008Examples, all values typicalTradenameBHmax Br Hcb Hcj[kJ/m³] [mT] [kA/m] [kA/m]Koerox I 4/22 PA 4 135 100 220Koerox I 9/22 PA 9 220 160 230Koerox I 12/23 PA 12 260 190 240Koerox I 14/24 PA 14 280 200 250Koerox I 9/18 PS 10 230 170 210Koerox I 11/18 PS 12 250 160 200additional grades are available upon requestand can be taylor-made regarding specific projects<strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>Harkortstrasse 60D - 45145 Essen© <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>

KOEROX HI – Injection molded Ferrite + NdFeBJuly 2008Examples, all values typicalTradenameBHmax Br Hcb Hcj[kJ/m³] [mT] [kA/m] [kA/m]Koerox HI 19 PA 19 320 220 280Koerox HI 22 PA 22 350 230 300Koerox HI 28 PA 28 390 245 330Koerox HI 28 PS 28 390 245 335additional grades are available upon requestand can be taylor-made regarding specific projects<strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>Harkortstrasse 60D - 45145 Essen© <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>

KOEROX I / HI - AdvantagesJuly 2008• Cost effective solution for large series• Shape flexibility, value added features due to rawmaterial price (especially ferrite)• Insert technique / combination with plastic parts• Orientation and magnetization during molding• Automation of complete production process• High temperature applications with PPS-binder• KOEROX HI close the „magnetic gap“ betweenplastic bonded Ferrite and NdFeB<strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>Harkortstrasse 60D - 45145 Essen© <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>

KOEROX I – Sample PicturesJuly 2008<strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>Harkortstrasse 60D - 45145 Essen© <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>

KOEROX I / HI - ApplicationsJuly 2008• Motors (e.g. BLDC-, stepper-)•Timer• Generators• Sensors (e.g. position-, speed-, ABS-)• Pumps• Couplings<strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>Harkortstrasse 60D - 45145 Essen© <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>

Automotive ApplicationsJuly 2008• Electric window and sun roof• Seat adjustment and recline•Wiper• Brake and Clutch cylinder sensors• Safety belt sensor• Crankshaft sensor• Steering sensor• Pencil coils• Dashboard applications<strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>Harkortstrasse 60D - 45145 Essen© <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>

Automotive ApplicationsJuly 2008•ABS• Throttle control• Air condition actuator•Door lock• Emission control• Crankshaft sensor• Battery cooling• Fuel pump• .......<strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>Harkortstrasse 60D - 45145 Essen© <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>

Sintered NdFeB for Hybrid Electrical Machines - ExampleJuly 2008• Grade name N30EHS• Max. application temperature: 200°C• Weight loss less than 1mg/cm²typ. Values Br [mT] HcJ [kA/m] HcB [kA/m] BHmax (kJ/m3]RT 1120 3050 870 240150°C 965 1350 725 175180°C 915 1000 705 160<strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>Harkortstrasse 60D - 45145 Essen© <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>

July 2008<strong>Magnet</strong>s are „attractive“they are connecting people!THANK YOU<strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>Harkortstrasse 60D - 45145 Essen© <strong>ECS</strong> <strong>Magnet</strong> <strong>Engineering</strong> <strong>GmbH</strong>

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