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In today's rapidly developing new energy vehicle industry, the performance and reliability of the electric motor, as its core drive component, directly determine the vehicle's power output, range, and safety performance. However, the motor manufacturing process is complex, involving numerous metal processing and assembly steps. With even the slightest carelessness, tiny magnetic impurities such as iron filings and rust can enter key components, becoming "invisible killers" during motor operation. Against this backdrop, strong magnetic rods are quietly playing the role of "quality gatekeepers" in motor manufacturing, and their critical role cannot be ignored.

Strong magnetic rods are capable of performing critical tasks thanks to their superior technical features:

1. High-Intensity Magnetic Field: Made from rare earth permanent magnets (such as NdFeB), they deliver magnetic field strengths exceeding 8,000 gauss, effectively attracting micron-sized ferromagnetic impurities.

2. Temperature Stability: Utilizing high-performance magnetic materials with high intrinsic coercivity and high operating temperature, they maintain stable magnetic properties across a wide range of motor manufacturing environments.

3. Structural Diversity: Magnetic rods can be designed in various sizes, shapes, and magnetic strengths to meet diverse application scenarios and installation requirements, meeting the diverse requirements of motor manufacturing.

Strong magnetic rods, with their powerful iron removal capabilities, are used throughout the entire process of new energy vehicle motor manufacturing, from core processing to winding production to final assembly, silently protecting the quality and performance of the motor.

1. Motor Core Production: The "Nemesis" of Iron Filings

The production of motor cores is inseparable from silicon steel sheets. During the punching, shearing, and lamination processes, the mechanical forces of the equipment cause wear on the cutting tools and dies, leading to the generation of iron filings.

These seemingly insignificant iron filings can be extremely harmful if they enter the motor core. During motor operation, the iron filings within the core generate additional eddy current losses under the influence of the alternating magnetic field, causing severe heating of the core. This not only reduces motor efficiency but, over time, can damage the core and shorten the motor's lifespan.

High-strength magnetic rods are installed at the discharge port of silicon steel sheet processing equipment. Their powerful magnetic field acts like a keen "iron filing hunter," rapidly attracting iron filings. Made of rare earth permanent magnets with a high magnetic energy product, they can achieve magnetic field strengths exceeding 8,000 gauss, easily capturing even micron-sized iron filings.

2. Winding Production: The "Guardian" of Insulation

Enameled wire is the "blood vessels" of the motor windings, and the integrity of its insulation directly determines the safe operation of the motor. Iron impurities from worn winding dies or the raw materials themselves can enter the windings along with the enameled wire. Under the long-term effects of current heating and electromagnetic forces, iron impurities can easily pierce the insulation, causing short circuits between turns and leading to motor failure.

Inserting strong magnetic rods into the enameled wire delivery pipeline intercepts iron impurities at the source, ensuring the purity of the windings. Data shows that the use of strong magnetic rods increases motor power generation efficiency by approximately 8%, contributing to additional vehicle range. Higher power generation efficiency means that vehicles can travel farther with the same amount of power, precisely meeting consumers' demand for longer driving range.

3. Motor Assembly: The "Gatekeeper" of Purity

Strong magnetic rods also play an indispensable role in the motor assembly process. The motor casing, end caps, and internal connectors can also carry impurities such as iron filings during processing and handling.

Strong magnetic rods can be installed at key locations on assembly equipment to remove iron from components entering the assembly area, ensuring a clean environment within the motor and preventing various failures caused by iron impurities.

Finally, why do new energy vehicle motors require strong magnetic rods in particular?

New energy vehicle drive motors primarily include permanent magnet synchronous motors and induction asynchronous motors, with permanent magnet synchronous motors accounting for 94% of the domestic market.

These motors typically utilize neodymium iron boron permanent magnets, offering advantages such as high power density, high operating efficiency, high torque, and smooth operation. However, they also place higher demands on cleanliness:

1. Efficiency Requirements: New energy vehicle motors must maintain high efficiency across a wide speed range. Any excess loss caused by iron impurities will impact range.

2. Compact Design: Motors are trending towards higher speeds and smaller sizes, resulting in more sophisticated internal structures and increased sensitivity to impurities.

3. Reliability Requirements: As a core component of the vehicle, the reliability of the motor is directly related to its safety and service life.

Rod magnets, the "long-distance runners" in the magnetic world, have become indispensable components in various industries and applications, from speakers, sensors, motors to magnetic therapy equipment, with their clear magnetic field direction, good axial action distance, excellent stability and economy. Although they may be surpassed by more modern powerful magnets in terms of absolute magnetic strength, rod magnets are still an irreplaceable and practical choice in areas that require directionality, long action distance, high temperature stability and low cost.

What is a bar magnet?

A bar magnet, as the name implies, is a long (cylindrical or cuboid) permanent magnet. It is one of the most basic and intuitive forms in the permanent magnet family. Its core physical properties are:

* Clear pole distribution: The two ends of the bar form a stable North Pole (N) and South Pole (S), which are the areas with the strongest magnetic force.

* Directivity of magnetic field: The magnetic field mainly extends along the long axis of the bar, forming a clear closed magnetic flux line between the two poles. The magnetic field in the middle area of the bar is relatively weak.

* Material composition: The most common material is ferrite (ceramic magnet) because of its low cost, good corrosion resistance and stability. Neodymium iron boron (NdFeB) or aluminum nickel cobalt (AlNiCo) are used in high-performance applications, which can provide stronger magnetic force.

Core performance and unique charm

1. Directed magnetic field, clear and controllable: Its long strip structure naturally guides the direction of the magnetic field, and the two poles are clear, which makes it very advantageous in applications that require magnetic force in a specific direction (such as sensors, magnetic stirring).

2. Balance between strength and size: Although the magnetic force per unit volume may not be as good as some compact magnets (such as square magnets), by increasing the length, it can achieve a significant magnetic range in a specific direction.

3. Strong and durable: Especially sintered ferrite rods, which have excellent corrosion resistance, temperature stability (operating temperature can reach 250°C or even higher) and physical hardness, are not easy to demagnetize, and have a long service life.

4. Economical and practical: Ferrite rod magnets are one of the most cost-effective permanent magnets and are suitable for large-scale applications.

How to make it?

There are two main processes for making rod magnets:

1. Sintering process (mainstream):

* Raw material mixing: Mix ferrite (SrFe12O19 or BaFe12O19) or rare earth magnetic powder (such as NdFeB) with a binder, etc.

* Pressing: The mixture is pressed into a rod-shaped mold under a strong magnetic field. Magnetic field orientation is a key step, which makes the easy magnetization axis of the magnetic powder particles align along the length of the rod, giving the magnetic rod anisotropy (that is, the magnetic properties are optimal along the length).

* High-temperature sintering: The pressed green sheet is sintered and solidified in a high-temperature furnace (about 1200-1300°C for ferrite and about 1000-1100°C for NdFeB) to form a dense microcrystalline structure.

* Magnetization: The cooled "green sheet" is placed in an ultra-strong pulsed magnetic field for magnetization to activate its magnetism.

* Surface treatment and testing: Coating (such as epoxy, zinc, nickel) may be applied to enhance corrosion resistance, followed by strict dimensional, appearance and magnetic performance testing.

2. Bonding process:

* Mixing magnetic powder (such as ferrite, NdFeB or SmCo) with plastic (such as nylon, rubber) or resin.

* Made into a rod shape by injection molding or compression molding.

* The advantages are that complex shapes can be manufactured, high dimensional accuracy, and good toughness; the disadvantages are that the magnetic properties are usually lower than sintered magnets of the same material, and the temperature resistance is poor.

rod magnets

Ubiquitous:

Bar magnets are active in many fields due to their unique shape and stable performance:

* Education and demonstration: A classic teaching aid for physics classrooms to demonstrate magnetic poles, magnetic field lines, and magnetic interactions.

* Industrial sensing and detection:

* Magnetic sensors: Used to detect position, speed, and rotation speed (such as automotive ABS wheel speed sensors).

* Door magnetic switches: The core component for detecting the open and closed status of doors and windows in security systems.

* Magnetic separators: Adsorb and remove ferromagnetic impurities in recycling, mining, and food processing.

* Electronics and electrical:

* Speakers/receivers: Key components for providing a constant magnetic field inside traditional dynamic speakers.

* DC motors: Rod magnets are used in some small DC motors (such as toy motors) to provide a stator magnetic field.

* Magnetic stirrers: The core of the stirrer (often wrapped in Teflon) is the magnetic bar, which is driven by a rotating magnetic field at the bottom of the beaker.

* Daily necessities: magnetic door curtains, tool box fasteners, magnetic hooks, etc.

* Medical and scientific research: They are also used in some experimental equipment and simple magnetic therapy equipment (scientificity and standardization should be noted). They can even be found in some early or auxiliary components of magnetic resonance imaging (MRI) systems.