Development of magnetic circuits using the 3D printing method​

• Structured magnetic circuit design using FEM magnetic model​

• Optimization of magnetic flux, mass and eddy current generation level​

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3D printing enables the production of structured magnetic circuits that were unmanufacturable with previous technologies. ​

When we design a magnetic circuit, we usually have the following requirements:​

1. Constant cross-section for the entire magnetic flux path. ​

• Air conducts magnetic flux by more than 3​

• Orders worse than steel. Steel is able to effectively conduct magnetic flux only up to a certain value of magnetic saturation. After reaching this value, the ability to conduct magnetic flux drops sharply to the level of air. It can therefore be said that the narrowest point of the circuit limits the maximum achievable mag. flow throughout the circuit. The larger cross-section in other parts of the circuit is just a waste of material that increases the weight of the mag. circuit.​
  A rod structure created using 3D printing allows to design a mag. circumference so that the cross-section in all parts of the mag. circuit was constant. This minimizes the weight of the circuit.​

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2.Eddy current minimization.  ​

• With rapid changes in the intensity of the mag. the field induces an electric voltage in the electrically conductive material, which induces the flow of an electric current. These eddy currents are undesirable for some devices (transformers, solenoid valves, etc.) because they increase losses, require cooling and increase response time. ​
  If the magnetic circuit is made of suitably arranged electrically insulated rods on the surface (the rods follow the magnetic field lines in steady state), the eddy currents will be greatly reduced. The production of these structured cores is made possible by 3D printing technology

Design and optimization of magnetic circuits ​

• Magnetic circuit design in the ANSYS Electronics Desktop environment ​

• Simulation of static and transient phenomena associated with a magnetic field​

• Work with simple 2D models and complex 3D solids

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• Based on the results of magnetic simulations, we are able to propose modifications leading to the improvement of the functional properties of electromagnetic devices​

  • Increasing and optimizing position-dependent force progression for solenoid valves​

  • Weight reduction for moving elements in magnetic circuits while maintaining magnetic fluxes​

  • Eddy current loss reduction​

  • Reducing the elmag response time. device