Case Study / WATER PUMP WITH FOURFOLD PERFORMANCE /
THE PATH TO SUCCESS
Previously, our client sourced electric auxiliary water pumps from various manufacturers. Despite their appealing design, the drive performance was consistently insufficient across all brands.
The client laid out a clear challenge for us: How could we achieve four times the pump’s performance while retaining the existing design?
And there was another requirement: The rotor is to be used as an impeller for the pump and assembled onto a shaft.
Existing design
Improved performance
Custom magnetization
THE PATH TO SUCCESS
It was apparent: A fourfold increase in pump performance required a magnetic material far stronger than the previously used hard ferrite. Thus, sintered NdFeB emerged as the sole feasible choice. Furthermore, the rotor operates in water, necessitating protective measures for the NdFeB-magnets against the cooling medium.
The Solution
The rotor’s magnetization was defined as 8-pole: Each magnetic pole comprised two individual NdFeB magnets. Therefore, each rotor was equipped with 16 block magnets. To prevent these individual NdFeB magnets from coming into contact with one another, the rotor was designed with pockets for precisely positioning the block magnets.
Following the assembly of the individual magnets, a secondary injection molding process was undertaken to seal the rotor, safeguarding it against water exposure.
The Success:
We’ve navigated through a series of complex challenges to achieve a comprehensive solution:
- The rotor enables a dual functionality as pump impeller for a water pump rotor has been realized.
- The magnet has been seamlessly integrated into the pump, complete with an integrated bearing on the shaft.
- Even with the rotor’s operation in water, we’ve successfully harnessed high-performance NdFeB material. This was made possible through a specialized magnetization approach, significantly enhancing performance by constructing a pole from two permanent magnets for an 8-pole magnetization of the rotor..
