October 2012

Feature Article

Three-Axis Magnetic Field Measurement: From Nanoteslas to 14 Tesla

A new generation of handheld 3-axis magnetometers, introduced a few years ago, is capable of measuring magnetic field strengths in the range from milliteslas to 3 tesla. [1] Recent developments have extended this measurement range upward, to 14 T, as well as downward, into the nanoteslas, all within the same family of ultra-compact, USB-powered instruments. The keys are innovative sensor technologies and calibration. <read more>

Research & Development

Dry-Run Experiments Verify Key Aspect of Nuclear Fusion Concept
Magnetically imploded tubes called liners, intended to help produce controlled nuclear fusion at scientific “break-even” energies or better within the next few years, have functioned successfully in preliminary tests, according to a Sandia research paper. <read more>

Magnetics 2013: Preliminary Program Announced

MEDER electronic Announces 3-D Magnetic Mapping Of Reed Sensors

Optimize components and eliminate issues that may result in faulty operations
Meder electronic Inc., a manufacturer of precise, reliable, and long-lasting miniature switches, sensors and relays, announces its 3-dimensional magnetic mapping capabilities for reed sensors. This process allows designers to more accurately place sensors and magnetic components within a system, thus eliminating any issues that may result in faulty operation.

MEDER electronic conducts 3-D magnetic mapping by incrementally measuring the reed sensor’s closure and opening points as it enters and exits the influence of a magnetic field. This information is then analyzed, allowing the user to visualize the magnetic field in three dimensions. Understanding the interacting magnetic fields allows designers to better position the magnet and sensor in the system for optimal operation. 3-D mapping also helps designers adjust the magnetic sensitivity of the reed sensor and/or the magnet’s size and strength.

The ability to know where the key operating points are is critical to sensor applications, because it allows designers to properly position the magnet and sensor well within appropriate guard bands and avoid tolerance issues. It is particularly useful in applications using more than one reed sensor or more than one magnet. For applications in which ferromagnetic material like iron, steel, nickel or cobalt are present in the area where sensing takes place, 3-D modeling becomes quite extensive and unpredictable, so magnetic mapping is the only way to know for sure where the boundaries are.

In addition to ensuring operations are well within the magnetic envelopes to avoid tolerance issues, 3D magnetic mapping helps designers optimize the sensor and magnet components, which can significantly reduce costs.

Linear Actuator Packs Powerful Peak Force of 500 lbs.
BEI Kimco Magnetics, a brand of Custom Sensors & Technologies, Inc., has introduced the High Force Linear Actuator Model LA100-93-000A. The new actuator packs a peak force of 500 lbs, a strength that typically requires two actuators to achieve. With approximately two times both peak and continuous force ratings compared to BEI Kimco’s previous models, the device is a significant advancement in the product offering.

In addition to its high peak force rating, the actuator features a continuous force of 292 lbs. with 2-inch total stroke. Other important characteristics include semi-housed construction with built in shaft and bushings that orient the coil assembly concentric to the field assembly. This key design attribute makes actuator mounting fast and easy for the customer. The unit measures 10 inches in diameter and 9.3 inches long at mid stroke.

“The LA100 VCA is very similar in construction to our smaller actuators but bigger by a factor of two – it’s basically two actuators in one,” said Jim McNamara, senior applications engineer, VCA. “This capability expands our application versatility. Unique to the market, there are other actuators with 500 lbs. of force, but none that we know of that also provide a 2-inch stroke.”

The LA100 is suitable for use in applications that require an actuator force of 500 lbs. and high speed. Typical uses include environmental stress testing for lab equipment and military and aerospace equipment, as well as other applications in industrial, medical and testing environments.

AVX Develops High Quality Multilayer Organic Capacitors
AVX Corp., a manufacturer of advanced passive components and interconnect solutions, has developed a 500 and 250 VDC, 0603 case size surface mount capacitor capable of supporting frequencies ranging from 1 MHz to well above 5 GHz.  Designated the MLO3 series, the advanced organic RF capacitors maintain high Q and high self resonance while providing low ESR values at high frequencies. Based on AVX’s patented multilayer low-loss organic (MLO) technology, the polymer-based organic capacitors use high-conductivity copper interconnects in a multilayer fashion.

The ability to fabricate these components on large area substrates with sophisticated laser-direct imaging yields low profile, low ESR and high-performance RF capacitors with improved cost benefits and tolerance control. Additionally, AVX’s MLO Capacitors are expansion matched to printed circuit boards for improved reliability.

“AVX’s new line of organic capacitors represents a revolutionary departure from traditional passive SMT components,” said Larry Eisenberger, product manager at AVX. “The multilayer low-loss organic RF capacitor’s state-of-the-art design ultimately increases performance characteristics while decreasing costs.”

The RoHS-compliant RF capacitors are rated for 50 to 500 VDC, and feature capacitance values ranging from 0.1 pF to 2.5 pF and capacitance tolerance to +/- 0.02 pF. Available in 0603 case size with a 100 percent tin finish, the MLO3 series features stable NPO characteristics and an operating temperature range of -55°C to +125°C.

AVX’s MLO3 series surface mount capacitors are well suited for usage in RF power and low noise amplifiers, filter networks and MRI systems.

Power Transformer Design Site Demonstrates Benefits of Software Automation
A new website to help engineers accelerate and improve the design of electrical power transformers and AC line reactors has been launched by Cobham Technical Services.

Designed to be a useful resource for engineers seeking to optimize the performance of power transformers or reactors the new website provides clear insight into the benefits of automating the design process using finite element modeling, simulation and analysis by means of an on-demand detailed technical audio visual presentation.
‘Introduction to Transformer Design’ demonstrates the virtual design process. It explores the Opera design software to illustrate how finite element analysis (FEA) techniques enable conceptual designs of power transformers and reactors to be created, analyzed and optimized easily. By allowing users to prove designs before building physical prototypes, this approach reduces production costs and shortens time-to-market significantly – and provides a simple means of fine-tuning design ideas to meet specific goals such as higher efficiency or reduction of materials.
Subjects covered include the definition of model geometry, finite element shapes, mesh density and material type, as well as transformer or reactor configuration, containment and winding layout. Open-circuit, short-circuit, inrush current and mutual inductance tests are described in detail, together with results analysis options. The presentation also highlights how it's possible to extensively automate the design-analyze-optimize process.

The presentation includes benchmark results on an internationally agreed family of problems defined to test the accuracy of simulation software in modeling transformers. Structural and thermal analysis capabilities are also covered briefly, showing how the electromagnetic FEA tool can encompass every aspect of transformer design and qualification. For engineers wishing to gain a more in-depth appreciation of multiphysics simulation, the website provides a link to a further detailed presentation.

The website also provides a dynamic overview of the low-frequency electromagnetic design automation software package Opera, as well as a wealth of information about finite element application areas and capabilities. Cobham is also further populating the site with technical papers and application notes on transformer design and optimization.

New Magnetic Separator for Flexible-Hose, Pneumatic Line Systems
Industrial Magnetics, Inc. has announced a line extension of their Rare-Earth Bullet Magnet, called the 4JIT Bullet, designed for flexible-hose pneumatic line systems to improve product purity and protect processing machinery from tramp metal damage.

Consisting of a 100 percent stainless, two-part body, the BM4JIT's inlet and outlet is designed to install to a flexible hose system, allowing dry powder and granular materials to pass through the magnetic housing and be purified of metal contaminants. Access to the magnetic circuit is achieved by opening the tri-clover clamp on the housing and removing the lower body to clean collected tramp metal.

Because it installs to flexible line pneumatic systems, the BM4JIT is a portable and versatile magnetic solution and can be used ahead of processing equipment to protect machinery from tramp metal damage and at bulk load out zones to ensure product purity.

The 4JIT Bullet is designed to operate leak-free at up to 130 psi and is capable of operation in explosive environments. Standard design is available for 3 inches, 4 inches and 5 inches line sizes, with custom options available upon request.

Electron Energy Corp. Expands Capacity with Opening of Second Facility
Electron Energy Corp. (EEC), an expert developer and leading producer of rare earth magnets, has significantly expanded capacity with the opening of its second manufacturing facility. The additional 44,800 sq ft, located at 300 Running Pump Road in Lancaster, PA, more than doubles EEC floor space and enables them to improve efficiency and meet the growing demand for EEC products and services. The building will house the finishing operations—machining, testing, magnetizing, packing and shipping. The new facility will also enable the company to expand production of complex and larger magnet assemblies. With approximately 132 employees today, EEC is positioned as a significant American rare earth magnet producer with customers throughout the world.

In a statement on the opening of the second facility President Michael Walmer, said, “EEC magnets help our customers maintain their leadership in keeping the world safer, healthier and more informed. Demand is increasing and this additional manufacturing space is essential in our ongoing commitment to growth and serving our growing customer base.”

EEC is a fully integrated US supplier that develops and produces custom Samarium Cobalt (SmCo) and Neodymium-Iron-Boron (NdFeB) sintered permanent magnets, assemblies and systems. Founded in 1970, they are experts at providing rare earth permanent magnets for aerospace, military, medical, electronics, motion control and instrumentation applications. Known for their ability to precisely control material compositions, they partner with customers as a virtual 'in-house' source of magnet technology.

For more information about Electron Energy Corporation's magnets, design engineering services and magnet assemblies and systems, call toll-free at 1-800-824-2735 or visit the website. The staff of engineering specialists is available for free technical consultations.

IMC Completes Design Work for Centralized RE Separation Plant
Innovation Metals Corp. (IMC) has announced the completion by Genivar, Inc., the company’s engineering consultants, of a set of process flow diagrams (PFDs) for the extraction and purification stages of IMC’s future critical rare-earth element (REE) separation facility, to be located in Bécancour, Quebec.

Genivar worked closely on this project with IMC’s China-based REE separation consultants, an engineering group with extensive real-world expertise in REE separation facility design and operation. This work was undertaken as part of the prefeasibility study being conducted by Genivar for IMC.

Starting with a mixed REE carbonate feedstock, produced by blending individual feedstock received from various future REE producers, the process starts with an acid-leaching phase, to solubilize the REEs, followed by a cascade of separation stages based on solvent-extraction techniques. The result will be the formation of 13 distinct high-purity rare-earth chloride products.

“This unique collaborative effort to develop the PFDs and associated mass-balance calculations for our Facility is ongoing,” said Gareth Hatch, President of IMC, “and is a critical part of IMC’s strategy for the production of separated REEs in Quebec. Our two consulting groups are working closely together on the completion of the process-design work for the subsequent precipitation and calcination stages of the process to produce the final REE products.”

Once completed, the full set of PFDs will be tested first at the bench scale, and subsequently in a pilot plant, to be constructed and operated in Quebec.

“Our announcement today marks an inflection point for the rare-earth industry outside of China,” said Patrick Wong, CEO of IMC. “IMC is now one of very few companies outside of China with detailed quantitative designs for a critical REE separation plant. It will be the first centralized Facility of its kind available to future producers of critical REEs, for the development of marketable products by low-cost toll processing, and where end users can own separation capacity.”

Bunting Magnetics Europe Limited Acquires E-Magnets UK Limited
Bunting Magnetics Europe Limited, a manufacturing and sales operation center based in Berkhamsted, England for Bunting Magnetics Company, has acquired E-Magnets UK Limited, located in Sheffield, England.

E-Magnets UK Ltd specializes in direct and wholesale supply of magnetic products throughout the UK and the world through its website.  The company was founded in 2005 by Alistair Richardson, whom will continue to oversee the company’s everyday operations.  The E-Magnets UK brand name has become synonymous with quality and is recognized as a highly respected and leading name within the various magnetic markets.

This acquisition by Bunting Magnetics Europe bolsters their market leadership and puts them one step closer to their strategic growth plan. “We are expanding our capabilities in today’s rapidly growing e-commerce environment,” said Robert J. Bunting, Bunting Magnetics owner and CEO. “E-Magnets UK  expands Bunting’s market presence in the UK and abroad, while at the same time significantly increases our online business presence which, until today, was done through our e-commerce sites magnetuk.com and buymagnets.com.  E-Magnets UK has outstanding market recognition for their product assortment and is well known within the European Union.”

New Information on PM Materials Published
The Metal Powder Industries Federation (MPIF) has published the 2012 edition of MPIF Standard 35, Materials Standards for PM Structural Parts. Aimed at design/materials engineers and purchasing agents, the 96-page standard contains new information on many of the 98 industry-approved ferrous, nonferrous, and stainless steel materials used to make powder metallurgy (PM) parts.

The revised standard features new materials and mechanical property data for prealloyed steel (FL-5108), hybrid low-alloy steel (FLN2-3905), and diffusion-alloyed steel (FD-0101) as well as 400 series stainless steel (SS-409LE and SS-409LNi).  A new section for strain-controlled fatigue data is included.

It also contains new or revised engineering information including hardenability (Jominy) data for hybrid low-alloy steel (FLN2-3905), diffusion-alloyed steel (FD-0105), and coefficient of thermal expansion (CT-1000). All materials property values are presented in inch–pound and SI units throughout the standard.

The new standard is available in several versions at a list price of $60: hard-copy printed editions, CD-ROM, or downloadable digital (pdf) format. It can be purchased online (www.mpif.org) along with other MPIF materials standards covering powder-forged steel PM parts, metal injection molded (MIM) parts, and PM self-lubricating bearings.

Event Listings

Learn the Basics of Magnetics, Attend a Bootcamp!

The Bootcamp Workshops focus on the basics of Magnetics and will take place on Wednesday, February 6, 2013 in Orlando, Fla. at the Rosen Plaza hotel. If you need to understand magnets better for your job, want to get more from the conference presentations or are new to the field, then Basic – Bootcamp I is the right place to start. If something more advanced is what you are looking for, attend Bootcamp II.

Dr. Stan Trout has been offering Bootcamps since 2007 and has trained more than 100 students, putting to use his more than 35 years of experience in the permanent and rare earth industries. Dr. Trout has a B.S. in Physics from Lafayette College and a M.S. and a Ph.D. in Metallurgy and Materials Science from the University of Pennsylvania. Stan is a contributing columnist for Magnetics Business & Technology magazine, the Director of the Magnet Business for Molycorp Minerals, LLC, and is a consultant to the Magnetics Industry. His consultancy Spontaneous Materials provides practical solutions in magnetic materials, the rare earths, technical training and technical writing.

Basic – Bootcamp I (taking place from 8 AM to 12 PM) assumes that one has little or no background in magnetics. The Bootcamp I workshop will cover the fundamental magnetic concepts such as hysteresis, what is magnetism, units, basic processing, magnetizing and thermal effects.

Advanced – Bootcamp II (taking place from 1 PM to 5 PM) assumes someone has either taken a previous Bootcamp or has some basic technical understanding of magnetics. After a brief review of the basics, including self-demagnetization and loadlines, we will discuss raw materials and their pricing, advanced processing techniques, manufacturability, design basics, new design case studies and what’s new on the horizon.

Attend both Bootcamps for a full day of training and save! Basic/Advanced Bootcamp Package (8 AM to 5 PM).

Limited Seating Available - Register now for a discounted rate!

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