EP3147918A1 - Device and method of manufacturing annular permanent magnets - Google Patents

Device and method of manufacturing annular permanent magnets Download PDF

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Publication number
EP3147918A1
EP3147918A1 EP16001814.9A EP16001814A EP3147918A1 EP 3147918 A1 EP3147918 A1 EP 3147918A1 EP 16001814 A EP16001814 A EP 16001814A EP 3147918 A1 EP3147918 A1 EP 3147918A1
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Prior art keywords
cavity
powder
compression means
core
force
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EP16001814.9A
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German (de)
French (fr)
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EP3147918B1 (en
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Martin Krengel
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Wilo SE
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Wilo SE
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/0253—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing permanent magnets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/1035—Liquid phase sintering
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/105—Sintering only by using electric current other than for infrared radiant energy, laser radiation or plasma ; by ultrasonic bonding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/10—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
    • B22F5/106—Tube or ring forms
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/0253—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing permanent magnets
    • H01F41/0266—Moulding; Pressing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/105—Sintering only by using electric current other than for infrared radiant energy, laser radiation or plasma ; by ultrasonic bonding
    • B22F2003/1051—Sintering only by using electric current other than for infrared radiant energy, laser radiation or plasma ; by ultrasonic bonding by electric discharge

Definitions

  • the invention relates to a device for producing annular permanent magnets by electrical discharge sintering, comprising a plurality of, an annular cavity for receiving a magnetizable metallic powder defining tool parts and a controllable electric pulse generator, wherein at least two of the tool parts form electrodes and are electrically connected to the pulse generator, and the Tool parts at least one of the cavity in the radial direction outwardly limiting outer shape, as well as two the cavity in the axial direction limiting, relatively axially movable compression means comprise, wherein at least one of the compression means in the direction of the cavity is subjected to force or kraftbeetzschlagbar.
  • the invention relates to a method for producing annular permanent magnets by electrical discharge sintering, in particular using the aforementioned device, in which a magnetizable metallic powder is introduced into the cavity and exposed to an electric pulse current flowing between the electrodes such that the powder is at least partially melted at the same time a force is exerted in the direction of the cavity on the powder to compress the powder in the melt state.
  • Ring-shaped permanent magnets are used, for example, for rotors of modern permanent-magnet electric motors. Their production is comparatively complex, long-lasting and expensive.
  • the preparation is usually carried out by conventional sintering of magnetic powder, wherein a heating of the powder under Mechanical pressure in a conventional manner, in particular by electrical heating elements, which are integrated in a form containing the powder.
  • the heating to sintering temperature lasts comparatively long. Furthermore, the cooling of the sintered workpiece also takes time.
  • the EDS method is used to achieve densification of iron powder or a cemented carbide powder, such as tungsten carbide, by the pulsed discharge of electrical energy into the powder.
  • a corresponding device 1 for this according to the prior art shows FIG. 1 ,
  • the device comprises a plurality of tool parts 3, 4, 5, which delimit a cylindrical cavity 11, and a controllable electrical pulse current generator, which has a capacitor 9 and a pulse current transformer 8.
  • FIG. 1 is located in the cavity already to be compacted, electrically conductive powder 2.
  • the cavity 11 is limited in the radial direction to the outside by a hollow cylindrical outer mold 3 and in the axial direction by two compression means 4, 5, at least partially in the axial direction in the the cavity comprising the cavity outer shape form fit into extend.
  • At least the upper compression means 4 is axially movable and is of a mechanical force F applied, which is generated for example by a hydraulic system 10 and transmitted via a pressure pin 7a on the compression means 4.
  • the powder 2 is thereby pressed against the lower compression means 5, which is supported against a further pressure pin 7b and receives the pressure force accordingly.
  • the two force-transmitting or force-absorbing compression means 4, 5 are designed to be electrically conductive and simultaneously constitute the electrodes.
  • the current flow I and the power transmission direction are thus parallel.
  • tools and punch arrangements in EDS systems generally work with a current flow in the pressing direction.
  • the shape of the permanent magnets so produced however, one is limited to thin or flat workpieces, since the resistance of the powder with their length increases. As a result, the current decreases with increasing thickness. The melting effect of the pulse current and the degree of melting at the powder particle contact points is thus the smaller, the greater the distance between the electrodes introducing the current. The fusion is incomplete with long expansions in the pressing direction. Thus, in the case of thick workpieces, the case arises that the powder particles do not melt together well in the middle of the powder quantity. The workpieces crumble apart. Thus, only permanent magnets in the form of simple round flat slices or cuboids can be produced. By contrast, the ring-shaped permanent magnets used in the construction of permanent-magnet electric motors for the rotors can not readily be produced by the EDS method according to the prior art.
  • an apparatus for producing annular permanent magnets by means of electrical discharge sintering is proposed in which the magnetic powder receiving cavity in the radial direction outwardly by the outer shape, in the radial direction inwardly delimited by a coaxially extending to the outer core and in the axial direction by the compression means is, wherein the outer mold and the core form the electrodes and the compression means electrically isolate the electrodes from each other.
  • a method is proposed in which the pulse flow within the cavity in the radial direction between the outer mold and the core flows, and the force of at least one of the two axially limiting the compression means in the axial direction is transmitted to the powder, wherein the Compression means electrically isolate the outer mold and the core from each other.
  • the permanent magnets to be produced are in their axial height, and is correspondingly the height of the cavity, not fixed.
  • the cavity may be formed flat, i. that their radial width is greater than or equal to their axial length, so that annular disk-shaped permanent magnets can be produced.
  • the cavity can also be higher than wide, so that it increasingly has the shape of a hollow cylinder with increasing height.
  • the inventive method is thus particularly suitable for producing high hollow cylindrical permanent magnets, preferably just those in which the axial length is equal to or greater than the radial thickness. Accordingly, for the production of these permanent magnets, the cavity may have an axial length which is greater than the distance between the core and the outer wall.
  • the contour of the annular permanent magnets can basically be arbitrary. Accordingly, the geometric shape of the cavity forming the annular space is not fixed. This applies both to the outer contour of the permanent magnets or to the inner contour of the outer contour that defines the cavity outwardly, as well as to its inner contour or the outer contour of the inner cavity defining the cavity.
  • the outer contour of the core in cross section may correspond to a circular, oval, square or polygonal basic shape. Of technically greatest importance here is also a circular outer contour of the core, but also an angular outer contour is advantageous because it can form a rotation.
  • the core is pin-shaped, so that it is possible to produce permanent magnets in the form of a hollow profile.
  • At least one of the compression means has a central opening into which the core is retractable due to the relative movement of the compression means.
  • the outer mold and the core are stationary tool parts. As a result, the electrodes can be contacted better and easier. Because in contrast to the prior art no moving tool parts must be electrically contacted in this case. While in the device according to FIG. 1 the compression means 4, 5 form the electrodes, of which at least one is axially movable, the tool parts now used as electrodes outer mold and core can form immovable tool parts. This simplifies electrical contacting because the electrical connection between the movable electrode and the supply current from the pulse generator does not endure the mechanical shock experienced by the movable compression means due to extrusion of the molten powder particles or at least their surface into the interparticle spaces.
  • compression means merely expresses an involvement in the compression of the powder, but does not imply that a Force is exerted on the powder.
  • only one of the compression means actively exert a force on the powder and the other compression means passively absorb this force, so that only one-sided pressing takes place.
  • both compression means can also be subjected to a force of force in the axial direction and independently of one another in the direction of the cavity, ie. actively exert a force on the powder.
  • the two-sided pressing has the advantage that a higher total pressure acts on the powder and the powder is better compressed because the above-described press cone is reduced or becomes a double cone.
  • the compression means can consist of a ceramic material.
  • the outer mold and / or the core may be made of copper.
  • the powder can be introduced into the cavity as a loose powder bed or as a mechanically pre-pressed powder compact.
  • the compression means due to the application of force to the powder cause a mechanical pre-pressing before the electrical discharge sinter.
  • FIG. 2 shows a schematic representation of an inventive device 1 for the production of permanent magnets with a ring shape.
  • the device 1 makes it possible to produce ring magnets of any axial length using electrical discharge sintering.
  • the device 1 provides an annular cavity 11, which serves to receive a magnetic powder 2, which is introduced into the cavity 11 as a loose powder bed or as a mechanically precompressed powder compact.
  • a magnetic powder 2 is already present in the cavity 11.
  • the cavity is delimited by four tool parts 3, 4, 5, 6, namely in the radial direction outwards by an outer mold 3, in the radial direction inwards by a core 6, and in the axial direction by two compression means 4, 5.
  • the outer mold 3 has the shape of a hollow cylinder, although it may have any outer contour. Within the outer mold 3, a cylindrical cavity is formed, which comprises the cavity 11. Coaxial with the outer mold 3, the core 6 extends through this cavity and thus forms it or the cavity 11 to form an annular space. The core 6 is pin-shaped. The distance between the core and outer shape defines the thickness D of the permanent magnet to be produced.
  • one of the two compression means 4, 5 extends at least partially positively into the cavity and thus limits it in the axial direction.
  • the distance between these compression means 4, 5 defines the height or axial length L of the permanent magnet to be produced.
  • the cavity thus has an axial length L that is greater than the thickness D.
  • the compression means 4, 5 are cylindrical and have a coaxial opening 13 either in the form of a bore over the entire axial length as in the case of the lower compression means 5 or in the form of a blind hole as in the case of the upper compression means 4, to accommodate the core 6 ,
  • the inner diameter of the opening 13 is thus adapted to the outer diameter of the core 6, so that core 6 and compression means 4, 5, can be positively inserted into each other or driven.
  • Both compression means 4, 5 are arranged axially movable. They are acted upon independently of each other in the direction of the cavity 11 by a force F and thus form against the powder 2 pressing punch.
  • the force F is generated by a respective hydraulic system 10 and transmitted via bolts 7a, 7b to the respective compression means 4, 5.
  • only one of the compression means 4, 5, is axially movable and kraftbeaufschlagt, as in the device 1 in FIG. 1 the case is.
  • the outer mold 3 and the core 6 are electrically conductive, designed for example consisting of copper. They form electrodes and are connected via a connecting cable with a controllable pulse current generator 8, 9, which is represented here schematically by a pulse transformer 8 and a capacitor 9.
  • a controllable pulse current generator 8 which is represented here schematically by a pulse transformer 8 and a capacitor 9.
  • outer mold 3 and core 6 are fixed, i. not immovable. They can be contacted better and there is no risk that the connection line 12 dissolves.
  • the pulse transformer 8 generates from the charge stored in the capacitor 9, a current pulse I of about 300kA and a few milliseconds in length, as in FIG. 1a is shown.
  • the compression means 4, 5 are made of a non-conductive material, such as a ceramic, and thus isolate outer mold 3 and core 6 from each other.
  • the current pulse I flows between outer mold 3 and core 6 through the powder 2, i. in the radial direction and thus perpendicular to the force F. This results in a short current path and a homogeneous compression by the discharge sintering.

Abstract

Die Erfindung betrifft eine Vorrichtung (1) und ein Verfahren zur Herstellung ringförmiger Permanentmagnete durch elektrisches Entladungssintem. Die Vorrichtung, umfasst mehrere, eine ringförmige Kavität (11) zur Aufnahme eines magnetisierbaren metallischen Pulvers (2) definierende Werkzeugteile (3, 4, 5, 6) und einen steuerbaren elektrischen Impulsstromgenerator (8, 9), wobei zumindest zwei der Werkzeugteile (3, 4, 5, 6) Elektroden bilden und mit dem Impulsstromgenerator (8, 9) elektrisch verbunden sind. Die Werkzeugteile (3, 4, 5, 6) umfassen zumindest eine die Kavität (11) in radialer Richtung nach außen begrenzende Außenform (3), einen die Kavität (11) in radialer Richtung nach innen begrenzenden, koaxial zur Außenform (3) angeordneten Kern (6) sowie zwei die Kavität (11) in axialer Richtung begrenzende, relativ zueinander axialbewegliche Kompressionsmittel (4, 5), wobei zumindest eines der Kompressionsmittel (4, 5) in Richtung der Kavität (11) kraftbeaufschlagt oder kraftbeaufschlagbar ist. Außenform (3) und Kern (6) bilden die Elektroden. Die Kompressionsmittel (4, 5) isolieren die Elektroden elektrisch voneinander, so dass der Stromfluss senkrecht zur Kraft liegt. Auf diese Weise können homogen verdichtete Ringmagnete beliebiger Länge auf einfache Weise und in kurzer Zeit hergestellt werden.The invention relates to a device (1) and a method for producing annular permanent magnets by means of electrical discharge sintering. The device comprises a plurality of tool parts (3, 4, 5, 6) defining an annular cavity (11) for receiving a magnetizable metallic powder (2) and a controllable electric pulse current generator (8, 9), at least two of the tool parts (3 , 4, 5, 6) form electrodes and are electrically connected to the pulse current generator (8, 9). The tool parts (3, 4, 5, 6) comprise at least one outer mold (3) delimiting the cavity (11) in the radially outward direction, a cavity (11) radially inwardly delimiting, coaxial with the outer mold (3) Core (6) and two the cavity (11) in the axial direction limiting, relative to each other axially movable compression means (4, 5), wherein at least one of the compression means (4, 5) in the direction of the cavity (11) is subjected to force or kraftbeaufschlagbar. Outer shape (3) and core (6) form the electrodes. The compression means (4, 5) electrically isolate the electrodes from each other so that the current flow is perpendicular to the force. In this way, homogeneously compressed ring magnets of any length can be produced in a simple manner and in a short time.

Description

Die Erfindung betrifft eine Vorrichtung zur Herstellung ringförmiger Permanentmagnete durch elektrisches Entladungssintern, umfassend mehrere, eine ringförmige Kavität zur Aufnahme eines magnetisierbaren metallischen Pulvers definierende Werkzeugteile und einen steuerbaren elektrischen Impulsstromgenerator, wobei zumindest zwei der Werkzeugteile Elektroden bilden und mit dem Impulsstromgenerator elektrisch verbunden sind, und die Werkzeugteile zumindest eine die Kavität in radialer Richtung nach außen begrenzende Außenform, sowie zwei die Kavität in axialer Richtung begrenzende, relativ zueinander axialbewegliche Kompressionsmittel umfassen, wobei zumindest eines der Kompressionsmittel in Richtung der Kavität kraftbeaufschlagt oder kraftbeaufschlagbar ist. Des Weiteren betrifft die Erfindung ein Verfahren zur Herstellung ringförmiger Permanentmagnete durch elektrisches Entladungssintern, insbesondere unter Verwendung der vorgenannten Vorrichtung, bei dem ein magnetisierbares metallisches Pulver in die Kavität eingebracht und einem zwischen den Elektroden fließenden elektrischen Impulsstrom derart ausgesetzt wird, dass das Pulver zumindest teilweise aufgeschmolzen wird, wobei gleichzeitig eine Kraft in Richtung der Kavität auf das Pulver ausgeübt wird, um das Pulver im Schmelzzustand zu verdichten.The invention relates to a device for producing annular permanent magnets by electrical discharge sintering, comprising a plurality of, an annular cavity for receiving a magnetizable metallic powder defining tool parts and a controllable electric pulse generator, wherein at least two of the tool parts form electrodes and are electrically connected to the pulse generator, and the Tool parts at least one of the cavity in the radial direction outwardly limiting outer shape, as well as two the cavity in the axial direction limiting, relatively axially movable compression means comprise, wherein at least one of the compression means in the direction of the cavity is subjected to force or kraftbeaufschlagbar. Furthermore, the invention relates to a method for producing annular permanent magnets by electrical discharge sintering, in particular using the aforementioned device, in which a magnetizable metallic powder is introduced into the cavity and exposed to an electric pulse current flowing between the electrodes such that the powder is at least partially melted at the same time a force is exerted in the direction of the cavity on the powder to compress the powder in the melt state.

Ringförmige Permanentmagnete werden beispielsweise für Rotoren moderner permanenterregter Elektromotoren verwendet. Ihre Herstellung ist vergleichsweise aufwändig, langdauernd und teuer. Die Herstellung erfolgt in der Regel durch herkömmliches Sintern von Magnetpulver, wobei ein Aufheizen des Pulvers unter mechanischem Druck auf konventionelle Art, insbesondere durch elektrische Heizelemente, die in einer das Pulver enthaltenden Form integriert sind. Das Aufheizen auf Sintertemperatur dauert dadurch vergleichsweise lang. Ferner braucht auch das Abkühlen des gesinterten Werkstücks Zeit.Ring-shaped permanent magnets are used, for example, for rotors of modern permanent-magnet electric motors. Their production is comparatively complex, long-lasting and expensive. The preparation is usually carried out by conventional sintering of magnetic powder, wherein a heating of the powder under Mechanical pressure in a conventional manner, in particular by electrical heating elements, which are integrated in a form containing the powder. The heating to sintering temperature lasts comparatively long. Furthermore, the cooling of the sintered workpiece also takes time.

Demgegenüber sind Verfahren zur Pulverkompaktierung durch Kurzzeitsintern dem Fachmann als EDS (Electric Discharge Sintering) oder synonym CDS (Capacitor Discharge Sintering) bekannt. Eine diese Verfahren und entsprechende Vorrichtungen zu ihrer Ausführung ausführlich beschreibende Veröffentlichung ist " Outside Mainstream Electronic Database: Review of Studies Conducted in the USSR and Post-Soviet Countries on Electric Current-Assisted Consolidation of Powder Materials", Eugene A. Olevsky, Elena V. Aleksandrova, Alexandra M. Ilyina, Dina V. Dudina, Alexander N. Novoselov, Kirill Y. Pelve and Eugene G. Grigoryev, Materials 2013, 6, Seiten 4375-4440, doi:10.3390/ma6104375 . Des Weiteren beschreiben das US-Patent US 3,241,956 das Grundprinzip des EDS. Ein Verfahren zur Anpassung der Druckkraft während der Pulverkompaktierung ist in der europäischen Patentanmeldung EP 2 198 993 A1 beschrieben. Diese Literatur wird hiermit für die Erläuterung der hier beschriebenen Erfindung in Bezug genommen. Auf ausführliche Erläuterung der Technologie wird daher verzichtet.On the other hand, processes for powder compaction by short-term sintering are known to the person skilled in the art as EDS (Electric Discharge Sintering) or synonymously CDS (Capacitor Discharge Sintering). A publication detailing these methods and corresponding apparatuses for their execution is " Outside Mainstream Electronic Database: Review of Studies Conducted in the USSR and Post-Soviet Countries on Electric Current-Assisted Consolidation of Powder Materials, "Eugene A. Olevsky, Elena V. Aleksandrova, Alexandra M. Ilyina, Dina V. Dudina, Alexander N Novoselov, Kirill Y. Pelve and Eugene G. Grigoryev, Materials 2013, 6, pp. 4375-4440, doi: 10.3390 / ma6104375 , Furthermore, the US patent US 3,241,956 the basic principle of the EDS. One method of adjusting the compressive force during powder compaction is in the European patent application EP 2 198 993 A1 described. This literature is hereby incorporated by reference for the explanation of the invention described herein. Detailed explanation of the technology is therefore omitted.

Das EDS -Verfahren wird eingesetzt, um eine Verdichtung von Eisenpulver oder einem Pulver aus Hartmetall, beispielsweise Wolframcarbid, durch die impulsartige Entladung einer elektrischen Energie in das Pulver zu erreichen. Eine entsprechende Vorrichtung 1 hierfür nach dem Stand der Technik zeigt Figur 1.The EDS method is used to achieve densification of iron powder or a cemented carbide powder, such as tungsten carbide, by the pulsed discharge of electrical energy into the powder. A corresponding device 1 for this according to the prior art shows FIG. 1 ,

Die Vorrichtung umfasst mehrere Werkzeugteile 3, 4, 5, die eine zylindrische Kavität 11 begrenzen, sowie einen steuerbaren elektrischen Impulsstromgenerator, der einen Kondensator 9 und einen Impulsstromtransformator 8 aufweist. In Figur 1 befindet sich in der Kavität bereits ein zu verdichtendes, elektrisch leitfähiges Pulver 2. Die Kavität 11 wird in radialer Richtung nach außen durch eine hohlzylindrische Außenform 3 und in axialer Richtung durch zwei Kompressionsmittel 4, 5 begrenzt, die sich zumindest teilweise in axialer Richtung in den die Kavität umfassenden Hohlraum der Außenform formschlüssig hinein erstrecken. Dabei ist zumindest das obere Kompressionsmittel 4 axialbeweglich und wird von einer mechanischen Kraft F beaufschlag, die beispielsweise von einer Hydraulik 10 erzeugt und über einen Druckbolzen 7a auf das Kompressionsmittel 4 übertragen wird. Dieses überträgt die Druckkraft F wiederum auf das Pulver 2 und wirkt wie ein Stempel. Das Pulver 2 wird dadurch gegen das untere Kompressionsmittel 5 gepresst, welches sich gegen einen weiteren Druckbolzen 7b abstützt und die Druckkraft entsprechend aufnimmt. Die beiden kraftübertragenden bzw. kraftaufnehmenden Kompressionsmittel 4, 5 sind elektrisch leitend ausgeführt und stellen gleichzeitig die Elektroden dar. Der Stromfluss I und die Kraftübertragungsrichtung liegen somit parallel. Allgemein arbeiten Werkzeuge und Stempelanordnungen bei EDS-Anlagen in der Regel mit einem Stromfluss in Pressrichtung.The device comprises a plurality of tool parts 3, 4, 5, which delimit a cylindrical cavity 11, and a controllable electrical pulse current generator, which has a capacitor 9 and a pulse current transformer 8. In FIG. 1 is located in the cavity already to be compacted, electrically conductive powder 2. The cavity 11 is limited in the radial direction to the outside by a hollow cylindrical outer mold 3 and in the axial direction by two compression means 4, 5, at least partially in the axial direction in the the cavity comprising the cavity outer shape form fit into extend. At least the upper compression means 4 is axially movable and is of a mechanical force F applied, which is generated for example by a hydraulic system 10 and transmitted via a pressure pin 7a on the compression means 4. This transmits the pressure force F in turn to the powder 2 and acts like a stamp. The powder 2 is thereby pressed against the lower compression means 5, which is supported against a further pressure pin 7b and receives the pressure force accordingly. The two force-transmitting or force-absorbing compression means 4, 5 are designed to be electrically conductive and simultaneously constitute the electrodes. The current flow I and the power transmission direction are thus parallel. In general, tools and punch arrangements in EDS systems generally work with a current flow in the pressing direction.

Zum Verdichten wird elektrische Energie in dem Kondensator 9 gespeichert und durch den Impulstransformator 8 innerhalb von wenigen Millisekunden in das Pulver 2 entladen. Ein Verlauf der Prozessgrößen Strom, Temperatur und Druck zeigt Figur 2. Sie zeigt den impulsförmigen Gleichstrom bei gleichzeitig konstantem Druck. Ferner zeigt die gestrichelte Linie die Temperatur im Pulver, die während des Stromimpulses auf ein Vielfaches ansteigt. Denn aufgrund des hohen Stroms von ca. 300 kA und des hohen ohmschen Widerstands zwischen den Pulverpartikelkontaktpunkten wird an diesen Kontaktpunkten Joulsche Wärme generiert, die so groß ist, dass die Pulverpartikelkontaktpunkte in eine schmelzflüssige Phase übergehen. Durch die gleichzeitig auf das Pulver ausgebübte Druckkraft wird diese Phase in die Partikelzwischenräume gepresst, wodurch das in den Zwickeln lokalisierte Porenvolumen infiltriert wird. Nach der Abkühlung des prozessierten Pulvers liegt ein dichtes Gefüge vor, das vom technologischen Standpunkt aus verschweißt und nicht gesintert wurde. Gleichwohl spricht die Fachwelt bei diesem Prozess von Sintern. Je nach Aufbau der Kondensatorladeeinheit ist eine vollständige Wiederaufladung der Kondensatoren innerhalb von weniger als 6s gewährleistet. Die schnelle Kondensatoraufladung in Verbindung mit der schnellen Verdichtung erlaubt die Herstellung von bis zu 10 Werkstücken pro Minute. Aus diesem Grund ist das Verfahren besonders im Hinblick auf eine wirtschaftliche Herstellung von pulververdichteten Werkstücken attraktiv.For compressing electrical energy is stored in the capacitor 9 and discharged by the pulse transformer 8 within a few milliseconds in the powder 2. A progression of the process variables current, temperature and pressure shows FIG. 2 , It shows the pulsed direct current with constant pressure. Furthermore, the dashed line shows the temperature in the powder, which increases during the current pulse to a multiple. Because of the high current of about 300 kA and the high ohmic resistance between the powder particle contact points Joule heat is generated at these contact points, which is so large that the powder particle contact points merge into a molten phase. The pressure force exerted on the powder at the same time presses this phase into the interparticle spaces, thereby infiltrating the pore volume located in the interstices. After cooling of the processed powder is a dense structure, which was welded from the technological point of view and not sintered. Nevertheless, experts in this process speak of sintering. Depending on the design of the capacitor charging unit, a complete recharging of the capacitors is ensured within less than 6 seconds. The fast capacitor charging in conjunction with the rapid compaction allows the production of up to 10 workpieces per minute. For this reason, the method is particularly attractive in terms of economical production of powder-compacted workpieces.

Hinsichtlich der Form der so herstellbaren Permanentmagnete ist man jedoch auf dünne oder flache Werkstücke beschränkt, da der Widerstand der Pulvermenge mit ihrer Länge zunimmt. Dadurch nimmt der Strom mit zunehmender Dicke ab. Die Schmelzwirkung des Impulsstroms und der Schmelzgrad a n den Pulverpartikelkontaktpunkten ist somit umso kleiner, je größer der Abstand zwischen den den Strom einbringenden Elektroden ist. Die Verschmelzung ist bei langen Ausdehnungen in Pressrichtung unvollständig. So tritt bei dicken Werkstücken der Fall auf, dass die Pulverpartikel in der Mitte der Pulvermenge nicht gut zusammenschmelzen. Die Werkstücke bröckeln vielmehr auseinander. So können nur Permanentmagnete in Gestalt einfacher runder flacher Scheiben oder Quader hergestellt werden. Die im Bau von permanenterregten Elektromotoren für die Rotoren verwendeten ringförmigen Permanentmagnete lassen sich mit dem EDS-Verfahren nach dem Stand der Technik dagegen nicht ohne Weiteres herstellen.With regard to the shape of the permanent magnets so produced, however, one is limited to thin or flat workpieces, since the resistance of the powder with their length increases. As a result, the current decreases with increasing thickness. The melting effect of the pulse current and the degree of melting at the powder particle contact points is thus the smaller, the greater the distance between the electrodes introducing the current. The fusion is incomplete with long expansions in the pressing direction. Thus, in the case of thick workpieces, the case arises that the powder particles do not melt together well in the middle of the powder quantity. The workpieces crumble apart. Thus, only permanent magnets in the form of simple round flat slices or cuboids can be produced. By contrast, the ring-shaped permanent magnets used in the construction of permanent-magnet electric motors for the rotors can not readily be produced by the EDS method according to the prior art.

Es ist Aufgabe der vorliegenden Erfindung, ein Verfahren und eine Vorrichtung bereitzustellen, das bzw. die die Herstellung ringförmiger Permanentmagnete für Elektromoren in kürzeren Prozessierzeiträumen ermöglicht.It is an object of the present invention to provide a method and an apparatus which enables the production of annular permanent magnets for electric motors in shorter processing periods.

Diese Aufgabe wird durch eine Vorrichtung mit den Merkmalen des Anspruchs 1 und durch ein Verfahren mit den Merkmalen des Anspruchs 8 gelöst. Vorteilhafte Weiterbildungen sind in den Unteransprüchen angegeben und werden nachfolgend erläutert.This object is achieved by a device having the features of claim 1 and by a method having the features of claim 8. Advantageous developments are specified in the subclaims and are explained below.

Erfindungsgemäß wird eine Vorrichtung zur Herstellung ringförmiger Permanentmagnete mittels elektrischem Entladungssintern vorgeschlagen, bei der die das Magnetpulver aufnehmende Kavität in radialer Richtung nach außen durch die Außenform, in radialer Richtung nach innen durch einen sich koaxial zur Außenform erstreckenden Kern sowie in axialer Richtung durch die Kompressionsmittel begrenzt ist, wobei die Außenform und der Kern die Elektroden bilden und die Kompressionsmittel die Elektroden elektrisch voneinander isolieren. Entsprechend wird ein Verfahren vorgeschlagen, bei dem der Impulsstrom innerhalb der Kavität in radialer Richtung zwischen der Außenform und dem Kern fließt, und die Kraft von zumindest einem von zwei die Kavität in axialer Richtung begrenzenden Kompressionsmitteln in axialer Richtung auf das Pulver übertragen wird, wobei die Kompressionsmittel die Außenform und den Kern elektrisch voneinander isolieren.According to the invention, an apparatus for producing annular permanent magnets by means of electrical discharge sintering is proposed in which the magnetic powder receiving cavity in the radial direction outwardly by the outer shape, in the radial direction inwardly delimited by a coaxially extending to the outer core and in the axial direction by the compression means is, wherein the outer mold and the core form the electrodes and the compression means electrically isolate the electrodes from each other. Accordingly, a method is proposed in which the pulse flow within the cavity in the radial direction between the outer mold and the core flows, and the force of at least one of the two axially limiting the compression means in the axial direction is transmitted to the powder, wherein the Compression means electrically isolate the outer mold and the core from each other.

Versuche mit diesem Verfahren, respektive dieser Vorrichtung haben gezeigt, dass sich ein Magnetpulver auf dieser Weise verdichten lässt. Bei geeigneter Wahl der Prozessparameter derart, dass die Gesamttemperatur der Pulvermenge 400°C nicht überschreitet, bleiben die magnetischen Eigenschaften des Pulvers erhalten. Eine derartige Vorrichtung sowie ein derartiges Verfahren ermöglichen vor allem die Anwendung des elektrischen Entladungssinterns (EDS) zur Herstellung ringförmiger Permanentmagnete beliebiger axialer Länge, da diese Länge unabhängig vom Abstand der Elektroden zueinander ist. Stromfluss und Kraftfluss wirken rechtwinklig zueinander auf das Magnetpulver. Die Kavität bildet einen Ringraum, der homogen vom Strom durchflossen wird, so dass auch eine homogene Aufschmelzung des Magnetpulvers erreicht wird. Unter einem Magnetpulver versteht der Fachmann ein magnetisierbares metallisches, d.h. elektrische leitendes Pulver, wie es üblicherweise zur Herstellung von Permanentmagneten verwendet wird.Experiments with this method, or this device have shown that a magnetic powder can be compressed in this way. With a suitable choice of the process parameters such that the total temperature of the powder does not exceed 400 ° C, the magnetic properties of the powder are retained. Such a device as well as such a method allow above all the use of electrical discharge sintering (EDS) for the production of annular permanent magnets of any axial length, since this length is independent of the distance of the electrodes from each other. Current flow and force flow act at right angles to each other on the magnetic powder. The cavity forms an annular space, which is flowed through homogeneously by the current, so that a homogeneous melting of the magnetic powder is achieved. Magnetic powder is understood by those skilled in the art to mean a magnetizable metallic, i. electrically conductive powder, as is commonly used to make permanent magnets.

Wie bereits ausgeführt, sind die herzustellenden Permanentmagnete in ihrer axialen Höhe, und ist in entsprechender Weise die Höhe der Kavität, nicht festgelegt. So kann die Kavität flach ausgebildet sein, d.h. dass ihre radiale Breite größer oder gleich ihrer axialen Länge ist, so dass ringscheibenförmige Permanentmagnete herstellbar sind. Die Kavität kann aber auch höher als breit sein, so dass sie mit steigender Höhe zunehmend deutlich die Form eines Hohlzylinders besitzt.As already stated, the permanent magnets to be produced are in their axial height, and is correspondingly the height of the cavity, not fixed. Thus, the cavity may be formed flat, i. that their radial width is greater than or equal to their axial length, so that annular disk-shaped permanent magnets can be produced. The cavity can also be higher than wide, so that it increasingly has the shape of a hollow cylinder with increasing height.

Die besondere Stärke der erfindungsgemäßen Vorrichtung sowie des entsprechenden Verfahrens gegenüber dem Stand der Technik gemäß Fig. 1 zeigt sich, wenn das Verhältnis von Länge zur Dicke der herzustellenden Permanentmagnete das Verhältnis 1:1 deutlich überschreitet. Denn im Gegensatz zum Stand der Technik führen Dichteschwankungen über der Höhe nicht zu einer Inhomogenen Verdichtung. Vielmehr ist die Verdichtung aufgrund des radialen Stromflusses stets homogen über die axiale Länge. Hierzu sei folgender Hintergrund erläutert.The particular strength of the device according to the invention and the corresponding method over the prior art according to Fig. 1 shows up when the ratio of length to thickness of the permanent magnets to be produced significantly exceeds the ratio 1: 1. In contrast to the state of the art, density fluctuations above the height do not lead to inhomogeneous compression. Rather, the compression due to the radial current flow is always homogeneous over the axial length. The following background is explained.

Bei der Ausübung einer Druckkraft auf einen Pulverhaufen nimmt diese mit zunehmendem Abstand vom Krafteinleitungsort aufgrund der Reibungsverluste zwischen den Pulverpartikeln ab. Es entsteht ein sogenannter Presskegel, der umso ausgeprägter ist, je höher der Pulverhaufen ist. Somit ist die Dichte des Pulverpresslings über die axiale Länge nicht konstant. Ein axial fließender Strom auf dem Weg von der einen Elektrode zur anderen Elektrode erfährt dann im höher verdichteten Bereich aufgrund der größeren Berührungsfläche der Pulverpartikel einen lokal geringeren Widerstand und im niedriger verdichteten Bereich einen lokal entsprechend höheren Widerstand, so dass in axialer Richtung betrachtet innerhalb des Pulvers keine homogene Wärmeerzeugung vorliegt. Somit sind auch die Schmelzebildung an den Pulverpartikelkontaktpunkten sowie die magnetischen Eigenschaften des Werkstücks nicht homogen. Es kann passieren, dass die Pulverpartikel im höher verdichteten Bereich nicht vollständig verschmelzen.When exerting a compressive force on a pile of powder, this decreases with increasing distance from the point of application due to the friction losses between the powder particles. The result is a so-called press cone, which is the more pronounced, depending higher the powder heap is. Thus, the density of the powder compact over the axial length is not constant. An axially flowing current on the way from one electrode to the other electrode then experiences a locally lower resistance in the higher-compressed region due to the larger contact surface of the powder particles and a locally correspondingly higher resistance in the lower-compressed region, so that viewed in the axial direction within the powder there is no homogeneous heat generation. Thus, the melt formation at the powder particle contact points as well as the magnetic properties of the workpiece are not homogeneous. It can happen that the powder particles in the higher-density area do not fuse completely.

Dieses bei hohen Ringwerkstücken auftretende Phänomen wird bei dem erfindungsgemäßen Verfahren aufgrund des radialen Stromflusses verhindert, weil der Widerstand maßgeblich durch die Länge der Strompfade bestimmt ist und diese Länge bei radial gegenüberliegender Anordnung der Elektroden zur Herstellung hoher Permanentmagnete kleiner ist als bei einem axialen Strompfad nach dem Stand der Technik ist. Das erfindungsgemäße Verfahren eignet sich damit insbesondere, hohe hohlzylindrische Permanentmagnete herzustellen, vorzugsweise eben solche, bei denen die axiale Länge gleich oder größer als die radiale Dicke ist. Entsprechend kann zur Herstellung dieser Permanentmagnete die Kavität eine axiale Länge aufweisen, die größer als der Abstand zwischen dem Kern und der Außenwand ist.This phenomenon, which occurs at high ring workpieces, is prevented in the method according to the invention due to the radial current flow, because the resistance is significantly determined by the length of the current paths and this length is smaller with radially opposite arrangement of the electrodes for producing high permanent magnets than with an axial current path after Prior art is. The inventive method is thus particularly suitable for producing high hollow cylindrical permanent magnets, preferably just those in which the axial length is equal to or greater than the radial thickness. Accordingly, for the production of these permanent magnets, the cavity may have an axial length which is greater than the distance between the core and the outer wall.

Da hier die radialen Strompfade kürzer sind als sie nach dem Stand der Technik bei einem Stromfluss in axialer Richtung wären, wirken sich Dichteinhomogenitäten weniger auf die Verschmelzung der Pulverpartikel und damit weniger auf die magnetischen Eigenschaften des Endprodukts aus.Since here the radial current paths are shorter than they would be in the axial direction in the current art, density inhomogeneities have less effect on the fusion of the powder particles and thus less on the magnetic properties of the final product.

Die Kontur der ringförmigen Permanentmagnete kann grundsätzlich beliebig sein. Entsprechend ist auch die geometrische Form des die Kavität bildenden Ringraums nicht festgelegt. Dies gilt sowohl für Außenkontur der Permanentmagnete respektive für die dies ausbildende Innenkontur der die Kavität nach außen begrenzenden Außenform, als auch für ihre Innenkontur respektive die dies ausbildende Außenkontur des die Kavität nach innen begrenzenden Kerns.The contour of the annular permanent magnets can basically be arbitrary. Accordingly, the geometric shape of the cavity forming the annular space is not fixed. This applies both to the outer contour of the permanent magnets or to the inner contour of the outer contour that defines the cavity outwardly, as well as to its inner contour or the outer contour of the inner cavity defining the cavity.

So kann die Innenkontur der Außenform im Querschnitt einer kreisrunden, ovalen, quadratischen oder mehreckige Grundform entsprechen. Technisch von besonderer Bedeutung und für die Herstellung von Rotoren für Elektromotoren verwendbar sind jedoch ringförmige Permanentmagnete mit kreisförmiger Außenkontur.Thus, the inner contour of the outer shape in cross section of a circular, oval, square or polygonal basic shape correspond. However, from a technical point of view and for the production of rotors for electric motors usable annular permanent magnets with circular outer contour.

Ferner kann die Außenkontur des Kerns im Querschnitt einer kreisrunden, ovalen, quadratischen oder mehreckige Grundform entsprechen. Von technisch größter Bedeutung ist hier ebenfalls eine kreisförmige Außenkontur des Kerns, jedoch ist auch eine eckige Außenkontur vorteilhaft, da sie eine Verdrehsicherung bilden kann.Furthermore, the outer contour of the core in cross section may correspond to a circular, oval, square or polygonal basic shape. Of technically greatest importance here is also a circular outer contour of the core, but also an angular outer contour is advantageous because it can form a rotation.

Vorzugsweise ist der Kern stiftförmig, so dass sich Permanentmagnete in Form eines Hohlprofils herstellen lassen.Preferably, the core is pin-shaped, so that it is possible to produce permanent magnets in the form of a hollow profile.

Geeigneterweise weist zumindest eines der Kompressionsmittel eine zentrale Öffnung auf, in die der Kern infolge der Relativbewegung der Kompressionsmittel zueinander einfahrbar ist.Suitably, at least one of the compression means has a central opening into which the core is retractable due to the relative movement of the compression means.

Von besonderem Vorteil ist es, wenn die Außenform und der Kern stationäre Werkzeugteile sind. Hierdurch lassen sich die Elektroden besser und einfacherer kontaktieren. Denn im Gegensatz zum Stand der Technik müssen in diesem Fall keine beweglichen Werkzeugteile elektrisch kontaktiert werden. Während bei der Vorrichtung gemäß Figur 1 die Kompressionsmittel 4, 5 die Elektroden bilden, von denen zumindest eines axialbeweglich ist, können die nun als Elektroden verwendeten Werkzeugteile Außenform und Kern unbewegliche Werkzeugteile bilden. Dies vereinfacht die elektrische Kontaktierung, weil die elektrische Verbindung zwischen der beweglichen Elektrode und der den Strom vom Impulsstromgenerator zuleitenden Zuführung nicht den mechanischen Ruck aushalten, den das bewegliche Kompressionsmittel infolge des Fließpressens der aufgeschmolzenen Pulverpartikel oder zumindest ihrer Oberfläche in die Partikelzwischenräume erfährt.It is particularly advantageous if the outer mold and the core are stationary tool parts. As a result, the electrodes can be contacted better and easier. Because in contrast to the prior art no moving tool parts must be electrically contacted in this case. While in the device according to FIG. 1 the compression means 4, 5 form the electrodes, of which at least one is axially movable, the tool parts now used as electrodes outer mold and core can form immovable tool parts. This simplifies electrical contacting because the electrical connection between the movable electrode and the supply current from the pulse generator does not endure the mechanical shock experienced by the movable compression means due to extrusion of the molten powder particles or at least their surface into the interparticle spaces.

Es sei angemerkt, dass der Begriff "Kompressionsmittel" lediglich eine Beteiligung an der Kompression des Pulvers zum Ausdruck bringt, jedoch nicht impliziert, dass eine Kraft auf das Pulver ausgeübt wird. So kann in einer Ausführungsvariante der Erfindung nur eines der Kompressionsmittel aktiv eine Kraft auf das Pulver ausüben und das andere Kompressionsmittel diese Kraft passiv aufnehmen, so dass nur ein einseitiges Pressen erfolgt.It should be noted that the term "compression means" merely expresses an involvement in the compression of the powder, but does not imply that a Force is exerted on the powder. Thus, in one embodiment of the invention, only one of the compression means actively exert a force on the powder and the other compression means passively absorb this force, so that only one-sided pressing takes place.

Gemäß einer bevorzugten Ausführungsvariante können jedoch auch beide Kompressionsmittel axialbeweglich und unabhängig voneinander in Richtung der Kavität kraftbeaufschlagt oder kraftbeaufschlagbar sein, d.h. aktiv eine Kraft auf das Pulver ausüben. Das zweiseitige Pressen hat den Vorteil, dass ein höherer Gesamtdruck auf das Pulver wirkt und das Pulver besser verdichtet wird, weil der oben beschriebene Presskegel reduziert wird bzw. zu einem Doppelkegel wird.According to a preferred embodiment variant, however, both compression means can also be subjected to a force of force in the axial direction and independently of one another in the direction of the cavity, ie. actively exert a force on the powder. The two-sided pressing has the advantage that a higher total pressure acts on the powder and the powder is better compressed because the above-described press cone is reduced or becomes a double cone.

Um die Elektroden gut voneinander zu isolieren und gleichzeitig mechanische Kräfte aufnehmen oder übertragen zu können, können die Kompressionsmittel aus einem keramischen Material bestehen. Unabhängig davon können die Außenform und/ oder der Kern aus Kupfer bestehen.In order to isolate the electrodes well from each other and at the same time to be able to absorb or transmit mechanical forces, the compression means can consist of a ceramic material. Regardless, the outer mold and / or the core may be made of copper.

Zur Durchführung des Verfahrens kann das Pulver als lockere Pulverschüttung oder als mechanisch vorgepresster Pulverpressling in die Kavität eingebracht werden. In ersterem Fall bewirken die Kompressionsmittel infolge der Kraftausübung auf das Pulver eine mechanische Vorpressung vor dem elektrischen Entladungssintem.To carry out the process, the powder can be introduced into the cavity as a loose powder bed or as a mechanically pre-pressed powder compact. In the former case, the compression means due to the application of force to the powder cause a mechanical pre-pressing before the electrical discharge sinter.

Mit diesem erfindungsgemäßen Verfahren ist es möglich, Magnete in einem Prozessschritt herzustellen, wobei die Werkstücke nach dem elektrischen Entladungssintern noch magnetisiert werden müssen. Dies kann innerhalb der Vorrichtung oder außerhalb, in einer separaten Vorrichtung erfolgen, in dem die Werkstücke einem starken, entsprechend der gewünschten Magnetisierungsrichtung orientierten magnetischen Feld ausgesetzt werden. Der zweite Ansatz verfolgt das Ziel, mittels EDS zunächst ein Halbzeug herzustellen, das in einem nachfolgenden Prozessschritt durch Warmfließpressen die gewünschten mechanischen und magnetischen Eigenschaften erreicht.With this method according to the invention, it is possible to produce magnets in one process step, wherein the workpieces still have to be magnetized after electrical discharge sintering. This can be done inside the device or outside, in a separate device, in which the workpieces are exposed to a strong, oriented according to the desired direction of magnetization magnetic field. The second approach pursues the goal of initially producing a semifinished product by means of EDS, which achieves the desired mechanical and magnetic properties by hot extrusion in a subsequent process step.

Weitere Merkmale und Vorteile der Erfindung werden nachfolgend anhand eines Ausführungsbeispiels und der beigefügten Figur 2 beschrieben.Further features and advantages of the invention will be described below with reference to an embodiment and the attached FIG. 2 described.

Figur 2 zeigt eine schematische Darstellung einer erfindungsgemäßen Vorrichtung 1 zur Herstellung von Permanentmagneten mit einer Ringform. Die Vorrichtung 1 ermöglicht es, Ringmagnete beliebiger axialer Länge unter Anwendung des elektrischen Entladungssinterns herzustellen. FIG. 2 shows a schematic representation of an inventive device 1 for the production of permanent magnets with a ring shape. The device 1 makes it possible to produce ring magnets of any axial length using electrical discharge sintering.

Hierzu stellt die Vorrichtung 1 eine ringförmige Kavität 11 bereit, die der Aufnahme eines Magnetpulvers 2 dient, welches als lose Pulverschüttung oder als mechanisch vorkomprimierter Pulverpressling in die Kavität 11 eingebracht wird. In Figur 2 ist bereits Magnetpulver 2 in der Kavität 11 vorhanden. Die Kavität wird von vier Werkzeugteilen 3, 4, 5, 6 begrenzt, nämlich in radialer Richtung nach außen durch eine Außenform 3, in radialer Richtung nach innen durch einen Kern 6, sowie in axialer Richtung durch zwei Kompressionsmittel 4, 5.For this purpose, the device 1 provides an annular cavity 11, which serves to receive a magnetic powder 2, which is introduced into the cavity 11 as a loose powder bed or as a mechanically precompressed powder compact. In FIG. 2 Magnetic powder 2 is already present in the cavity 11. The cavity is delimited by four tool parts 3, 4, 5, 6, namely in the radial direction outwards by an outer mold 3, in the radial direction inwards by a core 6, and in the axial direction by two compression means 4, 5.

Die Außenform 3 hat die Gestalt eines Hohlzylinders, obgleich sie eine beliebige Außenkontur haben kann. Innerhalb der Außenform 3 ist ein zylindrischer Hohlraum gebildet, der die Kavität 11 umfasst. Koaxial zur Außenform 3 erstreckt sich der Kern 6 durch diesen Hohlraum und formt ihn respektive die Kavität 11 somit zu einem Ringraum. Der Kern 6 ist stiftförmig ausgebildet. Der Abstand zwischen Kern und Außenform definiert die Dicke D des herzustellenden Permanentmagneten.The outer mold 3 has the shape of a hollow cylinder, although it may have any outer contour. Within the outer mold 3, a cylindrical cavity is formed, which comprises the cavity 11. Coaxial with the outer mold 3, the core 6 extends through this cavity and thus forms it or the cavity 11 to form an annular space. The core 6 is pin-shaped. The distance between the core and outer shape defines the thickness D of the permanent magnet to be produced.

Jeweils eines der beiden Kompressionsmittel 4, 5 erstreckt sich zumindest teilweise formschlüssig in den Hohlraum hinein und begrenzt diesen somit in axialer Richtung. Der Abstand zwischen diesen Kompressionsmitteln 4, 5 definiert die Höhe bzw. axiale Länge L des herzustellenden Permanentmagneten. Die Kavität besitzt somit eine axiale Länge L, die größer als die Dicke D ist.In each case one of the two compression means 4, 5 extends at least partially positively into the cavity and thus limits it in the axial direction. The distance between these compression means 4, 5 defines the height or axial length L of the permanent magnet to be produced. The cavity thus has an axial length L that is greater than the thickness D.

Die Kompressionsmittel 4, 5 sind zylindrisch und haben eine koaxiale Öffnung 13 entweder in Form einer Bohrung über die gesamte axiale Länge wie im Falle des unteren Kompressionsmittels 5 oder in Form eines Sacklochs wie im Falle des oberen Kompressionsmittels 4 ausgeführt ist, um den Kern 6 aufzunehmen. Der Innendurchmesser der Öffnung 13 ist somit an den Außendurchmesser des Kerns 6 angepasst, so dass Kern 6 und Kompressionsmittel 4, 5, formschlüssig ineinander geschoben oder gefahren werden können.The compression means 4, 5 are cylindrical and have a coaxial opening 13 either in the form of a bore over the entire axial length as in the case of the lower compression means 5 or in the form of a blind hole as in the case of the upper compression means 4, to accommodate the core 6 , The inner diameter of the opening 13 is thus adapted to the outer diameter of the core 6, so that core 6 and compression means 4, 5, can be positively inserted into each other or driven.

In der Ausführungsvariante gemäß Figur 2 sind beide Kompressionsmittel 4, 5 axialbeweglich angeordnet. Sie werden unabhängig voneinander in Richtung der Kavität 11 von einer Kraft F beaufschlagt und bilden somit gegen das Pulver 2 drückende Stempel. Die Kraft F wird von jeweils einer Hydraulik 10 erzeugt und über Bolzen 7a, 7b auf das jeweilige Kompressionsmittel 4, 5 übertragen. Es besteht jedoch auch die Möglichkeit, dass nur eines der Kompressionsmittel 4, 5, axialbeweglich und kraftbeaufschlagt ist, wie dies bei der Vorrichtung 1 in Figur 1 der Fall ist.In the embodiment according to FIG. 2 Both compression means 4, 5 are arranged axially movable. They are acted upon independently of each other in the direction of the cavity 11 by a force F and thus form against the powder 2 pressing punch. The force F is generated by a respective hydraulic system 10 and transmitted via bolts 7a, 7b to the respective compression means 4, 5. However, there is also the possibility that only one of the compression means 4, 5, is axially movable and kraftbeaufschlagt, as in the device 1 in FIG. 1 the case is.

Die Außenform 3 und der Kern 6 sind elektrisch leitend, beispielsweise aus Kupfer bestehend ausgeführt. Sie bilden Elektroden und sind über ein Anschlusskabel mit einem steuerbaren Impulsstromgenerator 8, 9 verbunden, der hier schematisch durch einen Impulstransformator 8 und einen Kondensator 9 repräsentiert ist. Im Gegensatz zu den Kompressionsmitteln 4, 5 sind Außenform 3 und Kern 6 feststehend, d.h. nicht unbeweglich. Sie können so besser kontaktiert werden und es besteht kein Risiko, dass sich die Anschlussleitung 12 löst.The outer mold 3 and the core 6 are electrically conductive, designed for example consisting of copper. They form electrodes and are connected via a connecting cable with a controllable pulse current generator 8, 9, which is represented here schematically by a pulse transformer 8 and a capacitor 9. In contrast to the compression means 4, 5, outer mold 3 and core 6 are fixed, i. not immovable. They can be contacted better and there is no risk that the connection line 12 dissolves.

Der Impulstransformator 8 generiert aus der in dem Kondensator 9 gespeicherten Ladung einen Stromimpuls I von ca. 300kA und wenigen Millisekunden Länge, wie es in Figur 1a dargestellt ist. Die Kompressionsmittel 4, 5 bestehen aus einem nicht leitenden Material, beispielsweise aus einer Keramik, und isolieren somit Außenform 3 und Kern 6 voneinander.The pulse transformer 8 generates from the charge stored in the capacitor 9, a current pulse I of about 300kA and a few milliseconds in length, as in FIG. 1a is shown. The compression means 4, 5 are made of a non-conductive material, such as a ceramic, and thus isolate outer mold 3 and core 6 from each other.

Da das Magnetpulver elektrisch leitend ist, fließ der Stromimpuls I zwischen Außenform 3 und Kern 6 durch das Pulver 2, d.h. in radialer Richtung und folglich senkrecht zur Kraft F. Dadurch ergeben sich ein kurzer Strompfad und eine homogene Verdichtung durch das Entladungssintern.Since the magnetic powder is electrically conductive, the current pulse I flows between outer mold 3 and core 6 through the powder 2, i. in the radial direction and thus perpendicular to the force F. This results in a short current path and a homogeneous compression by the discharge sintering.

Da die Kontaktpunkte zwischen den einzelnen Pulverpartikeln einen ohmschen Widerstand bilden, entsteht dort infolge des hohen Stroms joulsche Wärme, die so groß ist, dass zumindest die Oberfläche der Pulverpartikel zumindest teilweise aufgeschmolzen wird. Durch die gleichzeitig von den Kompressionsmitteln 4, 5 auf das Pulver 2 ausgebübte Druckkraft wird diese Schmelze in die Partikelzwischenräume gepresst und füllen somit die ehemaligen Freiräume zwischen Pulverpartikeln, d.h. das Porenvolumen aus. Dabei bewegen sich die Kompressionsmittel 4, 5 rückartig weiter in den Hohlraum hinein und verkleinern somit die Kavität 11. Es entsteht somit ein dichtes Gefüge. Fast ebenso schnell wie das Aufheizen des Pulvers erfolgte, kühlt das hergestellte Werkstück ab.Since the contact points between the individual powder particles form an ohmic resistance, there arises Joule heat due to the high current, which is so large that at least the surface of the powder particles is at least partially melted. By simultaneously exerted by the compression means 4, 5 on the powder 2 compressive force, this melt is in the Particle interstices pressed and thus fill the former spaces between powder particles, ie the pore volume. In this case, the compression means 4, 5 move backward into the cavity and thus reduce the cavity 11. This results in a dense structure. Almost as fast as the heating of the powder took place, the produced workpiece cools down.

Dieses wird anschließend einem starken magnetischen Feld ausgesetzt und auf diese Weise magnetisiert, so dass der gewünschte Ringmagnet erhalten wird.This is then exposed to a strong magnetic field and magnetized in this way, so that the desired ring magnet is obtained.

BezugszeichenlisteLIST OF REFERENCE NUMBERS

11
EDS-VorrichtungEDS device
22
Magnetpulvermagnetic particle
33
Außenformexternal form
44
oberes Kompressionsmittelupper compression means
55
unteres Kompressionsmittellower compression means
66
Kerncore
7a, 7b7a, 7b
Druckbolzenpushpin
88th
Impulstransformatorpulse transformer
99
Kondensatorcapacitor
1010
Hydraulikhydraulic
1111
Kavitätcavity
1212
Anschlusskabelconnection cable
1313
Öffnungopening

Claims (10)

Vorrichtung (1) zur Herstellung ringförmiger Permanentmagnete durch elektrisches Entladungssintern, umfassend mehrere, eine ringförmige Kavität (11) zur Aufnahme eines magnetisierbaren metallischen Pulvers (2) definierende Werkzeugteile (3, 4, 5, 6) und einen steuerbaren elektrischen Impulsstromgenerator (8, 9), wobei zumindest zwei der Werkzeugteile (3, 4, 5, 6) Elektroden bilden und mit dem Impulsstromgenerator (8, 9) elektrisch verbunden sind, und die Werkzeugteile (3, 4, 5, 6) zumindest eine die Kavität (11) in radialer Richtung nach außen begrenzende Außenform (3), sowie zwei die Kavität (11) in axialer Richtung begrenzende, relativ zueinander axialbewegliche Kompressionsmittel (4, 5) umfassen, wobei zumindest eines der Kompressionsmittel (4, 5) in Richtung der Kavität (11) kraftbeaufschlagt oder kraftbeaufschlagbar ist, dadurch gekennzeichnet, dass die Kavität (11) in radialer Richtung nach innen durch einen koaxial zur Außenform (3) angeordneten Kern (6) begrenzt ist, wobei die Außenform (3) und der Kern (6) die Elektroden bilden und die Kompressionsmittel (4, 5) die Elektroden elektrisch voneinander isolieren.Device (1) for producing annular permanent magnets by electrical discharge sintering, comprising a plurality of tool parts (3, 4, 5, 6) defining an annular cavity (11) for receiving a magnetizable metallic powder (2) and a controllable electric pulse current generator (8, 9 ), wherein at least two of the tool parts (3, 4, 5, 6) form electrodes and are electrically connected to the pulse current generator (8, 9), and the tool parts (3, 4, 5, 6) at least one of the cavity (11) in the radial direction outwardly delimiting outer shape (3), and two the cavity (11) in the axial direction limiting, relative to each other axially movable compression means (4, 5), wherein at least one of the compression means (4, 5) in the direction of the cavity (11 ) is subjected to force or kraftbeaufschlagbar, characterized in that the cavity (11) in the radial direction inwardly by a coaxial with the outer mold (3) arranged core (6) is limited, wherein the outer mold (3) and the core (6) form the electrodes and the compression means (4, 5) electrically isolate the electrodes from each other. Vorrichtung (1) nach Anspruch 1, dadurch gekennzeichnet, dass die Kavität (11) eine axiale Länge (L) aufweist, die gleich oder größer als der Abstand zwischen dem Kern (6) und der Außenwand (3) ist.Device (1) according to claim 1, characterized in that the cavity (11) has an axial length (L) which is equal to or greater than the distance between the core (6) and the outer wall (3). Vorrichtung (1) nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass der Kern (6) stiftförmig ist.Device (1) according to claim 1 or 2, characterized in that the core (6) is pin-shaped. Vorrichtung (1) nach einem der vorherigen Ansprüche, dadurch gekennzeichnet, dass die Kavität (11) hohlzylindrisch ist, insbesondere einen hohlen Kreiszylinder bildet.Device (1) according to one of the preceding claims, characterized in that the cavity (11) is hollow cylindrical, in particular forms a hollow circular cylinder. Vorrichtung (1) nach einem der vorherigen Ansprüche, dadurch gekennzeichnet, dass zumindest eines der Kompressionsmittel (5, 6) eine zentrale Öffnung (13) aufweist, in die der Kern (6) infolge der Relativbewegung der Kompressionsmittel (5, 6) zueinander einfahrbar ist.Device (1) according to one of the preceding claims, characterized in that at least one of the compression means (5, 6) has a central opening (13) into which the core (6) due to the relative movement of the compression means (5, 6) retractable to each other is. Vorrichtung (1) nach einem der vorherigen Ansprüche, dadurch gekennzeichnet, dass beide Kompressionsmittel (4, 5) axialbeweglich und unabhängig voneinander in Richtung der Kavität (11) kraftbeaufschlagt oder kraftbeaufschlagbar sind.Device (1) according to one of the preceding claims, characterized in that both compression means (4, 5) are axially movable and independently of each other in the direction of the cavity (11) subjected to force or kraftbeaufschlagbar. Vorrichtung (1) nach einem der vorherigen Ansprüche, dadurch gekennzeichnet, dass die Kompressionsmittel (4, 5) aus einem keramischen Material bestehen.Device (1) according to one of the preceding claims, characterized in that the compression means (4, 5) consist of a ceramic material. Verfahren zur Herstellung ringförmiger Permanentmagnete durch elektrisches Entladungssintern, bei dem ein magnetisierbares metallisches Pulver (2) in eine ringförmige, durch mehrere Werkzeugteile (3, 4, 5, 6) definierte Kavität (11) eingebracht und einem zwischen zumindest zwei der Werkzeugteile (3, 4, 5, 6) fließenden elektrischen Impulsstrom (I) derart ausgesetzt wird, dass das Pulver (2) zumindest teilweise aufgeschmolzen wird, wobei gleichzeitig von zumindest einem der Werkzeugteile (5, 6) eine Kraft (F) in Richtung der Kavität auf das Pulver (2) ausgeübt wird, um das Pulver (2) im Schmelzzustand zu verdichten, dadurch gekennzeichnet, dass der Impulsstrom (I) in radialer Richtung zwischen einer die Kavität (11) nach außen begrenzenden Außenform (3) und einem die Kavität (11) nach innen begrenzenden, sich koaxial zur Außenform (3) erstreckenden Kern (6) fließt, und die Kraft (F) von zumindest einem von zwei die Kavität (11) in axialer Richtung begrenzenden Kompressionsmitteln (4, 5) in axialer Richtung auf das Pulver (2) ausgeübt wird, wobei die Kompressionsmittel (4, 5) die Außenform (3) und den Kern (6) elektrisch voneinander isolieren.Method for producing annular permanent magnets by electrical discharge sintering, in which a magnetizable metallic powder (2) is introduced into an annular cavity (11) defined by a plurality of tool parts (3, 4, 5, 6) and between at least two of the tool parts (3, 4, 5, 6) is exposed in such a way that the powder (2) is at least partly melted, at the same time by at least one of the tool parts (5, 6) a force (F) in the direction of the cavity on the Powder (2) is applied to compress the powder (2) in the melt state, characterized in that the pulse stream (I) in the radial direction between the cavity (11) outwardly bounding outer mold (3) and the cavity (11 ) inwardly delimiting, coaxially with the outer mold (3) extending core (6) flows, and the force (F) of at least one of the two cavity (11) in the axial direction limiting Kompressionsm in the axial direction on the powder (2), wherein the compression means (4, 5) electrically isolate the outer mold (3) and the core (6) from each other. Verfahren nach Anspruch 8, dadurch gekennzeichnet, dass das Pulver (2) mechanisch vorverdichtet und anschließend in die Kavität (11) eingebracht wird.A method according to claim 8, characterized in that the powder (2) is mechanically precompressed and then introduced into the cavity (11). Verfahren nach Anspruch 8 oder 9, dadurch gekennzeichnet, dass das von beiden Kompressionsmitteln (4, 5) eine Kraft (F) in axialer Richtung auf das Pulver (2) übertragen wird.A method according to claim 8 or 9, characterized in that the two compression means (4, 5) a force (F) in the axial direction is transmitted to the powder (2).
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