Designing a custom Halbach array involves balancing complex variables.
Magnetic field strength vs. volume, holding force vs. temperature, and structural integrity vs. weight.
A slight miscalculation in the magnetic vector can result in a 20% loss of performance.
Or catastrophic mechanical failure.
We bridge the gap between theoretical physics and manufacturability.
Our engineering team uses Finite Element Analysis (FEA) and Multiphysics Simulation software (ANSYS Maxwell).
They can model your assembly before a single magnet is cut.
We help you reduce material costs, optimize flux paths, and ensure safety factors are met.
Core Simulation Capabilities
Break this down by the “Physics” involved to show depth of knowledge.
A. Electromagnetic (EMag) Analysis
Flux Density Mapping:
We can generate 2D and 3D color maps.
Show the B-field distribution (Tesla/Gauss) in the air gap and surrounding space.
Force & Torque Calculation:
Precise prediction of Linear Thrust (N), Holding Force (N), and Torque (Nm) profiles.
Demagnetization Prediction:
We simulate the operating point (Pc) of the magnets under load.
Ensure they do not cross the “Knee” of the BH curve.
Prevent irreversible demagnetization.
B. Thermal & Multiphysics
Eddy Current Loss:
For high-speed rotors and undulators, we calculate the heat generated by eddy currents in the magnets and sleeve materials.
Temperature Coupling:
We model how rising temperatures affect magnetic output (Reversible Temperature Coefficient).
Select the correct grade (SH, UH, EH) for your environment.
C. Mechanical Stress Analysis
Rotational Stress:
For high-speed Halbach rotors, we simulate the Centrifugal Force and Hoop Stress on the retention sleeve (Carbon Fiber/Inconel) to prevent bursting.
Assembly Forces:
Halbach arrays generate massive internal repulsion forces.
We analyze the shear stress on the adhesive bond lines.
And recommend the optimal structural epoxy.
The Engineering Workflow (How We Work)
“We do not just run software; we engineer for manufacturability (DFM).”
1). Concept Review:
You send us your constraints (e.g., “I need 1.5 Tesla in a 20mm bore”).
2). Material Optimization:
We select the most cost-effective magnet grade that meets the spec.
E.g., “Switching from N52 to N48SH saves 15% cost with only 2% flux loss.”
3). FEA Simulation:
We build the 3D model and run the physics solver.
4). The Report: You receive a detailed engineering report including:
– Vector Plots: Visualizing the direction of the magnetic field.
– Field Homogeneity Graph: Plotting the uniformity along the critical axis.
– Safety Factor Verification: Confirming mechanical sleeve strength.
5). Prototyping:
Once the digital twin is approved, we move to physical production.
Deliverables Checklist
3D STEP / IGES Files of the optimized magnet assembly.
Magnetic Field Map (PDF) containing 2D cross-sections and data tables.
Harmonic Analysis (For Undulators/Dipoles).
Material Certification (BH Curves) for the specific batch to be used.
Technical Tools We Use
Software:
– ANSYS Maxwell
Validation Hardware:
– 3-Axis Helmholtz Coils
– Lake Shore Gaussmeters
– Fluxmeters
Optimize your magnetic circuit today
Sending a drawing is free.
Building a failed prototype is expensive.
Send us your CAD or Requirements.
Our engineering team will perform a preliminary feasibility review.
And provide a quote for full Simulation & Design services within 48 hours.
