EWEC 2010

1. Automated Magnetizing Solutions for Permanent Magnet Generators (PMG)Metis Instruments & Equipment NV EWEC 2010 Proprietary Information of Metis Confidential

2. Content • Magnetizing: what, why and when • ‘Metis Instruments & Equipment’ in a nutshell • Automated solution for Permanent Magnet Generator (high speed) • Solutions for Direct Drive • Prototyping solutions Proprietary Information of Metis Confidential

3. Magnetizing: What? Apply a strong magnetic field during a short time to allign the magnetic domains. • Short: milliseconds • Strong: 3 to 6 Tesla • Using discharge of the energy of a capacitor bank to drive the windings in dedicated yoke Proprietary Information of Metis Confidential

4. Magnetizing: Not why, when! • Single magnets by the supplier • Single magnets prior to glueing • In sub-assembly after glueing • On rotor after mounting • In generator after complete assembly The later, the better! Proprietary Information of Metis Confidential

5. Magnetizing a PM:chooze your moment Magnet supplier Issues: Transportation Handling Single magnet storage Storage space Dirt accumulation Handling Safety Glueing time Solutions: Small magnetizer Axial coil fixture Subcomponent Assembly Handling ! Safety Handling errors Mounting time Solutions: Larger magnetizer Axial coil fixture Proprietary Information of Metis Confidential

6. Magnetizing:chooze your moment Rotor assembly Solution: Larger magnetizer Dedicated yoke Fully automated system Or docking / slave system Handling !! Safety Dirt accumulation Generator assembly ... Solution: Limited due to access Proprietary Information of Metis Confidential

7. Advantages of‘late’ magnetization • Faster Production • Reduced mounting time of magnets • Reduced total production time • Safer production • Avoid difficult handling of pre-magnetized magnets • Avoid storage of large amounts of pre-magnetized material and components • Magnets are activated at later stage of production process • Controlled production • In-line inspection of product performance parameters • Automated magnetizing process avoid magnet orientation errors • Improve product quality • Better tolerances on magnet positioning • Ability to influence field profile • Opens design opportunities Proprietary Information of Metis Confidential

8. Metis in a nutshell Metis is a fast growing high-tech company that specialises in industrial magnetism • History • Founded in 1998 • Based in Leuven, Belgium. • Spin-off of the University of Leuven, Belgium • Product lines • Industrial magnetizing technology • Magnetic properties testers for the industry • Turn-key pulsed field installations for research centres Proprietary Information of Metis Confidential

9. Metis in a nutshell Metis designs and manufactures all its products in house • Metis design • FE design of magnetizing fixtures and magnetic assemblies • CAD design of mechanics • CAE design of electronics • Metis manufacturing • Metis final assembly and testing of its products in its work-shop in Leuven. • Metis production facilities contain: • Lathes, milling machine, ... • Vacuum installation • Electronics lab • Metis works together with a variety of specialized suppliers Proprietary Information of Metis Confidential

10. Magnetizing EquipmentComplete production units • Metis delivers totally integrated production solutions • Automation mechanics are designed for the forces of pulsed magnetizing • Solutions are equipped with process & quality control systems • Metis has a vast experience in magnetizing large rotors for electrical machines Proprietary Information of Metis Confidential

11. Magnetizing EquipmentWind Power Industry Solution Proprietary Information of Metis Confidential

12. Magnetizing EquipmentProviding the solution • Material properties • Modelling • Magnetizing yoke • Magnetizing sequence • Proces sequence • Quality control Proprietary Information of Metis Confidential

13. Permanent Magnet SaturationMagnetizing field strength Map • Based on our experience and measurements • 2.5 T  99 % • 3.0 T  99.9 % • Magnetizing field only required for < 1 ms Proprietary Information of Metis Confidential

14. Magnetizing EquipmentMagnetizing calculations Calculation and optimization of: • Magnetizing energy, depending on saturation levels and rotor layout • Mechanical forces during magnetizing process • Cooling requirements for desired rep-rates • Coil parameters and electric steel sheet layout Proprietary Information of Metis Confidential

15. Magnetizing principle • Rotor too large for full magnetization in one shot: • Impractical manipulation • Magnetizing energy too high • Therefore: • Stepwise magnetization • Automated process Proprietary Information of Metis Confidential

16. Metis Case Study 600 mm rotor – 10 poles Proprietary Information of Metis Confidential

17. Metis Case Study Axially traveling yoke Proprietary Information of Metis Confidential

18. Metis Case Study Axially traveling yoke Proprietary Information of Metis Confidential

19. Metis Case Study Axially traveling yoke Proprietary Information of Metis Confidential

20. Wind Power Industry Solution Process monitoring • Measurement of magnetizing current: • Standard on every CDM magnetizer • Measures magnetizing current • Compares against minimal value: OK / NOK • Real-time Feedback of magnetic field characteristics • Measurement of magnetic flux via flux coil in magnetizing fixture • Global measurement • Magnetic flux relates direct to generator performance • Integrated in fixture Proprietary Information of Metis Confidential

21. Quality control • Feedback • Gauss meter • Local, subject to air gap > not suited • Flux meter via search coil • Global measurement • Measures related to performance • Integrated in yoke Proprietary Information of Metis Confidential

22. Quality controlFlux measurement Flux Scan afterwards much easier Axial distance Proprietary Information of Metis Confidential

23. MagnetizingGeared PM generators Proprietary Information of Metis Confidential

24. MagnetizingGeared PM generators Proprietary Information of Metis Confidential

25. MagnetizingGeared PM generators Proprietary Information of Metis Confidential

26. Gearless PM Generators “Direct Drives” Proprietary Information of Metis Confidential

27. Industrial Magnetizing solutionfor an inside rotor Proprietary Information of Metis Confidential

28. Direct Drive PMGIntegrated solution • Put a docking station in the production street • Rotation provided by production street • Magnetizing head travels over the pole • Mechanically self-supporting • Mostly a compact system Proprietary Information of Metis Confidential

29. Direct Drive PMGIntegrated solution • Access the rotor in the stator housing • Either by opening up a small part of the stator • Provide a traveling head in the stator segment • Or use the stator winding • They are not designed for • -> mechanical / magnetic issues Proprietary Information of Metis Confidential

30. Schematics of the Yokeoutside rotor Proprietary Information of Metis Confidential

31. A solution for aDirect Drive system • Magnetizing Yoke • 1-2 active poles (symmetric) • Mechanically supported against surface • active axial length 100-200 mm • Optionally skewed • Energy requirements ~60 kJ • Rep-rate: 1-3 minutes per shot Proprietary Information of Metis Confidential

32. Prototype Service For small series Incorporate magnetizing in the validation proces Proprietary Information of Metis Confidential

33. Prototype Service Proprietary Information of Metis Confidential

34. Available installation Mounting frame 2 m diameter 2-10 ton rotor Automation Yoke support Magnetizer cabinet 100+100 kJ Variable cost Magnetizing yoke Mounting adapters Handling Prototype Serviceavailable summer 2010 Proprietary Information of Metis Confidential

35. Automated Magnetizing Solutions for Permanent Magnet Generators (PMG) Summary Proprietary Information of Metis Confidential

36. SummaryProduction Advantages • Faster • Reduced mounting time of magnets • Magnetization time typically 1-2 hours/rotor • Flexible • Different rotor lengths & types • Safer • No handling of pre-magnetized material • Magnets are activated after assembly • Controlled • In-line inspection • No human errors • Improved product quality • Better magnet positioning tolerances • Influence neutral zone & skewness Proprietary Information of Metis Confidential

37. Magnetizing EquipmentWhy Metis as your partner? • Industry innovator: • Design of energy efficient fixtures with FEM and proprietary software • Energy efficient magnetizing makes process economical • Mechanical design of automations suited for pulsed field magnetizing forces • Vast experience in large rotor magnetization • First system successfully delivered into wind power industry • Experience in rotating machines industry • Vast experience in magnet materials & measurement of magnetic properties • HyMPulse customers include leading companies • HyMAC customers include leading wind power companies • Providing combined solutions of magnetization and magnetic measurement • Providing industrially proven turn-key production units • High-level of technical service and support Proprietary Information of Metis Confidential

38. Feasibility analysis & OfferRequired information • To asses the feasibility of a magnetizing solution and to prepare a detailed offer, Metis needs the following information: • 2D model of range of generators to be magnetized • Dimensions and axes lengths • Dimensional tolerances on diameter • Magnet dimensions • Properties of magnetic material • Desired process time per unit (rep.rate) Proprietary Information of Metis Confidential

39. Wind Power Industry SolutionBudget drivers • Typical system containing: • Automation structure with rotational and linear axis • 100 kJ Magnetizer (required magnetizing energy depends on rotor layout and desired process time) • One Fixture : can be exchanged for different rotor types (within limits of automation dimensions) • On-line quality control with flux coil • Panel PC with steering software • Industrial enclosure and CE certification Proprietary Information of Metis Confidential

40. Your partner for magnetism Contact Metis Metis Instruments & Equipment Kapeldreef 60 3001 Leuven Belgium Voice: +32 16 298 344 Fax: +32 16 298 319 E-Mail: contact@metis.be Web: www.metis.be Proprietary Information of Metis Confidential