With axial flux rotors, incorporating permanent magnets (PMs), recognized as key to achieving the most energy-efficient, yet lightweight, powertrain for electric vehicles (EVs), automotive engineers are facing a major challenge: how and when these magnets are best magnetized. Pre-assembly, or in-situ, in other words, once the rotors have been assembled.

Until recently, the former has been preferred: with pre-saturated PMs being fitted into the rotors.

While this approach may allow for higher saturation levels, the subsequent assembly of the rotors is complicated, time-consuming, and error-prone, with a high probability of the magnets breaking during the process.

Magnetizing the PMs when they are in-situ within the rotors, however, averts the aforementioned pitfalls, while achieving saturation levels up to, or exceeding, 99%.

With over 60 years’ experience in the production of magnetizers and magnetics measuring equipment, a worldwide clientele, and with a special emphasis on the automotive industry, Laboratorio Elettrofisico (LE) is perfectly placed to address these issues.

Integrating seamlessly into your production line, LE’s custom-designed in-situ magnetization station expedites the time taken to magnetize the rotors, doing so on a one-shot basis, thereby reducing cycle-time as well as time-to-market. Supply chain complexity is cut, moreover, while quality control of this critical part of the powertrain construction process is brought in-house, directly to the factory floor.

Whether from its home base in northern Italy, or from its international outposts in the USA, India, and China, Laboratorio Elettrofisico is on hand to provide tailor-made solutions to the world’s EV manufacturers.

For more on our magnetization station for the automotive industry, consult: https://www.laboratorio.elettrofisico.com/magnetizing-station/