Realization of performance optimized continuous Halbach pattern in magnetic composites for diverse applications

This thesis presents a comprehensive study on the application of composite magnets in two industrial scenarios: the development of a linear actuator and the enhancement of ski equipment with magnetic attachment systems. In both cases, non-uniform magnetization is employed, specifically in the form of a continuous adaptation of the Halbach array.

In the first application, the thesis explores the replacement of sintered magnets, typically used in permanent magnet motors, with composite magnets to reduce production costs while maintaining performance. The final prototype is functional but delivers a force reduced by 30% compared to the original. The thesis also presents an optimization of the stator's ferrous body, allowing for in-situ winding and further reducing manufacturing costs.

The second application aims to replace the traditional glue used with climbing skins with a flexible composite magnetic strip to enhance user experience. This technology is applied to two cases: cross-country skiing and mountaineering. For the latter, the results are promising but require further development, particularly in achieving sufficient magnetic force. In contrast, the cross-country skiing case result in a working product and to the development of a production line ready to supply the first batch of magnetic skins.

The thesis covers the design and optimization of magnetic patterns, as well as the development of a magnetizer tailored to this application, using finite element analysis and prototyping. For the cross-country case, a cooling system is developed to achieve a production rate that aligns with industrial needs.

The results of the thesis demonstrate the potential of composite magnets and the possibilities offered by unconventional magnetic patterns, paving the way for future advancements in magnetic material technology.