Aluminium is lightweight and strong.
It is used extensively in the aerospace industry and
increasingly in the high end automotive industry too.
Heat treatment is a means of increasing the strength
of cast aluminium components by subjecting the aluminium
component to a series of thermal cycles. Depending
on the composition of the aluminium alloy and type
of heat treatment, the strength of the part can increase
by up to 50%.
Use of stainless steel shafts
and fasteners are important in components that need
to have a long working life, excellent fatigue resistance,
good anti corrosion properties where the failure of
the component due to vibrations, corrosion, stress
must be kept to a minimum.
With the help of FEA
software, the structure of the PMG is designed to
be robust with a strong bearing house, thick walls,
strong rotor and shaft structures.
The use of Finite Element Analysis (FEA) helps the
prediction and therefore prevention of stress points.
However, FEA is difficult to perform on complex parts
and requires careful modelling and setup in order
to get meaningful results. We have engineers who have
years of experience specialised in modelling and testing
complex mechanical parts and perform verification
tests to prove the results and hence enable us to
improve on the failure rate of the component.
We used original
SKF/NSK fully sealed bearings as these are one of
the best bearings in the world. The ful contact sealed
bearings do a better job of retaining grease within
the bearing housing, thus, keeping the bearing lubricated
for longer giving it a longer and smoother operational
life. In addition, the sealed bearing also keeps out
moisture and dust which also improves its performance.
C3 clearance bearings are looser bearing which are
used to allow for a lower resistive torque without
resorting to using unsealed bearings which may feel
loose in the short term but are prone to wear, tear
and rust which will eventually cause the bearings
to fail anyway.
Use of NdFeB rare
earth magnets which have a working temperature of
150 degrees celcius with high HcJ, Br, and BH performance.
A high working temperature will ensure that the PMG
will carry on working for a longer time as the magnets
will not demagnetise that easily compared with lower
rated magnets.
The magnets all have high intrinsic coercive force
(HcJ), residual flux density (Br), and energy product
(BH) values which means that these are high strength
magnets capable of producing more power than normal
magnets.
The windings have a temperature rating of 180 degrees
celcius for an extended operational life and protection
against overheating which may result in short circuits
or fires.
All aluminium parts are anodised
to form a hard oxide layer which is stronger than
paint and other soft coating protection against corrosion
when exposed to the environment. Other means of protection
are prone to abrasion and wear which will reduce the
effectiveness of the protective layer against corrosion.
High
potential insulation testing using 1kV power supply
is performed to check for the integraty of the insulation
of the windings and wires to ensure that there is
no electrical failure. The units are also stressed
by drawing maximum power for extended periods of time
and short circuiting the output to overload/brake
the PMG occasionally to ensure that the unit is performing
well.
Computer
assisted design software packages are used extensively
in the company. These include specialised sofware
which perform 3D-modeling tasks, FEA analysis which
include magenetic field simulation and mechanical
stress simulations. Use of modern industrial software
packages which are designed specially to help engineers
design, simulate, analysis and modify their designs
on computer before even a single component if made
reduces the time required to design, manufacture and
optimise a particular component or part. These are
industry recognised packages which have been tried,
tested, improved and upgraded throughout the years
Quality
checks are performed at least 6 times at different
stage with specially designed proprietary tools &
jigs.
At every major stage of the manufacture, strict quality
control is applied to the proccessed parts to ensure
that all manufactured parts meet with the strict criterior
that we lay down. We would rather have a wast component
than to have a failed part in service.
Specially inhouse designed tools and jigs are used
extensively during the manufacturing and the inspection
phases. These help to ensure a tight control over
the machining and assembly processes so that there
is consistency in the products and also ensure high
performance of the PMGs as alot of the performance
is determine by the precise machining and assembly
of the PMG parts.
At the end of the day, the outward
appearance of a product is an important factor to
grab the attention of the customer. We ensure that
our finishes are of a high quality and long lasting
such that it not only has an appearance effect but
also acts as a protective layer.
MODEL LIST
We have successfully producing over thousands of PMGs
to European and American customers. Please find the model
list as below for your interest. Alternatively, We are
more than pleased to customise a design for the client
to enable a perfect fit to their system requirements.
This can be a modification based on one of our existing
designs or one could be developed for you from scratch.
Please click for more about customised Design Manufacture..
