Reduction in Current Consumption of Small DC Motor with Rare-Earth Flexible Bonded Magnets Prepared by Powder Compacting Press and Hot Rolling

Abstract

The usage of high-performance rare-earth magnets is one of the key technologies in the development of efficient small motors. Ring-shaped melt-spun Nd-Fe-B bonded magnets, prepared using a powder compacting press and/or injection molding, are generally used in typical applications to small efficient motors. For exploiting the maximum characteristics according to the variety of magnetic powder, however, the preparation method of the magnet, the magnet form, and the motor design needs to be changed for high-productivity as well as for improving total performance, including the magnetic properties of bonded magnets. This paper reports recent achievements in new preparation processes for rare-earth bonded magnets and small motors using new materials other than Nd-Fe-B melt-spun powder. This paper especially focuses on the method for maximally exploiting certain rare-earth magnetic powders . Furthermore, reduction in the current consumption of the small DC motor using the developed technique is reported.