External air core flux measurement system for a production magnetizing system

1. An external Air Core Flux Measurement System or device ( 30 ) for a production magnetizing system ( 40 ) comprising:

a. an instrumentation air coil ( 31 ) of a set of various components for flux measurement, the instrumentation air coil ( 31 ) being separated and independent from any reluctance imparted from a magnetizing coil ( 50 ) in the production magnetizing system ( 40 );

b. a magnetizing flux gauge ( 32 ) combined with a fixturing structure ( 32 A) to hold the separate and independent instrumentation air coil ( 31 );

c. manufacturing equipment ( 42 , 43 ) that transfers a rotor coil ( 51 ) to be measured from the magnetizing coil ( 50 ) to the separate and independent instrumentation air coil ( 31 ) that is secured by the fixturing structure ( 32 A);

d. a set of reading instrumentation ( 39 ) for providing test data from the instrumentation air coil ( 31 ) to a set of several quality tests;

e. wherein the fixturing structure ( 32 A) is made of durable, non-ferrous and non-magnetic materials that hold the instrumentation air coil ( 31 ) and the set of reading instrumentation ( 39 ) separated from the magnetizing coil ( 50 );

f. a connection ( 37 A) to a power source ( 38 ) for the magnetizing flux gauge ( 32 ) and a connection ( 37 A) to the set of reading instrumentation ( 39 ); and

g. a control wiring to the set of reading instrumentation ( 39 );

wherein using the external Air Core Flux Measurement System or device ( 30 ) to compare flux reluctance measurements of two or more magnetized rotors provides a flux measurement data capability with reduced variation that demonstrates a GR&R correlation to defect detection linked to a realistic process failure mode indicating a missing magnet; minimizes or eliminate an effect of temperature resulting from the charge or discharge of high current through the magnetizing coil ( 50 ); and minimizes an effect of residual flux bias resulting from a magnetization cycle.

2. The external Flux Measurement System or device ( 30 ) according to claim 1 , wherein the set of various components for flux measurement is selected from a group consisting of air with stiff coil wires, plastic cores and ceramic coils.

3. The external Air Core Flux Measurement System or device ( 30 ) according to claim 1 , wherein the fixturing structure ( 32 A) made of durable materials is a set of various materials selected from group consisting of non-ferromagnetic material, stainless steel, composite materials, high strength and high temperature resistant plastic, copper, and bronze.

4. The external Air Core Flux Measurement System or device ( 30 ) according to claim 1 , wherein the power source ( 38 ) for the magnetizing flux gauge is selected from a group consisting of high (240 V plus) voltage AC, Low voltage AC (<240 V), AC or DC voltage.

5. The external Air Core Flux Measurement System or device ( 30 ) according to claim 1 , wherein the set of several quality tests is selected from a group consisting of defect detection; Motor Back EMF; Flux Measurement Capability; Gage R&R; reluctance (R) (resistance losses); and Variation Analysis (VSA).

6. An external Air Core Flux Measurement System or device ( 30 ) which uses a process comprised of:

Step 1—a rotor ( 51 ) is advanced by manufacturing equipment ( 42 , 43 ) into a magnetizing fixture ( 53 );

Step 2 Meanwhile a capacitive discharge magnetizing supply ( 52 ) builds up power for charging the rotor ( 51 );

Step 3—an electronic switch ( 55 ) is closed; and

Step 3.1—magnetizing current surges through a magnetizing coil ( 50 );

Step 3.2—the rotor ( 51 ) accepts the EMF and the magnetizing coil ( 50 ) is charged wherein the rotor is now a magnetized or charged rotor;

Step 4—next the magnetized or charged rotor ( 51 ) is withdrawn from the magnetizing coil ( 50 ) by a piece manufacturing equipment ( 42 );

Step 5—next the magnetized or charged rotor is raised by the piece manufacturing equipment ( 42 ) and exposed to a magnetic flux gauge ( 32 ) with a separate and independent instrumentation air coil ( 31 );

Step 5.1—the instrumentation air coil ( 31 ) to indicate the magnetic flux of the magnetized rotor ( 51 ) through a connection ( 37 B) to a flux reading instrumentation ( 39 );

Step 5.2—the flux reading instrumentation ( 39 ) indicates the magnetic flux of the magnetized rotor ( 51 ) which is outside of the interference by the separate and independent magnetizing coil ( 50 );

Step 5.3—the reading of the magnetized rotor ( 51 ) by the instrumentation air coil ( 31 ) indicated on the reading instrumentation ( 39 ) and thereby eliminates all the cumulative reluctance (R) of the separate and independent magnetizing coil ( 50 ) and hence reduces variation of the reading by the flux reading instrumentation ( 39 ) of the magnetic flux gauge ( 32 ) since the flux of the separate and independent magnetizing coil ( 50 ) is eliminated;

wherein using the external Air Core Flux Measurement System or device ( 30 ) to compare flux reluctance measurements of two or more magnetized rotors provides a flux measurement capability data capability with reduced variation that demonstrates a GR&R correlation to defect detection linked to a realistic process failure mode indicating a missing magnet; minimizes or eliminate an effect of temperature resulting from the charge or discharge of high current through the magnetizing coil ( 50 ); and minimizes an effect of residual flux bias resulting from a magnetization cycle.