1. Proprietary Information of Metis Confidential Automated Magnetizing Solutions for Permanent Magnet Generators (PMG) Metis Instruments & Equipment NV EWEC 2010

2. Proprietary Information of Metis Confidential Content Magnetizing: what, why and when ‘Metis Instruments & Equipment’ in a nutshell Automated solution for Permanent Magnet Generator (high speed) Solutions for Direct Drive Prototyping solutions

3. Proprietary Information of Metis Confidential Magnetizing: What? Apply a strong magnetic field during a short time to allign the magnetic domains. Short: milliseconds Strong: 3 to 6 Tesla Using discharge of the energy of a capacitor bank to drive the windings in dedicated yoke

4. Proprietary Information of Metis Confidential Magnetizing: Not why, when! Single magnets by the supplier Single magnets prior to glueing In sub-assembly after glueing On rotor after mounting In generator after complete assembly The later, the better!

5. Proprietary Information of Metis Confidential Magnetizing a PM: chooze your moment Magnet supplier Single magnet storage Subcomponent Assembly Issues: Transportation Handling Storage space Dirt accumulation Handling Safety Glueing time Solutions: Larger magnetizer Axial coil fixture Solutions: Small magnetizer Axial coil fixture Handling ! Safety Handling errors Mounting time

6. Proprietary Information of Metis Confidential Magnetizing: chooze your moment Rotor assembly Generator assembly Handling !! Safety Dirt accumulation... Solution: Larger magnetizer Dedicated yoke Fully automated system Or docking / slave system Solution: Limited due to access

7. Proprietary Information of Metis Confidential Faster Production –Reduced mounting time of magnets –Reduced total production time Safer production –Avoid difficult handling of pre-magnetized magnets –Avoid storage of large amounts of pre-magnetized material and components –Magnets are activated at later stage of production process Controlled production –In-line inspection of product performance parameters –Automated magnetizing process avoid magnet orientation errors Improve product quality –Better tolerances on magnet positioning –Ability to influence field profile Opens design opportunities Advantages of ‘late’ magnetization

8. Proprietary Information of Metis Confidential Metis in a nutshell Metis is a fast growing high-tech company that specialises in industrial magnetism History –Founded in 1998 –Based in Leuven, Belgium. –Spin-off of the University of Leuven, Belgium Product lines –Industrial magnetizing technology –Magnetic properties testers for the industry –Turn-key pulsed field installations for research centres

9. Proprietary Information of Metis Confidential Metis in a nutshell Metis designs and manufactures all its products in house Metis design –FE design of magnetizing fixtures and magnetic assemblies –CAD design of mechanics –CAE design of electronics Metis manufacturing –Metis final assembly and testing of its products in its work-shop in Leuven. –Metis production facilities contain: Lathes, milling machine,... Vacuum installation Electronics lab –Metis works together with a variety of specialized suppliers

10. Proprietary Information of Metis Confidential Metis delivers totally integrated production solutions Automation mechanics are designed for the forces of pulsed magnetizing Solutions are equipped with process & quality control systems Metis has a vast experience in magnetizing large rotors for electrical machines Magnetizing Equipment Complete production units

11. Proprietary Information of Metis Confidential Magnetizing Equipment Wind Power Industry Solution

12. Proprietary Information of Metis Confidential Magnetizing Equipment Providing the solution Material properties Modelling –Magnetizing yoke –Magnetizing sequence Proces sequence Quality control

13. Proprietary Information of Metis Confidential Permanent Magnet Saturation Magnetizing field strength Map Based on our experience and measurements 2.5 T  99 % 3.0 T  99.9 % Magnetizing field only required for < 1 ms

14. Proprietary Information of Metis Confidential Magnetizing Equipment Magnetizing calculations Calculation and optimization of: Magnetizing energy, depending on saturation levels and rotor layout Mechanical forces during magnetizing process Cooling requirements for desired rep-rates Coil parameters and electric steel sheet layout

15. Proprietary Information of Metis Confidential Magnetizing principle Rotor too large for full magnetization in one shot: –Impractical manipulation –Magnetizing energy too high Therefore: –Stepwise magnetization –Automated process

16. Proprietary Information of Metis Confidential Metis Case Study 600 mm rotor – 10 poles

17. Proprietary Information of Metis Confidential Metis Case Study Axially traveling yoke

18. Proprietary Information of Metis Confidential Metis Case Study Axially traveling yoke

19. Proprietary Information of Metis Confidential Metis Case Study Axially traveling yoke

20. Proprietary Information of Metis Confidential Wind Power Industry Solution Process monitoring Measurement of magnetizing current: –Standard on every CDM magnetizer –Measures magnetizing current –Compares against minimal value: OK / NOK Real-time Feedback of magnetic field characteristics –Measurement of magnetic flux via flux coil in magnetizing fixture –Global measurement –Magnetic flux relates direct to generator performance –Integrated in fixture

21. Proprietary Information of Metis Confidential Quality control Feedback –Gauss meter Local, subject to air gap > not suited –Flux meter via search coil Global measurement Measures related to performance Integrated in yoke

22. Proprietary Information of Metis Confidential Quality control Flux measurement Flux Scan afterwards much easier Axial distance

23. Proprietary Information of Metis Confidential Magnetizing Geared PM generators

24. Proprietary Information of Metis Confidential Magnetizing Geared PM generators

25. Proprietary Information of Metis Confidential Magnetizing Geared PM generators

26. Proprietary Information of Metis Confidential Gearless PM Generators “Direct Drives”

27. Proprietary Information of Metis Confidential Industrial Magnetizing solution for an inside rotor

28. Proprietary Information of Metis Confidential Direct Drive PMG Integrated solution Put a docking station in the production street –Rotation provided by production street –Magnetizing head travels over the pole –Mechanically self-supporting –Mostly a compact system

29. Proprietary Information of Metis Confidential Direct Drive PMG Integrated solution Access the rotor in the stator housing –Either by opening up a small part of the stator –Provide a traveling head in the stator segment –Or use the stator winding They are not designed for -> mechanical / magnetic issues

30. Proprietary Information of Metis Confidential Schematics of the Yoke outside rotor

31. Proprietary Information of Metis Confidential A solution for a Direct Drive system Magnetizing Yoke –1-2 active poles (symmetric) –Mechanically supported against surface –active axial length 100-200 mm Optionally skewed –Energy requirements ~60 kJ –Rep-rate: 1-3 minutes per shot

32. Proprietary Information of Metis Confidential Prototype Service For small series Incorporate magnetizing in the validation proces

33. Proprietary Information of Metis Confidential Prototype Service

34. Proprietary Information of Metis Confidential Prototype Service available summer 2010 Available installation –Mounting frame 2 m diameter 2-10 ton rotor –Automation –Yoke support –Magnetizer cabinet 100+100 kJ Variable cost –Magnetizing yoke –Mounting adapters –Handling

35. Proprietary Information of Metis Confidential Automated Magnetizing Solutions for Permanent Magnet Generators (PMG) Summary

36. Proprietary Information of Metis Confidential Summary Production Advantages Faster –Reduced mounting time of magnets –Magnetization time typically 1-2 hours/rotor Flexible –Different rotor lengths & types Safer –No handling of pre-magnetized material –Magnets are activated after assembly Controlled –In-line inspection –No human errors Improved product quality –Better magnet positioning tolerances –Influence neutral zone & skewness

37. Proprietary Information of Metis Confidential Industry innovator: –Design of energy efficient fixtures with FEM and proprietary software –Energy efficient magnetizing makes process economical –Mechanical design of automations suited for pulsed field magnetizing forces Vast experience in large rotor magnetization –First system successfully delivered into wind power industry –Experience in rotating machines industry Vast experience in magnet materials & measurement of magnetic properties –HyMPulse customers include leading companies –HyMAC customers include leading wind power companies Providing combined solutions of magnetization and magnetic measurement Providing industrially proven turn-key production units High-level of technical service and support Magnetizing Equipment Why Metis as your partner?

38. Proprietary Information of Metis Confidential Feasibility analysis & Offer Required information To asses the feasibility of a magnetizing solution and to prepare a detailed offer, Metis needs the following information: 2D model of range of generators to be magnetized Dimensions and axes lengths Dimensional tolerances on diameter Magnet dimensions Properties of magnetic material Desired process time per unit (rep.rate)

39. Proprietary Information of Metis Confidential Wind Power Industry Solution Budget drivers Typical system containing: –Automation structure with rotational and linear axis –100 kJ Magnetizer (required magnetizing energy depends on rotor layout and desired process time) –One Fixture : can be exchanged for different rotor types (within limits of automation dimensions) –On-line quality control with flux coil –Panel PC with steering software –Industrial enclosure and CE certification

40. Proprietary Information of Metis Confidential Your partner for magnetism Contact Metis Metis Instruments & Equipment Kapeldreef 60 3001 Leuven Belgium Voice:+32 16 298 344 Fax:+32 16 298 319 E-Mail:contact@metis.becontact@metis.be Web:www.metis.bewww.metis.be