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Electromagnets- a Case Study ELECTROMAGNETS- A CASE STUDY AT KAKKU ELECTRONIC & POWER CONTROL COMPANY, LIGHT INDUSTRIAL AREA, BHILAI, CHHATTISGARH, INDIA This project report and case study aims to celebrate the special qualities of Electromagnets and tries to describe the complete process of how industry grade electromagnets are ordered, designed, manufactured, and tested. I have explained the procedure thoroughly by utilizing the knowledge gained while interning at Kakku Electronic & Power Ltd. NEELANSH KAABRA DPS, BHILAI, CHHATTISGARH INDIA NOVEMBER-DECEMBER 2019 INTRODUCTION Magnets play an integral role in our lives. This case study aims to highlight the importance of magnets in the human world, the special qualities of electromagnets and about the actual process of making industry grade electromagnets. Magnets are objects that generate a magnetic field, a force-field that either pulls or repels certain materials, such as steel and iron. The focus of this case study will be on a special type of magnet known as Electromagnets. Electromagnets work on a fundamental force called electromagnetism. In the 19th Century, Hans Christian Ørsted noticed that a wire with a current running through it affected a nearby compass. The current was creating a magnetic field. Later research showed that electric current and magnetism are actually two aspects of the same force. This force works both ways – a moving magnetic field creates electric current. An Electromagnet can be defined as a magnet which functions on electricity. Unlike a permanent magnet, the strength of an electromagnet can be altered. By controlling the electric current we can control the magnetic field, i.e., the strength of electric field controls the strength of magnetic field also. In fact, the poles of an electromagnet can even be reversed by reversing the flow of electricity. If the current flow is cut, the property of magnetism ceases to exist and that’s why an electromagnet is classified as a temporary magnet. A simplified view of an atom, with a nucleus and orbiting electrons We know that an electrical current moving through a wire creates a magnetic field. But a magnet's field doesn't come from a large current traveling through a wire; it comes from the movement of electrons. Even though an atom's electrons don't move very far, their movement is enough to create a tiny magnetic field. Since paired electrons spin in opposite directions, their magnetic fields cancel one another out. Atoms of ferromagnetic elements, on the other hand, have several unpaired electrons that have the same spin. Iron, for example, has four unpaired electrons with the same spin. Because they have no opposing fields to cancel their effects, these electrons have an orbital magnetic moment. The magnetic moment is a vector; it has a magnitude and a direction. It's related to both the magnetic field strength and the torque that the field exerts. A whole magnet's magnetic moments come from the moments of all of its atoms. An iron atom and its four unpaired electrons In metals like iron, the orbital magnetic moment encourages nearby atoms to align along the same north-south field lines. Iron and other ferromagnetic materials are crystalline. As they cool from a molten state, groups of atoms with parallel orbital spin line up within the crystal structure. This forms the magnetic domains. You may have noticed that the materials that make good magnets are the same as the materials magnets attract. This is because magnets attract materials that have unpaired electrons that spin in the same direction. In other words, the quality that turns a metal into a magnet also attracts the metal to magnets. Many other elements are diamagnetic -- their unpaired atoms create a field that weakly repels a magnet. A few materials don't react with magnets at all. DIFFERENCE BETWEEN ELECTROMAGNET AND PERMANENT MAGNET Electromagnet Permanent Magnet The magnetic properties are displayed when Magnetic properties exist when the material is current is passed through it magnetized The strength is adjusted depending upon the The strength depends upon the nature of the amount of flow of current material used in its creation Removal of magnetic properties is temporary Once magnetic properties is lost, it becomes useless It requires a continuous supply of electricity to It doesn’t require a continuous supply of electricity maintain its magnetic field. to maintain its magnetic field It is usually made of soft materials It is usually made of hard materials The poles of this kind of magnet can be altered The poles of this kind of magnet cannot be changed. with the flow of current TYPES OF ELECTRO MAGNETS HIGH FIELD ELECTROMAGNETS Most powerful electro magnet in the world at US National High Magnetic field Laboratory, Florida Superconducting electromagnets When a magnetic field higher than the ferromagnetic limit of 1.6 T is needed, superconducting electromagnets can be used. Instead of using ferromagnetic materials, these use superconducting windings cooled with liquid helium, which conduct current without electrical resistance. These allow enormous currents to flow, which generate intense magnetic fields. Superconducting magnets are limited by the field strength at which the winding material ceases to be superconducting. Current designs are limited to 10–20 T, with the current (2017) record of 32 T. The necessary refrigeration equipment and cryostat make them much more expensive than ordinary electromagnets. However, in high power applications this can be offset by lower operating costs, since after startup no power is required for the windings, since no energy is lost to ohmic heating. They are used in particle accelerators and MRI machines. Bitter electromagnets Both iron-core and superconducting electromagnets have limits to the field they can produce. Therefore, the most powerful man-made magnetic fields have been generated by air-core non superconducting electromagnets of a design invented by Francis Bitter in 1933, called Bitter electromagnets. Instead of wire windings, a Bitter magnet consists of a solenoid made of a stack of conducting disks, arranged so that the current moves in a helical path through them, with a hole through the center where the maximum field is created. This design has the mechanical strength to withstand the extreme Lorentz forces of the field, which increase with B2. The disks are pierced with holes through which cooling water passes to carry away the heat caused by the high current. The strongest continuous field achieved solely with a resistive magnet is 37.5 T as of 31 March 2014, produced by a Bitter electromagnet at the Radboud University High Field Magnet Laboratory, Netherlands. The strongest continuous magnetic field overall, 45 T, was achieved in June 2000 with a hybrid device consisting of a Bitter magnet inside a superconducting magnet. The factor limiting the strength of electromagnets is the inability to dissipate the enormous waste heat, so more powerful fields, up to 100 T, have been obtained from resistive magnets by sending brief pulses of high current through them; the inactive period after each pulse allows the heat produced during the pulse to be removed, before the next pulse. Explosively pumped flux compression A hollow tube type explosively pumped flux compression generator The most powerful manmade magnetic fields have been created by using explosives to compress the magnetic field inside an electromagnet as it is pulsed; these are called explosive pumped flux compression generators. The implosion compresses the magnetic field to values of around 1000 T for a few microseconds. While this method may seem very destructive, it is possible to redirect the brunt of the blast radially outwards so that neither the experiment nor the magnetic structures are harmed. These devices are known as destructive pulsed electromagnets. Uses of Electromagnets Clearly, there's a wide range of electromagnet applications between small, homemade science experiments and the Earth itself. Some electromagnet uses are given in the points mentioned below: Motors and Generators Transformers Pickups, Relays (control switches) Electric bells and buzzers Loudspeakers and headphones , Amplifiers Actuators such as valves Magnetic recording and data storage equipment: tape recorders, VCR’s, Hard disks MRI machines Scientific equipment such as mass spectometers, Particle accelerators Magnetic Locks, Magnetic separation equipment, used for separating magnetic from nonmagnetic material, for example separating ferrous metal from other material in scrap. Industrial lifting magnets Induction heating for cooking, manufacturing, and hyperthermia therapy Spacecraft Propulsion Systems Induction Heating MAGNETS MANUFACTURING AT KAKKU INDUSTRIES, BHILAI, INDIA Kakku Electronic & Power Control Company (An Enterprise of Kakku E & P Control Pvt Ltd.), Bhilai, was founded in the year 1968 with a clear vision of "Make in India" through Import Substitution of EOT Crane electrics required by Core sector Industries both in India and abroad. Steadily but surely, the “KAKKU” tag made its presence felt in major Industries and its Product range which began with Electrical Relays, forayed into Control & Selector Switches, Conveyor Safety Switches , Master Controllers, Limit Switches, AC & DC Electro Magnetic Brakes, Lifting Electromagnets and many more. KAKKU has 49+ years of experience with providing wide area of specialty services works listed above. A Company involved in servicing, maintenance and repairs of widest-range of Control Gears and
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