WO2018204832A1 - Manufacturing of permanent magnet arrays with controlled convergence - Google Patents

Abstract

Methods and means for the automated manufacturing of linear permanent magnet (PM) arrays in rows. A convergence device may be used that restricts movement of PM elements from PM cartridges as the PM elements are formed into PM array rows. The PM elements may be brought nearer as the PM elements travel through the convergence device while being restricted from magnetically aligning by flipping, translation, or other uncontrolled motion. Various means for movement of the PM elements through the convergence device are described as well as use of saturation bars and other means of securing PM array rows into a PM array.

Description

MANUFACTURING OF PERMANENT MAGNET ARRAYS WITH CONTROLLED CONVERGENCE

RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application No. 62/501,612 filed May 4, 2017, entitled "MANUFACTURING METHOD AND MEANS FOR PERMANENT MAGNET ARRAYS," which is incorporated herein by reference in its entirety.

FIELD

The present disclosure generally relates to permanent magnet (PM) arrays and means for producing PM arrays such as Halbach arrays.

BACKGROUND

Magnetic force adheres to the inverse square law, which dictates that doubling the distance between magnets results in reducing the force by a factor of four. Thus, magnetic force is highly sensitive to spatial placement, magnetic pole direction accuracy, and concentration of materials.

Although relatively expensive, rare earth materials such as neodymium result in magnetic force and energy product much greater than many other material use for magnet production resulting in the lowest cost per unit per magnetic energy.

The permanent magnet (PM) manufacturing industry is mature, with many standardized grades, shapes, sizes, and coatings that are readily available. One key industry area that is underdeveloped is the packaging of PM material, where individual companies tend to package PM material according to their own manufacturing process instead of according to the needs of customers. Similar packaging is due to efficient use, availability, and characteristics of materials but no standardization has been established.

Supporting industries related to PM applications include: materials, tools for handling and manipulating PM elements, nonmagnetic tools that avoid the use of ferromagnetic materials that are attracted to PM elements, electronic field orientation and field strength sensors, magnetic field viewing film, and bonding materials for magnetic elements.

Arrays of PMs are used in a wide variety of applications such as brushless motors, lasers, levitation devices, coupling devices, and particle accelerators. A Halbach array is an unnatural arrangement of PM elements where individual PM are rotated 90 degrees from adjacent PM elements. An unnatural arrangement is where the magnetic pole positions must be placed and held by force to overcome the PM elements' natural tendency to align the north pole (N) face to south pole (S) face. This type of alignment focuses the forces of attraction, repulsion, and torque at various positions along the array, which especially in the context of PMs comprising rare earth metals, may be relatively strong. Collectively, these PM arrays create force vectors that concentrate the magnetic field in different areas and cause irregular persistence, saturation, and penetration. For instance, PM arrays such as Halbach arrays have been used to, among other applications, to create a uniform field inside a circular array of magnets oriented around a linear vacuum tube to focus the beam of a particle accelerator.

A Halbach array can be selectively designed to increase the PM's magnetic force that is focused to a magnetic side of the array, while canceling out the diametric side to a near zero field. Halbach arrays are most commonly arranged in linear rows, cylindrical, and spherical shapes, with each arrangement having distinct and separate advantages, uses, and applications as known to those versed in the art. PMs oriented into a Halbach array have since been widely researched, developed, and used in many applications such as; machines, motors, levitation devices, particle accelerators, other equipment, and tools.

Common methods of creating a fixed Halbach array may include removing permanent magnet material and introducing a reinforcing member such as an embedded bar on magnet face or rod equidistant through the interior of the magnet. Especially for larger PMs, assembling a Halbach array may be extremely dangerous due to the high forces within inherently unstable PM configurations required for a Halbach array. Specifically, PM elements may suddenly, unintentionally, and unexpectedly move and clash together with great force to other PMs or any surrounding ferromagnetic material. In the event of this undesired potential movement, shattering of clashing PMs may create shrapnel that can cause serious bodily harm such as eye injury (including blindness), crushed flesh, broken bones, or the dismemberment of fingers, hands, and feet. There continues to be a lack of a reliable means to reduce the risk serious of injury when constructing PM arrays. SUMMARY

Accordingly, the present disclosure proposes utilities (e.g., apparatuses and methods) that may facilitate efficient, accurate, and safe production of PM arrays. Specifically, the utilities presented herein may controllably constrain PM elements to form PM arrays. This controlled constraint of the PM elements may include passing PM elements through a convergence device. The convergence device may reduce inter-PM element spacing as the PM elements are passed through the convergence device. As may be appreciated, when the PM elements are converged, the magnetic forces acting between the elements may increase. As described above, this force may result in PM elements twisting, flipping, or otherwise moving as the PM elements attempt to orient into a natural configuration (e.g., to align polarities). For strong and/or large magnets, this movement may become quite dangerous. Accordingly, using the convergence device in which the PM elements are constrained, the PM elements may more easily and safely be configured into an unnatural PM element configuration in a PM array.

The convergence device may include one or more convergence channels that provide a constrained pathway for PM elements 100. In turn, the PM elements 100 may be brought into closer spaced relation in the convergence channel(s) such that the PM elements 100 may move only in a single degree of freedom, thus preventing the PM elements from twisting, flipping, or otherwise moving in a direction other than the direction associated with the single degree of freedom.

The convergence channel(s) may form PM array rows that are located to form a PM array. The PM array rows may be deposited into a PM array holder that is constrained by a PM array holder mold. In turn, controlled constraint of the PM elements may continue through array formation at which time the PM elements in the array may be secured relative to one another.

As may be appreciated, the utilities described herein may be useful for increasing production volume of PM arrays. In addition, the amount of human labor required to produce PM arrays may be reduced. Additionally, the utilities may minimize training and reduce the human skill needed to produce a PM array. In addition, equipment used to produce PM arrays may be reduced size such that the mobility of such equipment may be increased. In turn, the cost of PM array production may be reduced as compared to previously proposed techniques. In addition, the accuracy and precision of PM arrays may be improved through the utilities described herein. For instance, the utilities described herein may reduce need for recesses, gaps, holes or the like in PM elements and/or a PM array. In turn, the utilities may facilitate minimized disruptions, discontinuities, and weakness of a magnetic field in a resulting PM array.

Also, because the utilities may reduce the chance for PM elements to repulse, twist, flip, or separate from an intended position in the PM array and/or from equipment during the production of the PM array, the safety of the production of PM arrays may be improved. Additionally, the utilities may reduce noise during production of PM array. The utilities may also minimize material use, specifically PM, ferromagnetic, and rare earth materials. Moreover, the utilities may minimize PM alterations required after manufacturing. The utilities may also reduce the chance for structural failure of containment. In view of this, reinforcing means may be reduced or eliminated, thus saving time, cost, and complexity of PM arrays. In addition, the utilities may reduce part count of PM array production. Resulting PM arrays may have reduced PM corrosion potential. Accordingly, the utilities may provide increased durability of PM arrays and increase reliability of PM element retention. In turn, the utilities may provide increased PM array offerings to the market.

A first aspect includes an apparatus for manufacturing a permanent magnet (PM) array. The apparatus includes a convergence device comprising a plurality of convergence channels extending between an input of the convergence device and an output of the convergence device. The plurality of convergence channels are each sized to receive a PM element such that the PM element is moveable relative to the convergence channel only in a single degree of freedom between the input and the output. The convergence channels define a first configuration of PM elements at the input and a second configuration of adjacent PM elements at the output such that a spacing between the adjacent PM elements is less in the second configuration than in the first configuration. The apparatus also includes a plurality of PM cartridges that are located relative to the convergence device such that an outlet of each PM cartridge is positioned relative to a different corresponding one of the plurality of convergence channels.

A number of feature refinements and additional features are applicable to the first aspect. These feature refinements and additional features may be used individually or in any combination. As such, each of the following features that will be discussed may be, but are not required to be, used with any other feature or combination of features of the first aspect. For instance, in an embodiment, the plurality of PM cartridges may contain a plurality of PM elements in a predetermined polar orientation relative to the PM cartridge. The plurality of PM cartridges may be oriented relative to the input of the convergence device to position PM elements at the outlet of respective ones of the plurality of PM cartridges in a predetermined relative polar orientation. In this regard, the predetermined relative polar orientation between adjacent PM elements of the plurality of PM cartridges is maintained between the first configuration and the second configuration. As such, a PM array row discharged from the convergence device may have the predetermined relative polar orientation between PM elements in the row (e.g., to define a Halbach array or the like). The second configuration at the output of the convergence device may include a PM array row. The PM array row may include a plurality of PM elements in abutting adjacent engagement.

The plurality of PM cartridges may each comprise a biasing member that biases PM elements within the PM cartridge toward the outlet of the PM cartridge. As such, when a PM element is moved from the cartridge to the convergence device, a subsequent PM element may be biased into position at an outlet of the cartridge.

In an embodiment, the apparatus may include a PM array holder located relative to the output portion to receive a PM array row from the output portion. The PM array holder may include an adhesive to which the PM array row is adhered. The PM array holder may be operative to receive an adhesive to which the PM array row is adhered after receipt of the PM array row in the PM array holder. In addition, the apparatus may include a PM array holder mold in which the PM array holder is located. The PM array holder mold may be selectively advanceable relative to the output of the convergence device upon receipt of the PM array row from the output. In an embodiment, the PM array holder mold may include a base member and side flanges that define a PM array holder recess into which the PM array holder is locatable. The side flanges may be selectively removable from the base member (e.g., to assist in releasing the PM array from the PM array holder mold once the PM array is created). The base member may include a linear bearing to facilitate the selective advancement of the PM array holder relative to the output of the convergence device.

Accordingly, the PM array holder may receive a plurality of PM array rows from the output of the convergence device to form a PM array relative to the PM array holder. The PM array holder mold may be advanced by a first PM array row ejected from the output of the convergence device acting on a second PM array row that is engaged with the PM array holder. The PM array holder mold may be restrained from linear movement by a force less than an ejection force of the first PM array row acting on the second PM array row.

In an embodiment, a saturation bar may be used to assist in containing the magnetic field of a PM array or PM element. As such, the apparatus may include a saturation bar that is located in a partially overlapping orientation relative to adjacent PM array rows in the PM array. The saturation bar may be selectively engageable with the PM array holder mold to locate the saturation bar in the partially overlapping orientation. The saturation bar may engage the side flanges of the PM array holder mold to provide the selective engagement of the saturation bar.

In an embodiment, the apparatus may include a convergence actuator. The convergence actuator may be operative to move a corresponding plurality of PM elements from the respective outlets of each of the plurality of PM cartridges to the input portion of the convergence device and through the convergence channels to the output of the convergence device to form a PM array row at the output of the convergence device. The convergence actuator may include a linear actuator that acts on the PM elements at the outlets of the plurality of PM cartridges to advance the PM elements in the convergence channels. The PM cartridges may be located relative to the linear actuator such that the linear actuator shears the PM elements at the outlet of the PM cartridge from a plurality of PM elements contained within the PM cartridge.

In an alternate embodiment, the convergence actuator may include biasing members in each of the plurality of PM cartridges. In this regard, the apparatus may further include a linear actuator located at the output of the convergence device that engages the PM array row at the output of the convergence device to move the PM array row in a PM array holder. The linear actuator may include a ram that is moveable relative to an adhesive comb comprising a plurality of adhesive grooves. The PM array row contacts the adhesive comb such that adhesive in the plurality of adhesive groves is applied to the PM array row prior to being moved into the PM array holder.

In an embodiment, the apparatus may include a veil applicator located relative to the output of the convergence device that is operative to apply a veil to the PM array row at the output. The veil may be applied between PM array rows and saturation bars. In this regard, the veil may provide mechanical protection to a PM array. Additionally or alternatively, the veil may reduce the contact of adhesive with the saturation bar to assist in removal of the saturation bar from the PM array once created.

A second aspect may include an apparatus for manufacturing a permanent magnet (PM) array. The second aspect includes a plurality of PM cartridges each operative to contain a plurality of PM elements in a predetermined polar orientation. The apparatus further includes a convergence device comprising a plurality of convergence channels corresponding to the plurality of PM cartridges. The apparatus includes an input portion of the convergence device operative to receive PM elements from the plurality of PM cartridges into corresponding ones of the plurality of convergence channels. The convergence channels are sized to receive the PM elements such that the PM elements may move relative to the convergence channels in a single degree of freedom. The apparatus also includes an output portion of the convergence device from which PM elements are discharged from the convergence channels in a PM array row. Specifically, a spacing between PM elements in the PM array row is less than a spacing between corresponding PM elements at the input portion.

A number of feature refinements and additional features are applicable to the second aspect. These feature refinements and additional features may be used individually or in any combination. As such, each of the features described above in relation to the first aspect may be, but are not required to be, used with any other feature or combination of features of the second aspect.

A third aspect includes a method for producing a permanent magnet (PM) array. The method includes locating a plurality of PM cartridges in corresponding relative relation to each of a plurality of convergence channels of a convergence device. Each PM cartridge contains a plurality of PM elements in a predetermined polar orientation relative to the PM cartridge. The method also includes transferring PM elements from an outlet of each one of the plurality of PM cartridges into a corresponding convergence channel of the convergence device and moving the PM elements from an input of the convergence device to an output of the convergence device. A spacing between PM elements is reduced from the input to the output. The method also includes constraining the movement of the PM elements in the convergence channels to a single degree of freedom during the moving and outputting a PM array row from the output of the convergence device.

A number of feature refinements and additional features are applicable to the third aspect. These feature refinements and additional features may be used individually or in any combination. As such, each of the following features that will be discussed may be, but are not required to be, used with any other feature or combination of features of the third aspect.

For example, in an embodiment the locating may include arranging the plurality of PM cartridges such that the plurality of PM elements of the plurality of cartridges are in a predetermined relative polar orientation relative to one another. In turn, the method may also include maintaining the predetermined relative polar orientation during the moving. The PM array row may include a plurality of array row PM elements in the predetermined relative polar orientation. The PM array row may include a plurality of abutting array row PM elements.

In an embodiment, the method may include biasing the PM elements in each PM cartridge toward the outlet of the PM cartridge. The method may also include adhering a plurality of PM array rows that are each output from the convergence device to form a PM array. The PM array may be located in a PM array holder. In this regard, the method may include receiving the PM array row at a PM array holder after the outputting. The adhering may include adhering the plurality of PM array rows to the PM array holder. In an embodiment, the method may include providing an adhesive between the plurality of PM array rows and the PM array holder. The providing may occur prior to receipt of the plurality of PM array rows at the PM array holder. Alternatively, the providing may occur subsequent to receipt of the plurality of PM array rows at the PM array holder.

The method may also include retaining the PM array holder in a PM array holder mold.

The PM array holder mold may be selectively advanceable relative to the output of the convergence device. In turn, the method may include advancing the PM array holder mold upon the outputting of the PM array row from the output of the convergence device. The advancing may include applying a force on the PM array holder mold in response to the outputting of the PM array row. The PM array holder mold may be secured by a securing force that is overcome by the force applied on the PM array holder mold in response to the outputting of the PM array row.

In an embodiment, the method may include locating a saturation bar in overlapping relation relative to adjacent PM array rows that have been output from the convergence device. In turn, the method may include securing the saturation bar in the overlapping relation by engaging the saturation bar to the PM array holder mold relative to the adjacent PM array rows. The method may include actuating a convergence actuator to facilitate the moving of the PM elements from the input of the convergence device to the output of the convergence device. In an embodiment, the actuating may include acting on a series of PM elements in the convergence device to move the series of PM elements from the input of the convergence device to the output of the convergence device. The convergence actuator may contact PM elements at the outlet of each of the plurality of PM cartridges. In this regard, the convergence actuator may include a linear actuator that acts on the PM elements at the outlets of the plurality of PM cartridges to advance the PM elements in the convergence channels. Alternatively, the convergence actuator comprises biasing members in each of the plurality of PM cartridges. In this regard, the method may include transferring, by action of a linear actuator on the PM elements, the PM array row from the output of the convergence device to a PM array holder. The method may also include applying an adhesive to the PM array row with an adhesive comb comprising a plurality of adhesive grooves positioned relative to a ram. The PM array row may contact the adhesive comb such that adhesive in the plurality of adhesive groves is applied to the PM array row prior to being moved into the PM array holder.

The method may also include applying a veil to the PM array row after the outputting. As described above, the veil may provide protection to the PM array and may assist in controlling an adhesive used to form the PM array row.

A fourth aspect includes an apparatus for manufacturing a permanent magnet (PM) array. The apparatus includes a convergence device that includes a plurality of divider channels that each accept at least one PM element in a predetermined polar orientation. The plurality of divider channels are operative to restrict movement of the PM element in the divider channel to a single degree of freedom of movement relative to the divider channel. The apparatus includes at least one biasing member located relative to the plurality of divider channels that biases the PM element in each of the plurality of divider channels in a direction toward an outlet of the plurality of divider channels. The apparatus also includes a PM array mold located relative to the outlet of the divider channel. The apparatus includes a retention member removably positionable relative to the outlet of the plurality of divider channels to control movement of the PM elements in each of the plurality of divider channels from the outlet of the divider channel. The PM elements are selectively discharged from the plurality of divider channels into the PM array mold upon removal of the retention member from the outlet of the plurality of divider channels.

A number of feature refinements and additional features are applicable to the fourth aspect. These feature refinements and additional features may be used individually or in any combination. As such, each of the following features that will be discussed may be, but are not required to be, used with any other feature or combination of features of the fourth aspect.

For instance, the plurality of divider channels may correspond to PM element positions in a PM array produced by the apparatus. The plurality of divider channels may correspond to a plurality of PM array rows comprising a plurality of PM element positions. The PM elements may be positioned in the plurality of divider channels in a relative polar orientation.

In an embodiment, the plurality of divider channels may each accept a plurality of PM elements. The retention member may in turn be operative to singluate one of the plurality of PM elements for each of the divider channels for discharge from the plurality of divider channels.

In an embodiment, the divider channels and the PM array holder may be configured for relative movement therebetween. The divider channels and the PM array holder may be configured to move apart to increase separation therebetween after the discharge of a plurality of PM elements from respective ones of the divider channels. The separation of the divider channels and the PM array holder may allow for introduction of adhesive between the plurality of PM elements after discharge from the divider channels.

A fifth aspect includes a method for manufacturing a permanent magnet (PM) array. The method includes loading PM elements into a plurality of divider channels each corresponding to a PM element position in a PM array. The PM elements are loaded into the plurality of divider channels to have a predetermined relative polar orientation. The method also includes biasing the PM elements toward respective outlets of each of the plurality of divider channels and retaining the PM elements in the plurality of divider channels by positioning a retention member relative to the outlets of the plurality of divider channels. The method further includes positioning a PM array holder relative to the outlets of the plurality of divider channels and displacing the retention member from the outlets to permit discharge of the plurality of PM elements from the divider channels. In turn, the method includes discharging the plurality of PM elements in response to the biasing. Accordingly, the method includes locating the plurality of PM elements with respect to the PM array holder.

A number of feature refinements and additional features are applicable to the fifth aspect. These feature refinements and additional features may be used individually or in any combination. As such, each of the following features that will be discussed may be, but are not required to be, used with any other feature or combination of features of the fifth aspect.

For instance, in an embodiment the method may include singulating the PM elements at the outlet of the plurality of divider channels such that a single PM element is discharged from each of the plurality of divider channels upon the displacing and discharging. In addition, the method may include returning the retention member to a position relative to the outlet of the plurality of divider channels to restrict further discharge of PM elements from the divider channels after the discharging.

In an embodiment, the method may include separating the plurality of divider channels and the PM array holder after the locating. Additionally, the method may include introducing an adhesive between the plurality of PM elements that have been discharged from the divider channels. The introducing may include advancing the adhesive relative to the plurality of PM elements that have been discharged from the divider channels in corresponding relation to a rate of separation of the plurality of divider channels and the PM array holder.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic view of an embodiment of an apparatus for manufacturing a PM array.

FIG. 2A illustrates an embodiment of a PM element.

FIG. 2B is an embodiment of a PM array row.

FIG. 2C illustrates an embodiment of a PM array.

FIG. 2D is a perspective view of an embodiment of a Halbach array row with 5 PM elements.

FIG. 2E is a perspective view of an embodiment of a PM array row with different sized

PM elements in the width direction. FIG. 2F is a perspective view of an embodiment of a PM array row and PM array with different sized PM elements in the length and width direction.

FIG. 3 is a perspective overview of an embodiment of an apparatus for PM array production.

FIG. 4A is a cross sectional side view of an embodiment of an apparatus for PM array production in a beginning stage of the cartridges, biasing member, PM elements, impact damper, and convergence ram.

FIG. 4B is a cross sectional side view of a secondary stage of the embodiment of Fig.

4A.

FIG 4C is a cross sectional side view of a final stage of the embodiment of Fig. 4A.

FIG. 5A is an isometric view of an embodiment of PM cartridges loaded into a convergence device of an embodiment of an apparatus for producing a PM array.

FIG. 5B is a top view of the embodiment of Fig. 5A.

FIG. 6 is a perspective side view of an embodiment of a support structure, adjustment rod, veil bracket and veil.

FIG. 7 is a perspective view of an embodiment of a base beam, PM array holder mold, PM array restraint, and stoppage block.

FIG. 8A is a perspective exploded view of an embodiment of a PM array holder and a finished PM array within the PM array holder.

FIG. 8B is a perspective exploded view of an embodiment of a PM array holder and a finished PM array within the PM array holder with a veil applied thereto.

FIG. 9 is a side cross sectional view of the embodiment of Fig. 3.

FIG. 10 is a close up perspective view of an output of an embodiment of a convergence device where PM elements exit a convergence ramp with an embodiment of saturation bar attachment.

FIG. 11 is an end view of a PM array row disposed in a PM array holder retained by a PM array holder mold with a saturation bar.

Fig. 12 is a perspective view of a plurality of saturation bars disposed relative to a PM array holder mold having a PM array disposed in a PM array holder retained by the PM array holder mold.

FIG. 13 is an isometric overview of another embodiment of an apparatus for producing PM arrays. FIG. 14 is a front view of the embodiment of Fig. 13.

FIG. 15A is a perspective view of an embodiment of a ram assembly with a convergence ram and plate in an open position.

FIG. 15B is a perspective view of the embodiment of the ram assembly of Fig. 15A with the convergence ram and plate in a closed position.

FIG 16A is a cross sectional side view of the ram assembly disposed relative to the convergence device of the embodiment of Fig. 13 in a first position.

FIG 16B is a cross sectional side view of the ram assembly disposed relative to the convergence device of the embodiment of Fig. 13 in a second position.

FIG 16C is a cross sectional side view of the ram assembly disposed relative to the convergence device of the embodiment of Fig. 13 in a third position.

FIG 16D is a cross sectional side view of the ram assembly disposed relative to the convergence device of the embodiment of Fig. 13 in a fourth position.

FIG 16E is a cross sectional side view of the ram assembly disposed relative to the convergence device of the embodiment of Fig. 13 in a fifth position.

FIG. 17 is a perspective overview of another embodiment of an apparatus for producing a PM array.

FIG. 18A is a front view illustrating a first step of the embodiment of Fig. 17.

FIG. 18B is a front view of a second step of the embodiment of Fig. 17.

FIG. 18C is a front view of a third step of the embodiment of Fig. 17.

FIG. 18D is a front view of a fourth step of the embodiment of Fig. 17.

FIG. 19 is a perspective view of an embodiment of an apparatus for producing a PM array.

FIG. 20 illustrates an embodiment of a manufacturing method flow chart.

DETAILED DESCRIPTION

While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that it is not intended to limit the invention to the particular form disclosed, but rather, the invention is to cover all modifications, equivalents, and alternatives falling within the scope of the invention as defined by the claims.

Fig. 1 depicts a schematic view an embodiment of an apparatus 150 for manufacture of a PM array 120. The apparatus 150 comprises a convergence device 400 that may be used to form PM array rows 110 to produce a PM array 120. As will be described in greater detail below, the apparatus 150 may include cartridges 200 that may each contain one or more PM elements 100. The cartridges 200 may be located (e.g., positioned, oriented, indexed, disposed, or otherwise situated) relative to the convergence device 400. PM elements 100 from the cartridges 200 may move to the convergence device 400 and, by controllably guiding PM elements through the convergence device 400, the convergence device 400 may output a PM array row 110.

The convergence device 400 may receive PM elements 100 provided at a first spacing at an input 402 of the convergence device 400. This first spacing may be provided to maintain the PM elements 100 from the cartridges 200 in a spaced-apart relation to reduce magnetic forces resulting from interaction of the magnetic fields of adjacent PM elements 100. As may be appreciated, this may allow for the PM elements 100 to relatively safely and controllably be positioned as the magnetic forces acting between PM elements 100 are reduced according to the inverse square law. The convergence device 400 may constrainedly engage the PM elements 100 and provide a PM array row 110 comprising a plurality of PM elements 100 at an output 404 of the convergence device 400. The PM array row 110 may provide the PM elements 100 comprising the PM array row 110 at a second spacing in which the PM elements 100 are closer to one another. As will be described in greater detail below, the convergence device 400 may be configured so as to controllably and safely converge the PM elements 100 from the input 402 to the output 404 to form the PM array rows 110.

The apparatus 150 may also comprise a PM array holder 240 into which PM array rows

110 may be located after being discharged from the output 404 of the convergence device 400. The PM array holder 240 may be located relative to a PM array holder mold 320. The PM array holder mold 320 may be advanceable relative to the convergence device 400 upon receipt of a PM array row 110. For instance, upon discharge of a PM array row 110 from the output 404 of the convergence device 400, the discharged PM array row 110 may act upon a PM array row 110 that has been previously engaged with the PM array holder 240 as will be discussed in greater detail below. The PM array holder mold 320 may move relative to the convergence device 400 to accept the discharged PM array row 110 in the PM array holder mold 240. Accordingly, the PM array holder mold 320 may resist movement absent application of a force corresponding to the discharge of a PM array row 110 from the convergence device 400. In other words, the PM array holder mold 320, and in turn PM array holder 240, may remain stationary until a PM array row 110 is discharged from the convergence device 400 to advance the PM array holder mold 320. This may reduce the likelihood or even prevent magnetic forces within the PM array 120 formed in the PM array holder 240 from causing movement of the PM array holder mold 320 and/or dislocation of the PM element 100 from the PM array 120. Accordingly, the PM array rows 110 may be secured to the PM array holder 240 to comprise a PM array 120. As will be described in greater detail below, this may include securing the PM array rows 110 to one another and/or relative to the PM array holder 240 by use of adhesives, mechanical interference, or other means.

As may be appreciated, PM elements 100 may be contained in one or more cartridges 200 for interface with the convergence device 400 to introduce PM elements 100 to the convergence device 400. The PM elements 100 may be provided in the cartridge 200 in a predetermined polar orientation. This may include all PM elements 100 sharing a common polar orientation or may include different PM elements 100 within the cartridge 200 having different predetermined polar orientations. As will be described in greater detail below, this may allow presentation of PM elements 100 to the convergence device 400 at the input 402 in a predetermined relative polar orientation between adjacent PM elements 100 (e.g., to produce a PM array 120 of a given configuration such as a Halbach array). Accordingly, after PM elements 100 are oriented into desired magnetic field direction, PM elements 100, which may have identified and marked poles, may be placed or otherwise loaded into PM cartridges 200.

The PM cartridges 200 may be sized so as to fix and constrain any PM elements 100 located in the PM cartridge 200. The cartridges 200 may comprise elongated channels that allow individual PM elements 100 to be oriented in a consistently maintained predetermined polar orientation. That is, the cartridges 200 may allow movement of the PM elements 100 in a single degree of freedom within the cartridge 200 (e.g., along the length of the cartridge while preventing or resisting PM elements 100 from flipping, rotating, or translating in a direction perpendicular to the length of the cartridge 200). The cartridges 200 may be made from non-ferromagnetic material that may include, but is not limited to, stainless steel, aluminum, plastic, fiber composites, or any other appropriate non-ferromagnetic material. Additionally or alternatively, the cartridges 200 may comprise selective use and/or placement of a ferromagnetic material to selectively provide retention or guidance for PM elements 100 as may be desired. In any regard, the cartridges 200 may help to insure the integrity and preservation of PM element orientation, protect the PM elements from damage, and may standardize the transport packaging of individual PM elements 100.

With reference to Figs. 2A-2F, various configurations of PM elements 100, PM array rows 110, and PM arrays 120 are described. As will be appreciated, any of the disclosed various configurations of PM elements 100, PM array rows 110, and PM arrays 120 are contemplated for use and/or production by the embodiments described in the present disclosure. Accordingly, while the embodiments described herein may be illustrated as producing relatively regular PM array rows 110 of equal and regular PM element 100 spacing from cubic PM elements 100, it may be appreciated that any of the various configurations described in Figs. 2B-2F may be realized using the embodiments described herein. In turn, PM elements 100 and PM arrays 120 produced according to the disclosure herein may include PM elements 100 of varying widths, lengths, and heights and/or may include staggered rows with at least partially overlapping PM element 100 arrangement. Moreover, while linear PM array rows 110 and corresponding linear PM arrays 120 are shown and described, the embodiments described herein could be modified appropriately to produce PM array rows 110 and corresponding PM arrays 120 in any appropriate configuration including, for example, cylindrical arrays, circular arrays, arcuate arrays, Y-shaped, forked, channeled, or any other appropriate shape. In this regard, reference to a PM array row 110 is not intended to limit the disclosure to linear arrays and it may be appreciated that PM array rows 110 may comprise any of the foregoing shapes including arcuate rows or the like.

With reference to Fig. 2A, a permanent magnet (PM) element 100 may be made from any number of different materials; however, a preferred material, at this time, is neodymium ferrite. PM elements 100 may be manufactured in standardized sizes, shapes, and magnetization (pole) direction. In Figs. 2A-2F, PM elements 100 include arrows indicative of a pole direction of each PM element 100. In this regard, the arrow may generally point from the south pole to the north pole of the PM element 100. PM elements 100 may preferably be, but are not necessarily, plated with nickel or coated with epoxy, elastomeric, dielectric, or other coating. Such coating may provide protection to the PM elements 100 with respect to mechanical damage and/or conductive isolation. In this regard, the coating may assist in reducing the potential for chipping, cracking, or wear of the PM element 100. Moreover, the coating may act as a dielectric, effectively conductively isolating the PM elements 100 which themselves may be conductive. The length, width, thickness, shape and size of PM elements 100 may be chosen to create a wide range of PM element design matrixes including but not limited to a PM array 120 as shown in Fig. 2C where the PM array 120 comprises a relatively regular (in shape, spacing, and arrangement) PM array 120. A PM array 120 may comprise a plurality of PM array rows 110, one of which is shown in isolation in Fig. 2B. One specific example of a PM array 120 may be a Halbach array, which may comprise five PM elements 100 that have the magnetic field direction vector rotated 90 degrees from adjacent PM elements 100 in the PM array 120 as shown in Fig. 2D. However, as stated above, PM arrays 120 (e.g., alternatively configured Halbach arrays) of more than five PM elements 100 are contemplated including PM arrays 120 of any appropriate shape and/or configuration including as shown in Figs. 2B, 2E, and 2F. Specifically, Fig. 2E depicts a PM array row 110 with PM elements 100 comprising different widths. Fig. 2F depicts a PM array 120 comprising PM elements 100 having different widths and lengths. As such, a PM array 120 as described herein is not intended to be limited to linear, regular arrays as shown in Fig. 2C, and may encompass any appropriate configuration including complex arrays.

PM elements 100 may undergo a process that may include identification of pole direction to allow for marking or labeling of a pole orientation of the PM element 100. For instance, the arrow indicator shown in Figs. 2A-2F may be physically marked on the PM elements 100 (e.g., on or within a coating thereof). This may assist in verification of orientation accuracy. In any regard, verifying the orientation of PM elements 100 may be performed manually, optically, by electro sensing, and/or by mechanical sensing means. Common sensing means may include magnetic viewing film, electronic pole identifiers, or by using another previously identified magnet (e.g., another PM element 100 that has been previously marked or whose polarity is known).

With further reference to Fig. 3, an embodiment of an apparatus 152 is shown that may be used to manufacture PM arrays 120. The apparatus 152 may include a convergence device 400 for accepting PM elements 100 from cartridges 200 located relative to the convergence device 400. The apparatus 152 may also include a base beam 300 that supports a PM array holder mold 320 for positioning a PM array holder 240 (not shown in Fig. 3) relative to the convergence device 400 for receipt of PM array rows 110.

A support frame 310 as shown in detail in Fig. 6 may be provided relative to the base beam 300 and the PM array holder mold 320 to supportably engage cartridges 200 and/or the convergence device 400 in relative position to the PM array holder mold 320. The support frame 310 may be made of any one of a number of custom manufactured stock or premanufactured stock (e.g., angled material) and may be placed relative to (e.g., over) the base beam 300.

The support frame 310 may provide an attachment point for mounting cartridge guides 330 (shown in Fig. 5A) that may provide discrete positioning of corresponding cartridges 200 engaged with the cartridge guides 330. In this regard, the cartridge guide 330 may allow for placement of the cartridges 200 in a constrained position relative to other cartridges 200 (e.g., to manage or reduce interacting magnetic forces therebetween). The cartridge guides 330 may allow for a cartridge 200 to be controllably moved into a production position relative to the convergence device 400. For instance, it may be appreciated that even in a spaced apart position as shown in Fig. 5A, the cartridges 200 may be difficult to locate relative to one another due to the magnetic forces acting between PM elements 100 in respective ones of the cartridges 200. For instance, if a first cartridge 200 positioned between two other cartridges 200 is to be replaced, it may require significant force to replace the first cartridge 200. Moreover, it may be difficult to locate the first cartridge 200 as the other two cartridges may resist repositioning of the first cartridge 200. In this regard, the cartridge guides 330 may comprise brackets that extend away from the support frame 310. The bracket may allow a cartridge 200 to be positioned within the cartridge guide 330 in a tiled-away position from the production position shown in Fig. 5A. In turn, the cartridge 200 may be tilted into the production position. The cartridge guide 330 may resist twisting or lateral forces tending to move the first cartridge 200 away from the production position. In turn, the cartridge 200 may be engaged into the production position shown in Fig. 5A with constrained alignment provided by the cartridge guide 330.

The support frame 310 may be made from non-ferromagnetic, rigid, and durable, material such as stainless steel or composites that may be made from glass, plastic, or carbon fibers. The support frame 310 may also be the attachment point for positioning a cartridge guide 330 as shown in Fig. 5A. The support frame 310 may secure the convergence device 400 for positioning relative to the PM array holder 240.

The support frame 310 may also provide a location for the mounting of a veil bracket 350. The veil bracket 350 may support a veil roll 352 from which a veil material 355 may be dispensed for application to a PM array 120 located in the PM array holder 240 as described in greater detail below. These components may be secured to the support frame 310 by bolt and nut or any other appropriate means including adhesives, welding, or the like.

The support frame 310 may position the convergence device 400 relative to a recess of the PM array holder mold 320 in which the PM array holder 240 may be positioned. This positioning of the PM array holder mold 320 may provide clearance for a PM array holder 240 to be located relative to the PM array holder mold 320. An adjustment rod 312 (shown in Fig. 6) may be provided to allow for fine tuning of the positioning between the PM array holder mold 320 relative to the convergence device 400. The adjustment rod 312 may position the convergence device 400 and/or the PM array holder mold 320 by applying force in either horizontal direction while the PM array holder mold 320 travels along the length of the base beam 300. Adjustment of the adjustment rod 312 may move the support frame 310 or individual components (e.g., the convergence ramp 430) to locate the output 404 of the convergence device 400 relative to the PM array holder 240.

The cartridges 200 may include or interface with a biasing member 202 (shown in Figs.

4A-4C) to bias PM elements 100 contained in the cartridge 200 toward an outlet 204 of the cartridge 200. Examples of biasing members 202 may include, but are not limited to, a mechanical actuator, spring, human powered concentric plunger to advance PM elements 100 through a hollow structure of the cartridges 200 that contain the PM elements 100. In an embodiment, a cartridge 200 may rely on gravity in relation to the orientation of the cartridge 200 and/or magnetic forces present between PM elements 100 to bias PM elements 100 toward an outlet 204 of the cartridge 200. In an embodiment, the biasing member 202 may comprise a spring provided in the cartridge 200 to move a concentric plunger to advance the PM elements 100 through the cartridge 200. As such, while the biasing member 202 is shown in Figs. 4A-4C as extending beyond a portion of the cartridge 200 opposite the outlet 204, the biasing member 202 may be wholly contained within the cartridge 200. With further reference to Figs. 4A-4C, the base of the convergence device 400 may be aligned with an impact damper 405 that is positioned relative to the outlet 204 of the cartridges 200 to dampen PM element 100 and cartridge 200 contact with the convergence device 400. The impact damper 405 may be provided on the cartridge 200 and/or the convergence device 400. This may assist in reducing the likelihood of PM elements 100 incurring damage, such as chipping, breaking, or removing a coating as described above. The impact damper 405 may be made from materials including but not limited to rubber, another elastomeric material, plastic, protective coating like epoxy, or other appropriate material that provides sufficient protection and dampening of the PM elements 100.

The cartridges 200 may guide the PM elements 100 into the convergence device 400.

PM elements 100 within the cartridges 200 may be constrained on the convergence block 400 until the desired quantities of cartridges 200 are loaded into the convergence block 400. Once the desired quantities of cartridges 200 are loaded into the convergence block 400, the PM element 100 feed rate may be determined and the optional biasing member 202 may begin to push PM elements 100 through the cartridges 200.

Specifically, as illustrated in Figs. 4A-4C, a PM element 100 may be sheared off or otherwise singulated from the PM elements 100 in the cartridge 200 by the use of the convergence actuator 420. In a first position, PM elements 100 are biased toward the outlet 204 such that the PM elements 100 may be in a columnar orientation with a PM element 100 located at the outlet 204. As shown in Fig. 4B, the convergence actuator 420 may comprise a linear actuator (e.g., that is hydraulic, electrical, pneumatic, electromagnetic, human powered, robotic, or the like) that may shear a PM element 100 at the outlet 204 from the column 206 of PM elements 100 in the cartridge 200. In turn, a PM element 100 may be moved from the cartridge 200 to the convergence device 400. As shown in Fig. 4C, the convergence actuator 420 may cycle to an initial position such that the column 206 is advanced by the biasing member 202 and a subsequent PM element 100 in the column 206 is disposed at the outlet 204. This process may iterate such that individual PM elements 100 are moved from the cartridge 200 to the convergence device 400.

In an initialization of the convergence device 400, the convergence device 400 may be primed prior to introduction of PM elements 100. For instance, this may include manually introducing priming elements (e.g., of a similar shape/size as PM elements 100) into the convergence device 400. Alternatively, cartridges 200 with priming elements may be provided to introduce the priming elements into the convergence device 400. The priming elements may be non-magnetic. As such, the priming elements may not undergo magnetic interaction such that any potential repulsion forces acting on PM elements 100 may not be present. In turn, the priming elements may be advanced through the convergence block 400 until priming elements are constrainedly ejected from the outlet 404 of the convergence device 400. In turn, PM elements 100 may be introduced such that the initial PM elements 100 introduced into the convergence device 400 may be constrained in a downstream direction (i.e., toward the outlet 404) by the priming elements. Accordingly, even if PM elements 100 within the convergence device 400 are repelled from one another, the PM elements 100 may not separate due to the fully constrained configuration provided by other PM elements 100 and/or priming elements. Similarly, priming elements may be introduced at the end of a PM array 120 production to purge PM elements 100 within the convergence device 400 to the outlet 404.

The convergence actuator 420 may push the individual PM elements from the convergence block 400 and into convergence channels 410 defined in the convergence device as shown in Figs. 5A-5B. The convergence channels 410 may establish flow streams 210 of PM elements 100 within the convergence device 400. PM elements 100 may be advanced along the flow stream 210 as additional PM elements 100 are introduced into the convergence channels 410. That is, as the convergence actuator 420 moves a PM element 100 from the cartridge 200 into the convergence device 400, the PM elements 100 in the convergence channels 410 may be advanced along the flow streams 210 from the inlet 402 to the outlet 404 of the convergence device 400. Accordingly, the convergence actuator 420 may control the PM elements 100 feed rate, timing, and direct the alignment of each cartridge 200 flow stream 210 with respect to and coordinated with other cartridge 200 flow streams 210 of PM elements 100.

As may be appreciated from Figs. 2B-2F, PM arrays 120 and PM array rows 110 may comprise a plurality of PM elements 100 in a predetermined relative polar orientation. In turn, PM element positions within a PM array may correspond to cartridges 200 that may each provide a flow stream 210 of PM elements. Each flow stream 210 may correspond to a respective PM element position within a PM array row 110. Accordingly, PM elements 100 that are in the predetermined polar orientation in the cartridge 200 may be placed relative to the convergence device 400 to create a plurality of flow streams 210 of PM elements 100 into corresponding convergence channels 410 (best seen in Fig. 5B) of the convergence device 400 where desired alignments can be assigned to each respective flow stream 210.

In this regard, the embodiment shown in Figs. 3-5B depict six cartridges 200 corresponding to six flow streams 210 that each correspond to a PM element position within a PM array row 110 to be produced. In this embodiment, the PM elements 100 contained in the cartridges 200 may comprise cubic shaped PM elements 100. However, it will be understood that number of cartridges 200, the positioning of cartridges 200, and/or the configuration of the PM elements 100 may be modified without limitation as described above (e.g., including during PM array 120 production to create spaces and/or Y shapes in the PM array 120). For instance, cartridges 200 may be added, removed, or reoriented to produce the desired shape, width, or height of PM array rows 110 and thus PM arrays 120 as described above. The cartridges 200 may vary in number, size, and/or orientation to produce the desired design matrix of the PM array rows 110 thus PM arrays 200. The cartridges 200 may constrain PM elements 100 for the creation of three-dimensional shapes of PM arrays 120 as well.

Some or all of PM elements 100 may be optionally bonded to adjacent PM elements

100 within the cartridges 200 to create more complex arrays to further exploit the magnetic fields. Bonding means that may be used to bond PM elements 100 include but are not limited to UV cure epoxy, heat accelerated cure epoxy, or other various forms of adhesive with desirable characteristics.

With continued reference to Figs. 5A and 5B, the convergence device 400 may comprise a convergence block 406 including a plurality of convergence channels 410 that may each correspond to a flow stream 210 of PM elements 100. The convergence device 400 may also comprise the convergence actuator 420.

In Fig. 5A, the convergence block 406 is shown as being open for purposes of illustration only, such that in practice, the convergence block 406 may comprise a closed structure with the convergence channels 410 passing therethrough. In this regard, unlike in Fig. 5A, the convergence channels 410 may not be visible, or may only be visible through a transparent covering that encloses the convergence channels 410.

Each of the convergence channels 410 may be correspondingly sized so as to receive a PM element 100 therein such that the PM element 100 may only move in one degree of freedom relative to the convergence channel 410 between the input 402 and the output 404. That is, the PM element 100 may be allowed to translate between the input 402 and the output 404 along a length of the convergence channel 410 (i.e., along the flow stream 210) without rotating, flipping, or otherwise translating in a direction different than in a direction along the flow stream 210. The restriction of movement of the PM elements 100 may at least partially come from the adjacent relation of PM elements 100 (or priming elements during initialization or purging of the convergence device 400) in the convergence channels 410. That is, a PM element may be prevented from advancing or retracting in the convergence channel 410 due to the plurality of PM elements 100 stacked in the convergence channel 410 corresponding to the flow stream 210. Accordingly, a PM element 100 may be advanced in the convergence channel 410 only upon actuation of the convergence actuator 420 to advance the PM elements 100 along the flow streams 210 within each convergence channel 410.

PM elements 100 may be introduced into the convergence channels 410 of the convergence block 406 from corresponding outlets 204 of the cartridges 200. The PM elements in the respective convergence channels 410 may follow flow streams 210 corresponding to the respective convergence channel 410 into which the PM elements are located. In turn, a PM array row 110 may be formed in the convergence device 400 such that the PM elements comprising the PM array row 110 are constrained through the convergence ramp 430 the output 404 of the convergence device 400 where the PM array row 110 may be located relative to a PM array holder 240 as described in greater detail below.

The convergence block 400 may begin to create PM arrays 110 by the constrained movement of PM elements 100 into the convergence channels 410. The convergence channels 410 may have a narrowing material division between PM elements 100. The convergence channel 400 allows the PM element 100 flow streams 210 to begin the permanent placement at a safe and controllable rate. As the flow streams 210 converge, the magnetic fields will begin to interact through the convergence device 400. Controlling this interaction is a key safety factor, as the PM elements 100 may attempt to react by flipping, spinning, or colliding to reorient themselves to align their fields.

As PM elements 100 are fed into the convergence channels 410, individual PM element 100 poles may again be verified to eliminate any magnetic pole orientation error. The convergence channel 410 provides the final PM array row 110 alignment before PM array rows 110 are advanced through the convergence ramp 430 and placed into the PM array holder mold 320, thus creating permanent PM array 120. The convergence channel 410 may direct the converging of the flow of aligned and/or bonded PM elements 100 into desired arrangement resulting with closely packed PM elements 100 into a PM array rows 110 devoid of unwanted spaces, gaps, or magnetic field discontinuities. The convergence channel 410 may be made from durable, yet non- ferromagnetic materials such as various forms of metal including, but not limited to, stainless steel or aluminum. Alternatively, the convergence channel 410 may be made from a composite such as carbon, plastic, fiber, or other appropriate combinations.

In this regard, as the magnetic forces acting between PM elements 100 in the convergence actuator 400 build, the PM elements may be constrained by the convergence channels 410. Accordingly, even though the magnetic forces between adjacent PM elements 100 in the convergence device 400 may build to relatively strong levels, the containment provided by the convergence channels 410 may restrict or prevent the PM elements 100 from moving in any direction except for in the single degree of freedom allowed by the convergence channels 410. As such, the PM elements 100 may be converged into PM array rows 110 in a controlled and safe manner even as the magnetic forces acting on the PM elements 100 builds as the PM elements 100 are moved closer to one another.

Optionally interrupting the flow streams 210 of PM elements 100 to create groups and spacing of selectively fixed numbers of PM elements 100, then reorienting analogous groupings from other flow streams 210 (as will become more closely defined in the specification according to various embodiments) to form a more complex or compound PM array rows 110.

The convergence actuator 420 may force the constrained and closely packed PM array rows 110 through the convergence block 406 and into convergence ramp 430. The convergence actuator 420 may continue to advance the PM array rows 110 until the PM array rows 110 are discharged from the outlet 404 to be positioned into the chosen PM array holder 240. The convergence ramp 430 may allow PM array rows 110 to safely be applied to the PM array holder 240 at a controlled speed and distance via the convergence ramp 430.

With additional reference to Figs. 7-8B, a PM array holder 240 may be provided for receipt of PM array rows 120. The PM array holder 240 may comprise a substantially linear material that retains the PM arrays 120 in a substantially permanent configuration. The PM array holder 240 may be made from any suitable material including but not limited to fiber reinforced plastic or composite material. Such materials may be made by any appropriate technique including, for instance, pultrusion, wet lay-up, pre-impregnated, vacuum formed, resin infusion, autoclave, etc. Alternatively, PM array holder 240 may be formed out of other, preferably, dielectric materials. The cross-sectional form of the PM array holder 240 may comprise a channel, hat section (as depicted in Figs. 8A, 8B, and 11), or any other shape whereby the high field surface of the PM elements 100 may not substantially occluded from the vertical or horizontal directions. Alternatively, the PM array holder 240 may comprise vertical protrusions at the sides to protect the PM array 120 from contact while transporting or installation at the location of final use.

With specific reference to Fig. 7, the base beam 300 may be provided that may support, position, and/or guide a PM array holder mold 320. The PM array holder mold 320 may supportably engage a PM array holder 240. In turn, the convergence device 400 may be positioned relative to the base beam 300, PM array holder mold 320, and PM array holder 240 to allow for PM array rows 110 discharged from the output 404 of the convergence device 400 to be received by the PM array holder 240.

In an embodiment, the base beam 300 may comprise an I-beam configuration. The base beam 300 may be constructed of many non-ferromagnetic materials, most common of which includes stainless steel, aluminum, and plastic or fiber composites.

A PM array holder path constraint 325 may provide horizontal and/or vertical constraint of the PM Array holder 320 relative to the base beam 300 including but not limited to a linear bearing, wheeled device, fitted spacers, or means for constraining the PM array holder mold 320 relative to the base beam 300 as shown in Fig. 8A and 8B. In this regard, the PM array holder mold 320 may be constrained for linear movement in a single direction relative to the convergence device 400.

Before the PM elements 100 are converged by the convergence device 400 into a desired orientation for final placement and bonding, the PM array holder 240 may be assembled. The PM array holder 240 may comprise the final placement for PM elements 100 such that the PM array holder 240 may hold bonded PM arrays rows 110 ejected from the convergence device 400 into a desired length, width, and distribution to create a PM array 120. PM array holder 240 may be made from durable, readily available material that can be constructed into custom forms. Such materials include, but are not limited to, composites of plastic, glass, other non-ferromagnetic metals, para-aramid synthetic fiber (e.g., Kevlar^® branded material provided by E. I. Du Pont De Nemours and Company Corporation), ultra- high-molecular-weight polyethylene, and/or carbon fibers. The present embodiment may use pre-impregnated fiber for the PM array holder 240. Pre-impregnated fiber may include glass, plastic, or carbon fiber that has resin, epoxy, or adhesive applied to it before layup, placement, use, or curing.

The PM array holder mold 320 may provide a rigid housing for the desired form, shape, or configuration of PM array holder 240 throughout a layup process and PM array 120 production. The PM array holder mold 320 may comprise multiple pieces that may be selectively decoupled. For instance, the PM array holder mold 320 may comprise a base member 324 to which side flanges 326 may be selectably engaged. In this regard, the recess 328 into which the PM array holder 240 and PM array 120 are to be located. The side flanges 326 may be selectively removable from the base member 324 to, for example, help facilitate removal of a PM array holder 240 with an adhered PM array 120 after curing of the adhesive used to bond the PM array 120. The side flanges 326 may also include holes 332 to facilitate engagement of saturation bars 370 as will be described in greater detail below. The side flanges 326 may be selectively engageable with the base member 324 in any appropriate manner including by way of an interference fit, fasteners, or the like. The PM array holder path constraint 325 may be provided on the base member 324 as shown.

The PM array holder mold 320 may be capped at one end or both ends with a PM array restraint 322. The PM array restraint 322 may fit flush with the PM array holder mold 320 providing a primary point of resistance for the beginning and end of the PM array holder 240. That is, the first PM array row 110 for a given PM array 120 may be discharged in contacting engagement with the PM array restraint 322 to restrain a PM array row 110 from advancing relative to the convergence device 400 beyond a location to which the PM array row 110 is advanced by the convergence device 400. This may result in the PM array holder mold 320 being selectively advanced as described above. Accordingly, the PM array restraint 322 may assist in maintaining constrained arrangement of the PM array rows 110 to facilitate bonding or other activities.

A stoppage block 360 may also be provide to restrict linear movement of the PM array holder mold 320 along the base beam 330. The stoppage block 360 may act as a sprag clutch, ratchet, clamping device, or other means of restricting linear movement of the PM array holder mold 320 to maintain the PM array holder 320 in a desired position relative to the output 404 of the convergence device 400. The stoppage block 360 may apply a force that may be overcome by the force of a discharged PM array row 110 acting on the PM array restraint 320 and/or a previously discharged PM array row 110. That is, actuation of the convergence actuator 420 may press a PM array row 110 at the output 404 of the convergence device 400 against the PM array restraint 322 and/or stoppage block 360. The PM array restraint 322 may comprise a block of rigid material that may provide a stiff point for the convergence actuator 420 to push against creating a consistent and even force for until the PM arrays 120 are positioned for placement of saturation bars 370 relative thereto as will be described in greater detail below.

The PM array restraint 322 may be made from either magnetic or non-ferromagnetic material including, but not limited to, stainless steel, aluminum, fiber, glass, wood, or others appropriate materials. Primary functions for the PM array holder mold 320 may be to provide a rigid form, shape, or configuration for the PM array holder 240 and provide flow rate regulation between a convergence actuator 420 and the PM array holder 240 along the base beam 300 as additional PM array rows 110 are placed.

Enhancements to the PM array holder mold 320 may be provided such as spaced holes, slots, segments of removed material or removable or detachable material to provide optional means for accelerating the curing of adhesive material. Such means may include, but are not limited to, UV light of various wavelengths, applying mild heat, or vacuum bagging. The mild heat accelerated curing may remain below a discrete temperature due to the susceptibility of PM elements 100 to temporally or permanently lose magnetization, magnetic field strength, or pole magnetization tolerance.

Any material that is taught as being non-ferromagnetic may be so specified for the undesired magnetic attraction at that point in the process. Certain embodiments may utilize ferromagnetic material for certain components depending on the use case. These components include but are not limited to cartridges, convergence channels, convergence devices, PM array holder mold, or base beam. For instance, it may be desirable to use ferromagnetic material to provide saturation of the magnetic field of PM elements 100, PM array rows 110, or a PM array 120 at any point in the production. As such, any component described herein may comprise ferromagnetic material to provide such saturation or any other purpose (e.g., to induce movement of a PM element 100 or the like).

With additional reference to Fig. 9, the convergence device 400 may also comprise a convergence ramp 430. The convergence ramp 430 may also constrain PM elements 100 to a single degree of freedom such that PM elements 100 in the convergence ramp 420 are restricted or prevented from flipping, twisting, or moving in a direction perpendicular to a flow stream 210 direction. As can be appreciated in Fig. 9, the convergence ramp 430 may be sloped in a direction toward the output 404. The slope of the convergence ramp 430 may allow for a PM array row 110 to be discharged into a PM array holder 240 while allowing the PM array holder 240 clearance when passing relative to the convergence device 400.

Fig. 9 also illustrates the manner in which the convergence actuator 420 may act on a PM element 100 at an outlet 204 of a cartridge 200 to introduce PM elements 100 into convergence channels 410. As is illustrated in Fig. 9, a series of PM elements 100 may be arranged in abutting engagement such that the convergence actuator 420 may advance all of the PM elements 100 in the series along the flow stream 210. In turn, actuation of the convergence actuator 420 may result in discharge of a PM array row 110 at the output 404 to acct on the PM array holder 320 to advance the PM array holder 320.

Fig. 9 also depicts saturation bars 370 that may be located relative to the PM arrays 110 once discharged from the convergence device 400. During the application of pressure from the convergence ramp 430, a saturation bar 370 may be located relative to one or more PM array rows 110. The saturation bar 370 may be made of a magnetic material including, but not limited to, mild, hot, or cold rolled steel. With further reference to Figs. 10-12, a saturation bar 370 may be located relative to PM array rows 110 of a PM array 120 as the PM array rows 110 are discharged from the outlet 404 of the convergence device 400. The saturation bar 370 may provide for saturation of a magnetic side of the PM array 120 to reduce the magnetic field in the space opposite the saturation bar 370 once applied to the PM array 120 to assist in containing the magnetic field produced by the PM array 120. In an embodiment, a saturation bar 370 may be applied in a partially overlapping relation to adjacent PM array rows 110. This may allow for a saturation bar 370 to engage a PM array 110 as it is partially ejected from the output 404 as shown in Fig. 10. That is, only a portion of the PM array row 110 needs to be emerged from the output 404 for the saturation bar 370 to partially overlappingly engage the PM array row 110.

Accordingly, the saturation bar 370 may be engaged with the PM array holder mold 320. This may include clamplingly engaging the PM array rows 110, which may mechanically stabilize the PM array rows 110 relative to the PM array holder mold 320. Application of a saturation bar 370 may occur prior to, concurrently with, or after application or introduction of an adhesive to bond the PM array 120.

As shown in Figs. 10 and 11, screw pins 375 may be located on each end of the saturation bar 370. A saturation bar 370 may be placed to cover half of a first PM array row 110 and half of a second (e.g., newly placed) PM array row 110 that may be a bonded PM array row 110 placed in the PM array holder 240. Once the saturation bar 370 is lowered into placement through holes 332 on the PM array holder mold 320, screw pin nuts 377 may be secured to the screw pins 375 of the saturation bar 370 that have passed through the holes 332 in the PM array holder mold 320. The saturation bars 370 may provide consistent force and accurate alignment of PM array row 110, PM array holder 240 and PM array holder mold 320 as shown in the end view of Fig. 11. The screw pins 375 and screw pin nuts 377 may add force to secure the PM array rows 110 and PM array holder mold 320 as the screw pin nuts 377 are tightened on the opposing side of the PM array holder mold 320 voids.

Alternatively, the saturation bars 370 may be made from non-ferromagnetic material that act as clamps for the PM array rows 110 to apply consistent constraint and clamping force without containing the magnetic field until a bonding or adhesive material is introduced. If non-ferromagnetic material is used for the saturation bar 370, then additional caution may be needed as the PM element's 100 magnetic field may be exposed and likely to attract magnetic material at a high and dangerous force.

The application of continued constraint to PM array row 110 (or compound array) and

PM array holder mold 320 may assist in providing a secure and accurate alignment of PM elements for holding and attachment of the PM array row (110) (or compound array) whereby the resulting PM array row 110 (or compound array) may be optionally mounted to other devices or structures while retaining PM array 110 (or compound array) alignment and protecting the magnetic field. The saturation bars 370 may be small enough that they can be removed from the PM array holder mold 320 without extreme force by human, robotic, mechanical, or other means.

A veil bracket 350 may supportably engage a veil roll 352 from which veil material 355 may be dispensed to cover PM array rows 110. The application of the veil 355 to the exposed face of PM array rows 110 may provide further protection of PM array rows 110 or the resulting PM array 120. The veil 355 may be applied to the PM array row 110 prior to application of a saturation bar 370. The veil 355 may serve as a protective barrier and encapsulation layer between the newly bonded PM array rows 110 and saturation bars 370 for any adhesive material that may be squeezed through individual PM elements 100. Application of the veil 355 may also optionally provide a sacrificial layer in case of adhesive material leak. In addition, vacuum bagging cure procedures can may be applied at this point. PM arrays 120 may be applied to, fitted, or installed into standardized array sleeve packaging to protect and further organize final PM arrays 120 for safe handling, efficient shipping, and final assembly according to customer needs. Array sleeves may be manufactured from nonferromagnetic material such as composites comprising of plastics, fiber, glass, foam, or other materials. These materials may allow the safe, time efficient, and low-cost handling of PM arrays 120.

Figs. 14-16C depict an alternative embodiment 154 of an apparatus for manufacture of PM arrays 120. The embodiment of the apparatus 154 shown in Figs. 14-16B may generally include alternative methods and elements. However, the apparatus 154 may comprise any and all off the previous teachings except as noted specifically below. Accordingly, any of the foregoing features and/or details described above are applicable to the following embodiment unless expressly stated otherwise.

For instance, the apparatus 154 may comprise an alternative convergence device 400'. Cartridges 200 may guide the various flow streams 210 of aligned and/or optionally bonded PM elements into at least two elongated convergence channels 410 provided in a convergence block 406 of the convergence device 400'. The convergence channel 410 may constrain the PM element 100 feed rate, timing, and direct the alignment of each cartridge 200 flow stream 210 with respect to and coordinated with other cartridge 200 flow streams 210 of PM elements 100. The convergence channel 410 may accomplish this constraint by a narrowing material division between PM elements 100. The convergence channel 410 may allow the PM element 100 flow streams 210 to enter the convergence device in a separated, safe, and controlled distance. As the streams 210 converge, the magnetic fields may begin to interact through the convergence channel 410. Controlling this interaction may provide a key safety factor, as the PM elements 100 may react to adjacent fields by flipping, spinning, or colliding to reorient themselves to align their fields.

Unlike the apparatus 152, apparatus 154 may provide a convergence actuator 420 to advance the PM elements through the convergence device 400' in the form of the biasing member 202. That is, the cartridges 200 may provide PM elements 100 at outlets 204 of the cartridges 200 at an inlet 402 of the convergence device 400'. Rather than a convergence actuator 420 comprising a linear acting actuator in the case of the convergence device 400, the PM elements may be advanced through the convergence device 400' by influence of the biasing member 202 to form a PM array row 110. As will be described in greater detail below, a ram assembly 440 may be provided relative to the convergence device 400' to move the PM array row 110 from the outlet 404 of the convergence device 400' to a PM array holder 240.

As PM elements 100 are fed into convergence channel 410 the individual PM element 100 poles may again be verified to eliminate any magnetic pole orientation error or deviation. The convergence channel 410 may be made from durable, yet nonferromagnetic materials such as various forms of metal including stainless steel or aluminum. Alternatively, the convergence channels 410 may be made from a composite including, but not limited to, plastic, fiber, or other appropriate combinations.

The flow streams 210 of PM elements 100 may be optionally interrupted to create groups and spacing of selectively fixed numbers of PM elements 100. In turn, analogous groupings from other flow streams 210 may be reoriented to form a more complex or compound PM array rows 110 as will be described in greater detail below.

The convergence channel 410 may be oriented to converge the flow of aligned and/or bonded PM elements 100 into desired arrangement resulting with closely packed PM elements 100 into PM array rows 110 devoid of unwanted spaces, gaps, or magnetic field discontinuities into a PM array retainer 340. Specifically, the PM elements 100 may be in adjacent, contacting engagement. The PM array retainer 340 may provide final PM element 100 alignment before PM elements 100 are placed and bonded into PM array holder 240 by a ram assembly 440. The PM array retainer 410 may be made from durable, yet nonferromagnetic materials such as various forms of stainless steel, aluminum, or a composite that may be made of plastic, fiber, or other appropriate combinations.

The ram assembly 440 may operate to place the closely packed PM array rows 110 into a PM array holder 240. This process is shown in progression in Figs. 16A-16C. The PM array holder 240 may be the final location for bonded PM arrays rows 110 in a desired length, width, and distribution. The PM array holder 240 may be provided in any manner as described above in relation to the embodiment of Figs. 3-5B.

With reference to Figs 15A and 15B, the ram assembly 440 may comprise a convergence ram 445 and a plate 442. The convergence ram 445 and the plate 442 may be moveable between an open position shown in Fig. 15A and a closed position shown in Fig.

15B. The plate 442 may be engaged with a guide bolt 444 that is positioned in a slot 446 in the convergence ram 445. In this regard, the slot 446 may define an extent of travel of the plate 442 relative to the convergence ram 445.

Additionally, there may be a spring member disposed between the convergence ram

445 and plate 442 that biases the ram assembly 440 into one of the open or closed positions.

For instance, in an embodiment, the ram assembly 440 may be biased into the open position such that absent application of a force, the ram assembly 440 may remain in the open position. Accordingly, it may require application of a force (e.g., by an appropriate actuator) to dispose the ram assembly in the closed position. The spring member may extend relative to the guide bold 445 and spring towers 448 on the convergence ram 445 to dispose the ram assembly 440 in the open position.

When in the open position, adhesive distribution grooves 447 may be exposed on the plate 442. In this regard, the adhesive distribution grooves 447 may be provided to receive an adhesive for application to a PM array row 110 as will be described in greater detail below.

When in the closed position, the convergence ram 450 may include a retractable adhesive comb 449 that conformably engages the adhesive distribution grooves 447. In this regard, when moving between the open and closed position, the retractable adhesive comb 449 may travel along the adhesive distribution grooves 447 displacing any adhesive in the adhesive distribution grooves 447 out of the adhesive distribution grooves 447 (e.g., in a direction along which the convergence ram 450 travels to a distal location beyond the plate 442).

With further reference to Fig. 16A, a cross sectional view of the PM array retainer 340 is shown. As may be appreciated, the ram assembly 440 may be in a first position. In the first position, the ram assembly 440 may be in the open position as shown in Fig. 15A. In the first position, the ram assembly 440 may be located away from the outlet 404 of the convergence device 400' where PM array rows 110 are formed. Accordingly, an adhesive may be applied to the adhesive distribution grooves 447.

As may also be seen in Fig. 16A, a retention clip 452 may be engaged with a column

206 of PM elements 100 disposed in the convergence device 400. The retention clip 452 may retain the column 206 in the position shown in Fig. 16A with force being maintained by the biasing member 202 of the cartridges 200 containing the PM elements 100. As such, the PM elements 100 may continue to be constrained by the retention clip 452 when the ram assembly 440 is in the first position.

In Fig. 16B, the ram assembly 440 may be advanced to a second position. In this regard, the plate 442 in the open position may displace the retention clip 452 to a retracted position, thus allowing the column 206 of PM elements 100 to be advanced toward the plate 442. In turn, the PM array row 110 at the outlet 404 of the convergence device 400' may contact the plate 442. In this regard, an adhesive provided in the adhesive distribution grooves 447 of the ram assembly 440 may contact the PM elements 100. That is, the adhesive groves 447 may be provided to contact a face of a PM array row 110 positioned upon from the PM array retainer 340. The PM array row 110 may be positioned and constrained by force on the adhesive groves 447 and by the biasing member 202.

In turn, with further reference to Fig. 16C, the ram assembly 440 may be lowered to a third position. As such, the PM array row 110 may be lowered from the receiving position of the PM array row 110 (a position corresponding to that shown in Fig. 16B) on the adhesive distribution grooves 447 of the ram assembly 440 and into the PM array holder 240 (a position corresponding to that shown in Fig. 16C). The ram assembly 440 may follow a discrete path to position PM array rows 110 into the PM array holder 240. The ram assembly 440 may be moved through the discrete path by automated convergence actuator 420 or human powered means to a position shown in Fig. 16C. For instance, the positions of the ram assembly 440 may be achieved by corresponding actuators in appropriate directions. Additionally or alternatively, a cam profile may be provided such that the ram assembly 440 follows the cam profile to move between the various positions discussed.

The ram assembly 440 may be moved to the closed position as shown in Fig. 16D when the ram assembly 440 is in the third position. In this regard, the PM array row 110 may be pressed into PM array holder 240 (e.g., by influence of the biasing member 202 acting on the column 206 of PM elements 100). Once PM array row 110 is in a desired position. In turn, the ram assembly 440 may be advanced such that the convergence ram 445 advances the PM array row 110 as shown in Fig. 16E such that the ram assembly 440 is in a fourth position. When in the fourth position, a ram ramp 450 on the convergence ram 445 may contact the column 206 of PM elements 100 to slightly move the column 206 away from the convergence ram 445. This may allow the retention clip 452 to be moved into the extended position as shown in Fig. 16A. Accordingly, the ram assembly 440 may cycle back to the first position and the cycle may repeat.

PM array rows 110 may be bonded to an adjacent PM array row 110 to form a PM array 120 or compound array. Newly formed PM array rows 110 may be pressed and bonded into PM array holder 240 via the convergence ram 445 and ram assembly 440. The ram assembly 440 may apply pressure to ensure bond of one PM array row 110 to another.

During the application of pressure from the convergence ram 430, a saturation bar 370 may be positioned relative to a PM array row 110. The saturation bar 370 may be generally provided according to the description above in relation to the embodiment described in Figs. 3-5B including material selection and/or means for selective engagement of the saturation bar 370 relative to the PM array rows 110.

Many other embodiments can stem from the above two embodiments including but not limited to process set up and execution, alternative curing means, actuator types, material usage, and automation of the steps taught within the disclosure

In yet another embodiment shown in Fig. 15, cartridges 200 may be placed above a rotating convergence device 407. The convergence device 407 may include voids for the PM elements 100 to be placed into from the cartridges 200. Single or multiple PM elements 100 may be placed into the voids of the convergence device 407 depending on the specific design of the PM array 120 to be produced. Optionally, if a PM array row 110 is constructed within the convergence device 407, it can use accelerated means to bond the PM elements 100 to each other before depositing the bonded PM array row 110 into the PM array holder 240.

The convergence device 407 that includes PM elements 100 loaded into the convergence device 407 voids may rotate either clockwise or counter clockwise. The rotating convergence device 407 may place PM elements 100 or PM array rows 110 of a specific design into the PM array holder 240 when the distance between the convergence device 407 and PM array holder 240 is at a narrowest point. The convergence device 407 can deposit one, or more PM elements 100 at once. Optionally the convergence device 407 can deposit entire PM array rows 110 into the PM array holder 240. This process is continued until a desired length or shape is achieved.

A rigid, sliding veil 355 that constrains the PM elements 100 from rotating, flipping, or colliding after PM elements 100 are placed into the PM array holder 240 may be provided. Optionally, consistent constraint of the PM elements 100 may be achieved by the magnetic force between the PM elements 100 and the magnetic PM array holder mold 240. The magnetic force of the PM elements 100 may penetrate the PM array holder 240 and may be saturated into the PM array holder mold 320.

A further embodiment of an apparatus for manufacture of a PM array 120 is shown in Figs 17-18D. PM elements 100 may be oriented into divider channels 380 to create PM array rows 300 of high or low complexity. Several identical streams of PM elements 100 may be loaded in single or multiple divider channels 380 or the streams can be steady, row, segment, or batch of flow streams 210. Linear rows of PM elements 100 may be loaded into divider channels 380 sequentially. Additional rows of PM elements 100 may be loaded until desired orienting of array is complete.

After the divider channels 380 are loaded with PM elements 100, the orientation accuracy of PM elements 100 may be validated, a biasing member 202 may enter the divider channels 380 and apply force until PM elements 100 are constrained against retaining pins 385 in desired PM array rows 110. The PM elements 100 disposed in each divider channel 380 may be biased against a retaining pin 385 as shown in Fig. 18A. The retaining pin 385 may restrict movement of the PM elements 100 out of the divider channels 385. Accordingly, the divider channels 385 may be positioned relative to a PM array holder mold 320 and a PM array holder 240 as shown in Figs. 17-18D.

Each divider channel 385 may correspond to a respective PM array element location in a PM array 120. As such, the divider channels 385 may correspond to a plurality of PM array rows 110 such that by loading all divider channels 385, PM elements 100 for an entire PM array 120 may be oriented at the outlet of the divider channels 385 and held in the divider channel 385 by the retaining pin.

The retaining pins 385 may be removed and the PM array rows 110 may be contacted with the PM array holder 240. As the PM elements 100 are constrained against the PM array holder 240 the divider channels 380 may be moved away from the PM array holder 240 at a distance less than the height of the PM elements 100.

Once PM elements (100) are sufficiently inhibited from rotating, flipping, spinning, or colliding, an adhesive material may be applied. Adhesive material may be drawn through the minute spaces between the constrained PM array rows 110. Optionally, as the adhesive material is applied, the divider channels 380 may be retracted. This may expose the PM array rows 110 to be fully encapsulated in epoxy or resin. Adhesive material can be various forms of epoxy or other adhesive materials.

The applying of continued constraint to PM array row 110 and PM array holder mold 320 to properly insure a secure and accurate alignment holds and attachment takes place of PM array row 110 whereby the resulting PM array row 110 can be optionally mounted to other devices or structures while retaining PM array 110 alignment and protecting the magnetic field.

Once PM elements 100 are discharged from the outlet of the divider channels 385, the retaining pin 385 may be moved back into position relative to the outlet to restrict discharge of additional PM elements 100. In this regard, the retaining pin 385 may be used to singluate PM elements 100 from the divider channels 385. As such, the steps shown in Figs. 18A-18D may be repeated to form a plurality of PM arrays 120 such that a single PM element 100 may be discharged from the divider channels 385 upon each cycle of the method.

Fig. 20 depicts a method 200 in relation to production of a PM array. The method 200 may include manufacture 502 of PM elements. Additionally, the method may include orientation 504 of the PM elements, which may include a subsequent verification 506 of the orientation.

As described above, PM elements may be provided in cartridges for use in manufacturing a PM array. As such, the method 200 may include manufacture 508 of a cartridge and inspection 510 of a cartridge. In this regard, a cartridge may be provided such that the oriented PM elements may be packaged 514 into the cartridge. The method 500 may optionally include bonding 512 of PM elements prior to or subsequent to the packaging 514.

In turn, the packaged cartridges may be provided to guide 518 PM elements from the cartridge into convergence channels as described above. This may result in an empty cartridge, which may be recycled 520 to undergo inspection 510 for subsequent use (e.g., in an iterative or substantive instance of the method 500). Prior to, concurrent to, or after the guiding 518, optional PM bonding 522 may also occur.

The method 500 may include converging PM elements to create PM array rows as generally described above. Again, optional bonding 522 of PM elements may occur at this time as well.

The method 500 may include manufacturing 528 and inspection 530 of a PM array holder mold. In turn, the PM array holder mold may be provided such that the method 500 may include positioning 532 a PM array row relative to the PM array holder mold. Subsequent PM array rows may be added 534 to the PM array holder mold to create a PM array. The creation of the PM array may include introduction of adhesive to the PM array holder and/or PM array holder mold. IN turn, the method 500 may include constraint 536 of the PM elements during a cure process. This may include optional accelerated curing 538. Additionally, application 542 of a veil and/or sensors may be provided in the method 500. The PM array may be removed from the PM array holder mold and the PM array hold may be recycled 540 for subsequent use by undergoing additional inspection 530. Also, the method 500 may include inserting 544 a PM array into appropriate packaging for transport and/or installation of the PM array.

In view of the foregoing, the present disclosure provides a number of embodiments related to the production of a PM array. In this regard, the following comprises a description of embodiments in a numbered description as follows:

1. An apparatus for manufacturing a permanent magnet (PM) array, comprising:

a convergence device comprising a plurality of convergence channels extending between an input of the convergence device and an output of the convergence device, wherein the plurality of convergence channels are each sized to receive a PM element such that the PM element is moveable relative to the convergence channel only in a single degree of freedom between the input and the output, and wherein the convergence channels define a first configuration of PM elements at the input and a second configuration of adjacent PM elements at the output such that a spacing between the adjacent PM elements is less in the second configuration than in the first configuration; and

a plurality of PM cartridges that are located relative to the convergence device such that an outlet of each PM cartridge is positioned relative to a different corresponding one of the plurality of convergence channels.

2. The apparatus of embodiment 1, wherein the plurality of PM cartridges contain a plurality of PM elements in a predetermined polar orientation relative to the PM cartridge.

3. The apparatus of any one of embodiments 1 or 2, wherein the plurality of PM cartridges are oriented relative to the input of the convergence device to position PM elements at the outlet of respective ones of the plurality of PM cartridges in a predetermined relative polar orientation. 4. The apparatus of any one of embodiments 1-3, wherein the predetermined relative polar orientation between adjacent PM elements of the plurality of PM cartridges is maintained between the first configuration and the second configuration.

5. The apparatus of any one of embodiments 1-4, wherein the second configuration comprises a PM array row.

6. The apparatus of any one of embodiments 1-5, wherein the PM array row comprises a plurality of PM elements in abutting adjacent engagement.

7. The apparatus of any one of embodiments 1-6, wherein the plurality of PM cartridges each comprise a biasing member that biases PM elements within the PM cartridge toward the outlet of the PM cartridge.

8. The apparatus of any one of embodiments 1-7, further comprising:

a PM array holder located relative to the output portion to receive a PM array row from the output portion.

9. The apparatus of any one of embodiments 1-8, wherein the PM array holder comprises an adhesive to which the PM array row is adhered.

10. The apparatus of any one of embodiments 1-8, wherein the PM array holder is operative to receive an adhesive to which the PM array row is adhered after receipt of the PM array row in the PM array holder.

11. The apparatus of any one of embodiments 1-8, further comprising:

a PM array holder mold in which the PM array holder is located, wherein the PM array holder mold is selectively advanceable relative to the output of the convergence device upon receipt of the PM array row from the output.

12. The apparatus of any one of embodiments 1-11, wherein the PM array holder mold comprises a base member and side flanges that define a PM array holder recess into which the PM array holder is locatable.

13. The apparatus of any one of embodiments 1-12, wherein the base member comprises a linear bearing to facilitate the selective advancement of the PM array holder relative to the output of the convergence device.

14. The apparatus of any one of embodiments 1-13, wherein the PM array holder receives a plurality of PM array rows from the output of the convergence device to form a PM array relative to the PM array holder. 15. The apparatus of any one of embodiments 1-14, wherein the PM array holder mold is advanced by a first PM array row ejected from the output of the convergence device acting on a second PM array row that is engaged with the PM array holder.

16. The apparatus of any one of embodiments 1-15, wherein the PM array holder mold is restrained from linear movement by a force less than an ejection force of the first PM array row acting on the second PM array row.

17. The apparatus of any one of embodiments 1-12, further comprising:

a saturation bar that is located in a partially overlapping orientation relative to adjacent PM array rows in the PM array.

18. The apparatus of any one of embodiments 1-17, wherein the saturation bar is selectively engageable with the PM array holder mold to locate the saturation bar in the partially overlapping orientation.

19. The apparatus of any one of embodiments 1-17, wherein the saturation bar engages the side flanges of the PM array holder mold to provide the selective engagement of the saturation bar.

20. The apparatus of any one of embodiments 1-19, further comprising:

a convergence actuator operative to move a corresponding plurality of PM elements from the respective outlets of each of the plurality of PM cartridges to the input portion of the convergence device and through the convergence channels to the output of the convergence device to form a PM array row at the output of the convergence device.

21. The apparatus of any one of embodiments 1-20, wherein the convergence actuator comprises a linear actuator that acts on the PM elements at the outlets of the plurality of PM cartridges to advance the PM elements in the convergence channels.

22. The apparatus of any one of embodiments 1-21, wherein the PM cartridges are located relative to the linear actuator such that the linear actuator shears the PM elements at the outlet of the PM cartridge from a plurality of PM elements contained within the PM cartridge.

23. The apparatus of any one of embodiments 1-20, wherein the convergence actuator comprises biasing members in each of the plurality of PM cartridges.

24. The apparatus of any one of embodiments 1-23, further comprising: a linear actuator located at the output of the convergence device that engages the PM array row at the output of the convergence device to move the PM array row in a PM array holder.

25. The apparatus of any one of embodiments 1-24, wherein the linear actuator comprises a ram that is moveable relative to an adhesive comb comprising a plurality of adhesive distribution grooves, wherein the PM array row contacts the adhesive comb such that adhesive in the plurality of adhesive groves is applied to the PM array row prior to being moved into the PM array holder.

26. The apparatus of any one of embodiments 1-25, further comprising:

a veil applicator located relative to the output of the convergence device that is operative to apply a veil to the PM array row at the output.

27. An apparatus for manufacturing a permanent magnet (PM) array, comprising:

a plurality of PM cartridges each operative to contain a plurality of PM elements in a predetermined polar orientation;

a convergence device comprising a plurality of convergence channels corresponding to the plurality of PM cartridges;

an input portion of the convergence device operative to receive PM elements from the plurality of PM cartridges into corresponding ones of the plurality of convergence channels, wherein the convergence channels are sized to receive the PM elements such that the PM elements may move relative to the convergence channels in a single degree of freedom; and

an output portion of the convergence device from which PM elements are discharged from the convergence channels in a PM array row, wherein a spacing between PM elements in the PM array row is less than a spacing between corresponding PM elements at the input portion.

28. The apparatus of embodiment 27, wherein the plurality of PM cartridges each contain a plurality of PM elements in a predetermined polar orientation relative to the PM cartridge.

29. The apparatus of any one of embodiments 27 or 28, wherein the plurality of PM cartridges are oriented relative to the input portion of the convergence device to position PM elements at the outlet of respective ones of the plurality of PM cartridges in a predetermined relative polar orientation at the input portion. 30. The apparatus of any one of embodiments 27-29, wherein the predetermined relative polar orientation between adjacent PM elements of the plurality of PM cartridges is maintained between the input portion and the output portion.

31. The apparatus of any one of embodiments 27-30, wherein the PM array row comprises a plurality of PM elements in abutting adjacent engagement.

32. The apparatus of any one of embodiments 27-31, wherein each PM cartridge of the plurality of PM cartridges comprise a biasing member that biases the PM elements contained by the PM cartridge toward an outlet of the PM cartridge.

33. The apparatus of any one of embodiments 27-32, further comprising:

a PM array holder located relative to the output portion of the convergence device to receive the PM array row when discharged from the output portion of the convergence device.

34. The apparatus of any one of embodiments 27-33, wherein the PM array holder comprises an adhesive to which the PM array row is adhered after receipt of the PM array row in the PM array holder.

35. The apparatus of any one of embodiments 27-33, wherein the PM array holder is operative to receive an adhesive to which the PM array row is adhered after receipt of the PM array row in the PM array holder.

36. The apparatus of any one of embodiments 27-33, further comprising:

a PM array holder mold into which the PM array holder is located, wherein the PM array holder mold is advanceable relative to the output portion of the convergence device upon receipt of a PM array row from the output.

37. The apparatus of any one of embodiments 27-36, wherein the PM array holder mold comprises a base member and side flanges that define a PM array holder recess into which the PM array holder is locatable.

38. The apparatus of any one of embodiments 27-37, wherein the base member comprises a linear bearing to facilitate the selective advancement of the PM array holder relative to the output portion of the convergence device.

39. The apparatus of any one of embodiments 27-38, wherein the PM array holder receives a plurality of PM array rows from the output portion of the convergence device to form a PM array relative to the PM array holder. 40. The apparatus of any one of embodiments 27-39, wherein the PM array holder mold is advanced by a first PM array row ejected from the output portion of the convergence device acting on a second PM array row that is engaged with the PM array holder.

41. The apparatus of any one of embodiments 27-40, wherein the PM array holder mold is restrained from linear movement by a force less than an ejection force of the first PM array row acting on the second PM array row.

42. The apparatus of any one of embodiments 27-37, further comprising:

a saturation bar that is located in a partially overlapping orientation relative to adjacent PM array rows in the PM array.

43. The apparatus of any one of embodiments 27-42, wherein the saturation bar is selectively engageable with the PM array holder mold to locate the saturation bar in the partially overlapping orientation.

44. The apparatus of any one of embodiments 27-43, wherein the saturation bar engages the side flanges of the PM array holder mold to provide the selective engagement of the saturation bar.

45. The apparatus of any one of embodiments 27-44, further comprising:

a convergence actuator operative to move a corresponding plurality of PM elements from the respective outlets of each of the plurality of PM cartridges to the input portion of the convergence device and through the convergence channels to the output portion of the convergence device to form a PM array row at the output portion of the convergence device.

46. The apparatus of any one of embodiments 27-45, wherein the convergence actuator comprises a linear actuator that acts on the PM elements at the outlets of the plurality of PM cartridges to advance the PM elements in the convergence channels.

47. The apparatus of any one of embodiments 27-46, wherein the PM cartridges are located relative to the linear actuator such that the linear actuator shears the PM elements at the outlet of the PM cartridge from a plurality of PM elements contained within the PM cartridge.

48. The apparatus of any one of embodiments 27-45, wherein the convergence actuator comprises biasing members in each of the plurality of PM cartridges.

49. The apparatus of any one of embodiments 27-48, further comprising: a linear actuator located at the output portion of the convergence device that engages the PM array row at the output portion of the convergence device to move the PM array row into a PM array holder.

50. The apparatus of any one of embodiments 27-49, wherein the linear actuator comprises a ram moveable relative to an adhesive comb comprising a plurality of adhesive distribution grooves, wherein the PM array row contacts the adhesive comb such that adhesive in the plurality of adhesive groves is applied to the PM array row prior to being moved into the PM array holder.

51. The apparatus of any one of embodiments 27-50, further comprising:

a veil applicator located relative to the output of the convergence device that is operative to apply a veil to the PM array row at the output.

52. A method for producing a permanent magnet (PM) array, comprising:

locating a plurality of PM cartridges in corresponding relative relation to each of a plurality of convergence channels of a convergence device, each PM cartridge containing a plurality of PM elements in a predetermined polar orientation relative to the PM cartridge; transferring PM elements from an outlet of each one of the plurality of PM cartridges into a corresponding convergence channel of the convergence device;

moving the PM elements from an input of the convergence device to an output of the convergence device, wherein a spacing between PM elements is reduced from the input to the output;

constraining the movement of the PM elements in the convergence channels to a single degree of freedom during the moving; and

outputting a PM array row from the output of the convergence device.

53. The method of any one of embodiments 52, wherein the locating comprises arranging the plurality of PM cartridges such that the plurality of PM elements of the plurality of cartridges are in a predetermined relative polar orientation relative to one another.

54. The method of either one of embodiments 52 or 53, further comprising:

maintaining the predetermined relative polar orientation during the moving, wherein the PM array row comprises a plurality of array row PM elements in the predetermined relative polar orientation.

55. The method of any one of embodiments 52-54, wherein the PM array row comprises a plurality of abutting array row PM elements. 56. The method of any one of embodiments 52-55, further comprising:

biasing the PM elements in each PM cartridge toward the outlet of the PM cartridge.

57. The method of any one of embodiments 52-56, further comprising:

adhering a plurality of PM array rows that are each output from the convergence device to form a PM array.

58. The method of any one of embodiments 52-56, further comprising:

receiving the PM array row at a PM array holder after the outputting.

59. The method of any one of embodiments 52-58, wherein the adhering comprising adhering the plurality of PM array rows to the PM array holder.

60. The method of any one of embodiments 52-59, further comprising:

providing an adhesive between the plurality of PM array rows and the PM array holder.

61. The method of any one of embodiments 52-60, wherein the providing occurs prior to receipt of the plurality of PM array rows at the PM array holder.

62. The method of any one of embodiments 52-60, wherein the providing occurs subsequent to receipt of the plurality of PM array rows at the PM array holder.

63. The method of any one of embodiments 52-58, further comprising:

retaining the PM array holder in a PM array holder mold, wherein the PM array holder mold is selectively advanceable relative to the output of the convergence device.

64. The method of any one of embodiments 52-63, further comprising:

advancing the PM array holder mold upon the outputting of the PM array row from the output of the convergence device.

65. The method of any one of embodiments 52-64, wherein the advancing comprises applying a force on the PM array holder mold in response to the outputting of the PM array row.

66. The method of any one of embodiments 52-65, wherein the PM array holder mold is secured by a securing force that is overcome by the force applied on the PM array holder mold in response to the outputting of the PM array row.

67. The method of any one of embodiments 52-63, further comprising:

locating a saturation bar in overlapping relation relative to adjacent PM array rows that have been output from the convergence device.

68. The method of any one of embodiments 52-67, further comprising: securing the saturation bar in the overlapping relation by engaging the saturation bar to the PM array holder mold relative to the adjacent PM array rows.

69. The method of any one of embodiments 52-68, further comprising:

actuating a convergence actuator to facilitate the moving of the PM elements from the input of the convergence device to the output of the convergence device.

70. The method of any one of embodiments 52-69, wherein the actuating comprises acting on a series of PM elements in the convergence device to move the series of PM elements from the input of the convergence device to the output of the convergence device.

71. The method of any one of embodiments 52-70, wherein the convergence actuator contacts PM elements at the outlet of each of the plurality of PM cartridges.

72. The method of any one of embodiments 52-71, wherein the convergence actuator comprises a linear actuator that acts on the PM elements at the outlets of the plurality of PM cartridges to advance the PM elements in the convergence channels.

73. The method of any one of embodiments 52-70, wherein the convergence actuator comprises biasing members in each of the plurality of PM cartridges.

74. The method of any one of embodiments 52-73, further comprising:

transferring, by action of a linear actuator on the PM elements, the PM array row from the output of the convergence device to a PM array holder.

75. The method of any one of embodiments 52-74, further comprising:

applying an adhesive to the PM array row with an adhesive comb comprising a plurality of adhesive distribution grooves positioned relative to a ram, wherein the PM array row contacts the adhesive comb such that adhesive in the plurality of adhesive groves is applied to the PM array row prior to being moved into the PM array holder.

76. The method of any one of embodiments 52-75, further comprising:

applying a veil to the PM array row after the outputting.

77. An apparatus for manufacturing a permanent magnet (PM) array, comprising:

a convergence device comprising a plurality of divider channels that each accept at least one PM element in a predetermined polar orientation, wherein the plurality of divider channels are operative to restrict movement of the PM element in the divider channel to a single degree of freedom of movement relative to the divider channel; at least one biasing member located relative to the plurality of divider channels that biases the PM element in each of the plurality of divider channels in a direction toward an outlet of the plurality of divider channels;

a PM array mold located relative to the outlet of the divider channel; and

a retention member removably positionable relative to the outlet of the plurality of divider channels to control movement of the PM elements in each of the plurality of divider channels from the outlet of the divider channel;

wherein the PM elements are selectively discharged from the plurality of divider channels into the PM array mold upon removal of the retention member from the outlet of the plurality of divider channels.

78. The apparatus of embodiment 77, wherein the plurality of divider channels correspond to PM element positions in a PM array produced by the apparatus.

79. The apparatus of either one of embodiments 52-78, wherein the plurality of divider channels correspond to a plurality of PM array rows comprising a plurality of PM element positions.

80. The apparatus of any one of embodiments 77-79, wherein the PM elements are positioned in the plurality of divider channels in a relative polar orientation.

81. The apparatus of any one of embodiments 77-80, wherein the plurality of divider channels each accept a plurality of PM elements, and wherein the retention member is operative to singluate one of the plurality of PM elements for each of the divider channels for discharge from the plurality of divider channels.

82. The apparatus of any one of embodiments 77-81, wherein the divider channels and the PM array holder are configured for relative movement therebetween.

83. The apparatus of any one of embodiments 77-82, wherein the divider channels and the PM array holder are configured to move apart to increase separation therebetween after the discharge of a plurality of PM elements from respective ones of the divider channels.

84. The apparatus of any one of embodiments 77-83, wherein the separation of the divider channels and the PM array holder allows for introduction of adhesive between the plurality of PM elements after discharge from the divider channels.

85. A method for manufacturing a permanent magnet (PM) array, comprising: loading PM elements into a plurality of divider channels each corresponding to a PM element position in a PM array, wherein the PM elements are loaded into the plurality of divider channels to have a predetermined relative polar orientation;

biasing the PM elements toward respective outlets of each of the plurality of divider channels;

retaining the PM elements in the plurality of divider channels by positioning a retention member relative to the outlets of the plurality of divider channels;

positioning a PM array holder relative to the outlets of the plurality of divider channels;

displacing the retention member from the outlets to permit discharge of the plurality of PM elements from the divider channels;

discharging the plurality of PM elements in response to the biasing; and

locating the plurality of PM elements with respect to the PM array holder.

86. The method of embodiment 85, further comprising:

singulating the PM elements at the outlet of the plurality of divider channels such that a single PM element is discharged from each of the plurality of divider channels upon the displacing and discharging.

87. The method of either one of embodiments 85-86, further comprising:

returning the retention member to a position relative to the outlet of the plurality of divider channels to restrict further discharge of PM elements from the divider channels after the discharging.

88. The method of any one of embodiments 85-87, further comprising:

separating the plurality of divider channels and the PM array holder after the locating.

89. The method of any one of embodiments 85-88, further comprising:

introducing an adhesive between the plurality of PM elements that have been discharged from the divider channels.

90. The method of any one of embodiments 85-89, wherein the introducing comprises advancing the adhesive relative to the plurality of PM elements that have been discharged from the divider channels in corresponding relation to a rate of separation of the plurality of divider channels and the PM array holder.

While the invention has been illustrated and described in detail in the drawings and foregoing description, such illustration and description is to be considered as exemplary and not restrictive in character. For example, certain embodiments described hereinabove may be combinable with other described embodiments and/or arranged in other ways (e.g., process elements may be performed in other sequences). Accordingly, it should be understood that only the preferred embodiment and variants thereof have been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected.

Claims

What is claimed is:

1. An apparatus for manufacturing a permanent magnet (PM) array, comprising:

a convergence device comprising a plurality of convergence channels extending between an input of the convergence device and an output of the convergence device, wherein the plurality of convergence channels are each sized to receive a PM element such that the PM element is moveable relative to the convergence channel only in a single degree of freedom between the input and the output, and wherein the convergence channels define a first configuration of PM elements at the input and a second configuration of adjacent PM elements at the output such that a spacing between the adjacent PM elements is less in the second configuration than in the first configuration; and

a plurality of PM cartridges that are located relative to the convergence device such that an outlet of each PM cartridge is positioned relative to a different corresponding one of the plurality of convergence channels.

2. The apparatus of claim 1, wherein the plurality of PM cartridges contain a plurality of PM elements in a predetermined polar orientation relative to the PM cartridge.

3. The apparatus of claim 2, wherein the plurality of PM cartridges are oriented relative to the input of the convergence device to position PM elements at the outlet of respective ones of the plurality of PM cartridges in a predetermined relative polar orientation.

4. The apparatus of claim 3, wherein the predetermined relative polar orientation between adjacent PM elements of the plurality of PM cartridges is maintained between the first configuration and the second configuration.

5. The apparatus of claim 4, wherein the second configuration comprises a PM array row.

6. The apparatus of claim 5, wherein the PM array row comprises a plurality of PM elements in abutting adjacent engagement.

7. The apparatus of claim 1, wherein the plurality of PM cartridges each comprise a biasing member that biases PM elements within the PM cartridge toward the outlet of the PM cartridge.

8. The apparatus of claim 1, further comprising:

a PM array holder located relative to the output portion to receive a PM array row from the output portion.

9. The apparatus of claim 8, wherein the PM array holder comprises an adhesive to which the PM array row is adhered.

10. The apparatus of claim 8, wherein the PM array holder is operative to receive an adhesive to which the PM array row is adhered after receipt of the PM array row in the PM array holder.

11. The apparatus of claim 8, further comprising:

a PM array holder mold in which the PM array holder is located, wherein the PM array holder mold is selectively advanceable relative to the output of the convergence device upon receipt of the PM array row from the output.

12. The apparatus of claim 11, wherein the PM array holder mold comprises a base member and side flanges that define a PM array holder recess into which the PM array holder is locatable.

13. The apparatus of claim 12, wherein the base member comprises a linear bearing to facilitate the selective advancement of the PM array holder relative to the output of the convergence device.

14. The apparatus of claim 13, wherein the PM array holder receives a plurality of PM array rows from the output of the convergence device to form a PM array relative to the PM array holder.

15. The apparatus of claim 14, wherein the PM array holder mold is advanced by a first PM array row ejected from the output of the convergence device acting on a second PM array row that is engaged with the PM array holder.

16. The apparatus of claim 15, wherein the PM array holder mold is restrained from linear movement by a force less than an ejection force of the first PM array row acting on the second PM array row.

17. The apparatus of claim 12, further comprising:

a saturation bar that is located in a partially overlapping orientation relative to adjacent PM array rows in the PM array.

18. The apparatus of claim 17, wherein the saturation bar is selectively engageable with the PM array holder mold to locate the saturation bar in the partially overlapping orientation.

19. The apparatus of claim 17, wherein the saturation bar engages the side flanges of the PM array holder mold to provide the selective engagement of the saturation bar.

20. The apparatus of claim 1, further comprising:

a convergence actuator operative to move a corresponding plurality of PM elements from the respective outlets of each of the plurality of PM cartridges to the input portion of the convergence device and through the convergence channels to the output of the convergence device to form a PM array row at the output of the convergence device.

21. The apparatus of claim 20, wherein the convergence actuator comprises a linear actuator that acts on the PM elements at the outlets of the plurality of PM cartridges to advance the PM elements in the convergence channels.

22. The apparatus of claim 21, wherein the PM cartridges are located relative to the linear actuator such that the linear actuator shears the PM elements at the outlet of the PM cartridge from a plurality of PM elements contained within the PM cartridge.

23. The apparatus of claim 20, wherein the convergence actuator comprises biasing members in each of the plurality of PM cartridges.

24. The apparatus of claim 23, further comprising:

a linear actuator located at the output of the convergence device that engages the PM array row at the output of the convergence device to move the PM array row in a PM array holder.

25. The apparatus of claim 24, wherein the linear actuator comprises a ram that is moveable relative to an adhesive comb comprising a plurality of adhesive distribution grooves, wherein the PM array row contacts the adhesive comb such that adhesive in the plurality of adhesive groves is applied to the PM array row prior to being moved into the PM array holder.

26. The apparatus of claim 1, further comprising:

a veil applicator located relative to the output of the convergence device that is operative to apply a veil to the PM array row at the output.

27. An apparatus for manufacturing a permanent magnet (PM) array, comprising:

a plurality of PM cartridges each operative to contain a plurality of PM elements in a predetermined polar orientation;

a convergence device comprising a plurality of convergence channels corresponding to the plurality of PM cartridges;

an input portion of the convergence device operative to receive PM elements from the plurality of PM cartridges into corresponding ones of the plurality of convergence channels, wherein the convergence channels are sized to receive the PM elements such that the PM elements may move relative to the convergence channels in a single degree of freedom; and

an output portion of the convergence device from which PM elements are discharged from the convergence channels in a PM array row, wherein a spacing between PM elements in the PM array row is less than a spacing between corresponding PM elements at the input portion.

28. The apparatus of claim 27, wherein the plurality of PM cartridges each contain a plurality of PM elements in a predetermined polar orientation relative to the PM cartridge.

29. The apparatus of claim 28, wherein the plurality of PM cartridges are oriented relative to the input portion of the convergence device to position PM elements at the outlet of respective ones of the plurality of PM cartridges in a predetermined relative polar orientation at the input portion.

30. The apparatus of claim 29, wherein the predetermined relative polar orientation between adjacent PM elements of the plurality of PM cartridges is maintained between the input portion and the output portion.

31. The apparatus of claim 27, wherein the PM array row comprises a plurality of PM elements in abutting adjacent engagement.

32. The apparatus of claim 27, wherein each PM cartridge of the plurality of PM cartridges comprise a biasing member that biases the PM elements contained by the PM cartridge toward an outlet of the PM cartridge.

33. The apparatus of claim 27, further comprising:

a PM array holder located relative to the output portion of the convergence device to receive the PM array row when discharged from the output portion of the convergence device.

34. The apparatus of claim 33, wherein the PM array holder comprises an adhesive to which the PM array row is adhered after receipt of the PM array row in the PM array holder.

35. The apparatus of claim 33, wherein the PM array holder is operative to receive an adhesive to which the PM array row is adhered after receipt of the PM array row in the PM array holder.

36. The apparatus of claim 33, further comprising:

a PM array holder mold into which the PM array holder is located, wherein the PM array holder mold is advanceable relative to the output portion of the convergence device upon receipt of a PM array row from the output.

37. The apparatus of claim 36, wherein the PM array holder mold comprises a base member and side flanges that define a PM array holder recess into which the PM array holder is locatable.

38. The apparatus of claim 37, wherein the base member comprises a linear bearing to facilitate the selective advancement of the PM array holder relative to the output portion of the convergence device.

39. The apparatus of claim 38, wherein the PM array holder receives a plurality of PM array rows from the output portion of the convergence device to form a PM array relative to the PM array holder.

40. The apparatus of claim 39, wherein the PM array holder mold is advanced by a first PM array row ejected from the output portion of the convergence device acting on a second

PM array row that is engaged with the PM array holder.

41. The apparatus of claim 40, wherein the PM array holder mold is restrained from linear movement by a force less than an ejection force of the first PM array row acting on the second PM array row.

42. The apparatus of claim 37, further comprising:

a saturation bar that is located in a partially overlapping orientation relative to adjacent PM array rows in the PM array.

43. The apparatus of claim 42, wherein the saturation bar is selectively engageable with the PM array holder mold to locate the saturation bar in the partially overlapping orientation.

44. The apparatus of claim 43, wherein the saturation bar engages the side flanges of the PM array holder mold to provide the selective engagement of the saturation bar.

45. The apparatus of claim 27, further comprising: a convergence actuator operative to move a corresponding plurality of PM elements from the respective outlets of each of the plurality of PM cartridges to the input portion of the convergence device and through the convergence channels to the output portion of the convergence device to form a PM array row at the output portion of the convergence device.

46. The apparatus of claim 45, wherein the convergence actuator comprises a linear actuator that acts on the PM elements at the outlets of the plurality of PM cartridges to advance the PM elements in the convergence channels.

47. The apparatus of claim 46, wherein the PM cartridges are located relative to the linear actuator such that the linear actuator shears the PM elements at the outlet of the PM cartridge from a plurality of PM elements contained within the PM cartridge.

48. The apparatus of claim 45, wherein the convergence actuator comprises biasing members in each of the plurality of PM cartridges.

49. The apparatus of claim 48, further comprising:

a linear actuator located at the output portion of the convergence device that engages the PM array row at the output portion of the convergence device to move the PM array row into a PM array holder.

50. The apparatus of claim 49, wherein the linear actuator comprises a ram moveable relative to an adhesive comb comprising a plurality of adhesive distribution grooves, wherein the PM array row contacts the adhesive comb such that adhesive in the plurality of adhesive groves is applied to the PM array row prior to being moved into the PM array holder.

51. The apparatus of claim 27, further comprising:

a veil applicator located relative to the output of the convergence device that is operative to apply a veil to the PM array row at the output.

52. A method for producing a permanent magnet (PM) array, comprising: locating a plurality of PM cartridges in corresponding relative relation to each of a plurality of convergence channels of a convergence device, each PM cartridge containing a plurality of PM elements in a predetermined polar orientation relative to the PM cartridge; transferring PM elements from an outlet of each one of the plurality of PM cartridges into a corresponding convergence channel of the convergence device;

moving the PM elements from an input of the convergence device to an output of the convergence device, wherein a spacing between PM elements is reduced from the input to the output;

constraining the movement of the PM elements in the convergence channels to a single degree of freedom during the moving; and

outputting a PM array row from the output of the convergence device.

53. The method of claim 52, wherein the locating comprises arranging the plurality of PM cartridges such that the plurality of PM elements of the plurality of cartridges are in a predetermined relative polar orientation relative to one another.

54. The method of claim 53, further comprising:

maintaining the predetermined relative polar orientation during the moving, wherein the PM array row comprises a plurality of array row PM elements in the predetermined relative polar orientation.

55. The method of claim 52, wherein the PM array row comprises a plurality of abutting array row PM elements.

56. The method of claim 52, further comprising:

biasing the PM elements in each PM cartridge toward the outlet of the PM cartridge.

57. The method of claim 52, further comprising:

adhering a plurality of PM array rows that are each output from the convergence device to form a PM array.

58. The method of claim 56, further comprising:

receiving the PM array row at a PM array holder after the outputting.

59. The method of claim 58, wherein the adhering comprising adhering the plurality of PM array rows to the PM array holder.

60. The method of claim 59, further comprising: providing an adhesive between the plurality of PM array rows and the PM array holder.

61. The method of claim 60, wherein the providing occurs prior to receipt of the plurality of PM array rows at the PM array holder.

62. The method of claim 60, wherein the providing occurs subsequent to receipt of the plurality of PM array rows at the PM array holder.

63. The method of claim 58, further comprising:

retaining the PM array holder in a PM array holder mold, wherein the PM array holder mold is selectively advanceable relative to the output of the convergence device.

64. The method of claim 63, further comprising:

advancing the PM array holder mold upon the outputting of the PM array row from the output of the convergence device.

65. The method of claim 64, wherein the advancing comprises applying a force on the PM array holder mold in response to the outputting of the PM array row.

66. The method of claim 65, wherein the PM array holder mold is secured by a securing force that is overcome by the force applied on the PM array holder mold in response to the outputting of the PM array row.

67. The method of claim 63, further comprising:

locating a saturation bar in overlapping relation relative to adjacent PM array rows that have been output from the convergence device.

68. The method of claim 67, further comprising:

securing the saturation bar in the overlapping relation by engaging the saturation bar to the PM array holder mold relative to the adjacent PM array rows.

69. The method of claim 52, further comprising:

actuating a convergence actuator to facilitate the moving of the PM elements from the input of the convergence device to the output of the convergence device.

70. The method of claim 69, wherein the actuating comprises acting on a series of PM elements in the convergence device to move the series of PM elements from the input of the convergence device to the output of the convergence device.

71. The method of claim 70, wherein the convergence actuator contacts PM elements at the outlet of each of the plurality of PM cartridges.

72. The method of claim 71, wherein the convergence actuator comprises a linear actuator that acts on the PM elements at the outlets of the plurality of PM cartridges to advance the PM elements in the convergence channels.

73. The method of claim 70, wherein the convergence actuator comprises biasing members in each of the plurality of PM cartridges.

74. The method of claim 52, further comprising:

transferring, by action of a linear actuator on the PM elements, the PM array row from the output of the convergence device to a PM array holder.

75. The method of claim 74, further comprising:

applying an adhesive to the PM array row with an adhesive comb comprising a plurality of adhesive distribution grooves positioned relative to a ram, wherein the PM array row contacts the adhesive comb such that adhesive in the plurality of adhesive groves is applied to the PM array row prior to being moved into the PM array holder.

76. The method of claim 52, further comprising:

applying a veil to the PM array row after the outputting.

77. An apparatus for manufacturing a permanent magnet (PM) array, comprising:

a convergence device comprising a plurality of divider channels that each accept at least one PM element in a predetermined polar orientation, wherein the plurality of divider channels are operative to restrict movement of the PM element in the divider channel to a single degree of freedom of movement relative to the divider channel;

at least one biasing member located relative to the plurality of divider channels that biases the PM element in each of the plurality of divider channels in a direction toward an outlet of the plurality of divider channels;

a PM array mold located relative to the outlet of the divider channel; and

a retention member removably positionable relative to the outlet of the plurality of divider channels to control movement of the PM elements in each of the plurality of divider channels from the outlet of the divider channel;

wherein the PM elements are selectively discharged from the plurality of divider channels into the PM array mold upon removal of the retention member from the outlet of the plurality of divider channels.

78. The apparatus of claim 77, wherein the plurality of divider channels correspond to PM element positions in a PM array produced by the apparatus.

79. The apparatus of claim 78, wherein the plurality of divider channels correspond to a plurality of PM array rows comprising a plurality of PM element positions.

80. The apparatus of claim 79, wherein the PM elements are positioned in the plurality of divider channels in a relative polar orientation.

81. The apparatus of claim 77, wherein the plurality of divider channels each accept a plurality of PM elements, and wherein the retention member is operative to singluate one of the plurality of PM elements for each of the divider channels for discharge from the plurality of divider channels.

82. The apparatus of claim 77, wherein the divider channels and the PM array holder are configured for relative movement therebetween.

83. The apparatus of claim 82, wherein the divider channels and the PM array holder are configured to move apart to increase separation therebetween after the discharge of a plurality of PM elements from respective ones of the divider channels.

4. The apparatus of claim 83, wherein the separation of the divider channels and the PM rray holder allows for introduction of adhesive between the plurality of PM elements after scharge from the divider channels.

85. A method for manufacturing a permanent magnet (PM) array, comprising:

loading PM elements into a plurality of divider channels each corresponding to a PM element position in a PM array, wherein the PM elements are loaded into the plurality of divider channels to have a predetermined relative polar orientation;

biasing the PM elements toward respective outlets of each of the plurality of divider channels;

retaining the PM elements in the plurality of divider channels by positioning a retention member relative to the outlets of the plurality of divider channels;

positioning a PM array holder relative to the outlets of the plurality of divider channels;

displacing the retention member from the outlets to permit discharge of the plurality of PM elements from the divider channels;

discharging the plurality of PM elements in response to the biasing; and

locating the plurality of PM elements with respect to the PM array holder.

86. The method of claim 85, further comprising:

singulating the PM elements at the outlet of the plurality of divider channels such that a single PM element is discharged from each of the plurality of divider channels upon the displacing and discharging.

87. The method of claim 86, further comprising:

returning the retention member to a position relative to the outlet of the plurality of divider channels to restrict further discharge of PM elements from the divider channels after the discharging.

88. The method of claim 85, further comprising:

separating the plurality of divider channels and the PM array holder after the locating.

89. The method of claim 88, further comprising:

introducing an adhesive between the plurality of PM elements that have been discharged from the divider channels.

90. The method of claim 89, wherein the introducing comprises advancing the adhesive relative to the plurality of PM elements that have been discharged from the divider channels in corresponding relation to a rate of separation of the plurality of divider channels and the PM array holder.