Electromagnets are made by wrapping, or coiling, wire around a core. A magnetic field forms when an electrical current is passed through the wire, and this field can be used to drive motion or exert force. By adjusting the current, it’s possible to control the magnetism and polarity of an electromagnet at a distance. It’s this ability to control the magnet remotely that makes it possible to activate and control components in robotic systems, including actuators, grippers and end of robotic arm tools, safety equipment, and sensors.
At Custom Coils, Inc., we specialize in designing and manufacturing custom electromagnets for a variety of applications, including robotics and automation equipment. Learn more about how we support this industry with expert electromagnetic coil manufacturing and other services.
How Electromagnets are Used for Robotics and Automation Applications
When current flows to an electromagnet, a magnetic field forms and ferromagnetic materials are drawn to it (or repelled, depending on the magnet’s polarity). When the current is off, that force stops. By controlling the strength, duration, and polarity of the magnetic field it’s possible to initiate, prevent, or control movement. Not only is movement created and controlled by electromagnets efficient and reliable, it can help prevent contamination or damage from improper handling.
Examples of how electromagnets are used in robotic applications include:
- Magnetic grippers. Robotic arms equipped with end-of-arm electromagnets can be used to pick up and hold components that are too small or delicate to be manipulated with mechanical grippers. This aids in assembly work, transferring pieces around a workstation, or removing components from a container or tray.
- Sensors. Electromagnets are used to detect the presence, position, or orientation of ferromagnetic components in an assembly by sensing their proximity to the magnet and giving a signal.
- Actuation. Certain coil configurations can be used to create a continuously rotating magnetic field, which in turn creates torque on magnetic objects. This in turn is used to move actuators that perform tasks like feeding raw materials or blanks, pushing, stacking, or dispensing products, raw materials, or labels.
- Assembly line components. Electromagnetic chucks hold workpieces in place without clamps or other hardware so they do not move during semi- or fully-automated assembly, welding, or machining; electromagnetic clutches hold rotating motor and drive parts together tightly to synch their motion and drive the equipment, such as large robotic arms, conveyors, or CNC machines.
- Safety brakes and locks. Because they can be quickly switched from on to off, electromagnets are used to actuate brakes or locking mechanisms that are held in place until the magnet is reactivated. The magnetic field is adjusted to attract or repel locking or breaking mechanisms like deadbolts, bars, clamps, etc., and hold them in place.
- Remote surgery and drug delivery. Electromagnets in tiny medical devices and mechanisms can be controlled remotely to inject medicines or move miniature instruments while inside the body. This allows for less invasive surgery and targeted drug delivery directly into tissue, joints, or tumors.
- Material handling. Arms or tools equipped with electromagnets can pick up and move or position magnetic metal components.
- Controlling robotic movement. Electromagnets can be used to place multiple dipoles in the robotic device, each with a different magnetization direction, magnetic force, and torque. These can be used to restrict the range of movement of a robotic arm.
Manufacturing Capabilities and Services
Our comprehensive engineering, design, and manufacturing services support robotics applications in these ways:
- Design and engineering services. Magnet power supply, magnetic interference assessment, operating conditions, heat generation.
- Prototyping and development. Development, refinement, and testing for single coil windings, larger batches, and variants of families of similar windings.
- Manufacturing and production. Small to large-volume production runs and quality assurance for coil assemblies, electromagnets, solenoids, and inductors.
- In-house production facility. Core- or pin-wound, or coreless coils in round, helical, or spherical configurations, as well as coils in various thicknesses, sizes, and shapes.
- Quality assurance. Dimensional, electrical, and magnetic field testing including leak, high pot, inductance, resistance, thermal, and standard field testing.
Why Work With Custom Coils, Inc.?
Working with Custom Coils has several benefits, including:
- Over 45 years of experience in electromagnetic coil design and manufacturing.
- End-to-end support for the lifecycle of your project, from design and prototyping through product release.
- Custom solutions for robotics applications, including actuation and motion control, safety braking and locking, object manipulation, and more.
- State-of-the-art facilities and all engineering, prototyping, testing, and production fully in-house.
- ISO 9001:2015 and ISO 13485 certifications and a commitment to quality.
- Lasting relationships built on collaboration to reach your goals.
Get Started With Custom Electromagnet Solutions
Custom Coils, Inc. supports the robotics and automation industry with decades of knowledge and experience in electromagnet design and creation. With end-to-end design and manufacturing capabilities, prototyping, and testing services, we deliver custom electromagnet products that meet your requirements. We are ISO 9001:2015 and ISO 13485 certified.
Contact us today to speak with a team member, or request a quote to get started on your electromagnet project.