Flywheel magneto with Laser welded rotor

Monday, 26 March, 2018

What is Magneto?
Magneto is basically an electrical generator which is used to produce power needed for two wheeler vehicles. An electrical generator (or a magneto) is the reverse of an electromagnet. In an electromagnet there is a coil of wire wound around an iron bar (the iron bar is called as the armature). When you apply current to the electromagnet's coil (e.g. with a battery), the coil creates a magnetic field in the armature. In a generator, you reverse the process. You move a magnet around the armature to create electric current in the coil.  It is categorized as a form of alternator, although it is usually regarded as distinct from most other alternators, which use field coils rather than permanent magnets. Whenever there is a relative motion between the conductor and the magnetic field, electricity can be produced.
In a magneto, permanent magnets are fitted on the rotating part (rotor) which creates a varying magnetic field in stator core. The conductors (copper windings) are wound on the stationary core. Whenever the windings experience a change in the magnetic field, a voltage is developed. The rate of change (acceleration and speed) of the engine is vital factor that affect the output of magneto. It is used for powering of elctrical system of the two wheeler vehicle.

Why magneto?
Magneto is used in the two wheeler vehicle for power generation. It acts as a flywheel (a rotating mechanical device that is used to store rotational energy and resist changes in rotational speed), thereby providing inertia and to smoothen torque transients of the engine

Working Principle of Flywheel Magneto
The Magneto works on the principle of electromagnetic induction, as the conductor moves across a magnetic field a voltage will be induced in the conductor.Typically, a mechanically driven rotor will rotate near a conductor which has a coil wrapped around it (stator), as the rotor rotates the flux is cut and hence, the voltage is induced and electric current flows through the coil.This induced voltage is supplied to regulator rectifier and electrical system of vehicle which is then sent to ignition coil where it is increased to thousands of voltage as per the requirement of the vehicle and the spark is created in the spark plug making the vehicle to start.

Why laser welded rotor assembly?
The fitment dimensions of the laser welded rotor assembly are same as that of the riveted rotor assembly. This assembly gives the same performance as that of the riveted rotor assembly but requires less manufacturing process and is more advantageous than the riveted rotor assembly. The riveting process and hot forging process are eliminated in the laser welding rotor assembly which is time consuming. Hence the time required for the fabrication of this type of rotor assembly is less. The laser welded rotor assembly gives more mechanical strength as compared to the existing one. The material cost of the hot forging taper bush which is used as the clutch sitting surface is saved. It also reduces manpower with the increase in productivity.
Applications
•One popular and common use of magnetos of today is for powering an electrical system of two wheeler vehicles.
Advantages
•Mechanical strength of the Flywheel Magneto with Laser Welded Rotor is high.
•The cost of the Flywheel Magneto with Laser Welded Rotor is reduced.
•Less time is required for manufacturing of Laser welded rotor.
•The riveting process required for the rotor to hold bush and cup together is eliminated as laser welding is done, no rivets are needed.
•The productivity is improved in Laser Welded Rotor as the processes required to manufacture this type of rotor is reduced.
•One of the advantage of the laser welded magneto is its simplicity.
Conclusion
The cost of Flywheel magneto is reduced. Since, the processes are eliminated. The cost of the material required for the taper of the laser welded rotor assembly is less as compared to riveted rotor assembly. The objective of the project to reduce product cost and improve productivity without affecting performance has been successfully achieved.

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Category: Manufacturing

Tags: flywheel magneto magneto magneto uses