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Powerful Industrial Magnets - Applications, Types, Strengths and Choosing the Right Solution

Powerful Industrial Magnets - Applications, Types, Strengths and Choosing the Right Solution

The Powerful World of Industrial Magnets

Industrial magnets may seem simple, but they play an incredibly important role in manufacturing, construction, and other industries. In fact, the global industrial magnet market is projected to reach $14.7 billion by 2025!

So what makes these magnets so useful? Here are some key facts about industrial magnets:

Types of Industrial Magnets

  • Permanent magnets - Made of materials like neodymium or samarium cobalt that maintain a constant magnetic field without external power. Used for lifting, holding, and separating.
  • Electromagnetic magnets - Electric current is used to induce a magnetic field. Allows for turning the magnet on/off and adjusting strength.

Industrial Applications

Industrial magnets have many important uses:

  • Lifting and moving materials like steel plates
  • Holding tools or components in place for manufacturing
  • Separating and removing metal contaminants from food processing
  • Magnets in motors, generators, brakes, and more electrical devices

Benefits of Industrial Magnets

PowerfulCan lift up to 1000x their weight in ferromagnetic materials
VersatileMany shapes/sizes for different applications
Cost EffectiveLower labor costs compared to manual material handling
SafeReduce workplace injuries related to heavy lifting

Industrial magnets may seem like simple pieces of metal, but their unique properties make them indispensable in all sorts of manufacturing and industrial processes. Understanding the capabilities of modern industrial magnets can help companies improve efficiency and safety!

Key Types of Industrial Magnets and Their Features

Industrial magnets come in various types, each with their own set of advantages and best uses. Here is an overview of some of the most common industrial magnet types and their key features and benefits:

Neodymium Magnets

  • Made of neodymium, iron, and boron alloy
  • Most powerful permanent magnet material
  • Can lift up to 1000 times their weight
  • Retain high magnetism in small sizes
  • Withstand high temps up to 80°C/176°F

Neodymium magnets offer excellent lifting power for their small size, making them ideal for applications where space is limited.

Samarium Cobalt Magnets

  • Made of samarium and cobalt alloy
  • Powerful - retain magnetism well at high temps
  • Withstand temps up to 300°C/572°F
  • High resistance to demagnetization
  • More expensive but very durable

Samarium cobalt magnets are ideal when high heat resistance is needed, such as holding tools for welding or high-temp industrial processes.

Ceramic (Ferrite) Magnets

  • Made of strontium or barium ferrite compounds
  • Lower cost than rare earth magnets
  • Resist demagnetization well
  • Withstand temps approximately 550°C/1022°F
  • Brittle - can crack if dropped or overheated

Ceramic magnets provide economical magnetic solutions for moderate strength needs, like holding signs and tools on machinery.

Alnico Magnets

  • Made of aluminum, nickel, and cobalt alloy
  • Withstand very high temps up to 1,320°C/2,420°F
  • Moderately strong magnetic field
  • Prone to demagnetization if heated/dropped

Alnico magnets are ideal for high temp environments like heat treating furnaces due to their exceptional heat resistance.

There are many other specialty magnets, but knowing the core types and their capabilities helps select the right industrial magnet for the job.

Key Industrial Applications of Magnets

Magnets serve important functions in all kinds of manufacturing and industrial processes. Here are some of the top ways industry applies the power of magnets:

Lifting and Moving Materials

  • Lifting magnets enable moving large heavy metal objects like steel beams, plates, coils etc.
  • Reduce need for cranes or forklifts to lift materials.
  • Electromagnetic lifters can be turned on/off for easy release of loads.
  • Powerful neodymium magnets enable small, compact lifters.

Holding and Fixturing

  • Permanent magnets hold tools, jigs, and fixtures in place for machining.
  • Reduce need for clamps, vises, bolts to hold items.
  • Enable flexible, quick tool changes on CNC machines.
  • Magnetic tables provide flat secure surface for assembly work.

Separating and Removing Metal

  • Draw off ferrous metal contaminants in food processing lines.
  • Protect equipment by removing fine metal particles from liquids and powders.
  • Lift nails, staples, and hardware from recycled wood and paper materials.
  • Separate aluminum and other non-ferrous metals for recycling.

Motors, Generators, and Sensors

  • Magnets are key components of electric motor and generator rotors/stators.
  • Create alternating current from rotating magnetic fields.
  • Hall Effect sensors use magnets to detect speed, position, current, and other variables.

Material Handling and Conveying

  • Magnetic conveyors move steel cans, drums, parts etc through production lines.
  • Reduce need for power-driven belt and roller conveyors.
  • Magnetic cranes lift and transfer loads around warehouses safely.

From raw steel production to finished goods assembly, magnets provide indispensable capabilities for handling, moving, and processing industrial materials.

Choosing the Right Industrial Magnet

With the wide variety of industrial magnet types and strengths available, selecting the right magnet for an application is important. Here are key factors to consider when choosing an industrial magnet:

Load Weight and Size

  • Consider the maximum load weight and dimensions you need to handle.
  • This determines the required magnetic force and magnet size.
  • A rule of thumb is to choose a magnet that can handle 2-3x the actual load weight.

Material Being Handled

  • Magnets only attract ferromagnetic materials like iron, steel, cobalt, nickel.
  • Won't attract non-ferrous metals like aluminum or copper.
  • The type of ferrous material affects the grip - test magnet on the actual load.

Temperature Resistance

  • Some inexpensive magnets like ferrite can crack or demagnetize above 175°F.
  • Applications with high heat require samarium cobalt or alnico magnets.
  • Consider maximum service temps - a welding magnet operates near 2500°F!

Durability and Environment

  • Frequent shocks or vibration can weaken magnets over time.
  • Moist, oily, or corrosive environments require coated magnets.
  • Brittle materials like ferrite ceramics chip easier than cast materials.

Cost Considerations

  • As a rule, neodymium and samarium cobalt cost more than ferrite or alnico.
  • Larger magnets are exponentially more expensive.
  • Evaluate cost vs performance tradeoffs for your specific application.

Consulting with an experienced magnet supplier is highly recommended when selecting an industrial magnet. They can help analyze your specific needs and operating conditions to choose the optimal magnetic solution.

Understanding Industrial Magnet Strengths

Industrial magnets come in a wide range of magnetic strengths tailored to different application needs. Here are some key things to know about industrial magnet power levels:

Magnetic Field Strength

  • Measured in Gauss (G) or Tesla (T) units
  • Levels for industrial magnets range from ~100 G to >10,000 G
  • Stronger magnetic fields provide greater lifting force
  • But reach diminishes faster from magnet surface

Pull Force Capacity

  • Force that magnet can exert, measured in pounds or kilograms
  • Varies greatly - from a few ounces to several tons
  • Related to magnetic field strength and magnet size
  • Higher strength enables lifting heavier loads

Maximum Service Temperature

  • Temperature above which magnets start to demagnetize
  • Ranges from 175°F for ferrite ceramics to over 2000°F for alnico
  • High temp applications require samarium cobalt or alnico

Resistance to Demagnetization

  • Ability to resist losing magnetism over time
  • Measured on a scale from Good to Excellent
  • Neodymium and samarium cobalt rate Excellent
  • Important for maintaining consistent performance

Consider the strength factors needed for the specific application. A supplier can help select an optimized magnet design, material, and power level to suit your industrial needs.

Buying Industrial Magnets with Amazon Prime

Amazon Prime provides fast, free shipping on over 10 million products, making it a convenient option for purchasing industrial magnets. Here are some tips for leveraging Amazon Prime for your industrial magnet needs:

Search for Reputable Brands

Amazon features magnets from many manufacturers. Focus your search on established, reputable magnet brands like:

  • Master Magnetics
  • Industrial Magnetics
  • CMS Magnetics
  • K&J Magnetics
  • Magnum Magnetics

Avoid unverified third-party sellers and look for Prime eligible products made by trusted industry names.

Utilize Product Specifications

Carefully read magnet product descriptions and technical specs like:

  • Material (Neodymium, Ferrite, etc)
  • Grade (N42, Y30, etc)
  • Maximum pull force
  • Coating type

This helps choose a magnet optimized for your application requirements.

Check Dimensions

Double check the dimensions of magnets to ensure the size matches your intended use prior to purchasing.

Compare Prices

Price compare similar magnets from different brands with the same specs to find the best value.

With a vast selection and fast free shipping, Amazon Prime helps easily procure industrial strength magnets from top manufacturers to suit your unique needs.

Walker Magnetics

Walker Magnetics is a company that designs and manufactures a wide range of permanent, electromagnetic, and electro-permanent magnet products and systems for industrial applications. The company has a reputation for quality and safety, and has spent over 100 years researching how to provide the safest, most reliable, and durable industrial magnets. Their self-contained lifting magnets are compact, versatile, easy to use, and can lift material up to 11,000 lbs without the need for separate equipment controls. Walker Magnetics also provides heavy lift magnets, scrap magnets, magnetic separation systems, magnetic chucks, and material handling magnets. The company was founded in 1896 by Oakley S. Walker, the inventor of the electromagnetic chuck, and has grown to become the largest company in the world providing custom design and manufacture of magnetic products for workholding, lifting, material handling, scrap magnets, and separation applications. In 2021, Industrial Magnetics, Inc. announced the acquisition of substantially all of the assets of Walker Magnetics Group, Inc., North America’s oldest industrial magnet manufacturer.

Industrial Magnetics

Industrial Magnetics, Inc. is a company that provides a wide range of industrial magnet products and solutions for various applications. Here are some key points about the company:

  • Industrial Magnetics, Inc. (IMI) provides both off-the-shelf and customer-specific industrial magnet products and solutions.
  • IMI is an industry leader in providing both permanent magnets and electromagnets for work holding, lifting, fixturing, conveying, and more.
  • The company's products include magnetic solutions for industrial applications, automation and lift assists, magnets and magnetic tools, and magnetic metal separation.
  • IMI's Tramp Metal Group designs and manufactures industrial magnetic separator solutions that protect equipment and purify product by removing metal contaminants.
  • In 2021, IMI acquired Walker Magnetics Group, Inc., which has created the market-leading provider of custom and standard magnetic products for workholding, lifting, material handling, scrap magnets, and separation applications.
  • IMI has been manufacturing magnets since 1961 and prides itself on quickly providing the best possible magnetic solution for its customers' requirements without sacrificing quality.
  • The company's LinkedIn page states that its mission is to "Make Things Better" and it has a team of brilliant engineers who develop innovative solutions, such as the Extended Length Plate Magnet, designed specifically for challenging situations with long, steep-angled chutes.
  • IMI's Low-Profile Transporter® LP magnetically transfers metal blanks, stampings, and parts in automated stations.
  • What Are The Different Types Of Magnets Used In Industrial Applications??

    Industrial magnets are used in various applications across different industries. Here are some of the different types of magnets used in industrial applications:

    1. Neodymium magnets: These rare earth magnets are the strongest type of permanent magnet and are used in applications that require high magnetic strength, such as motors, generators, and magnetic separators.
    2. Ceramic magnets: Also known as ferrite magnets, these are the most common type of magnet used in industrial applications. They are inexpensive, have good resistance to demagnetization, and are used in applications such as speakers, motors, and magnetic chucks.
    3. Electromagnets: These are temporary magnets that are created by passing an electric current through a coil of wire. They are used in applications such as lifting and holding heavy objects, magnetic separation, and MRI machines.
    4. Alnico magnets: These are made from a combination of aluminum, nickel, and cobalt, and are known for their high magnetic strength and temperature resistance. They are used in applications such as electric motors, sensors, and guitar pickups.
    5. Samarium cobalt magnets: These rare earth magnets are similar to neodymium magnets in terms of strength, but are more resistant to temperature changes. They are used in applications such as motors, sensors, and magnetic bearings.
    6. Heavy lift magnets: These are electromagnets that are designed to lift and move heavy objects, such as steel plates, pipes, and scrap metal. They are used in industries such as construction, manufacturing, and recycling.
    7. Magnetic chucks: These are used to hold and position ferromagnetic workpieces during machining operations. They are used in industries such as metalworking, woodworking, and automotive manufacturing.

    Overall, the type of magnet used in an industrial application depends on the specific requirements of the application, such as magnetic strength, temperature resistance, and durability.