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Magnetic Rubber for Industrial Applications

Magnetic rubber is a versatile material that, due to its unique properties, is used in a variety of industrial applications.

Magnetic Rubber for Industrial Applications

Magnetic rubber is a versatile material that is used in a variety of industrial applications due to its unique properties. This material is particularly appreciated for its ability to combine the flexibility of rubber with magnetic properties, making it ideal for a variety of uses. The most common applications include use in the lift industry. It is also widely used in sensors, switches, motors and encoders due to its precision and reliability in detecting and transmitting signals. The versatility of magnetic rubber makes it a strategic choice for numerous technological solutions in industry.

Flexible magnetic rubber

Manufacturing processes

Extrusion

Extrusion is an alternative process that is used to produce magnetic rubber profiles and shapes. In this method, the mixture of rubber and magnetic powder is heated and forced through a die to determine its shape. Extrusion can be used to create complex profiles that cannot be obtained by calendaring.

Calendering

Calendering is the most common method for producing magnetic rubber. In this process, the mixture of rubber and magnetic powder is passed between two hot rollers that crush and roll it into thin sheets. The rollers also exert a shearing force that orients the magnetic particles by aligning them in the same direction. This gives the anisotropic magnetic material its directional magnetic properties, i.e. a greater magnetic force in one direction than in others.

Areas of application

Position sensors
Position sensors
The flexibility of rubber magnets allows them to be easily integrated into sensor designs, even in complex shapes or tight spaces. Their ability to adapt to different geometries ensures accurate detection even in the presence of vibrations or shocks, making them ideal for applications in dynamic environments. The magnets can be placed on the moving body to be monitored or inside the sensor itself. They are used to create a magnetic field that changes according to the position of the moving body. The sensor detects this change in magnetic field and translates it into an electrical signal indicating the position of the moving body.
Speed sensors
Speed sensors
They are used in various devices, such as tachometers and revolution counters, to measure the rotational speed of motors, wheels or other rotating elements. Their sensitivity and precision make them indispensable for controlling and monitoring mechanical systems. Magnets are often mounted on rotors or wheels and pass close to Hall sensors or reed contacts. Each time a magnet passes close to the sensor, an electrical impulse is generated. The pulse frequency is proportional to the rotational speed of the magnet, which in turn is proportional to the speed of the rotating body.
Rotary encoders
Rotary encoders
They translate rotary motion into digital electrical signals with high resolution. They are used in computer numerical control (CNC) machines and robotics systems for the precise control of axes and joints. Their reliability and robustness ensure continuous and precise operation, even under harsh working conditions. The magnets are arranged on a rotating disc in coded configurations. A magnetic sensor detects the sequence of magnets as the disc rotates. The sequence of magnets encodes the angular position of the rotating disc.
Level Sensors
Level Sensors
They monitor the level of liquids or gases in tanks, vessels or pipelines. Their ability to detect the presence or absence of fluid allows them to automate filling, emptying or alarm systems. Their resistance to corrosion and chemicals makes them suitable for use with different types of fluids. The magnets can be placed on a float that rises or falls with the fluid level. The magnet moves closer to or further away from a Hall sensor or reed contact located on the tank body. The change in distance between the magnet and the sensor indicates the liquid level in the tank.
Reed Switches
Reed Switches
Reed switches are switching devices based on the magnetic principle. A reed contact inside the switch opens or closes in the presence of a magnetic field. The magnetic rubber magnets guarantee a precise and reliable magnetic field, even in vibrating environments or with electromagnetic disturbances. This makes them ideal for applications where high levels of security and precision are required, such as in burglar alarm systems or industrial safety devices. An external magnet is used to activate or deactivate the switch. When the magnet approaches the switch, the reed contacts inside it close, completing an electrical circuit. The switch can be used to activate or deactivate electrical devices or to signal the presence or absence of an object.
Hall Sensors
Hall Sensors
Hall sensors measure magnetic field strength and are used in motor control systems, position detectors and proximity sensors. Their high sensitivity and accuracy make them ideal for detecting small magnetic fields even in the presence of noise. Magnetic rubber magnets are compatible with hall sensors and offer flexibility, robustness and safety. Their ability to be molded into different shapes and sizes allows them to be adapted to a variety of applications. The magnets are not in direct contact with the Hall sensor. The sensor detects the magnetic field generated by the external magnet. The magnetic field strength is translated into an electrical signal indicating the distance or position of the magnet.
Elevators
Elevators
Rubber magnets play a crucial role in modern elevators, ensuring their safe and reliable operation. Their main application include:
  • Activation of safety brakes: in case of malfunction or overload, rubber magnets activate the safety brakes to stop elevator car quickly and controlled.
  • Cabin position detection: Encoded magnets installed along the elevator shaft allow for determining the exact position of the cabin, ensuring precise stopping at floors.
  • Door control: Rubber magnets control the opening and closing of elevator doors, ensuring a tight and secure closure. Their flexibility allows them to adapt to different types of doors and closing systems.

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