We worked with Danfoss, a manufacturer of magnetic bearing compressors that offer extended machine life and improved efficiency, to develop an automated magnetic field measurement system for quality assurance testing. Danfoss compressors rely on precisely controlled magnetic fields, but their existing manual measurement process is time-consuming, inaccurate, and makes it difficult to verify consistent shaft manufacturing standards.
We designed an automated system that measured magnetic flux distributions and generated 3D visual maps of the magnetic field around each shaft. Our design incorporates three coordinated motion systems: a linear actuator that moves a magnetic field sensor along the shaft’s length, a rotational stage that turns the shaft through 360 degrees to capture complete circumferential data, and a radial positioning system that moves the sensor away from the shaft to map how magnetic flux varied with distance from the center. The sensor collects readings throughout the scanning volume, and our software processes this data to create 3D models that make flaws and inconsistencies readily detectable.
Our automated method significantly reduces human error by limiting operator involvement to shaft loading and test initiation. The system improves measurement accuracy compared to manual testing while decreasing training requirements and labor costs for magnetized shaft inspection. The project delivers faster, more accurate, and more reliable testing that ensures each shaft meets Danfoss performance standards before installation in compressors.
