The Magnet Challenge
The team’s ultra-lightweight motor design depended on advanced permanent magnets to deliver maximum torque and efficiency. However, previous iterations revealed critical issues:
- Bonding failures caused by adhesives attaching to coatings instead of substrates.
- The circular multipole Halbach array introduced twisting forces that pushed magnets out of alignment during curing.
- A compressed development timeline left little room for trial and error.
To compete at the highest level, the Brunel Solar Car Team needed reliable magnet assemblies engineered for performance, safety, and speed of integration.
Engineering a Solution
Magnet Applications’ technical team partnered directly with the student engineers to overcome these hurdles:
- Supplied advanced NdFeB permanent magnets incorporating Grain Boundary Diffusion (GBD) technology for higher energy density and efficiency.
- Recommended optimized surface preparation, adhesive selection, and curing methods to ensure secure bonding.
- Guided the design of custom tooling to counteract Halbach array forces during assembly.
- Delivered and quality-checked the magnets, with Magnet Applications’ specialists traveling to Delft to oversee the successful build of the rotating magnet assemblies.
Results
- Successful assembly of both rotating magnet arrays in a single day.
- Significant time savings, eliminating months of testing and trial errors.
- Improved motor performance, achieving higher torque per unit of energy input.
- Hands-on knowledge transfer, equipping the student engineers with practical experience in magnet design and assembly.
Driving Sustainable Innovation
Magnet Applications’ collaboration with the Brunel Solar Car Team underscores the essential role of permanent magnets in advancing green energy technologies. By applying cutting-edge magnetic engineering, the Nuna 12S solar car demonstrated how renewable energy, advanced materials, and technical partnerships can deliver real-world performance gains.
This project reflects Magnet Applications’ commitment to supporting innovation — from scientific research to sustainable transportation — with engineered magnet solutions that power the technologies of tomorrow.
