Development and engineering
Magnet engineering & customised solutions: We develop and produce your magnet systems
Precision from the idea to series production
Anyone can do standard - we love a challenge and develop magnetic systems, customised solutions or assemblies that fit your application exactly. As inventors and manufacturers, we develop customised magnetic solutions where standard products reach their limits.
Behind every successful magnetic system is a well thought-out engineering process. At Brugger, we combine decades of experience in magnet technology with state-of-the-art manufacturing technologies. We support you from the initial sketch through simulation to reliable series production.
Our special systems page will give you an impression of our development services.
For us, engineering means: We turn your idea into a technically tested solution ready for series production.
At our Hardt site, we accompany you through the entire development process:
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Design: We plan your optimised magnetic system (CAD & design).
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Solve: We develop the most efficient way for production
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Prove: We guarantee through precise measurements that your solution will hold.
Certified quality assurance and test procedures
Reliable automation: high-precision production through robotics
For our customers, robotics means above all: consistent quality and attractive prices.
To bring your customised magnet systems into series production, we rely on state-of-the-art machinery with integrated robotics and automation. As inventors, we not only develop the product, but often also the appropriate automated production cell at the same time.
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Fully automated assembly: Our robots carry out high-precision assembly and joining processes that would be virtually impossible to achieve with such consistency manually.
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Intelligent sensor technology: Integrated camera systems and sensors monitor every movement in real time. This enables us to guarantee a 100 per cent good part rate directly in the line.
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Scalability: Thanks to our automation expertise at the Hardt site, we realise projects ranging from small pre-series to fully automated production of millions.
For you, this means maximum process stability and competitiveness - developed and implemented by experts who know how to efficiently utilise automation for complex magnetic assemblies.
Precise laser marking: permanent labelling for the highest demands
Labelling BRUGGER magnet systems with the laser
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A high-quality magnetic system deserves labelling that is just as durable as the product itself. With our state-of-the-art laser technology , we offer you precise and indestructible labelling directly in the production process.
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Counterfeit protection & traceability: We permanently apply serial numbers, batch codes or DataMatrix codes to a wide variety of surfaces.
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Customised branding: Whether company logos or specific component designations - our laser ensures a razor-sharp typeface that can withstand even extreme mechanical or chemical stress.
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Non-contact finishing: Thanks to the laser-based process, the labelling is carried out without thermal or mechanical stress on the magnetic system, which means that the material properties are fully retained.
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This integrated process step ensures that your components remain identifiable throughout the entire product life cycle - a key component of our comprehensive quality assurance at the Hardt site.
Innovative prototyping: rapid market entry through 3D printing
3D printer for prototypes and holding devices
Time is a decisive competitive factor. To shorten development cycles, we rely on additive manufacturing processes (3D printing).
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Prototype construction: Rapid visualisation and functional testing of your components.
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Fixture construction: Customised aids for efficient production.
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Flexibility: Fast customisation before the start of mass production.
3D printing plays a decisive role in development at BRUGGER. It is used to produce customised, complex and high-performance samples and prototypes. It is also used to produce tooling and manufacturing aids. Advances in 3D printing technology enable us to manufacture products with impressive precision and flexibility.
Further advantages of 3D printing:
- Products can be customised and improved quickly and efficiently throughout the development cycle
- Low material costs for prototyping
Validation on the test bench: certified measurement procedures for maximum safety
Trust is good, measurement data is better. In our in-house test laboratory, our developers and quality assurance staff subject your magnet systems to the most stringent load tests in order to guarantee the specified properties under real conditions.
Salt spray test for accelerated corrosion testing
Ocean feeling for our magnetic systems!
Corrosion resistance is a decisive quality and safety feature for many of our products. In our own salt spray chamber, we analyse the effects of salt spray on the rubber coatings and surfaces of our magnet systems. The salt spray test (in accordance with DIN EN ISO 9227 (NSS test)) is a standardised test for evaluating the corrosion protection effect of organic coatings, metallic coatings and chemical or physical surface treatments.
The test is carried out in accordance with various standards. The test objects are placed under standardised conditions in a test chamber in which a sprayed salt solution acts on the test objects. The special test chamber and the standardised conditions guarantee correct and reliable measurement results for our quality controls.
The salt spray test is carried out and monitored continuously until the specified test duration is reached. At BRUGGER, the test duration is usually 1000 hours. At the end of the test duration, the corrosion phenomena that have occurred on the test specimens are assessed, for example according to the degree of rust, blistering and corrosive infiltration of organic coatings.
Magnet measurement technology: Precise validation of magnetic characteristics and load capacity
Fluxmeter measurement:
Using state-of-the-art fluxmeters and Helmholtz coils, we measure the magnetic flux and the magnetic moment. This guarantees a constant magnetic quality throughout series production.
Adhesive force measurement:
We use precise test setups and measuring devices to determine the exact release or tear-off forces of your magnetic assemblies. This is how we ensure that the mechanical holding power exactly fulfils your requirements.
Spezial-Messtechnik für Kundenprojekte: Wir bauen Messgeräte, wenn "Standard" nicht ausreicht
Maßgeschneiderte Messtechnik für höchste Präzision – Entwicklung & Fertigung kundenspezifischer Messgeräte
Wenn Standard-Messtechnik an ihre Grenzen stößt, sind wir Ihr Partner für innovative Lösungen. Wir entwickeln und fertigen spezielle Messgeräte und Messtechnik für anspruchsvolle Kundenprojekte – von der Konzeption bis zur finalen Umsetzung. Unser Leistungsspektrum umfasst die gesamte Bandbreite der Messtechnik, angepasst an Ihre individuellen Anforderungen.
So haben wir beispielsweise für Kundenprojekte komplexe Magnetsysteme konstruiert und anschließend komplette Mess-Systeme entwickelt, um deren Leistung, Funktionalität und Präzision zu validieren. Profitieren Sie von unserer langjährigen Erfahrung in der präzisen Messtechnik und unserem Know-how in der Entwicklung kundenspezifischer Magnettechnologie.
Wir garantieren Ihnen Messgenauigkeit, Zuverlässigkeit und eine nahtlose Integration in Ihre Prozesse.
Drehmoment Messgerät
Um sicherzustellen, dass unsere Magnetkupplungen den geforderten Spezifikationen entsprechen hat unser Entwicklungsteam ein speziell auf diese Anwendung angepasstes Drehmoment-Messgerät gebaut.
Zur Validierung kundenspezifischer Anforderungen sowie zur präzisen Charakterisierung unserer Neuentwicklungen hat unser Engineering-Team einen spezialisierten Leistungsprüfstand für Magnetkupplungen realisiert.
Das System arbeitet nach dem Prinzip der gezielten Lastbeaufschlagung, wobei die auftretenden Kräfte über ein hochpräzises digitales Kraftmessgerät vom Typ Alluris FMI-B20 erfasst werden. Durch die hohe Abtastrate des Sensors detektieren wir selbst minimale Kraftänderungen und bestimmen über die Peak-Hold-Funktion exakt die maximale Abreißkraft. Aus dieser berechnet sich das übertragbare Drehmoment.
Als wichtiges Funktionsmerkmal verfügt die Anlage über eine integrierte Linearverstellung: Über eine präzise Spindel lässt sich der Luftspalt zwischen den Magnetrotoren stufenlos variieren. So können wir Leistungskurven für verschiedene Einbausituationen lückenlos dokumentieren und unsere Kupplungen perfekt auf die jeweilige Applikation abstimmen.