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: Fast 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
Sea 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.
Specialised measurement technology for customer projects: We build measuring devices when "standard" is not enough
Customised measurement technology for maximum precision - development & production of customised measuring devices
When standard measurement technology reaches its limits, we are your partner for innovative solutions. We develop and manufacture special measuring devices and measuring technology for demanding customer projects - from conception to final realisation. Our range of services covers the entire spectrum of measurement technology, customised to your individual requirements.
For example, we have designed complex magnet systems for customer projects and then developed complete measuring systems to validate their performance, functionality and precision. Benefit from our many years of experience in precise measurement technology and our expertise in the development of customised magnet technology.
We guarantee measurement accuracy, reliability and seamless integration into your processes.
Drehmoment Messgerät
Um sicherzustellen, dass unsere Magnetkupplungen den geforderten Spezifikationen entsprechen hat unser Entwicklungsteam ein speziell auf diese Anwendung angepasstes Drehmoment-Messgerät gebaut.
To validate customer-specific requirements and precisely characterise our new developments, our engineering team has created a specialised performance test bench for magnetic couplings.
The system works according to the principle of targeted load application, whereby the forces occurring are recorded using a high-precision Alluris FMI-B20 digital force measuring device. Thanks to the sensor's high sampling rate, we detect even minimal changes in force and use the peak hold function to precisely determine the maximum breakaway force. The transmittable torque is calculated from this.
An important functional feature of the system is its integrated linear adjustment: the air gap between the magnetic rotors can be infinitely varied using a precise spindle. This allows us to seamlessly document performance curves for different installation situations and perfectly customise our clutches to the respective application.
Project-specific Helmholtz coil
Customised magnetic measurement technology for the highest demands
A Halbach array is a special magnet arrangement that generates particularly strong magnetic fields - ideal for applications such as electric motors and MRI systems. For a current customer project, we have set up such an array and developed a project-specific Helmholtz coil to precisely test the raw magnets installed. The Helmholtz coil generates a homogeneous magnetic field in a comparatively large measuring space and is therefore ideal for determining the polarisation (anisotropy) of magnets. The test specimens are positioned in the centre of the coil using a double cardanic suspension. By applying a defined current, the magnets align themselves along their preferred direction (anisotropy axis). This makes it possible to check exactly whether the actual magnetisation axis corresponds to the one specified in the drawing.
As our existing measuring coils were not suitable for this project, we quickly developed a customised Helmholtz coil - using AI-supported calculation, our 3D printer and precision-manufactured windings. The result: a test device that is precisely tailored to the requirements of this project.