Situation
Autonomous robots for extreme industrial environments
A leading and innovative global player develops advanced solutions for the preparation and cleaning of steel surfaces. These include applications such as hydro-blasting, sandblasting, and other intensive cleaning processes.
For these applications, the customer uses specially developed robots that attach themselves to steel surfaces via a magnetic drive unit. These robots operate completely autonomously and are capable of moving freely in all directions: vertically, horizontally, and even upside down. This enables them to clean complex structures safely and efficiently, without human intervention in hazardous environments.
The performance and reliability of these robots strongly depend on the quality and design of the magnetic system. This system determines the holding force, stability, and freedom of movement of the robot.
Complication
Limited control over quality and development
The customer developed its current magnetic system over the years through a process of trial and error. While this resulted in a workable solution, it lacks a fundamentally engineered magnetic design.
Production of these magnetic systems is outsourced to a Chinese supplier, leading to several challenges:
- Inconsistent quality of supplied magnetic systems
- Lack of transparency in the production process
- No access to in-depth technical support
- Limited ability to collaborate on new developments
For a company focused on continuous innovation and product development, this creates a significant bottleneck. There is a clear need for a partner who can contribute not only in production but also at the engineering level.
Question
From supplier to development partner
The customer approached Bakker Magnetics with a twofold request:
- Support in the design and optimization of magnetic systems for new generations of robots
- Takeover of production of existing magnetic components, with improved quality assurance and communication
The key question: how can the existing system be made more efficient, reliable, and future-proof?
Solution
Smarter magnetic design through engineering and simulation
Bakker Magnetics started with a thorough analysis of the existing magnetic system. Using advanced magnetic calculations and simulations, insights were gained into:
- Flux distribution
- Loss mechanisms
- Effective utilization of magnetic material
The analysis showed that achieving the desired performance does not require more magnetic material, but a smarter configuration. By repositioning the magnets and optimizing the magnetic circuit:
- The magnetic field is used more efficiently
- The effective holding force increases
- The total magnetic volume can be reduced
In parallel, Bakker Magnetics implemented a controlled production process focused on consistency, quality, and repeatability.
Result
More performance with less material
The new magnetic configuration delivers clear and measurable benefits:
- Higher holding force using the same base material
- Weight reduction, improving robot dynamics
- Cost savings through more efficient material use
- Improved manoeuvrability, especially in complex positions
- Increased reliability due to consistent production quality
In addition, Bakker Magnetics successfully took over the production of the magnetic systems. This results in:
- A more transparent and efficient procurement process
- Shorter communication lines
- Faster development of new concepts
By combining engineering, simulation, and production under one roof, Bakker Magnetics helps customers not only improve existing systems but also accelerate future innovations.
For the customer, this marks a fundamental shift: from dependency on a supplier to collaboration with a true technical partner.
