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FAIZEAL · PRODUCT PAGE COPY · ENGLISH
Custom Disc Rotor Magnet Assembly for Robot Joint Motors — Segment Magnet Rotor Cores for Axial Flux Drives, FAIZEAL
Precision-Bonded Arc Magnet Rotors on Machined Steel Carriers — Lightweight, Balanced and Built to Your Drawing for Direct-Drive Robotics
FAIZEAL disc rotor magnet assemblies put segmented arc magnets exactly where a joint motor needs flux. FEA-optimised, balanced, built to CAD. Enquire now.
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This is the rotating heart of a direct-drive robot joint: a disc-type rotor that carries a full ring of segmented arc magnets on a machined steel carrier, positioned so that the magnetised face works directly across the stator air gap. There is no gearbox upstream of this part and no laminated stack behind it — the magnetic circuit, the structure and the mounting interface are resolved in a single compact component.
The construction is deliberately simple to specify and demanding to build. Arc segments are ground in matched sets so that every pole presents the same angular width and radial height; the carrier is machined on both faces, with the bore, bolt circle and threaded interfaces finished in the same setup; and every magnet is bonded over its full contact surface, then verified.
Placed under magnetic viewing film, the assembled rotor shows an even, symmetric multipole pattern — the visible signature of a rotor that will run smoothly at the air gap rather than excite vibration into the arm.
We manufacture this assembly as a custom component against customer drawings. Pole count, segment geometry, carrier thickness, balancing grade and surface treatment are engineering variables, and we settle them in finite-element simulation before the first block is cut.
Six construction decisions decide how this rotor behaves in a joint. Each is written below as a specification you can put on a purchase order.
Because the arc magnets sit directly at the working air gap, flux is not spent saturating a back iron. The full working face of the ring does its business at the gap, which is why disc rotors of this type deliver high torque in a short axial envelope — the property that makes direct-drive joints possible without a gearbox.
Every arc segment is wire-cut or ground to a common pole-arc and chamfer specification and assembled as a matched set. Uniform poles mean a near-sinusoidal air-gap field: low torque ripple, low cogging, quiet running, and smoother current waveforms from the joint's drive electronics.
The steel disc is not a magnet holder; it is the structural hub of the joint. Both faces are machined, the central bore is finished to its running fit, and the bolt circle and threaded holes accept the shaft, the encoder ring and the stator-adjacent hardware. Fewer parts, fewer interfaces, less runout stack-up.
The rotor is dynamically balanced after the magnets are fitted, at the grade your joint design calls for. Balancing the finished assembly — rather than the bare carrier — is what keeps vibration low at joint speed and protects the bearing arrangement on both sides.
Magnets are bonded with a high-temperature structural adhesive across the entire contact face, eliminating air pockets behind the segments and preventing fretting under torque reversals. Where the duty cycle demands it, we add mechanical retention — machined shoulders, rings or pinning — so the magnet ring cannot migrate even in an overload event.
Standard magnet protection is a triple-layer Ni-Cu-Ni plating, with epoxy or parylene available for washdown, chemical or high-humidity environments. Carrier materials and coatings are selected against the joint's cleanliness and corrosion requirements, from standard industrial to semiconductor-grade.
The rotor earns its place wherever torque must come from a thin disc. The first two duties dominate enquiries; the third collects the rest.
The primary application. Direct-drive and near-direct-drive joint modules want maximum torque in the smallest diameter, with no gearbox to add compliance, backlash and weight. A disc rotor with a full ring of matched segments gives the joint motor high air-gap flux density in a thin profile, which shortens the joint, lightens the arm and raises the torque-to-inertia ratio that decides how fast a robot accelerates and how precisely it stops.
The machined carrier accepts encoder rings and hollow-shaft routing, so the joint's sensing and cabling integrate against the same reference face.
The same construction serves axial-flux machines of every size. In an axial-flux motor the working face is the stator face, so a disc rotor with surface-mounted segments is the natural core: short axial length, high torque density, and a field that does its work at the gap rather than in a yoke. Whether the motor drives a robot joint, an e-mobility actuator or an aerospace control surface, the rotor is the component that sets its power density.
The assembly also fits torque-dense rotary applications beyond robotics: magnetically coupled rotary feedthroughs, gimbal and stabilisation drives, and precision test rigs — anywhere a compact, balanced, magnetically active disc must spin true.
FAIZEAL is a magnet engineering and manufacturing company, not a trading company. Disc rotor assemblies are built to customer specification as standard practice:
Custom rotor geometry, manufactured directly from your CAD drawing — diameter, bore, segment count, carrier thickness and mounting pattern.
FEA-optimised magnetic design, with pole count and segment geometry settled in simulation against your torque, ripple and temperature targets, and the simulation results supplied with the quotation.
Materials and protection selected for the duty, including magnet grade, bonding and retention method, carrier material and coating system.
Balancing, inspection and documentation to your joint's quality plan, including flux film verification of the finished assembly.
Send your CAD drawing and your duty cycle — torque, speed, working temperature and envelope — and our engineers will respond with a design proposal, an FEA-based assessment and a quotation within 24 hours. |
Prepared for FAIZEAL · Ningbo FAIZEAL Magnetic Technology Co., Ltd. · fzmag.com · Product page copy, disc rotor magnet assembly · 2026
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