Introduction
In the world of industrial material handling, where tons, speed and absolute reliability are essential, one technology has always been indispensable: the electromagnet.
While newer developments such as permanent electromagnets are often in the spotlight, electromagnets remain the unmatched solution to the toughest jobs. But what makes them so special, especially in the age of high-tech solutions? This blog post dives into the world of electromagnets and shows why they are still the first choice in steel mills, ports and recycling plants.
- Simply ingenious: The operating principle
The strength of electromagnets lies in their brilliant simplicity. By applying an electrical voltage, an aluminum coil around an iron core generates a strong, homogeneous magnetic field. The rule is as simple as it is effective:
- Current on = magnetic field on, full power.
- Current off = magnetic field immediately off, load off.
This direct controllability makes it the ideal tool for automated processes. There are no mechanical levers that break and no delayed shifting.
In combination with the control system developed by Mozelt in its generators, the magnetic field can also be built up slowly and slowly dissipated in a controlled manner. This can be set individually.
2. The Undoubted Advantages: Why the Industry Chooses Electromagnets
a) Maximum load-bearing capacity: Where others stop, they only begin
Electromagnets develop the highest magnetic force per area. They are the first and often only choice for:
- Steel slabs (10-45 tons)
- Heavy coils and strip steel
- Solid castings
- Full scrap containers
b) The master of difficult cases: Perfect for junk & Co.
This is their decisive advantage! In contrast to permanent and electropermanent magnets, which require smooth, solid steel parts, the electromagnet is the all-rounder for complex materials:
- Scrap: Its deep-acting magnetic field penetrates air pockets and magnetizes even irregular shapes safely.
- Dirty and rusted surfaces: The magnetic force is not so easy to keep dirt or rust away due to the depth effect.
- Inhomogeneous materials: Whether it’s a solid block or a pile of loose parts – the electromagnet grabs hold where other magnets fail.
c) Easy integration into automation
Electromagnets are the natural partner for modern industrial plants. Their control via generator control has been tried and tested for over 50 years, is robust and can be seamlessly integrated into existing control systems. The immediate response time enables high cycle rates, and the counter-excitation principle guarantees safe and residue-free placement – without unwanted residual magnetism.
d) Robustness for the harshest everyday life
Designed for 24/7 use in the most difficult environments, electromagnets resist:
- Extreme temperatures (e.g. in foundries)
- Shocks and vibrations (e.g. in drop ball operation)
- Dust, dirt and moisture (waterproof electromagnets are also possible)
3. Working environment: Where electromagnets shine
- Steel industry: From slab handling to coil transport.
- Scrap handling & recycling: The classic place of use, where robustness and power are paramount.
- Port and terminal operations: When loading and unloading bulk materials and scrap.
- Foundries & metallurgical plants: Handling slag and drop balls where other magnets would not survive.
4. The decision: When is an electromagnet the right choice?
Choose an electromagnet if:
- You need to move loads over 5 tonnes.
- You are dealing with scrap, uneven or soiled materials.
- You operate a high-cycle, automated system.
- Efficiency and robustness in continuous operation are in the foreground.
Conclusion
Electromagnets are not an outdated technology, but a specialized high-performance tool that is unmatched in its niche. Their combination of unbeatable power, adaptability to the most difficult materials and rugged reliability makes them the first choice for demanding industrial applications. In a world that strives for efficiency and power, electromagnets are and will remain the indispensable powerhouses of heavy industry.
For more information, visit our Lifting Magnets page: Electric Lifting Magnets