Magnetic coupler for reaction kettle based on 90-degree Halbach array and optimization design method thereof

Abstract

The invention provides a 90-degree Halbach array-based magnetic coupler for a reaction kettle, which comprises a sealing cover cylinder, an outer magnet support sleeve is rotatably connected to the outer side of the sealing cover cylinder, a plurality of outer magnets are arranged on the outer magnet support sleeve, an inner magnet support sleeve is rotatably connected to the inner part of the sealing cover cylinder, and a plurality of outer magnets are arranged on the inner magnet support sleeve. A plurality of outer magnets are arranged on the outer magnet supporting sleeve, a plurality of inner magnets are arranged on the inner magnet supporting sleeve, the outer magnets and the inner magnets are arranged according to a 90-degree Halbach array, the outer magnets are arrayed according to the fact that the magnetic induction intensity of the inner sides of the outer magnets is enhanced by the 90-degree Halbach array, and the inner magnets are arrayed according to the fact that the magnetic induction intensity of the outer sides of the inner magnets is enhanced by the 90-degree Halbach array. The invention further provides an optimal design method of the magnetic coupler, and an optimal design combination is found by adopting a multi-target parameterization optimal design method. The invention solves the technical problems of low magnetic field intensity between air gaps, low magnetic steel utilization rate, low maximum transmission torque and low design and development method efficiency of the existing magnetic coupler, and belongs to the technical field of magnetic drive reaction kettles.

Description

Technical Field

[0001] This invention belongs to the field of magnetically driven reactor technology, specifically relating to a magnetic coupler for reactors based on a 90° Halbach array and its optimized design method. Background Technology

[0002] In recent years, with the rapid development of the pharmaceutical, petrochemical and environmental protection industries, stricter requirements have been put forward for the stirring of flammable and explosive media, requiring the stirred tank to meet the standard of complete zero leakage. Magnetic reactors have effectively solved the above problems and achieved true zero leakage.

[0003] The main principle of a magnetic drive reactor is to utilize the magnetic force of two rotors for contactless transmission. Between the two rotors is a sealed cover capable of withstanding the high pressure of the reactor, thus achieving zero leakage in the high-pressure reactor and solving the problem that mechanical seals cannot achieve zero sealing under conditions of large shaft diameter, ultra-high pressure, and high torque transmission. Simultaneously, magnetic drive also offers the advantage of good operational stability. Because the inner and outer rotors do not directly contact each other, it effectively prevents the vibration of the outer rotor magnet from affecting the inner magnet. Conversely, vibrations of the inner magnet will not be transmitted to the outer magnet, and the two rotor magnets do not interfere with each other, resulting in a relatively stable overall operation of the equipment. Furthermore, the lack of direct contact between the inner and outer rotor magnets prevents overload caused by excessive stirring torque, which could lead to rotor slippage and damage to the entire transmission system should a problem occur with the power output shaft.

[0004] The core component of a magnetic reactor is the magnetic coupler. The working principle of the magnetic coupler follows Coulomb's law of magnetism, which states that two magnets separated by a certain distance can transfer power from one magnet to another through the coupling force of the magnets without any traditional mechanical components, due to the magnetic field induction effect, thus forming a non-contact torque transmission mechanism.

[0005] Currently, most magnetic couplers employ conventional magnet arrays. These arrays use alternating N and S poles arranged at 180-degree intervals, resulting in a uniform magnetic field strength on both the inner and outer sides of the magnet. However, in magnetic coupler operation, the magnetic field strength within the air gap is crucial; increasing this strength significantly improves the maximum transmission torque. Conventional magnet arrays generate relatively weak magnetic fields in the air gap, leading to low magnet utilization, limited maximum transmission torque, and high magnet investment costs.

[0006] Furthermore, current design and development methods for magnetic couplers are inefficient and cannot achieve optimal performance. The designed dimensions often result in wasted space and poor economic efficiency, and the overall size of the magnetic coupler is also relatively large. These problems urgently need to be addressed. Summary of the Invention

[0007] The purpose of this invention is to provide a magnetic coupler for a reactor based on a 90° Halbach array and its optimized design method, aiming to solve the technical problems of existing magnetic couplers, such as low magnetic field strength in the air gap, low utilization rate of magnets, low maximum transmission torque, and low efficiency of design and development methods.

[0008] To achieve the above objectives, the technical solution adopted by the present invention is as follows: a magnetic coupler for a reactor based on a 90° Halbach array is provided, including a sealed cover cylinder. An outer magnet support sleeve is rotatably connected to the outer side of the sealed cover cylinder, and a plurality of outer magnets are provided on the outer magnet support sleeve. An inner magnet support sleeve is rotatably connected to the inner side of the sealed cover cylinder, and a plurality of inner magnets are provided on the inner magnet support sleeve. Both the outer magnets and the inner magnets are arranged in a 90° Halbach array. The outer magnets are arrayed in a 90° Halbach array to enhance the magnetic induction intensity on their inner side, and the inner magnets are arrayed in a 90° Halbach array to enhance the magnetic induction intensity on their outer side.

[0009] In one embodiment, both the outer magnet and the inner magnet are shaped like thick tiles, with a thickness greater than 1.4 times the width of the air gap.

[0010] In this invention, the thicknesses of the outer magnet and the inner magnet may be equal or unequal.

[0011] In one embodiment, the outer magnet is bonded to the inner side of the outer magnet support sleeve, and the inner magnet is bonded to the outer side of the inner magnet support sleeve.

[0012] In one embodiment, an outer support water jacket is provided on the outer side of the outer magnet support sleeve, and the bottom end of the outer support water jacket is sealed to the bottom end of the sealing cover cylinder.

[0013] In one embodiment, the bottom end of the outer magnet support sleeve is provided with several irregularly shaped baffles evenly distributed around the circumference, and the top end of the outer magnet support sleeve is provided with several evenly distributed guide semi-tube blades around the circumference, the guide semi-tube blades penetrating the outer magnet support sleeve.

[0014] In one embodiment, a spiral heat exchange coil is surrounded on the outside of the outer magnet support sleeve. The bottom and top ends of the spiral heat exchange coil are respectively provided with an inlet and an outlet. Both the inlet and the outlet penetrate the outer support water jacket and extend to the outside of the outer support water jacket.

[0015] The present invention also provides an optimized design method for a magnetic coupler for a reactor based on a 90° Halbach array, wherein the optimized design of the magnetic coupler for a reactor based on a 90° Halbach array as described above specifically includes the following steps: S1: The maximum static magnetic torque of the ordinary array magnetic coupler and the 90° Halbach array magnetic coupler are simulated and calculated, and the simulation results are compared and analyzed. Based on the simulation results, the improvement of the maximum static magnetic torque of the 90° Halbach array magnetic coupler relative to the ordinary array magnetic coupler is determined, thereby determining the optimization direction. S2: Conduct experimental tests on ordinary array magnetic couplers, and compare and analyze the simulation results of the maximum static magnetic torque with the experimental results. Based on the deviation range between the simulation results and the experimental results, clarify the reliability of the simulation calculation model. S3: Simulation calculations were performed on the 90° Halbach array magnetic coupler to obtain the relationship curve between the maximum static magnetic torque of a single loop and the number of poles, thereby determining the optimal number of poles; S4: Optimize the 90° Halbach array magnetic coupler using a multi-objective parametric optimization design method at the optimal pole number: ① Set the dimensions of the 90° Halbach array magnetic coupler as parameters, and give the five key design variables of the 90° Halbach array magnetic coupler, with the following constraints: , Wherein, inRi represents the inner diameter of the inner magnet ring, inRi1 is the lower limit of inRi, and inRi2 is the upper limit of inRi; inRo represents the outer diameter of the inner magnet ring, inRo1 is the lower limit of inRo, and inRo2 is the upper limit of inRo; ouRo represents the outer diameter of the outer magnet ring, ouRo1 is the lower limit of ouRo, and ouRo2 is the upper limit of ouRo; angle represents the relative rotation angle between the inner and outer magnet rings, angle1 is the lower limit of angle, and angle2 is the upper limit of angle; hight represents the height of the inner and outer magnets, hight1 is the lower limit of hight, and hight2 is the upper limit of hight; the heights of the inner and outer magnets are equal, and the air gap width remains unchanged; the units of inRi, inRo, ouRo, and hight are mm, and the unit of angle is °. ② Experimentally sample the 5 key design variables in step ① to obtain several design points, and calculate the maximum static magnetic torque and the total volume of the permanent magnet at each design point through simulation. ③ Use the full second-order polynomial method to fit several design points in step ② to construct a response surface, and use a goodness-of-fit scatter plot to evaluate the goodness of fit of the response surface. ④ The multi-objective genetic algorithm Moga is used to optimize the response surface constructed in step ③ to obtain several candidate points. The candidate points are then simulated and verified, and the simulation verification results of several candidate points are compared and analyzed to obtain the maximum static magnetic torque and the minimum total volume of permanent magnets. The five key design variables of the candidate points corresponding to the maximum static magnetic torque and the minimum total volume of permanent magnets are the optimal dimensions of the 90° Halbach array magnetic coupler.

[0016] Preferably, in steps S1, S2 and S3, electromagnetic simulation calculations are performed using the simulation software Ansys Maxwell.

[0017] Preferably, in step S2, if the deviation between the simulation result and the experimental result of the maximum static torque is within 0-10%, the simulation calculation model is considered to have high credibility.

[0018] Preferably, in step S4, the Ansys DesignXplorer optimization design platform is used for multi-objective parametric optimization design. Specifically, in step ②, a central composite design CCD is used for experimental sampling, and the AnsysMaxwell simulation software is used to calculate the maximum static magnetic torque and the total volume of the permanent magnet at each design point. In step ③, the Taylor series expansion of the full second-order polynomial model is: , Where x1, x2, ..., x k All are independent variables, β1, β2, ..., β k All are polynomial coefficients, and k is the number of independent variables.

[0019] This invention provides a magnetic coupler for a reactor based on a 90° Halbach array and its optimized design method. Compared with the prior art, the advantages of this invention are: (1) The present invention provides a magnetic coupler for a reactor based on a 90° Halbach array. Both the outer magnet and the inner magnet are arranged in a 90° Halbach array. The outer magnet is arranged in a 90° Halbach array to enhance the magnetic induction intensity on its inner side, and the inner magnet is arranged in a 90° Halbach array to enhance the magnetic induction intensity on its outer side. The arrays of the outer magnet and the inner magnet are different. This combined effect can enhance the magnetic induction intensity in the air gap region, significantly enhance the magnetic field strength in the air gap, effectively improve the maximum transmission torque, and significantly improve the utilization rate of permanent magnets, save the amount of permanent magnets used, and reduce costs.

[0020] (2) This invention provides an optimized design method for a magnetic coupler for a reactor based on a 90° Halbach array. Combining experimental and simulation verification, a multi-objective parameterized optimization design method is adopted to find the optimal design combination, which effectively improves the maximum static magnetic torque of the magnetic coupler. Under the condition of maximum transmission torque, the amount of permanent magnets is reduced, achieving lightweighting of the magnetic coupler and reducing costs. It is economical, efficient in design and development, and highly practical. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of this application, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0022] Figure 1 A schematic diagram of a magnetic coupler for a reactor based on a 90° Halbach array is provided in one embodiment of this application; Figure 2 for Figure 1 The diagram shows a partial structural schematic of a magnetic coupler for a reactor based on a 90° Halbach array (without the outer support water jacket). Figure 3 for Figure 1 The diagram shows a partial cross-sectional structure of a magnetic coupler for a reactor based on a 90° Halbach array. Figure 4 for Figure 1 The diagram shows a single-ring inner and outer magnet ring structure of a magnetic coupler for a reactor based on a 90° Halbach array. The arrows indicate the magnetization direction, pointing from the N pole to the S pole. Figure 5 for Figure 1 The diagram shows a multi-ring inner and outer magnet ring structure for a magnetic coupler for a reactor based on a 90° Halbach array. The arrows indicate the magnetization direction, pointing from the N pole to the S pole. Figure 6 This is a schematic diagram of the magnet arrangement of a magnetic coupler for a conventional array reactor, where the arrows indicate the magnetization direction, pointing from the N pole to the S pole; Figure 7 for Figure 1 The diagram shows the magnet arrangement of a magnetic coupler for a reactor based on a 90° Halbach array. The arrows indicate the magnetization direction, pointing from the N pole to the S pole. Figure 8 Magnetic flux density contour plot of a magnetic coupler for a conventional array reactor; Figure 9 for Figure 1 The magnetic flux density contour map shown is for a magnetic coupler for a reactor based on a 90° Halbach array. Figure 10 The maximum torque value is transmitted through 24 rings of a magnetic coupler used in a conventional array of reactors. Figure 11 for Figure 1 The maximum torque value is transmitted by a 24-ring magnetic coupler for a reactor based on a 90° Halbach array. Figure 12 A flowchart illustrating an optimized design method for a magnetic coupler for a reactor based on a 90° Halbach array, provided as an embodiment of this application; Figure 13 A curve showing the relationship between the maximum static magnetic torque of a single ring and the number of poles in an optimized design method for a magnetic coupler for a reactor based on a 90° Halbach array, provided in an embodiment of this application; Figure 14 for Figure 13 The multi-objective optimization response surface of the optimization design method for magnetic couplers for reactors based on a 90° Halbach array is shown. Figure 15 for Figure 13 The scatter plot shows the goodness-of-fit of the multi-objective optimization response surface of the optimization design method for magnetic couplers for reactors based on a 90° Halbach array. Figure 16 for Figure 13 The optimization results of candidate points are shown in the optimization design method for magnetic couplers for reactors based on a 90° Halbach array.

[0023] Explanation of symbols in the diagram: 1. Sealing cover cylinder; 2. Outer magnet support sleeve; 3. Outer magnet; 4. Inner magnet support sleeve; 5. Inner magnet; 6. Outer support water jacket; 7. Turbulence vane; 8. Guide semi-pipe vane; 9. Spiral heat exchange coil; 901. Inlet; 902. Outlet; 10. Air gap area; 11. Inner magnet ring; 12. Outer magnet ring; 13. First magnet ring; 14. Second magnet ring; 15. Third magnet ring. Detailed Implementation

[0024] To make the technical problems, technical solutions, and beneficial effects to be solved by this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and are not intended to limit the scope of this application.

[0025] It should be noted that when a component is referred to as being "fixed" or "set" to another component, it can be directly or indirectly attached to that other component. When a component is referred to as being "connected" to another component, it can be directly or indirectly connected to that other component.

[0026] It should be understood that the terms "length," "width," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and should not be construed as indicating or implying that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on this application. Furthermore, the terms "first," "second," and "third," etc., are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0027] (a) Magnetic coupler for reactors based on 90° Halbach array Please see Figure 1 This is a schematic diagram of a magnetic coupler for a reactor based on a 90° Halbach array, provided in one embodiment of this application. For ease of explanation, only the parts relevant to this embodiment are shown, and are described in detail below: In one embodiment, please refer to Figures 2-4 and Figure 7 A magnetic coupler for a reactor based on a 90° Halbach array includes a sealed cover cylinder 1. An outer magnet support sleeve 2 is rotatably connected to the outside of the sealed cover cylinder 1. Several outer magnets 3 are provided on the outer magnet support sleeve 2. An inner magnet support sleeve 4 is rotatably connected to the inside of the sealed cover cylinder 1. Several inner magnets 5 are provided on the inner magnet support sleeve 4. Both the outer magnets 3 and the inner magnets 5 are arranged according to a 90° Halbach array. The outer magnets 3 are arrayed according to a 90° Halbach array to enhance the magnetic induction intensity on their inner side. The inner magnets 5 are arrayed according to a 90° Halbach array to enhance the magnetic induction intensity on their outer side.

[0028] The air gap region 10 refers to the area sandwiched between the outer magnet 3 and the inner magnet 5, formed by the outer side of the inner magnet 5 and the inner side of the outer magnet 3. This invention arranges both the outer magnet 3 and the inner magnet 5 in a 90° Halbach array. The outer magnet 3 is arranged in a 90° Halbach array to enhance the magnetic induction intensity on its inner side, while the inner magnet 5 is arranged in a 90° Halbach array to enhance the magnetic induction intensity on its outer side. The different array arrangements of the outer magnet 3 and the inner magnet 5 work together to enhance the magnetic induction intensity of the air gap region 10, significantly increasing the magnetic field strength within the air gap, effectively improving the maximum transmission torque, and significantly increasing the utilization rate of the permanent magnets, saving on the amount of permanent magnets used and reducing costs.

[0029] In use, the outer magnet support sleeve 2 is driven to rotate by an external power source. An outer magnet 3 is fixed on the outer magnet support sleeve 2, and the outer magnet 3 rotates synchronously with the outer magnet support sleeve 2. The inner magnet 5 and the outer magnet 3 are separated by a stationary sealing cover cylinder 1. Due to the magnetic force between the inner magnet 5 and the outer magnet 3, the rotation of the outer magnet 3 will cause the inner magnet 5 to rotate as well. The inner magnet 5 is mounted on the inner magnet support sleeve 4, and the inner magnet support sleeve 4 also rotates together. This completes the non-contact transmission of power from the outside of the sealing cover cylinder 1 to the inside of the sealing cover cylinder 1. The bottom end of the inner magnet support sleeve 4 is connected to an external reactor stirrer.

[0030] For details, please refer to Figure 4 and Figure 7 A plurality of outer magnets 3 on the outer magnet support sleeve 2 form an outer magnet ring 12. The outer magnets 3 are arranged in a 90° Halbach array to enhance the magnetic induction intensity on the inner side of the outer magnet ring 12. A plurality of inner magnets 5 on the inner magnet support sleeve 4 form an inner magnet ring 11. The inner magnets 5 are arranged in a 90° Halbach array to enhance the magnetic induction intensity on the outer side of the inner magnet ring 11. The array methods of the outer magnets 3 and the inner magnets 5 are different, and the number of poles of the outer magnets 3 and the inner magnets 5 are equal. In this embodiment, the magnetization direction of the outer magnet ring 12 in one cycle is up, left, down, and right, and the magnetization direction of the inner magnet ring 11 in one cycle is down, left, up, and right. Other magnetization directions can also be used, as long as the outer magnet ring 12 and the inner magnet ring 11 can jointly enhance the magnetic induction intensity of the air gap region 10.

[0031] Please see Figure 5 and Figure 7 The inner magnet ring 11 and the outer magnet ring 12 combine to form a magnet ring. Several magnet rings can be configured, such as... Figure 5 As shown, the first magnet ring 13, the second magnet ring 14, and the third magnet ring 15 are arranged in the same way.

[0032] In one embodiment, please refer to Figures 2-3Both the outer magnet 3 and the inner magnet 5 are shaped like thick tiles, with a thickness greater than 1.4 times the width of the air gap. The thick tile-shaped outer magnet 3 and inner magnet 5 can fit tightly against the outer magnet support sleeve 2 and the inner magnet support sleeve 4, reducing magnetic leakage. The thicknesses of the outer magnet 3 and inner magnet 5 can be equal or unequal.

[0033] In one embodiment, please refer to Figures 1-3 The outer magnet 3 is bonded to the inner side of the outer magnet support sleeve 2, and the inner magnet 5 is bonded to the outer side of the inner magnet support sleeve 4. In this embodiment, the outer magnet 3 and the inner magnet 5 are both fixed by strong adhesive, which is simple, stable, and easy to implement. For medium and low speeds below 300 rpm, the bonding method is sufficient to meet the requirements of long-term stable operation of the magnetic coupler.

[0034] In one embodiment, please refer to Figures 1-3 An outer support water jacket 6 is fitted on the outer side of the outer magnet support sleeve 2, and the bottom end of the outer support water jacket 6 is sealed to the bottom end of the sealing cover cylinder 1.

[0035] In one embodiment, please refer to Figures 1-2 The bottom end of the outer magnet support sleeve 2 is provided with several irregularly shaped turbulence blades 7 evenly distributed around the circumference, and the top end of the outer magnet support sleeve 2 is provided with several circumferentially distributed guide semi-pipe blades 8, which penetrate the outer magnet support sleeve 2.

[0036] During the synchronous transmission of the outer magnet 3 and the inner magnet 5, the magnetic field lines in the air gap region 10 will cut the stationary sealing cover cylinder 1, generating eddy current heat. This causes the sealing cover cylinder 1 to heat up. If the temperature of the sealing cover cylinder 1 is too high, it will affect the temperature of the outer magnet 3 and the inner magnet 5, thereby affecting their magnetism. Therefore, heat removal measures must be taken to remove the eddy current heat generated on the sealing cover cylinder 1 in a timely manner to prevent the outer magnet 3 and the inner magnet 5 from being demagnetized due to excessive temperature.

[0037] Cooling medium is added into the cavity formed by the sealing cover cylinder 1 and the outer support water jacket 6, and the cooling medium carries away the eddy current heat on the sealing cover cylinder 1. In order to enhance the flow rate and circulation of the cooling medium, irregularly shaped turbulence blades 7 are added to the bottom end of the outer magnet support sleeve 2 to turbulently accelerate the cooling medium, and guide semi-pipe blades 8 are added to the top end to guide the cooling medium. The turbulence blades 7 at the bottom end can turbulently move the cooling medium as the outer magnet support sleeve 2 rotates, so that the cooling medium can obtain a higher flow rate, thereby forming a low-pressure zone. The guide semi-pipe blades 8 at the top end can entrain the cooling medium. In this way, a circulation flow of the cooling medium from top to bottom is formed in the narrow air gap area 10. The effective circulation flow can remove the heat on the sealing cover cylinder 1 in time, so as to achieve the purpose of heat removal and cooling. The combination of the turbulence blades 7 and the guide semi-pipe blades 8 forms an effective circulating flow in the air gap region 10, which can enhance the flow rate and circulation performance of the cooling medium, effectively increase the convective heat transfer coefficient of the sealing cover cylinder 1, and strengthen the overall heat dissipation capability of the magnetic coupler.

[0038] The cooling medium can be water, ethylene glycol solution, or other types of cooling medium.

[0039] In one embodiment, please refer to Figures 1-2 The outer magnet support sleeve 2 is surrounded by a spiral heat exchange coil 9. The bottom and top of the spiral heat exchange coil 9 are respectively provided with an inlet 901 and an outlet 902. Both the inlet 901 and the outlet 902 pass through the outer support water jacket 6 and extend to the outside of the outer support water jacket 6.

[0040] To improve the heat dissipation and cooling effect, a spiral heat exchange coil 9 is installed on the outside of the outer magnet support sleeve 2. Cooling medium is introduced into the spiral heat exchange coil 9. The cooling medium enters from the inlet 901, moves through the spiral, and is discharged from the outlet 902. The heat generated by the sealing cover cylinder 1 is first transferred to the cooling medium located in the cavity formed by the sealing cover cylinder 1 and the outer support water jacket 6, and then transferred to the cooling medium inside the spiral heat exchange coil 9 through the tube wall. Finally, the cooling medium inside the spiral heat exchange coil 9 carries away the heat.

[0041] Currently, eddy current heat in magnetic couplers on reactors is mostly cooled directly, resulting in low heat removal efficiency and excessively high operating temperatures of the permanent magnets. This invention employs indirect cooling, which provides excellent heat removal and cooling effects. Furthermore, indirect cooling significantly reduces the requirements for impurity content and oxygen content in the cooling medium within the spiral heat exchange coil 9. This avoids the problems associated with direct cooling, such as the presence of high levels of impurities in the cooling medium that can easily enter the air gap region 10 and affect transmission efficiency, as well as the oxidation and corrosion of the permanent magnets caused by high oxygen content in the cooling medium.

[0042] In one embodiment, please refer to Figures 1-3 The outer magnet 3 and the inner magnet 5 are made of N52SH material, the sealing cover cylinder 1 is made of stainless steel, and the other parts are made of Q235 steel.

[0043] Please see Figures 6-7 The diagrams show the magnet arrangements for magnetic couplers used in reactors, specifically a conventional array and a 90° Halbach array. The arrows indicate the magnetization direction, pointing from the N pole to the S pole. Comparing the two array types, it can be seen that the permanent magnets in the conventional array are magnetized radially in two directions: one radially towards the center, and the other radially away from the center. Adjacent permanent magnets form an angle of approximately 180 degrees. In terms of pole number, each pair of adjacent permanent magnets in the conventional array constitutes one pole. The magnetic field strength is equal on both the inner and outer sides of the inner magnet ring in the conventional array, and the same applies to the outer magnet ring; therefore, there is no magnetic focusing characteristic. The 90° Halbach array uses a 90° magnetization method, with the magnetization directions of adjacent permanent magnets forming an angle of approximately 90 degrees with each other. In addition to the two magnetization directions of ordinary arrays, two tangential magnetization directions are added, for a total of four magnetization directions. In terms of the number of poles, every four adjacent permanent magnets form a pole, and the number of poles of the inner and outer magnets must be equal to achieve the coupling process.

[0044] Please see Figures 8-9 The figures show the magnetic induction intensity cloud diagrams of the magnetic couplers for the reactor using a conventional array and a 90° Halbach array, respectively. These were obtained through simulation calculations. A comparison of the two array types shows that, when the scale is the same, the magnetic induction intensity of the 90° Halbach array is greater within the air gap region 10.

[0045] Please see Figures 10-11 The maximum torque transmitted by the 24 rings of the magnetic coupler for the reactor using a conventional array and a 90° Halbach array are shown in the figures, obtained through simulation calculations. The horizontal axis represents the angular difference in rotation between the inner and outer magnets, and the vertical axis represents the change in torque experienced by the inner or outer magnet with respect to the rotation angle. Comparing the two array types, the maximum transmitted torque of the conventional array is 58 kNm, while the maximum transmitted torque of the 90° Halbach array is 80 kNm. This represents a 37.93% increase in maximum torque compared to the conventional array, demonstrating a significant improvement.

[0046] (II) Optimization Design Method for Magnetic Couplers for Reactors Based on 90° Halbach Array Please see Figure 12The flowchart below illustrates an optimized design method for a magnetic coupler for a reactor based on a 90° Halbach array, according to an embodiment of this application. For ease of explanation, only the parts relevant to this embodiment are shown, and are detailed below: In one embodiment, an optimization design method for a magnetic coupler for a reactor based on a 90° Halbach array is provided. The optimization design of the aforementioned magnetic coupler for a reactor based on a 90° Halbach array specifically includes the following steps: S1: Using the simulation software Ansys Maxwell, electromagnetic simulation calculations were performed on the maximum static magnetic torque of the ordinary array magnetic coupler and the 90° Halbach array magnetic coupler. The simulation results were compared and analyzed. Based on the simulation results, the improvement of the maximum static magnetic torque of the 90° Halbach array magnetic coupler relative to the ordinary array magnetic coupler was determined, thereby determining the optimization direction. If the maximum static magnetic torque of the 90° Halbach array magnetic coupler is improved compared to that of the ordinary array magnetic coupler, the 90° Halbach array magnetic coupler will be further optimized; if the maximum static magnetic torque of the 90° Halbach array magnetic coupler is reduced compared to that of the ordinary array magnetic coupler or the difference between the two is not significant, the ordinary array magnetic coupler will be further optimized.

[0047] S2: Conduct experimental tests on ordinary array magnetic couplers, and compare and analyze the Ansys Maxwell electromagnetic simulation results of the maximum static magnetic torque with the experimental results. Based on the deviation range between the simulation results and the experimental results, clarify the reliability of the simulation calculation model. If the deviation between the simulation result and the experimental result of the maximum static magnetic torque is within 0-10%, the simulation calculation model is considered to have high credibility and can be used as the basis for subsequent optimization design; if the deviation between the simulation result and the experimental result is large, it is necessary to analyze the calculation conditions of the simulation model and the experimental testing methods.

[0048] S3: Using the simulation software Ansys Maxwell, electromagnetic simulation calculations were performed on the 90° Halbach array magnetic coupler to obtain the relationship curve between the maximum static magnetic torque of a single loop and the number of poles, thereby determining the optimal number of poles. Under the optimal number of poles, the maximum static magnetic torque of the 90° Halbach array magnetic coupler is the largest.

[0049] S4: Under the optimal pole number, while ensuring the air gap width remains unchanged, the 90° Halbach array magnetic coupler is optimized using the Ansys DesignXplorer optimization design platform and a multi-objective parametric optimization design method. The maximum static magnetic torque and the minimum total volume of the permanent magnet are set as the optimization objectives. The specific steps are as follows: ① Set the dimensions of the 90° Halbach array magnetic coupler as parameters, and give the five key design variables of the 90° Halbach array magnetic coupler, with the following constraints: , Wherein, inRi represents the inner diameter of the inner magnet ring, inRi1 is the lower limit of inRi, and inRi2 is the upper limit of inRi; inRo represents the outer diameter of the inner magnet ring, inRo1 is the lower limit of inRo, and inRo2 is the upper limit of inRo; ouRo represents the outer diameter of the outer magnet ring, ouRo1 is the lower limit of ouRo, and ouRo2 is the upper limit of ouRo; angle represents the relative rotation angle between the inner and outer magnet rings, angle1 is the lower limit of angle, and angle2 is the upper limit of angle; hight represents the height of the inner and outer magnets, hight1 is the lower limit of hight, and hight2 is the upper limit of hight; the heights of the inner and outer magnets are equal, and the air gap width remains unchanged; the units of inRi, inRo, ouRo, and hight are mm, and the unit of angle is °. ② Using a central composite design (CCD), experimental sampling was conducted on the five key design variables in step ① to obtain several design points. Then, the simulation software Ansys Maxwell was used to calculate the maximum static magnetic torque and the total volume of the permanent magnet at each design point. ③ Use the full second-order polynomial method to fit several design points in step ② to construct a response surface, and use a goodness-of-fit scatter plot to evaluate the goodness of fit of the response surface. The Taylor series expansion of the all-second-order polynomial model is: , Where x1, x2, ..., x k All are independent variables, β1, β2, ..., β k All are polynomial coefficients, where k is the number of independent variables; ④ The response surface constructed in step ③ is optimized using a multi-objective genetic algorithm (Moga) to obtain several candidate points. The candidate points are then simulated and verified, and the simulation results of the candidate points are compared and analyzed to obtain the maximum static magnetic torque and the minimum total volume of the permanent magnet. The five key design variables of the candidate points corresponding to the maximum static magnetic torque and the minimum total volume of the permanent magnet are the optimal dimensions of the 90° Halbach array magnetic coupler.

[0050] (III) Specific Implementation Examples of the Optimization Design Method for Magnetic Couplers for Reactors Based on 90° Halbach Array An optimized design method for a magnetic coupler for a reactor based on a 90° Halbach array includes the following steps: S1: Using the simulation software Ansys Maxwell, electromagnetic simulation calculations were performed on the maximum static magnetic torque of the ordinary array magnetic coupler and the 90° Halbach array magnetic coupler. The simulation results were compared and analyzed. Based on the simulation results, the improvement of the maximum static magnetic torque of the 90° Halbach array magnetic coupler compared with the ordinary array magnetic coupler was determined, thereby determining the optimization direction.

[0051] The simulation results are shown in Table 1.

[0052] Table 1. Simulation results of maximum static torque for ordinary array and 90° Halbach array magnetic couplers.

[0053] As shown in Table 1, compared with ordinary array magnetic couplers, the maximum static magnetic torque of the magnetic coupler using the 90° Halbach array is effectively improved. The maximum static magnetic torque of ring 1 is improved by 30.03%, ring 2 by 32.00%, ring 3 by 34.27%, and ring 4 by 38.99%. The overall improvement in maximum static magnetic torque is significant, thus determining that the 90° Halbach array magnetic coupler should be further optimized.

[0054] S2: Conduct experimental tests on ordinary array magnetic couplers, and compare and analyze the Ansys Maxwell electromagnetic simulation results of the maximum static magnetic torque with the experimental results. Based on the deviation range between the simulation results and the experimental results, clarify the reliability of the simulation calculation model.

[0055] The results are shown in Table 2.

[0056] Table 2 Simulation and experimental results of the maximum static magnetic torque of the conventional array magnetic coupler

[0057] Table 2 shows that the deviations between the electromagnetic simulation results and the experimental results are as follows: Ring 1 deviation -0.88%, Ring 2 deviation 3.98%, Ring 3 deviation 4.11%, and Ring 4 deviation 6.20%. All of these deviations are within the allowable deviation range (0-10%) of engineering calculations, indicating that the simulation calculation model has high reliability and can be further optimized.

[0058] S3: Using the simulation software Ansys Maxwell, electromagnetic simulation calculations were performed on the 90° Halbach array magnetic coupler to obtain the relationship curve between the maximum static magnetic torque of a single loop and the number of poles, thereby determining the optimal number of poles. Under the optimal number of poles, the maximum static magnetic torque of the 90° Halbach array magnetic coupler is the largest.

[0059] The results are as follows Figure 13 As shown.

[0060] Depend on Figure 13 It is known that the maximum static magnetic torque of magnetic couplers with different pole numbers is different. For a 90° Halbach array magnetic coupler, the optimal pole number is 7, which means that four permanent magnets form one pole, the inner magnet ring has a total of 7 poles, and there are a total of 28 inner magnets; the outer magnet ring has a total of 7 poles, and there are a total of 28 outer magnets, for a total of 56 permanent magnets.

[0061] S4: Under the optimal pole number and while maintaining a constant air gap width, the 90° Halbach array magnetic coupler was optimized using the Ansys DesignXplorer optimization platform and a multi-objective parametric optimization design method. The maximum static magnetic torque and the minimum total permanent magnet volume were set as the optimization objectives. Before optimization, the maximum static magnetic torque of the 90° Halbach array magnetic coupler was 4450 N·m, and the total volume was 5059 cm³. 3 The specific steps are as follows: ① Set the dimensions of the 90° Halbach array magnetic coupler as parameters, and give the five key design variables of the 90° Halbach array magnetic coupler, with the following constraints: , Wherein, inRi represents the inner diameter of the inner magnet ring, inRo represents the outer diameter of the inner magnet ring, ouRo represents the outer diameter of the outer magnet ring, angle represents the relative rotation angle of the inner and outer magnet rings, and hight represents the height of the inner and outer magnets. The heights of the inner and outer magnets are equal, and the air gap width remains unchanged.

[0062] ② Using a central composite design (CCD), experimental sampling was conducted on the five key design variables in step ① to obtain 28 design points. Then, the simulation software Ansys Maxwell was used to calculate the maximum static magnetic torque and the total volume of the permanent magnet at each design point.

[0063] ③ The 28 design points from step ② are fitted using a fully second-order polynomial method to construct the response surface, such as... Figure 14 As shown, a goodness-of-fit scatter plot is used to evaluate the goodness of fit of the response surface, as follows. Figure 15 As shown; The Taylor series expansion of the all-second-order polynomial model is: , Where x1, x2, ..., x k All are independent variables, β1, β2, ..., β k All are polynomial coefficients, and k is the number of independent variables.

[0064] Please see Figure 15 The plot is a scatter plot of goodness-of-fit, with the horizontal axis representing the calculated values ​​at the design points and the vertical axis representing the predicted values ​​of the response surface, indicating the degree of fit between the predicted response surface values ​​and the calculated values ​​at the design points. Figure 15 As can be seen, the scatter points are mostly near the 45° line, which proves that the goodness of fit of the response is high.

[0065] ④ The response surface constructed in step ③ is optimized using a multi-objective genetic algorithm (Moga) to obtain three candidate points. The candidate points are then simulated and verified, and the simulation results of the three candidate points are compared and analyzed to obtain the maximum static magnetic torque and the minimum total volume of the permanent magnet. The five key design variables of the candidate points corresponding to the maximum static magnetic torque and the minimum total volume of the permanent magnet are the optimal dimensions of the 90° Halbach array magnetic coupler.

[0066] The results are as follows Figure 16 As shown.

[0067] Depend on Figure 16 It can be seen that, taking candidate point 3, its maximum torque is 4393.5 N·m, and its volume is 4646.2 cm³. 3 Compared to the parameters before optimization: the maximum static torque is 4450 N·m, and the total volume is 5059 cm³. 3 As can be seen, the maximum torque is reduced by 1.27%, which is within the allowable design deviation range, while the volume is reduced by 8.16%, resulting in a cost reduction of over 8%. Therefore, it can be determined that after optimization, the overall volume is significantly smaller while still achieving the maximum torque.

[0068] Therefore, the maximum static magnetic torque of the 90° Halbach array magnetic coupler is 4393.5 N·m, and the minimum total volume of the permanent magnet is 4646.2 cm³. 3 The five key design variables are: inRi = 208.94 mm, inRo = 252.26 mm, ouRo = 314.43 mm, angle = 12.505°, and height = 34.132 mm. These are the optimized dimensions for the 90° Halbach array magnetic coupler.

[0069] In summary, this invention provides a magnetic coupler for reactors based on a 90° Halbach array. Both the outer and inner magnets are arranged in a 90° Halbach array. The outer magnets are arrayed to enhance the magnetic induction intensity on their inner side, while the inner magnets are arrayed to enhance the magnetic induction intensity on their outer side. The different array configurations of the outer and inner magnets work together to enhance the magnetic induction intensity in the air gap region, significantly increasing the magnetic field strength within the air gap, effectively improving the maximum transmission torque, and significantly improving the utilization rate of permanent magnets, saving on the amount of permanent magnets used and reducing costs. This invention also provides an optimized design method for the magnetic coupler for reactors based on a 90° Halbach array. Combining experimental and simulation verification, a multi-objective parametric optimization design method is used to find the optimal design combination, effectively improving the maximum static magnetic torque of the magnetic coupler. Under the condition of maximum transmission torque, the amount of permanent magnets used is reduced, achieving a lightweight magnetic coupler with reduced costs, high economic efficiency, high design and development efficiency, and high practicality. This invention can be widely applied in the field of magnetically driven reactor technology.

[0070] The above-described embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application, and should all be included within the protection scope of this application.

Claims

1. A magnetic coupler for a reactor based on a 90° Halbach array, comprising a sealed cover cylinder (1), an outer magnet support sleeve (2) rotatably connected to the outer side of the sealed cover cylinder (1), a plurality of outer magnets (3) being provided on the outer magnet support sleeve (2), and an inner magnet support sleeve (4) rotatably connected to the inner magnet support sleeve (4), a plurality of inner magnets (5) being provided on the inner magnet support sleeve (4), characterized in that, Both the outer magnet (3) and the inner magnet (5) are arranged in a 90° Halbach array. The outer magnet (3) is arranged in a 90° Halbach array to enhance the magnetic induction intensity on its inner side, and the inner magnet (5) is arranged in a 90° Halbach array to enhance the magnetic induction intensity on its outer side.

2. The magnetic coupler for a reactor based on a 90° Halbach array according to claim 1, characterized in that, The outer magnet (3) and the inner magnet (5) are both designed to be in the shape of thick tiles, with a thickness greater than 1.4 times the width of the air gap.

3. The magnetic coupler for a reactor based on a 90° Halbach array according to claim 1, characterized in that, The outer magnet (3) is bonded to the inside of the outer magnet support sleeve (2), and the inner magnet (5) is bonded to the outside of the inner magnet support sleeve (4).

4. The magnetic coupler for a reactor based on a 90° Halbach array according to claim 1, characterized in that, The outer magnet support sleeve (2) is fitted with an outer support water sleeve (6), and the bottom end of the outer support water sleeve (6) is sealed to the bottom end of the sealing cover cylinder (1).

5. The magnetic coupler for a reactor based on a 90° Halbach array according to claim 4, characterized in that, The bottom end of the outer magnet support sleeve (2) is provided with several irregularly shaped turbulence blades (7) evenly distributed around the circumference, and the top end of the outer magnet support sleeve (2) is provided with several circumferentially distributed flow-guiding semi-pipe blades (8), and the flow-guiding semi-pipe blades (8) penetrate the outer magnet support sleeve (2).

6. The magnetic coupler for a reactor based on a 90° Halbach array according to claim 4, characterized in that, The outer magnet support sleeve (2) is surrounded by a spiral heat exchange coil (9). The bottom and top ends of the spiral heat exchange coil (9) are respectively provided with an inlet (901) and an outlet (902). The inlet (901) and the outlet (902) both penetrate the outer support water jacket (6) and extend to the outside of the outer support water jacket (6).

7. An optimized design method for a magnetic coupler for a reactor based on a 90° Halbach array, characterized in that, The optimized design of the magnetic coupler for the reactor based on the 90° Halbach array according to any one of claims 1-6 specifically includes the following steps: S1: The maximum static magnetic torque of the ordinary array magnetic coupler and the 90° Halbach array magnetic coupler are simulated and calculated, and the simulation results are compared and analyzed. Based on the simulation results, the improvement of the maximum static magnetic torque of the 90° Halbach array magnetic coupler relative to the ordinary array magnetic coupler is determined, thereby determining the optimization direction. S2: Conduct experimental tests on ordinary array magnetic couplers, and compare and analyze the simulation results of the maximum static magnetic torque with the experimental results. Based on the deviation range between the simulation results and the experimental results, clarify the reliability of the simulation calculation model. S3: Simulation calculations were performed on the 90° Halbach array magnetic coupler to obtain the relationship curve between the maximum static magnetic torque of a single loop and the number of poles, thereby determining the optimal number of poles; S4: Optimize the 90° Halbach array magnetic coupler using a multi-objective parametric optimization design method at the optimal pole number: ① Set the dimensions of the 90° Halbach array magnetic coupler as parameters, and give the five key design variables of the 90° Halbach array magnetic coupler, with the following constraints: ， Wherein, inRi represents the inner diameter of the inner magnet ring, inRi1 is the lower limit of inRi, and inRi2 is the upper limit of inRi; inRo represents the outer diameter of the inner magnet ring, inRo1 is the lower limit of inRo, and inRo2 is the upper limit of inRo; ouRo represents the outer diameter of the outer magnet ring, ouRo1 is the lower limit of ouRo, and ouRo2 is the upper limit of ouRo; angle represents the relative rotation angle between the inner and outer magnet rings, angle1 is the lower limit of angle, and angle2 is the upper limit of angle; hight represents the height of the inner and outer magnets, hight1 is the lower limit of hight, and hight2 is the upper limit of hight; the heights of the inner and outer magnets are equal, and the air gap width remains unchanged; the units of inRi, inRo, ouRo, and hight are mm, and the unit of angle is °. ② Experimentally sample the 5 key design variables in step ① to obtain several design points, and calculate the maximum static magnetic torque and the total volume of the permanent magnet at each design point through simulation. ③ Use the full second-order polynomial method to fit several design points in step ② to construct a response surface, and use a goodness-of-fit scatter plot to evaluate the goodness of fit of the response surface. ④ The multi-objective genetic algorithm Moga is used to optimize the response surface constructed in step ③ to obtain several candidate points. The candidate points are then simulated and verified, and the simulation verification results of several candidate points are compared and analyzed to obtain the maximum static magnetic torque and the minimum total volume of permanent magnets. The five key design variables of the candidate points corresponding to the maximum static magnetic torque and the minimum total volume of permanent magnets are the optimal dimensions of the 90° Halbach array magnetic coupler.

8. The optimized design method for a magnetic coupler for a reactor based on a 90° Halbach array according to claim 7, characterized in that, In steps S1, S2 and S3, electromagnetic simulation calculations are performed using the simulation software Ansys Maxwell.

9. The optimized design method for a magnetic coupler for a reactor based on a 90° Halbach array according to claim 7, characterized in that, In step S2, if the deviation between the simulation result and the experimental result of the maximum static torque is within 0-10%, the simulation calculation model is considered to have high credibility.

10. The optimized design method for a magnetic coupler for a reactor based on a 90° Halbach array according to claim 7, characterized in that, In step S4, the Ansys DesignXplorer optimization design platform is used for multi-objective parametric optimization design. Specifically, in step ②, a central composite design CCD is used for experimental sampling, and the AnsysMaxwell simulation software is used to calculate the maximum static magnetic torque and the total volume of the permanent magnet at each design point. In step ③, the Taylor series expansion of the full second-order polynomial model is: ， Where x1, x2, ..., x k All are independent variables, β1, β2, ..., β k All are polynomial coefficients, and k is the number of independent variables.

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