Magnetic coupling device

Abstract

A magnetic coupling device for magnetically coupling to a ferromagnetic workpiece may comprise a switchable magnetic flux source being switchable between a plurality of states. The switchable magnetic flux source including at least one rare earth permanent magnet having a north pole and a south pole and a first magnetic field strength and at least one electro-permanent magnet. The magnetic coupling device may further comprise a plurality of pole portions including a first north pole portion positioned to be magnetically coupled with the north pole of the at least one rare earth permanent magnet and a first south pole portion positioned to be magnetically coupled with the south pole of the at least one rare earth permanent magnet. The plurality of pole portions having a workpiece engagement interface having at least one workpiece engagement surface.

Description

MAGNETIC COUPLING DEVICERELATED APPLICATION

[0001] The present application claims the benefit of U.S. Provisional Application No. 63 / 621 ,623, filed January 17, 2024, the entire disclosure of which is expressly incorporated by reference.TECHNICAL FIELD

[0002] The present disclosure is related to magnetic coupling devices and in particular to magnetic coupling devices having at least one rare earth permanent magnet and at least one electro-permanent magnet.BACKGROUND

[0003] Magnetic coupling devices are known. Exemplary coupling devices are disclosed in US Patent No. 7012495, US Patent No. 8878639, and US Published Patent Application No. 20180311795.

[0004] It is known to have magnetic coupling devices with rare earth magnets. Exemplary rare earth magnets include neodymium (NdFeB) permanent magnets. It is known to have magnetic coupling devices with electro-permanent magnets.Exemplary electro-permanent magnets include an iron alloy, such as Alnico (AINiCo) electro-permanent magnets.SUMMARY

[0005] In an exemplary embodiment of the present disclosure, a magnetic coupling device for magnetically coupling to a ferromagnetic workpiece is provided. The magnetic coupling device comprising a switchable magnetic flux source and a plurality of pole portions. The switchable magnetic flux source being switchable between a plurality of states. The switchable magnetic flux source including at least one non-reversible permanent magnet having a north pole and a south pole and afirst magnetic field strength and at least one reversible magnet. The plurality of pole portions including a first north pole portion positioned to be magnetically coupled with the north pole of the at least one non-reversible permanent magnet and a first south pole portion positioned to be magnetically coupled with the south pole of the at least one non-reversible permanent magnet. Each of the plurality of pole portions having a workpiece engagement interface having at least one workpiece engagement surface. The plurality of states includes (a) an OFF state wherein a north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, a south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non- reversible permanent magnet, and the at least one reversible magnet has a second magnetic field strength generally equal to the first magnetic field strength of the at least one non-reversible permanent magnet; (b) a first ON state wherein the north pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non- reversible permanent magnet, and the at least one reversible magnet has a third magnetic field strength generally equal to or less than the first magnetic field strength of the at least one non-reversible permanent magnet; and (c) a second ON state wherein the north pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has a fourth magnetic field strength greater than the first magnetic field strength of the at least one non-reversible permanent magnet.

[0006] In an example thereof, in the OFF state of the plurality of states a first resultant magnetic field strength at the workpiece engagement surfaces is incapable of moving the ferromagnetic workpiece from a first position to a second position.

[0007] In another example thereof, in the second ON state of the plurality of states a second resultant magnetic field strength at the workpiece engagement surfaces is capable of moving the ferromagnetic workpiece from the first position to the second position.

[0008] In a further example thereof, wherein in the first ON state of the plurality of states a third resultant magnetic field strength at the workpiece engagement surfaces is capable of moving the ferromagnetic workpiece from the first position to the second position, the third resultant magnetic field strength at the workpiece engagement surfaces being less than the second resultant magnetic field strength at the workpiece engagement surfaces.

[0009] In another still example thereof, the magnetic coupling device further comprises a controller operatively coupled to the switchable magnetic flux source to control a current state of the plurality of states of the switchable magnetic flux source by controlling an orientation of the north pole and the south pole of the at least one reversible magnet and a magnitude of the magnetic field strength of the at least one elector-permanent magnet. In a variation thereof, the magnetic coupling device further comprises a housing supporting the switchable magnetic flux source and the plurality of pole portions. In another variation thereof, the housing and the plurality of pole portions are integrally formed. In a further variation thereof, the plurality of pole portions are removably coupled to the housing. In still another variation thereof, the controller is spaced apart from the housing such that the controller is not moveable with the housing. In yet another variation thereof, the controller is supported by the housing such that the controller is moveable with the housing.

[0010] In a further still example thereof, the plurality of states further includes at least two degaussing states to remove residual magnetism from the workpiece engagement interface of each of the plurality of pole portions. The at least two degaussing states including (d) a first degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversiblemagnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has a fifth magnetic field strength less than the first magnetic field strength of the at least one non-reversible permanent magnet; and (e) a second degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has a sixth magnetic field strength greater than the first magnetic field strength of the at least one non- reversible permanent magnet.

[0011] In yet another example thereof, the controller executes a degaussing sequence to remove residual magnetism from the workpiece engagement interface of each of the plurality of pole portions, the degaussing sequence including a plurality of degaussing states of the switchable magnetic flux source to generate an alternating magnetic field at the workpiece engagement interface of each of the plurality of pole portions over a time period. In a variation thereof, the plurality of degaussing states includes (d) a first degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has a fifth magnetic field strength less than the first magnetic field strength of the at least one non-reversible permanent magnet; and (e) a second degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has a sixth magnetic field strength greater than the first magnetic field strength of the at least one non- reversible permanent magnet. In another variation thereof, the plurality ofdegaussing states includes (f) a third degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has a seventh magnetic field strength less than the first magnetic field strength of the at least one non- reversible permanent magnet, the seventh magnetic field strength being greater than the fifth magnetic field strength; and (g) a fourth degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has an eighth magnetic field strength greater than the first magnetic field strength of the at least one non-reversible permanent magnet, the eighth magnetic field strength being less than the sixth magnetic field strength. In still another variation thereof, the plurality of degaussing states includes (h) a fifth degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has a ninth magnetic field strength less than the first magnetic field strength of the at least one non-reversible permanent magnet, the ninth magnetic field strength being greater than the seventh magnetic field strength; and (i) a sixth degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has a tenth magnetic field strength greater than the first magnetic field strength of the at least one non-reversible permanent magnet, the tenth magneticfield strength being less than the eighth magnetic field strength. In still a further variation, the degaussing sequence ends with the switchable magnetic flux source being in the OFF state. In yet still another variation, the degaussing sequence includes sequentially establishing the following states of the switchable magnetic flux source: one of the first degauss state and the second degauss state, the other of the first degauss state and the second degauss state, one of the third degauss state and the fourth degauss state, the other of the third degauss state and the fourth degauss state, one of the fifth degauss state and the sixth degauss state, the other of the fifth degauss state and the sixth degauss state, and the OFF state. In a further variation thereof, the degaussing sequence is to be performed by the controller while the workpiece contact interfaces are in contact with the ferromagnetic workpiece.

[0012] In a further example, a magnetic mass of the at least one reversible magnet is more than double a magnetic mass of the at least one non-reversible permanent magnet.

[0013] In still another example, a magnetic mass of the at least one reversible magnet is more than triple a magnetic mass of the at least one non-reversible permanent magnet.

[0014] In yet a further example thereof, a magnetic mass of the at least one reversible magnet is more than four times a magnetic mass of the at least one non- reversible permanent magnet.

[0015] In still yet a further example thereof the third magnetic field strength of the at least one reversible magnet is generally equal to the first magnetic field strength of the at least one non-reversible permanent magnet.

[0016] In a further still example thereof, the plurality of states further includes (d) a third ON state wherein the north pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has an eleventh magnetic field strength less than thethird magnetic field strength of the at least one reversible magnet and less than the first magnetic field strength of the at least one non-reversible permanent magnet.

[0017] In another still example thereof, the at least one non-reversible permanent magnet includes a first number of non-reversible permanent magnets and the at least one reversible magnet includes a second number of reversible magnets. In a variation thereof, the first number equals the second number. In another variation thereof, the second number is greater than the first number. In still another variation thereof, the first number is one. In still a further variation thereof, the first number of non-reversible permanent magnets and the second number of reversible magnets are positioned between an outer extent of the first north pole portion and an outer extent of the first south pole portion.

[0018] In yet still another example thereof, the at least one reversible magnet and the at least one non-reversible permanent magnet are vertically stacked.

[0019] In a further example thereof, a first non-reversible permanent magnet of the at least one non-reversible permanent magnet has an active N-S pole pair defined by a first plane, a second plane of the first non-reversible permanent magnet is perpendicular to the first plane and parallel to a longitudinal centerline plane of a first reversible magnet of the at least one reversible magnet, the second plane intersects the first reversible magnet. In a variation thereof, the longitudinal centerline plane of the first reversible magnet intersects the first non-reversible permanent magnet.

[0020] In yet still another example thereof, a first non-reversible permanent magnet of the at least one non-reversible permanent magnet has an active N-S pole pair defined by a first plane, a second plane of the first non-reversible permanent magnet is perpendicular to the first plane and parallel to a longitudinal centerline plane of a first reversible magnet of the at least one reversible magnet, the second plane is non-intersecting with the first reversible magnet. In a variation thereof, the second plane is non-intersecting with a second reversible magnet of the at least one reversible magnet. In another variation thereof, the first reversible magnet is on afirst side of the second plane and the second reversible magnet is on a second side of the second plane, the second side of the second plane being opposite the first side of the second plane. In still another variation thereof, the longitudinal centerline plane of the first reversible magnet intersects the first non-reversible permanent magnet.

[0021] In a further still example thereof, the at least one non-reversible permanent magnet includes a first number of non-reversible permanent magnets and the at least one reversible magnet includes a second number of reversible magnets and wherein the plurality of pole portions includes a third pole portion, and a first subset of the first number of non-reversible permanent magnets are positioned to be magnetically coupled with the first north pole portion and the first south pole portion and a second subset of the first number of non-reversible permanent magnets are positioned spaced apart from the first subset and to be magnetically coupled to the third pole portion and one of the first north pole portion and the first south pole portion. In a variation thereof, first subset of the first number of non-reversible permanent magnets and the second subset of the first number of non-reversible permanent magnets are supported by a common pole plate that includes the first north pole portion, the first south pole portion, and the third pole portion. In another variation thereof, the first number equals the second number. In still another variation thereof, a first one of the at least one non-reversible permanent magnet is rectilinear. In yet another variation thereof, a first one of the at least one reversible magnet is rectilinear. In a further variation thereof, the second number is greater than the first number.

[0022] In still another example thereof, each of plurality of pole portions includes a plurality of projections separated by a plurality of recesses, the plurality of projections collectively forming a workpiece contact interface of the respective pole portion.

[0023] In yet still another example thereof, each of the plurality of pole portions are movably coupled to the housing.

[0024] In still a further example thereof, each of the plurality of pole portions are fixedly coupled to the housing.

[0025] In yet still a further example thereof, the magnetic coupling device further comprises one or more sensors to determine a characteristic of a magnetic circuit present between the magnetic coupling device and the ferromagnetic workpiece to be coupled to the magnetic coupling device. In a variation thereof, the one or more sensors are supported by the housing and are spaced apart from the workpiece engagement interfaces of the plurality of pole portions.

[0026] In still yet a further example thereof, the at least one non-reversible magnet is an at least one rare earth permanent magnet. In a variation thereof, the at least one reversible magnet is an at least one electro-permanent magnet.

[0027] In another example thereof, the at least one reversible magnet is an at least one electro-permanent magnet.

[0028] In still another example thereof, the at least one reversible magnet has a plurality of set orientations for a north pole and a south pole and maintains a current orientation of the plurality of set orientations in the absence of an external characteristic.

[0029] In another exemplary embodiment of the present disclosure, a magnetic coupling device for magnetically coupling to a ferromagnetic workpiece is provided. The magnetic coupling device comprising a switchable magnetic flux source and a plurality of pole portions. The switchable magnetic flux source being switchable between a plurality of states. The switchable magnetic flux source including at least one non-reversible permanent magnet having a north pole and a south pole and a first magnetic field strength and at least one reversible magnet. The plurality of pole portions including a first north pole portion positioned to be magnetically coupled with the north pole of the at least one non-reversible permanent magnet and a first south pole portion positioned to be magnetically coupled with the south pole of the at least one non-reversible permanent magnet. Each of the plurality of pole portions having a workpiece engagement interfacehaving at least one workpiece engagement surface. The plurality of states includes at least two degaussing states to remove residual magnetism from the workpiece engagement interface of each of the plurality of pole portions. The at least two degaussing states including (a) a first degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has a fifth magnetic field strength less than the first magnetic field strength of the at least one non-reversible permanent magnet; and (b) a second degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has a sixth magnetic field strength greater than the first magnetic field strength of the at least one non- reversible permanent magnet.

[0030] In an example thereof, the magnetic coupling device further comprising a controller operatively coupled to the switchable magnetic flux source to control a current state of the plurality of states of the switchable magnetic flux source by controlling an orientation of the north pole and the south pole of the at least one reversible magnet and a magnitude of the magnetic field strength of the at least one reversible magnet. In a variation thereof, the magnetic coupling device further comprising a housing supporting the switchable magnetic flux source and the plurality of pole portions. In another variation thereof, the housing and the plurality of pole portions are integrally formed. In a further variation thereof, the plurality of pole portions are removably coupled to the housing. In yet another variation thereof, the controller is spaced apart from the housing such that the controller is not moveable with the housing. In still another variation thereof, the controller is supported by the housing such that the controller is moveable with the housing.

[0031] In another example thereof, the plurality of degaussing states includes (c) a third degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has a seventh magnetic field strength less than the first magnetic field strength of the at least one non-reversible permanent magnet, the seventh magnetic field strength being greater than the fifth magnetic field strength; and (d) a fourth degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non- reversible permanent magnet, and the at least one reversible magnet has an eighth magnetic field strength greater than the first magnetic field strength of the at least one non-reversible permanent magnet, the eighth magnetic field strength being less than the sixth magnetic field strength. In a variation thereof, the plurality of degaussing states includes (e) a fifth degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has a ninth magnetic field strength less than the first magnetic field strength of the at least one non-reversible permanent magnet, the ninth magnetic field strength being greater than the seventh magnetic field strength; and (f) a sixth degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has a tenth magnetic field strength greater than the first magnetic field strength of the at least one non-reversible permanent magnet, the tenth magnetic field strength being less than the eighth magnetic field strength.

[0032] In a further example thereof, subsequent to the at least two degaussing states the switchable magnetic flux source being in the OFF state.

[0033] In yet another example thereof, the degaussing sequence is to be performed by the controller while the workpiece contact interfaces are in contact with the ferromagnetic workpiece.

[0034] In a further exemplary embodiment of the present disclosure, a magnetic coupling device for magnetically coupling to a ferromagnetic workpiece is provided. The magnetic coupling device may comprise a housing; a switchable magnetic flux source supported by the housing, the switchable magnetic flux source being switchable between at least an OFF state and an ON state, the switchable magnetic flux source including at least one rare earth permanent magnet and at least one electro-permanent magnet; and a plurality of pole portions, each having a workpiece engagement interface having at least one workpiece engagement surface. The housing may include at least one cradle. The at least one cradle of the housing may receive the at least one electro-permanent magnet and support the at least one electro-permanent magnet in a spaced apart relationship relative to the at least one rare earth permanent magnet.

[0035] Other aspects and optional and / or preferred embodiments will become apparent from the following description provided below with reference to the accompanying drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0036] The above-mentioned and other features and advantages of this disclosure, and the manner of attaining them, will become more apparent and will be better understood by reference to the following description of exemplary embodiments taken in conjunction with the accompanying drawings, wherein:

[0037] FIG. 1 illustrates a representative view of an exemplary magnetic coupling device and associated controller;

[0038] FIG. 1A illustrates a side view of a first exemplary pole shoe for use with the magnetic coupling device of FIG. 1 ;

[0039] FIG. 1 B illustrates a side view of a second exemplary pole shoe for use with the magnetic coupling device of FIG. 1 ;

[0040] FIG. 1 C illustrates a side view of a third exemplary pole shoe for use with the magnetic coupling device of FIG. 1 ;

[0041] FIG. 1 D illustrates a side view of a first plurality of moveable pole pieces for use with the magnetic coupling device of FIG. 1 wherein each pole piece is in an extended position;

[0042] Fig. 1 E illustrates the first plurality of moveable pole pieces of FIG. 1 D wherein at least one of the first plurality of movable pole pieces are partially retracted to accommodate an uneven profile of a ferromagnetic workpiece;

[0043] FIG. 2 illustrates an upper perspective exploded view of the magnetic coupling device of FIG. 1 ;

[0044] FIG. 3 illustrates a lower perspective exploded view of the magnetic coupling device of FIG. 1 ;

[0045] FIG. 4 illustrates a cross-sectional view of the magnetic coupling device of FIG. 1 along lines 4-4 in FIG. 1 ;

[0046] FIG. 5 illustrates a cross-sectional view of the magnetic coupling device of FIG. 1 along lines 5-5 in FIG. 1 ;

[0047] FIG. 6 illustrates a representative view of the exemplary magnetic coupling device of FIG. 1 with the poles of the at least one electro-permanent magnet misaligned relative to the poles of the at least one rare earth permanent magnet;

[0048] FIG. 7 illustrates a representative view of the exemplary magnetic coupling device of FIG. 1 with the poles of the at least one electro-permanent magnet aligned relative to the poles of the at least one rare earth permanent magnet;

[0049] FIG. 7A illustrates the magnetic coupling device of FIG. 7 with the poles of at least one electro-permanent magnet misaligned relative to the poles of the at least one rare earth permanent magnet and the magnetic field strength of the at least one electro-permanent magnet being equal and opposite to the magnetic field strength of the at least one rare earth permanent magnet;

[0050] FIG. 7B illustrates the magnetic coupling device of FIG. 7 with the poles of the at least one electro-permanent magnet aligned relative to the poles of the at least one rare earth permanent magnet and the magnetic field strength of the at least one electro-permanent magnet being equal to the magnetic field strength of the at least one rare earth permanent magnet;

[0051] FIG. 7C illustrates the magnetic coupling device of FIG. 7 with the poles of the at least one electro-permanent magnet aligned relative to the poles of the at least one rare earth permanent magnet and the magnetic field strength of the at least one electro-permanent magnet being half of the magnetic field strength of the at least one rare earth permanent magnet;

[0052] FIG. 7D illustrates the magnetic coupling device of FIG. 7 with the poles of the at least one electro-permanent magnet misaligned relative to the poles of the at least one rare earth permanent magnet and the magnetic field strength of the at least one electro-permanent magnet being half and opposite to the magnetic field strength of the at least one rare earth permanent magnet;

[0053] FIG. 7E illustrates the magnetic coupling device of FIG. 7 with the poles of the at least one electro-permanent magnet aligned relative to the poles of the at least one rare earth permanent magnet and the magnetic field strength of the at least one electro-permanent magnet being one and a half times of the magnetic field strength of the at least one rare earth permanent magnet;

[0054] FIG. 7F illustrates the magnetic coupling device of FIG. 7 with the poles of the at least one electro-permanent magnet misaligned relative to the poles of the at least one rare earth permanent magnet and the magnetic field strength of the atleast one electro-permanent magnet being 20 percent greater than and opposite to the magnetic field strength of the at least one rare earth permanent magnet;

[0055] FIG. 7G illustrates the magnetic coupling device of FIG. 7 with the poles of the at least one electro-permanent magnet misaligned relative to the poles of the at least one rare earth permanent magnet and the magnetic field strength of the at least one electro-permanent magnet being 20 percent less and opposite to the magnetic field strength of the at least one rare earth permanent magnet;

[0056] FIG. 8 illustrates a representative view of the exemplary magnetic coupling device of FIG. 1 with the poles of the at least one electro-permanent magnet misaligned relative to the poles of the at least one rare earth permanent magnet and the magnetic coupling device contacting a stack of ferromagnetic workpieces;

[0057] FIG. 9 illustrates a representative view of the exemplary magnetic coupling device of FIG. 1 with the poles of the at least one electro-permanent magnet aligned relative to the poles of the at least one rare earth permanent magnet and the magnetic coupling device contacting the stack of ferromagnetic workpieces;

[0058] FIG. 10 illustrates a representative view of the exemplary magnetic coupling device of FIG. 1 with the poles of the at least one electro-permanent magnet aligned relative to the poles of the at least one rare earth permanent magnet and the magnetic coupling device separating a first ferromagnetic workpiece from a remainder of the stack of ferromagnetic workpieces;

[0059] FIG. 11 illustrates a representative view of the exemplary magnetic coupling device of FIG. 1 with the poles of the at least one electro-permanent magnet aligned relative to the poles of the at least one rare earth permanent magnet and the magnetic coupling device contacting a ferromagnetic workpiece;

[0060] FIG. 12 illustrates a representative view of a further exemplary magnetic coupling device;

[0061] FIG. 13 illustrates an upper perspective exploded view of the magnetic coupling device of FIG. 12;

[0062] FIG. 14 illustrates a front view of the magnetic coupling device of FIG. 12;

[0063] FIG. 15 illustrates a cross-sectional view of the magnetic coupling device of FIG. 12 along lines 15-15 in FIG. 12;

[0064] FIG. 16 illustrates a cross-sectional view of the magnetic coupling device of FIG. 12 along lines 16-16 in FIG. 12;

[0065] FIG. 17 illustrates a representative view of another exemplary magnetic coupling device;

[0066] FIG. 18 illustrates an upper perspective exploded view of the magnetic coupling device of FIG. 17;

[0067] FIG. 19 illustrates a cross-sectional view of the magnetic coupling device of FIG. 17 along lines 19-19 in FIG. 17;

[0068] FIG. 20 illustrates a cross-sectional view of the magnetic coupling device of FIG. 20 along lines 20-20 in FIG. 17;

[0069] FIG. 21 illustrates a representative view of another exemplary magnetic coupling device;

[0070] FIG. 22 illustrates a perspective exploded view of the magnetic coupling device of FIG. 21 ;

[0071] FIG. 23 illustrates a cross-sectional view of the magnetic coupling device of FIG. 21 along lines 23-23 in FIG. 21 ;

[0072] FIG. 24 illustrates a cross-sectional view of the magnetic coupling device of FIG. 21 along lines 24-24 in FIG. 21 ;

[0073] FIG. 25 illustrates a further exemplary magnetic coupling device;

[0074] FIG. 26 illustrates an upper perspective exploded view of the magnetic coupling device of FIG. 25;

[0075] FIG. 27 illustrates a cross-sectional view of the magnetic coupling device of FIG. 25 along lines 27-27 in FIG. 25;

[0076] FIG. 28 illustrates a cross-sectional view of the magnetic coupling device of FIG. 25 along lines

[0077] FIG. 29 illustrates multiple instances of the magnetic coupling device of FIG. 25 positioned adjacent each other;

[0078] FIG. 30 illustrates a first arrangement of the magnetic coupling devices of FIG. 29 wherein each of the at least one permanent magnets are oriented in the same direction;

[0079] FIG. 31 illustrates a second arrangement of the magnetic coupling devices of FIG. 29 wherein an orientation of the at least one permanent magnets alternate between adjacent magnetic coupling devices;

[0080] FIG. 32 illustrates another exemplary magnetic coupling device similar to FIG. 29 except that a common pole plate is provided for the magnetic circuits;

[0081] FIG. 33 illustrates an upper perspective view of a further exemplary magnetic coupling device having a common pole plate;

[0082] FIG. 34 illustrates a lower perspective view of the magnetic coupling device of FIG. 33 including a sectional view along lines 34-34 in FIG. 33;

[0083] FIG. 35 illustrates a lower perspective view of the magnetic coupling device of FIG. 33;

[0084] FIG. 36 illustrates a support structure including one of the exemplary magnetic coupling devices attached thereto;

[0085] FIG. 37 illustrates a mechanical gantry including one of the exemplary magnetic coupling devices suspended therefrom;

[0086] FIG. 38 illustrates a crane hoist including one of the exemplary magnetic coupling devices suspended therefrom; and

[0087] FIG. 39 illustrates a robotic system including one of the exemplary magnetic coupling device attached as an end of arm coupler.DETAILED DESCRIPTION OF THE DRAWINGS

[0088] For the purposes of promoting an understanding of the principles of the present disclosure, reference is now made to the embodiments illustrated in the drawings, which are described below. The embodiments disclosed herein are notintended to be exhaustive or limit the present disclosure to the precise form disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may utilize their teachings. Therefore, no limitation of the scope of the present disclosure is thereby intended. Corresponding reference characters indicate corresponding parts throughout the several views.

[0089] The terms "couples", "coupled", "coupler" and variations thereof are used to include both arrangements wherein the two or more components are in direct physical contact and arrangements wherein the two or more components are not in direct contact with each other (e.g., the components are "coupled" via at least a third component), but yet still cooperate or interact with each other.

[0090] In some instances throughout this disclosure and in the claims, numeric terminology, such as first, second, third, and fourth, is used in reference to various components or features. Such use is not intended to denote an ordering of the components or features. Rather, numeric terminology is used to assist the reader in identifying the component or features being referenced and should not be narrowly interpreted as providing a specific order of components or features.

[0091] With respect to terminology of inexactitude, the terms "about", “generally”, “substantially”, and "approximately" may be used, interchangeably, to refer to a measurement or condition (e.g. parallel, perpendicular, equal, double, and other types of conditions) that includes the stated measurement or condition and that also includes any measurements or conditions that are reasonably close to the stated measurement or condition. Measurements or conditions that are reasonably close to the stated measurement or condition deviate from the stated measurement or condition by a reasonably small amount as understood and readily ascertained by individuals having ordinary skill in the relevant arts. Such deviations may be attributable to measurement error, differences in measurement and / or manufacturing equipment calibration, human error in reading and / or setting measurements or conditions, minor adjustments made to optimize performance and / or structuralparameters in view of differences in measurements or conditions associated with other components, particular implementation scenarios, imprecise adjustment and / or manipulation of objects by a person or machine, and / or the like, for example. In the event it is determined that individuals having ordinary skill in the relevant arts would not readily ascertain values for such reasonably small differences, the terms "about", “generally”, “substantially”, and "approximately" can be understood to mean plus or minus 10% of the stated value or condition.

[0092] Referring to FIG. 1 , an exemplary magnetic coupling device 10 is shown. Magnetic coupling device 10 is configured to magnetically couple a ferromagnetic workpiece 12 (see FIG. 5). Magnetic coupling device 10 includes a housing 14, a switchable magnetic flux source 16, and a plurality of pole portions. Illustratively, the plurality of pole portions include a north pole portion 18 and a south pole portion 20.

[0093] The magnetic coupling devices herein include a switchable magnetic flux source, such as switchable magnetic flux source 16, including at least one non- reversible permanent magnet and at least one reversible permanent magnet. A non- reversible permanent magnet has a set orientation for its poles. A reversible permanent magnet has a plurality of set orientations for its north and south poles. An external characteristic, such as a current passing through a coil of wire, may be used to switch the poles of a reversible magnet from a first set orientation to a second set orientation or from the second set orientation back to the first set orientation. The reversible permanent magnet maintains its set pole orientation in the absence of an external characteristic, such as a current passing through a coil of wire. Thus, the magnetic characteristics of reversible magnets may be maintained in the absence of power to the magnetic coupling device. Exemplary non-reversible permanent magnets include rare earth permanent magnets. Exemplary rare earth permanent magnets include neodymium (NdFeB) permanent magnets. Exemplary reversible permanent magnets include electro-permanent magnets. Exemplary electro-permanent magnets include an iron alloy, such as Alnico (AINiCo) electro-permanent magnets. Each of the illustrated embodiments include at least one rare earth permanent magnet as an exemplary at least one reversible magnet and at least one electro-permanent magnets as an exemplary at least one reversible magnets. In other embodiments, other reversible magnets and / or other non- reversible magnets may be used.

[0094] Referring to FIG. 3, illustratively north pole portion 18 is shown as a pole shoe 24 having a workpiece interface 26, illustratively a flat surface profile 82 (see FIG. 1A). Pole shoe 24 is removably attached to a base 40 of housing 14 with a fastener 28. Further, pole shoe 24 is oriented relative to base 40 with locator pins 30. Similarly, south pole portion 20 is illustratively shown as a pole shoe 32 having a workpiece interface 34, illustratively a flat surface. Pole shoe 32 is removably attached to base 40 of housing 14 with a fastener 36. Further, pole shoe 32 is oriented relative to base 40 with locator pins 38. In embodiments, each of north pole portion 18 and south pole portion 20 are integrally formed as part of base 40 instead of separate components. In embodiments, each of workpiece interface 26 and workpiece interface 34 include at least one workpiece engagement surface, illustratively the flat surface in FIG. 3. Each of workpiece interface 26 and workpiece interface 34 may be planar (see surface profile 82 in FIG. 1 A), curved, contoured (see V-shaped profile 83 of FIG. 1 B), have a plurality of spaced apart projections (see profile 84 of FIG. 1 C), or any other suitable shape for contacting ferromagnetic workpiece 12. Each of workpiece interface 26 and workpiece interface 34 are made of a ferromagnetic material and may be a part of housing 14 or separate components coupled to housing 14, such as pole shoe 24 and pole shoe 32 in the illustrated embodiment. Exemplary arrangements of pole portions having spaced apart projections are disclosed in U.S. Patent No. 11 ,780,039, titled MAGNETIC LIFTING DEVICE HAVING POLE SHOES WITH SPACED APART PROJECTIONS, the entire disclosure of which is expressly incorporated by reference herein. In an example, the width of the projections are equal to a depth of the recesses between the projections. In another example, the width of the projections are equal to a width ofthe recesses between the projections. In a further example, a width of the projections is generally equal to a thickness of the ferromagnetic workpiece to be coupled to magnetic coupling device 10.

[0095] In embodiments, each of north pole portion 18 and south pole portion 20 include one or more movable pole portions. Exemplary movable pole portions are disclosed in Published PCT Application No. WO2023191914A1 , titled Magnetic coupling device with movable workpiece interfaces, the entire disclosure of which is expressly incorporated by reference herein. Referring to FIGS. 1 D and 1 E, a first exemplary north pole portion 90 is shown having a first pin 92 and a second pin 93. Each of pins 92 and 93 have a workpiece contact interface 94 and are biased in direction 95 with respective bias systems, illustratively springs 96. Referring to FIG. 1 E, pin 93 has contacted ferromagnetic workpiece 12 and been moved upward in direction 97. This ability of pins 92 and 93 to move in direction 97 allows pole portion 90 to adapt to a shape of ferromagnetic workpiece 12.

[0096] Switchable magnetic flux source 16 of magnetic coupling device 10 is switchable between an OFF state wherein a magnetic circuit is formed within housing 14 and an ON state wherein a magnetic circuit is formed from switchable magnetic flux source 16 through workpiece interface 26, through ferromagnetic workpiece 12, through workpiece interface 34, and back to switchable magnetic flux source 16 (as represented by the arrows shown in FIG. 5).

[0097] In embodiments, the switchable magnetic flux source includes at least one electro-permanent magnet 60 and at least one rare earth permanent magnet 62 and in the ON state a magnetic field strength of the at least one electro-permanent magnet 60 is generally equal to and aligned with a magnetic field strength of the at least one permanent magnet 62 such that the magnetic field strength available at the workpiece interfaces 26 and 34 is generally about twice the magnetic field strength of the at least one permanent magnet 62 and in the OFF state a magnetic field strength of the at least one electro-permanent magnet 60 is generally equal to and opposite a magnetic field strength of the at least one permanent magnet 62 such thatthe magnetic field strength available at the workpiece interfaces 26 and 34 is generally zero. In embodiments, switchable magnetic flux source 16 may be placed in at least one partial ON state wherein the strength of the magnetic circuit formed through ferromagnetic workpiece 12 is more than the OFF state and less than the ON state. In embodiments, the magnetic field strength of the at least one electropermanent magnet 60 is greater than and aligned with a magnetic field strength of the at least one permanent magnet 62 resulting in the strength of the magnetic circuit formed through the ferromagnetic workpiece 12 being greater than the ON state.

[0098] Switchable magnetic flux source 16 may include one or more permanent magnets and is configurable to have an overall north pole portion 50 and an overall south pole portion 52. Switchable magnetic flux source 16 includes at least one electro-permanent magnet 60 and at least one rare earth permanent magnet 62. Although a single electro-permanent magnet 60 and a single rare earth permanent magnet 62 are shown in FIGS. 1 -5, in embodiments magnetic coupling device 10 may include multiple electro-permanent magnets 60 and / or multiple rare earth permanent magnets 62.

[0099] Electro-permanent magnet 60 includes a base 65 having a first end 64 and a second end 66 and a coil of wire 68 placed about base 65. Base 65 may be made of an iron alloy, such as Alnico (AINiCo) or other suitable electro-permanent magnet material which may be magnetized by a current passing through coil 68 and remains magnetized when the current is absent. Coil 68 is coupled to a power source 70 through wires 72. Power source 70 is controlled by a controller 80 which controls the magnetic configuration of switchable magnetic flux source 16 through controlling the configuration of electro-permanent magnet 60. In embodiments, controller 80 is an electronic controller which controls the operation of power source 70.

[0100] As illustrated in FIG. 1 , electronic controller 80 includes a processor 81 with an associated computer readable medium, illustratively memory 85. Memory 85 includes a magnetic coupler state logic 86 which when executed by processor 81causes electronic controller 80 to instruct power source 70 to provide a specified current to coil of wire 68 so that magnetic coupling device 10 is placed in one of the plurality of states of magnetic coupling device 10. The term "logic" as used herein includes software and / or firmware executing on one or more programmable processors, application-specific integrated circuits, field-programmable gate arrays, digital signal processors, hardwired logic, or combinations thereof. Therefore, in accordance with the embodiments, various logic may be implemented in any appropriate fashion and would remain in accordance with the embodiments herein disclosed. A non-transitory machine-readable medium comprising logic can additionally be considered to be embodied within any tangible form of a computer- readable carrier, such as solid-state memory, magnetic disk, and optical disk containing an appropriate set of computer instructions and data structures that would cause a processor to carry out the techniques described herein. This disclosure contemplates other embodiments in which the magnetic coupler state logic is not microprocessor-based. Further, electronic controller 80 may be contained within a single device or be a plurality of devices networked together to provide the functionality described herein. In embodiments, controller 80 is part of magnetic coupling device 10. In embodiments, controller 80 is part of another system, such as robotic system 700, which includes magnetic coupling device 10.

[0101] In embodiments, electronic controller 80 changes the state of magnetic coupling device 10 in response to an input signal received from an input device 87. Exemplary input devices include sensors, switches, buttons, touch screens, microphones, detectors, controllers, and other devices whereby an operator may provide one of a tactile, audio, or visual input command. For example, in one embodiment, magnetic coupling device 10 is coupled to an end of arm of a robotic arm 704 of a robotic system 700 and input device 87 is a network interface over which controller 80 receives instructions from a robot controller 770 on when to place magnetic coupling device 10 in one of the plurality of states of magnetic coupling device 10. Exemplary network interfaces include a wired network connection and awireless network connection including one or more of an antenna, an optical receiver or transceiver, or other suitable wireless communication receivers or transceivers. Electronic controller 80 of magnetic coupling device 10 is able to control power source 70 automatically without human intervention. Thus, electronic controller 80 may execute logic which places magnetic device 10 in a series of states automatically based on parameters of the logic, at least one of the states being a partial on state or a hyper on state. In embodiments, the functionality of magnetic coupling device state logic 86 is executed by controller 770 of robot system 700 or other remote processing device.

[0102] Magnetic coupling device 10 further includes one or more output devices 88. Exemplary output devices include visual output devices and audio output devices. Exemplary visual output devices include lights, display screens, and other types of visual indicators or communication devices. Exemplary audio output devices include speakers and other types of audio indicator devices.

[0103] Electro-permanent magnet 60 is switchable between a first state wherein base 65 is magnetized to have a north pole corresponding to first end 64 of base 65 and a south pole corresponding to second end 66 of base 65 (see FIGS. 5 and 7) and a second state wherein base 65 is magnetized to have a north pole corresponding to second end 66 of base 65 and a south pole corresponding to first end 64 of base 65 (see FIG. 6). Additionally, by varying the characteristics of the current passing through coil 68 the strength of the first state and / or the second state may be decreased resulting in a less powerful magnetized base 65 or may be increased resulting in a more powerful magnetized base 65. In embodiments, electro-permanent magnet 60 may also be configured in a third state wherein base 65 is not magnetized.

[0104] In embodiments, input devices 87 include one or more sensors. Exemplary sensors include proximity sensors (e.g. ultrasound, inductive, magnetic, vision, and other suitable proximity sensors), temperature sensors, current sensors, magnetic characteristic sensors, and other suitable sensors. Controller 80 based oninput from one or more sensors may control the state of magnetic coupling device in a predictable manner. For example, using a proximity sensor, controller 80 may determine when magnetic coupling device contacts workpiece 12 and then alters switchable magnetic flux source 16 to a first state to couple the workpiece 12 to the magnetic coupling device and once workpiece 12 is lifted alters switchable magnetic flux source 16 to a second state to increase the holding force between magnetic coupling device 10 and workpiece 12.

[0105] Referring to FIG. 5, electro-permanent magnet 60 is in the first state (having a north pole at first end 64 and a south pole at second end 66). This aligns the north pole of electro-permanent magnet 60 with the north pole of rare earth permanent magnet 62 and the south pole of electro-permanent magnet 60 with the south pole of rare earth permanent magnet 62. This corresponds to an ON state of switchable magnetic flux source 16 when the magnetic field strength of electropermanent magnet 60 is generally equal to the magnetic field strength of rare earth permanent magnet 62. By lowering the magnetic strength of electro-permanent magnet 60 and keeping the poles as shown in FIG. 5, switchable magnetic flux source 16 may be placed in a partial ON state having a lower magnetic flux available at workpiece interface 26 and workpiece interface 34 of magnetic coupling device 10 for passage through ferromagnetic workpiece 12 than the ON state. By raising the magnetic strength of electro-permanent magnet 60 and keeping the poles as shown in FIG. 5, switchable magnetic flux source 16 may be placed in a hyper ON state having a higher magnetic flux available at workpiece interface 26 and workpiece interface 34 of magnetic coupling device 10 for passage through ferromagnetic workpiece 12 than the ON state. Further, by configuring electro-permanent magnet 60 in the second state (having a north pole at second end 66 and a south pole at first end 64), switchable magnetic flux source 16 is placed in an OFF state when the magnetic field strength of electro-permanent magnet 60 is generally equal to the magnetic field strength of rare earth permanent magnet 62. In this arrangement, the north pole of electro-permanent magnet 60 aligns with the south pole of rare earthpermanent magnet 62 and the south pole of electro-permanent magnet 60 aligns with the north pole of rare earth permanent magnet 62. Additional partial ON states may be established by either lowering or raising the magnetic field strength of electro-permanent magnet 60 and keeping the poles of electro-permanent magnet 60 in the second state. Although a single rare earth permanent magnet 62 and a single electro-permanent magnet 60 are illustrated in FIGS. 1-5, in embodiments, one or both of rare earth permanent magnet 62 and electro-permanent magnet 60 may be comprised of a plurality of respective permanent magnets which exhibit the functionality of the described rare earth permanent magnet 62 and / or electropermanent magnet 60.

[0106] In embodiments, at least one electro-permanent magnet 60 produces a larger magnetic force than at least one rare earth permanent magnet 62 and is thus capable of producing a hyper ON state with the arrangement shown in FIG. 5. As such, to place magnetic coupling device 10 in an OFF state, at least one electropermanent magnet 60 is configured in the second state (having a north pole at second end 66 and a south pole at first end 64) but at a reduced level from full capacity to balance at least one electro-permanent magnet 60 with at least one rare earth permanent magnet 62, such as about 90%.

[0107] Returning to FIG. 2, housing 14 includes a first cradle 100 and a second cradle 102. First cradle 100 includes an open end 104 and a support surface 106. Second cradle 102 includes an open end 108 and a support surface 110. Electro-permanent magnet 60 is received by open end 104 of first cradle 100 and open end 108 of second cradle 102. Support surface 106 of first cradle 100 supports first end 64 of base 65 of electro-permanent magnet 60 and support surface 110 of second cradle 102 supports second end 66 of base 65 of electro-permanent magnet 60. As shown in FIGS. 4 and 5, electro-permanent magnet 60 is in a spaced apart relationship relative to rare earth permanent magnet 62. Electro-permanent magnet 60 may be coupled to housing 14 without the use of cradles 100, 102, in embodiments.

[0108] Electro-permanent magnet 60 is retained in first cradle 100 and second cradle 102 with a cover 120. Cover 120 is located relative to base 40 with locator pins 122 and secured to base 40 with fasteners 124. Further, cover 120 includes an opening 126 through which wires 72 extend. In embodiments, cover 120 is part of a housing that includes one or both of power source 70 and controller 80.

[0109] An exemplary arrangement of electro-permanent magnet 60 relative to rare earth permanent magnet 62 is shown in FIGS. 1 -5. Referring to FIG. 2, rare earth permanent magnet 62 is a dipole magnet having an active N-S pole pair defined by a first plane 140 (which corresponds to the section shown in FIG. 4). In the illustrated embodiment, rare earth permanent magnet is cylindrically shaped and diametrically polarized. Other shapes are contemplated. Rare earth permanent magnet 62 is received in an opening 128 of base 40 of housing 14. A second plane 142 (see FIG. 1 ) of rare earth permanent magnet 62 is perpendicular to first plane 140 and (corresponds to the section shown in FIG. 5). Plane 142 also passes through a center axis 144 of electro-permanent magnet 60 and is thereby also a longitudinal centerline plane of electro-permanent magnet 60. In embodiments, second plane 142 is offset from center axis 144. As shown in FIG. 5, second plane 142 intersects electro-permanent magnet 60. Thus, in the illustrated embodiment, a longitudinal centerline plane (coincident with second plane 142) of electro-permanent magnet 60 intersects rare earth permanent magnet 62. Further, as shown in FIG. 4, first plane 140 intersects electro-permanent magnet 60.

[0110] Referring to FIG. 6, a representative view of magnetic coupling device 10 is shown with at least one electro-permanent magnet 60 in the second state (having a north pole at second end 66 and a south pole at first end 64) relative to at least one rare earth permanent magnet 62. Referring to FIG. 7, a representative view of magnetic coupling device 10 is shown with at least one electro-permanent magnet 60 in the first state (having a north pole at first end 64 and a south pole at second end 66) relative to at least one rare earth permanent magnet 62. This aligns the north pole of electro-permanent magnet 60 with the north pole of rare earthpermanent magnet 62 and the south pole of electro-permanent magnet 60 with the south pole of rare earth permanent magnet 62. Controller 80 controls when at least one electro-permanent magnet 60 is in the first state or the second state and the relative magnetic field strength of at least one electro-permanent magnet 60 relative to rare earth permanent magnet 62. In embodiments, controller 80 includes values for at least one electro-permanent magnet 60 for a plurality of states of the switchable magnetic flux source 16. A first portion of the plurality of states has at least one electro-permanent magnet 60 in the first state of FIG. 7 and a second portion of the plurality of states has at least one electro-permanent magnet 60 in the second state of FIG. 6.

[0111] FIGS. 7A-7G illustrate various exemplary states of switchable magnetic flux source 16. In each of FIGS. 7A-7G, at least one rare earth permanent magnet has a constant magnetic field strength represented by the number 100. Controller 80 may alter a magnitude of the magnetic field strength of at least one electropermanent magnet 60 and a direction of the magnetic field of at least one electropermanent magnet 60. The magnitude and direction of the magnetic field strength of at least one electro-permanent magnet is given in FIGS. 7A-7G as a relative value to the constant magnetic field strength of at least one rare earth permanent magnet 62. For example, a number -100 associated with at least one electro-permanent magnet 60 indicates that the magnetic field strength of at least one electro-permanent magnet 60 is equal to and opposite the magnetic field strength of at least one rare earth permanent magnet 62 while a number 50 associated with at least one electropermanent magnet 60 indicates that the magnetic field strength of at least one electro-permanent magnet 60 is 50% of and aligned with the magnetic field strength of at least one rare earth permanent magnet 62.

[0112] Referring to FIG. 7A, at least one electro-permanent magnet 60 has a magnetic field strength value of -100 which is equal to and opposite the magnetic field strength of at least one rare earth permanent magnet 62. This arrangement results in a magnetic circuit that is mostly self-contained in pole shoe 24 and poleshoe 32 and presents very little magnetic flux at workpiece interface 26 of pole shoe 24 and workpiece interface 34 of pole shoe 32 to couple magnetic coupling device 10 to an ferromagnetic workpiece 12. This state of switchable magnetic flux source 16 is an example of an OFF state.

[0113] Referring to FIG. 7B, at least one electro-permanent magnet 60 has a magnetic field strength value of 100 which is equal to and aligned with the magnetic field strength of at least one rare earth permanent magnet 62. This arrangement results in a potential magnetic circuit at workpiece interface 26 of pole shoe 24 and workpiece interface 34 of pole shoe 32 to couple magnetic coupling device 10 to an ferromagnetic workpiece 12 with a magnetic field strength of about 200 (twice the magnetic field strength of at least one rare earth permanent magnet 62). This state of switchable magnetic flux source 16 is an example of an ON state.

[0114] Referring to FIG. 7C, at least one electro-permanent magnet 60 has a magnetic field strength value of 50 which is 50% of at least one rare earth permanent magnet 62 and aligned with the magnetic field strength of at least one rare earth permanent magnet 62. This arrangement results in a potential magnetic circuit at workpiece interface 26 of pole shoe 24 and workpiece interface 34 of pole shoe 32 to couple magnetic coupling device 10 to a ferromagnetic workpiece 12 with a magnetic field strength of about 150 (one and a half times the magnetic field strength of at least one rare earth permanent magnet 62). This state of switchable magnetic flux source 16 is less than the state of FIG. 7B and is an example of a partial ON state.

[0115] Referring to FIG. 7D, at least one electro-permanent magnet 60 has a magnetic field strength value of -50 which is 50% of at least one rare earth permanent magnet 62 and opposite to the magnetic field strength of at least one rare earth permanent magnet 62. This arrangement results in a potential magnetic circuit at workpiece interface 26 of pole shoe 24 and workpiece interface 34 of pole shoe 32 to couple magnetic coupling device 10 to a ferromagnetic workpiece 12 with a magnetic field strength at workpiece interface 26 of pole shoe 24 and workpiece interface 34 of pole shoe 32 of about 50 (one half of the magnetic field strength of atleast one rare earth permanent magnet 62). This state of switchable magnetic flux source 16 is less than the state of FIG. 7B and FIG. 70 and is an example of another partial ON state.

[0116] Referring to FIG. 7E, at least one electro-permanent magnet 60 has a magnetic field strength value of 150 which is 150% of at least one rare earth permanent magnet 62 and aligned with the magnetic field strength of at least one rare earth permanent magnet 62. This arrangement results in a potential magnetic circuit at workpiece interface 26 of pole shoe 24 and workpiece interface 34 of pole shoe 32 to couple magnetic coupling device 10 to a ferromagnetic workpiece 12 with a magnetic field strength of about 250 (two and a half times the magnetic field strength of at least one rare earth permanent magnet 62). This state of switchable magnetic flux source 16 is more than the state of FIG. 7B and is an example of a hyper ON state.

[0117] An advantage, among others, of at least one electro-permanent magnet 60 being capable to provide a variable magnetic field strength is the ability to tailor the magnetic circuit of magnetic coupling device 10 to destack a ferromagnetic workpiece 12 from a stack of ferromagnetic workpieces 13 (see FIG. 8). Additionally, the ability to use magnetic coupling device 10 for multiple different types of ferromagnetic workpieces is enhanced.

[0118] Referring to FIG. 8, magnetic coupling device 10 is in the ON state of FIG. 7B. As illustrated in FIG. 8, the magnetic circuit generated by switchable magnetic flux source 16 extends into ferromagnetic workpiece 12 and additional portions of stack of ferromagnetic workpieces 13 due to a saturation of ferromagnetic workpiece 12. If magnetic coupling device 10 was moved upward in direction 19, it is likely that multiple instances of ferromagnetic workpiece 12 would be separated from the remainder of the stack 13 and carried by magnetic coupling device 10 to another location.

[0119] Referring to FIG. 9, magnetic coupling device 10 is in the partial ON state of FIG. 7C. As illustrated in FIG. 9, the magnetic circuit generated byswitchable magnetic flux source 16 largely remains confined in ferromagnetic workpiece 12 resulting in ferromagnetic workpiece 12 being separable from the remainder of the stack 13 as shown in FIG. 10 when magnetic coupling device 10 is moved in direction 19. Once ferromagnetic workpiece 12 is separated from the remainder of the stack 13, controller 80 may increase the holding force of magnetic coupling device 10 by placing switchable magnetic flux source 16 in a partial ON state with a higher magnetic field strength at workpiece interface 26 of pole shoe 24 and workpiece interface 34 of pole shoe 32, in the ON state (FIG. 7B), or in the hyper ON state (FIG. 7E). This would allow magnetic coupling device 10 to move at a higher rate to transport ferromagnetic workpiece 12. In one example, as mentioned herein, magnetic coupling device 10 is an end-of-arm tool of a robotic system 700 and the ability to increase the holding force of magnetic coupling device 10 on ferromagnetic workpiece 12 allows robotic system 700 to move a robotic arm 704 at its preferred speed between poses (see FIG. 39).

[0120] In another example, workpiece 12 may be destacked from stack 13 by controller 80 first placing magnetic coupling device 10 in the ON state or hyper ON state to couple multiple instances of workpiece 12. Magnetic coupling device 10 is then moved upward in direction 19. Subsequently, controller 80 reduces the magnetic strength of at least one electro-permanent magnet 60 which reduces the magnetic flux at workpiece interfaces of magnetic coupling device 10 and results in a bottom instance of workpiece 12 being dropped back into the container or onto the stack it was originally in or on. The magnetic strength of at least one electropermanent magnet 60 is continued to be reduced until a single instance of workpiece is left coupled to magnetic coupling device 10. In examples, a plurality of workpieces 12 are coupled to magnetic coupling device 10 and individual workpieces 12 may be dropped at respective stations for subsequent operations thereby reducing the number of trips a robotic system needs to make to place multiple workpieces 12.

[0121] Referring to FIG. 11 , ferromagnetic workpiece 12 is shown coupled to magnetic coupling device 10 with magnetic coupling device 10 in a hyper ON state.An advantage, among others, of at least one electro-permanent magnet 60 being capable to provide a variable magnetic field strength is the ability to have hyper ON states wherein the overall magnetic coupling capacity of magnetic coupling device 10 is increased which allows heavier workpieces (such as larger sheets having the same thicknesses) to be coupled to magnetic coupling device 10 due to the magnetic saturation of workpiece 12 with magnetic coupling device 10 being in the hyper ON state.

[0122] In embodiments, controller 80 may configure switchable magnetic flux source 16 in a plurality of states. The plurality of states may include (a) an OFF state wherein a north pole of the at least one electro-permanent magnet is magnetically coupled to the south pole of the at least one rare earth permanent magnet, a south pole of the at least one electro-permanent magnet is magnetically coupled to the north pole of the at least one rare earth permanent magnet, and the at least one electro-permanent magnet has a second magnetic field strength generally equal to the first magnetic field strength of the at least one rare earth permanent magnet; (b) a first ON state wherein the north pole of the at least one electro-permanent magnet is magnetically coupled to the north pole of the at least one rare earth permanent magnet, the south pole of the at least one electro-permanent magnet is magnetically coupled to the south pole of the at least one rare earth permanent magnet, and the at least one electro-permanent magnet has a third magnetic field strength generally equal to or less than the first magnetic field strength of the at least one rare earth permanent magnet; and (c) a second ON state wherein the north pole of the at least one electro-permanent magnet is magnetically coupled to the north pole of the at least one rare earth permanent magnet, the south pole of the at least one electropermanent magnet is magnetically coupled to the south pole of the at least one rare earth permanent magnet, and the at least one electro-permanent magnet has a fourth magnetic field strength greater than the first magnetic field strength of the at least one rare earth permanent magnet. Another advantage, among others, of at least one electro-permanent magnet 60 being capable to provide a variable magneticfield strength and to provide a magnetic field strength greater than at least one rare earth permanent magnet 62 is that switchable magnetic flux source 16 may be used to provide a degaussing functionality to magnetic coupling device 10. The degaussing functionality may be used to remove residual magnetism on north pole portion 18 and south pole portion 20 following handling of workpieces 12 using magnetic coupling device 10.

[0123] In embodiments, controller 80 when ferromagnetic workpiece 12 is moved to a location to be released from magnetic coupling device 10 may place switchable magnetic flux source 16 in the OFF state (see FIG. 7 A). In embodiments, either after placing magnetic coupling device 10 in the OFF state or prior to placing magnetic coupling device 10 in the OFF state, workpiece interface 34 may cycle switchable magnetic flux source 16 through a plurality of degaussing states wherein one or more lower strength magnetic circuits are formed between magnetic coupling device 10 and ferromagnetic workpiece 12. In embodiments, the plurality of degaussing states cycle between having the magnetic flow from north pole portion 18 to pole shoe 24 and from pole shoe 24 back to north pole portion 18. In embodiments, a plurality of degaussing states are provided which over time successively have smaller and smaller strength magnetic fields.

[0124] Referring to FIG. 7F, a first degaussing state is illustrated wherein at least one electro-permanent magnet 60 is shown having a magnetic field strength of -120 which is 20% higher than at least one rare earth permanent magnet 62 and opposite to at least one rare earth permanent magnet 62. In this arrangement, a magnetic circuit flows from south pole portion 20 to north pole portion 18. Referring to FIG. 7G, a second degaussing state is illustrated wherein at least one electropermanent magnet 60 is shown having a magnetic field strength of -80 which is 20% lower than at least one rare earth permanent magnet 62 and opposite to at least one rare earth permanent magnet 62. In this arrangement, a magnetic circuit flows from north pole portion 18 to south pole portion 20. In embodiments, workpiece interface 34 alters between the first degaussing state of FIG. 7F followed by the seconddegaussing state of FIG. 7G for one or more cycles, followed by altering between a third degaussing state (such as with a magnetic field strength of -115 for at least one electro-permanent magnet 60) and a fourth degaussing state (such as with a magnetic field strength of -85 for at least one electro-permanent magnet 60) for one or more cycles, and so one, until workpiece interface 34 places switchable magnetic flux source 16 in the OFF state. This cycling around the OFF state removes residual magnetism from north pole portion 18 and south pole portion 20. Although the difference of the magnetic field strength of at least one electro-permanent magnet 60 from at least one rare earth permanent magnet 62 is shown to be the same between successive states, in embodiments, the difference is not the same. Once the degaussing operation is complete and workpiece interface 34 places switchable magnetic flux source 16 in the OFF state, magnetic coupling device 10 may be moved upward in direction 19 to leave ferromagnetic workpiece 12 behind.

[0125] In embodiments, controller 80 executes a degaussing sequence logic to remove residual magnetism from the workpiece engagement interface of each of the plurality of pole portions 18, 20. The degaussing sequence logic may include a plurality of degaussing states of the switchable magnetic flux source 16 to generate an alternating magnetic field at the workpiece engagement interface of each of the plurality of pole portions 18, 20 over a time period. An exemplary degaussing sequence logic includes a first degauss state wherein the north pole of the at least one electro-permanent magnet is magnetically coupled to the south pole of the at least one rare earth permanent magnet, the south pole of the at least one electropermanent magnet is magnetically coupled to the north pole of the at least one rare earth permanent magnet, and the at least one electro-permanent magnet has a fifth magnetic field strength less than the first magnetic field strength of the at least one rare earth permanent magnet and a second degauss state wherein the north pole of the at least one electro-permanent magnet is magnetically coupled to the south pole of the at least one rare earth permanent magnet, the south pole of the at least one electro-permanent magnet is magnetically coupled to the north pole of the at leastone rare earth permanent magnet, and the at least one electro-permanent magnet has a sixth magnetic field strength greater than the first magnetic field strength of the at least one rare earth permanent magnet. The exemplary degaussing sequence logic may further include a third degauss state wherein the north pole of the at least one electro-permanent magnet is magnetically coupled to the south pole of the at least one rare earth permanent magnet, the south pole of the at least one electropermanent magnet is magnetically coupled to the north pole of the at least one rare earth permanent magnet, and the at least one electro-permanent magnet has a seventh magnetic field strength less than the first magnetic field strength of the at least one rare earth permanent magnet, the seventh magnetic field strength being greater than the fifth magnetic field strength and a fourth degauss state wherein the north pole of the at least one electro-permanent magnet is magnetically coupled to the south pole of the at least one rare earth permanent magnet, the south pole of the at least one electro-permanent magnet is magnetically coupled to the north pole of the at least one rare earth permanent magnet, and the at least one electropermanent magnet has an eighth magnetic field strength greater than the first magnetic field strength of the at least one rare earth permanent magnet, the eighth magnetic field strength being less than the sixth magnetic field strength. The exemplary degaussing sequence logic may further include a fifth degauss state wherein the north pole of the at least one electro-permanent magnet is magnetically coupled to the south pole of the at least one rare earth permanent magnet, the south pole of the at least one electro-permanent magnet is magnetically coupled to the north pole of the at least one rare earth permanent magnet, and the at least one electro-permanent magnet has a ninth magnetic field strength less than the first magnetic field strength of the at least one rare earth permanent magnet, the ninth magnetic field strength being greater than the seventh magnetic field strength and a sixth degauss state wherein the north pole of the at least one electro-permanent magnet is magnetically coupled to the south pole of the at least one rare earth permanent magnet, the south pole of the at least one electro-permanent magnet ismagnetically coupled to the north pole of the at least one rare earth permanent magnet, and the at least one electro-permanent magnet has a tenth magnetic field strength greater than the first magnetic field strength of the at least one rare earth permanent magnet, the tenth magnetic field strength being less than the eighth magnetic field strength.

[0126] The operating states of magnetic coupling device 10 discussed herein including in relation to FIGS. 6-11 are equally applicable to the additional magnetic coupling devices discussed herein. As such, the operating states are not repeated for each of the additional disclosed magnetic coupling devices. Additionally, each of the magnetic coupling devices disclosed herein may include any of the workpiece contact interfaces disclosed in FIGS. 1A-1 E either as part of a housing holding the respective rare earth permanent magnets and electro-permanent magnets or as part of pole shoes attached to the housing holding the respective rare earth permanent magnets and electro-permanent magnets.

[0127] Referring to FIGS. 12-16, another exemplary magnetic coupling device 500 is shown. Magnetic coupling device 500 is configured to magnetically couple a ferromagnetic workpiece 12 (see FIG. 15). Magnetic coupling device 500 includes a housing 502, a switchable magnetic flux source 516, and a plurality of pole portions. Illustratively, the plurality of pole portions include a north pole portion 518 and a south pole portion 522. Illustratively, north pole portion 518 and south pole portion 522 are shown as integral with housing 502 and include respective workpiece interfaces 520 and 524 (see FIG. 14). Workpiece interface 520 is separated from workpiece interface 524 by an air gap 526. In embodiments, north pole portion 518 and south pole portion 522 are separate pole shoes attached to housing 502.

[0128] Switchable magnetic flux source 516 of magnetic coupling device 500 is switchable between an OFF state wherein a magnetic circuit is formed within housing 502 and an ON state wherein a magnetic circuit is formed from switchable magnetic flux source 516 through workpiece interface 520, through ferromagneticworkpiece 12, through workpiece interface 524, and back to switchable magnetic flux source 516 (as represented by the arrows shown in FIG. 15).

[0129] In embodiments, the switchable magnetic flux source 516 includes at least one electro-permanent magnet 60 and at least one rare earth permanent magnet 562 and in the ON state a magnetic field strength of the at least one electropermanent magnet 60 is generally equal to and aligned with a magnetic field strength of the at least one permanent magnet 562 such that the magnetic field strength available at the workpiece interfaces 520 and 524 is generally about twice the magnetic field strength of the at least one permanent magnet 562 and in the OFF state a magnetic field strength of the at least one electro-permanent magnet 60 is generally equal to and opposite a magnetic field strength of the at least one permanent magnet 562 such that the magnetic field strength available at the workpiece interfaces 520 and 524 is generally zero. In embodiments, as discussed herein, switchable magnetic flux source 516 may be placed in at least one partial ON state wherein the strength of the magnetic circuit formed through ferromagnetic workpiece 12 is more than the OFF state and less than the ON state. In embodiments, the magnetic field strength of the at least one electro-permanent magnet 60 is greater than and aligned with a magnetic field strength of the at least one permanent magnet 562 resulting a hyper ON state wherein the strength of the magnetic circuit formed through the ferromagnetic workpiece is greater than the ON state.

[0130] Switchable magnetic flux source 516 may include one or more permanent magnets and is configurable to have an overall north pole portion 550 and an overall south pole portion 552 (see FIG. 15). Switchable magnetic flux source 516 includes at least one electro-permanent magnet 60 and at least one rare earth permanent magnet 562. Although a single electro-permanent magnet 60 and a single rare earth permanent magnet 562 are shown in FIGS. 12-16, in embodiments magnetic coupling device 10 may include multiple electro-permanent magnets 60 and / or multiple rare earth permanent magnets 562.

[0131] Electro-permanent magnet 60 includes a base 65 having a first end 64 and a second end 66 and a coil of wire 68 placed about based 65. Base 65 may be made of an iron alloy, such as Alnico (AINiCo) or other suitable electro-permanent magnet material which may be magnetized by a current passing through coil 68 and remain magnetized when the current is absent. Coil 68 is coupled to a power source 70 through wires 72. Power source 70 is controlled by a controller 80 which controls the magnetic configuration of switchable magnetic flux source 16 through controlling the configuration of electro-permanent magnet 60.

[0132] Electro-permanent magnet 60 is switchable between a first state wherein base 65 is magnetized to have a north pole corresponding to first end 64 of base 65 and a south pole corresponding to second end 66 of base 65 (see FIG. 15) and a second state wherein base 65 is magnetized to have a north pole corresponding to second end 66 of base 65 and a south pole corresponding to first end 64 of base 65. Additionally, by varying the characteristics of the current passing through coil 68 the strength of the first state and / or the second state may be decreased resulting in a less powerful magnetized base 65 or may be increased resulting in a more powerful magnetized base 65. In embodiments, electropermanent magnet 60 may also be configured in a third state wherein base 65 is not magnetized.

[0133] Referring to FIG. 13, rare earth permanent magnet 562 is a dipole magnet having an active N-S pole pair defined by a first plane 540 (which corresponds to the section shown in FIG. 16). In the illustrated embodiment, rare earth permanent magnet 562 is rectilinear in shape. Other shapes are contemplated. Rare earth permanent magnet 562 is received in an opening 504 of housing 502. As shown in FIG. 16, the opening 504 in housing 502 is sized such that a thin-walled portion 506 is provided along the plane 540 (see FIG. 12). The thin-walled portions assist in focusing the magnetic field of at least one rare earth permanent magnet 562 into north pole portion 518 and south pole portion 522 of housing 502.

[0134] A second plane 542 (see FIG. 12) of rare earth permanent magnet 562 is perpendicular to first plane 540 and (corresponds to the section shown in FIG. 15). Plane 542 also passes through a center axis 144 of electro-permanent magnet 60 and is thereby also a longitudinal centerline plane of electro-permanent magnet 60. In embodiments, second plane 542 is offset from center axis 144. As shown in FIG. 15, second plane 542 intersects electro-permanent magnet 60. Thus, in the illustrated embodiment, a longitudinal centerline plane (coincident with second plane 142) of electro-permanent magnet 60 intersects rare earth permanent magnet 62. Further, as shown in FIG. 16, first plane 540 intersects electro-permanent magnet 60.

[0135] Returning to FIG. 13, a non-ferromagnetic spacer 520 is positioned in opening 504 and supports at least one rare earth permanent magnet 562. Housing 502 includes cradles 522 and 524 to support respective ends 64 and 66 of at least one electro-permanent magnet 60. Cradles 522 and 524 support at least one electro-permanent magnet 60 is a spaced relationship relative to at least one rare earth permanent magnet 562. In embodiments, electro-permanent magnet 60 is retained in first cradle 522 and second cradle 524 with a cover (not shown), similar to cover 120 of magnetic coupling device 10.

[0136] Referring to FIG. 15, electro-permanent magnet 60 is in the first state (having a north pole at first end 64 and a south pole at second end 66). This aligns the north pole of electro-permanent magnet 60 with the north pole of rare earth permanent magnet 562 and the south pole of electro-permanent magnet 60 with the south pole of rare earth permanent magnet 562. This corresponds to an ON state of switchable magnetic flux source 516 when the magnetic field strength of electropermanent magnet 60 is generally equal to the magnetic field strength of rare earth permanent magnet 562. By lowering the magnetic strength of electro-permanent magnet 60 and keeping the poles as shown in FIG. 15, switchable magnetic flux source 516 may be placed in a partial ON state having a lower magnetic flux available at workpiece interface 520 and workpiece interface 524 of magneticcoupling device 500 for passage through ferromagnetic workpiece 12 than the ON state. By raising the magnetic strength of electro-permanent magnet 60 and keeping the poles as shown in FIG. 15, switchable magnetic flux source 516 may be placed in a hyper ON state having a higher magnetic flux available at workpiece interface 520 and workpiece interface 524 of magnetic coupling device 500 for passage through ferromagnetic workpiece 12 than the ON state. Further, by configuring electro-permanent magnet 60 in the second state (having a north pole at second end 66 and a south pole at first end 64), switchable magnetic flux source 516 is placed in an OFF state when the magnetic field strength of electro-permanent magnet 60 is generally equal to the magnetic field strength of rare earth permanent magnet 562. In this arrangement, the north pole of electro-permanent magnet 60 aligns with the south pole of rare earth permanent magnet 562 and the south pole of electropermanent magnet 60 with the north pole of rare earth permanent magnet 562. Additional partial ON states may be established by either lowering or raising the magnetic field strength of electro-permanent magnet 60 and keeping the poles of electro-permanent magnet 560 in the second state. Although a single rare earth permanent magnet 562 and a single electro-permanent magnet 60 are illustrated in FIGS. 12-16, in embodiments, one or both of rare earth permanent magnet 562 and electro-permanent magnet 60 may be comprised of a plurality of respective permanent magnets which exhibit the functionality of the described rare earth permanent magnet 562 and / or electro-permanent magnet 60.

[0137] Referring to FIGS. 17-20, another exemplary magnetic coupling device 200 is shown. Magnetic coupling device 200 generally includes the same components as magnetic coupling device 10, except that magnetic coupling device 200 incudes a plurality of electro-permanent magnet 60 in switchable magnetic flux source 16 and housing 214 is sized and shaped to accommodate rare earth permanent magnet 62 and the plurality of electro-permanent magnet 60.Additionally, as shown in FIG. 20, second plane 142 does not intersect any of the plurality of electro-permanent magnet 60 in switchable magnetic flux source 16. Inthe illustrated embodiment, the plurality of electro-permanent magnet 60 in switchable magnetic flux source 16 includes a first electro-permanent magnet positioned on a first side of second plane 142 and a second electro-permanent magnet positioned on a second side of second plane 142. In the illustrated embodiment, each of first electro-permanent magnet and second electro-permanent magnet are at the same height above at least one rare earth permanent magnet 62. In embodiments, housing 214 may be a unitary piece or comprised of multiple pieces coupled together. In embodiments, pole shoes, such as pole shoes 24 and 32, may be coupled to housing 214 and provide a workpiece contact interface to contact ferromagnetic workpiece 12. Exemplary pole shoes are further described in US Patent No. 11 ,772,214, titled MAGNETIC COUPLING DEVICE and PCT Published Patent Application No. WO2023191914A1 , titled MAGNETIC COUPLING DEVICE WITH MOVABLE WORKPIECE INTERFACES, the entire disclosures of which are expressly incorporated by reference herein.

[0138] Referring to FIGS. 21 -24, another exemplary magnetic coupling device 300 is shown. Magnetic coupling device 300 generally includes the same components as magnetic coupling device 10, except that magnetic coupling device 300 incudes a plurality of electro-permanent magnet 60 and a plurality of rare earth permanent magnet 62 in switchable magnetic flux source 16 and housing 314 is sized and shaped to accommodate the plurality of rare earth permanent magnet 62 and the plurality of electro-permanent magnet 60. Additionally, as shown in FIG. 23, second plane 142 corresponding to one of the rare earth permanent magnets 62 intersects a corresponding one of electro-permanent magnet 60. Although not illustrated in FIGS. 21 -24, housing 314 of magnetic coupling device 300 includes a cover (not shown).

[0139] Referring to FIGS. 25-28, another exemplary magnetic coupling device 600 is shown. Magnetic coupling device 600 is configured to magnetically couple a ferromagnetic workpiece 12 (see FIG. 27). Magnetic coupling device 600 includes a housing 602, a switchable magnetic flux source 616, and a plurality of pole portions.Illustratively, the plurality of pole portions include a north pole portion 618 and a south pole portion 622. Illustratively, north pole portion 618 and south pole portion 622 are shown as integral with housing 602 and include respective workpiece interfaces 620 and 624 (see FIG. 27). Workpiece interface 620 is separated from workpiece interface 624 by an air gap 626. In embodiments, north pole portion 618 and south pole portion 622 are separate pole shoes attached to housing 602.

[0140] Switchable magnetic flux source 616 of magnetic coupling device 600 is switchable between an OFF state wherein a magnetic circuit is formed within housing 602 and an ON state wherein a magnetic circuit is formed from switchable magnetic flux source 616 through workpiece interface 620, through ferromagnetic workpiece 12, through workpiece interface 624, and back to switchable magnetic flux source 616 (as represented by the arrows shown in FIG. 27).

[0141] In embodiments, the switchable magnetic flux source includes at least one electro-permanent magnet 630 and at least one rare earth permanent magnet 632 and in the ON state a magnetic field strength of the at least one electropermanent magnet 630 is generally equal to and aligned with a magnetic field strength of the at least one permanent magnet 632 such that the magnetic field strength available at the workpiece interfaces 620 and 624 is generally about twice the magnetic field strength of the at least one permanent magnet 632 and in the OFF state a magnetic field strength of the at least one electro-permanent magnet 630 is generally equal to and opposite a magnetic field strength of the at least one permanent magnet 632 such that the magnetic field strength available at the workpiece interfaces 620 and 624 is generally zero. In embodiments, as discussed herein, switchable magnetic flux source 616 may be placed in at least one partial ON state wherein the strength of the magnetic circuit formed through ferromagnetic workpiece 12 is more than the OFF state and less than the ON state. In embodiments, the magnetic field strength of the at least one electro-permanent magnet 630 is greater than and aligned with a magnetic field strength of the at least one permanent magnet 632 resulting in a hyper ON state wherein the strength of themagnetic circuit formed through the ferromagnetic workpiece 12 is greater than the ON state.

[0142] Switchable magnetic flux source 616 may include one or more permanent magnets and is configurable to have an overall north pole portion 634 and an overall south pole portion 636 (see FIG. 27). Switchable magnetic flux source 616 includes at least one electro-permanent magnet 610 and at least one rare earth permanent magnet 612. Although a single electro-permanent magnet 610 and a single rare earth permanent magnet 612 are shown in FIGS. 25-28, in embodiments magnetic coupling device 600 may include multiple electro-permanent magnets 610 and / or multiple rare earth permanent magnets 612.

[0143] Referring to FIG. 26, electro-permanent magnet 610 includes a base 614 having a first end 615 and a second end 617 and a coil of wire 620 placed about base 614 (see FIG. 28). Base 614 may be made of an iron alloy, such as Alnico (AINiCo) or other suitable electro-permanent magnet material which may be magnetized by a current passing through coil 620 and remain magnetized when the current is absent. Coil 620, similar to coil 68 for magnetic coupling device 10, is coupled to a power source 70 through wires 72. Power source 70 is controlled by a controller 80 which controls the magnetic configuration of switchable magnetic flux source 616 through controlling the configuration of electro-permanent magnet 610. In the illustrated embodiment, base 614 is rectilinear in shape. Other shapes are contemplated.

[0144] Electro-permanent magnet 610 is switchable between a first state wherein base 614 is magnetized to have a north pole corresponding to first end 615 of base 614 and a south pole corresponding to second end 617 of base 614 (see FIG. 27) and a second state wherein base 614 is magnetized to have a north pole corresponding to second end 617 of base 614 and a south pole corresponding to first end 615 of base 614. Additionally, by varying the characteristics of the current passing through coil 620 the strength of the first state and / or the second state may be decreased resulting in a less powerful magnetized base 614 or may be increasedresulting in a more powerful magnetized base 614. In embodiments, electropermanent magnet 610 may also be configured in a third state wherein base 614 is not magnetized.

[0145] Referring to FIG. 26, rare earth permanent magnet 612 is a dipole magnet having an active N-S pole pair defined by a first plane 640 (which corresponds to the section shown in FIG. 28). In the illustrated embodiment, rare earth permanent magnet 612 is rectilinear in shape. Other shapes are contemplated. Rare earth permanent magnet 612 is received in an opening 642 of a base 644 of housing 602. As shown in FIG. 26, the opening 642 in housing 602 is sized such that a thin walled portion 646 is provided along the plane 618 (see FIG. 28). The thin-walled portions 646 assist in focusing the magnetic field of at least one rare earth permanent magnet 612 into north pole portion 618 and south pole portion 622 of housing 602. A non-ferromagnetic insert 650 is placed in opening 642 and supports at least one rare earth permanent magnet 612.

[0146] Housing 602 further includes a first support 652 and a second support 654. Each of first support 652 and second support 654 includes a recess 656, 658, respectively. Recess 656 receives switchable magnetic flux source 616 of base 614 and recess 658 receives second end 617 of base 614. First support 652 and second support 654 are coupled to base 644, such as with fasteners (not shown). First support 652 and second support 654 support at least one electro-permanent magnet 610 is a spaced apart relationship relative to at least one rare earth permanent magnet 612.

[0147] A second plane 660 (see FIG. 25) of rare earth permanent magnet 612 is perpendicular to first plane 640 and (corresponds to the section shown in FIG. 27). Plane 660 also passes through electro-permanent magnet 610. Further, as shown in FIG. 28, first plane 640 intersects electro-permanent magnet 610.

[0148] Referring to FIG. 27, electro-permanent magnet 610 is in the first state (having a north pole at first end 615 and a south pole at second end 617). This aligns the north pole of electro-permanent magnet 610 with the north pole of rareearth permanent magnet 612 and the south pole of electro-permanent magnet 610 with the south pole of rare earth permanent magnet 612. This corresponds to an ON state of switchable magnetic flux source 616 when the magnetic field strength of electro-permanent magnet 610 is generally equal to the magnetic field strength of rare earth permanent magnet 612. By lowering the magnetic strength of electropermanent magnet 610 and keeping the poles as shown in FIG. 27, switchable magnetic flux source 616 may be placed in a partial ON state having a lower magnetic flux available at workpiece interface 620 and workpiece interface 624 of magnetic coupling device 600 for passage through ferromagnetic workpiece 12 than the ON state. By raising the magnetic strength of electro-permanent magnet 610 and keeping the poles as shown in FIG. 27, switchable magnetic flux source 616 may be placed in a hyper ON state having a higher magnetic flux available at workpiece interface 620 and workpiece interface 624 of magnetic coupling device 600 for passage through ferromagnetic workpiece 12 than the ON state. Further, by configuring electro-permanent magnet 610 in the second state (having a north pole at second end 617 and a south pole at first end 615), switchable magnetic flux source 616 is placed in an OFF state when the magnetic field strength of electropermanent magnet 610 is generally equal to the magnetic field strength of rare earth permanent magnet 612. In this arrangement, the north pole of electro-permanent magnet 610 aligns with the south pole of rare earth permanent magnet 612 and the south pole of electro-permanent magnet 610 with the north pole of rare earth permanent magnet 612. Additional partial ON states may be established by either lowering or raising the magnetic field strength of electro-permanent magnet 610 and keeping the poles of electro-permanent magnet 610 in the second state. Although a single rare earth permanent magnet 612 and a single electro-permanent magnet 610 are illustrated in FIGS. 25-28, in embodiments, one or both of rare earth permanent magnet 612 and electro-permanent magnet 610 may be comprised of a plurality of respective permanent magnets which exhibit the functionality of the described rare earth permanent magnet 612 and / or electro-permanent magnet 610.

[0149] Referring to FIGS. 26 and 27, a width 670 of at least one electropermanent magnet 610 is greater than a width 672 of at least one rare earth permanent magnet 612 and a length 674 of at least one electro-permanent magnet 610 is less than a length 676 of at least one rare earth permanent magnet 612. In embodiments, one or both of width 670 and length 674 is equal to width 672 and length 676. In embodiments, width 670 is less than width 672. In embodiments, length 674 is greater than length 676.

[0150] Referring to FIG. 29, multiple instances of magnetic coupling device 600 are illustrated. In embodiments, a magnetic coupling assembly is formed of multiple instances of magnetic coupling device 600. In examples, a base structure (not shown) couples each of magnetic coupling device 600 together. As shown in FIG. 30, the multiple instances of magnetic coupling device 600 may be arranged such that each magnetic coupling device 600 has north pole portion 618 to the left side and south pole portion 622 to the right side. Alternatively, as shown in FIG. 31 , the multiple instances of magnetic coupling device 600 may be arranged such that neighboring instances of magnetic coupling device 600 have respective north pole portions 618 or south pole portions 622 facing each other. When the multiple instances of magnetic coupling device 600 are spaced apart by a first distance each of magnetic coupling device 600 generates its own magnetic circuit through a ferromagnetic workpiece 12 coupled across the multiple instances of magnetic coupling device 600. When the multiple instances of magnetic coupling device 600 are spaced apart by a second distance less than the first distance, each of magnetic coupling device 600 generates its own magnetic circuit through a ferromagnetic workpiece 12 and additional magnetic circuits are formed through ferromagnetic workpiece 12 between adjacent magnetic coupling device 600. The additional magnetic coupling devices disclosed herein may also be deployed in groups and spaced to generate additional magnetic circuits between adjacent magnetic coupling devices.

[0151] Referring to FIG. 32, a modified version of magnetic coupling device 600’ is shown. Magnetic coupling device 600’ includes multiple at least one electropermanent magnet 610 and multiple at least one rare earth permanent magnet 612. Each of at least one rare earth permanent magnets 612 are carried by a common base 680 which includes multiple north pole portions 618 and multiple south pole portions 622. Magnetic coupling device 600’ forms a linear array having three instances of north pole portion 618 and two instances of south pole portion 622, although more or less instances of each may be provided. Each of at least one electro-permanent magnet 610 are supported by one or more of first support 652, second support 654, and a third support 682 having recesses on each side.

[0152] Referring to FIGS. 33-35, another modified version of magnetic coupling device 600” is shown. Magnetic coupling device 600” includes multiple at least one electro-permanent magnet 60 from magnetic coupling device 10 for each at least one rare earth permanent magnet 612. Each of at least one rare earth permanent magnets 612 are carried by a common base 690 which includes multiple north pole portions 618 and multiple south pole portions 622. Magnetic coupling device 600” forms a linear array having four instances of north pole portion 618 and three instances of south pole portion 622, although more or less instances of each may be provided. Each of at least one electro-permanent magnet 60 are supported by supports 694 having recesses 696 (see FIG. 34) to accommodate the respective electro-permanent magnets 60.

[0153] In embodiments, magnetic coupling device 10 and the other disclosed magnetic coupling devices may include one or more sensors to determine a characteristic of a magnetic circuit present between the respective magnetic coupling device and the ferromagnetic workpiece to be coupled to the magnetic coupling device. Exemplary sensors and detectable characteristics are disclosed in U.S. Patent No. 11 ,097,401 , titled MAGNETIC COUPLING DEVICE WITH AT LEAST ONE OF A SENSOR ARRANGEMENT AND A DEGAUSS CAPABILITY, the entire disclosure of which is expressly incorporated by reference herein. In embodiments,the disclosed magnetic coupling devices include a proximity sensor. Exemplary proximity sensors include inductive sensors, ultrasound sensors, photonic sensors, and other suitable sensors. The one or more sensors, in embodiments, are supported by the housing of the respective magnetic coupling device and are spaced apart from the workpiece engagement interfaces of the respective magnetic coupling device.

[0154] In embodiments, the magnetic coupling devices disclosed herein may be used as part of a fixture to hold a ferromagnetic part or an end-of-arm-tool for a robot which is able to couple and move a ferromagnetic part. The magnetic coupling devices may be used as the magnetic coupling devices disclosed in US Published Patent Application No. US20240269861A1, titled ADJUSTABLE END-OF-ARM TOOL OR FIXTURE; US Published Patent Application No. US20240269804A1 , titled COMPONENT HANDLING SYSTEMS AND METHODS; and US Patent Application No. 18 / 947,728, filed November 14, 2024, titled COMPONENT HANDLING SYSTEMS AND METHODS, the entire disclosures of which are expressly incorporated by reference herein.

[0155] Each of the disclosed magnetic coupling devices may be used in combination with mechanical lifting apparatus 900 (See FIG. 36) having a support structure 902. The mechanical lifting apparatus 900 lifts and transports ferromagnetic workpiece 12 from a first location to a second location through one or more magnetic coupling devices. Exemplary mechanical lifting apparatus 900 include mechanical gantries 904 (See FIG. 37), crane hoists 906 (see FIG. 38), and robotic systems 700 (see FIG. 39).

[0156] Exemplary mechanical gantries 904 include a pair of vertical support members having a horizontal cross member extending therebetween. Magnetic coupling device may be suspended from or coupled to the horizontal cross member through a mechanism to raise and lower magnetic coupling device relative to the horizontal cross member and hence to lift and transport a ferromagnetic workpiece 12 coupled to magnetic coupling device.

[0157] Exemplary crane hoists 906 include a chain mechanism that raises or lowers a first portion of chain hoist 906 relative to a second portion of chain hoist 906. Magnetic coupling device may be suspended from or coupled to the first portion of chain hoist 906. Hence, magnetic coupling device is raised and lowered with the first portion of chain hoist 906 which in turn lifts and transports a ferromagnetic workpiece 12 coupled to magnetic coupling device.

[0158] Referring to FIG. 39, an exemplary robotic system 700 is illustrated. The embodiments described in relation to robotic system 700 may be applied to other types of machines, (e.g., mechanical gantries, crane hoists, pick and place machines, etc.).

[0159] Robotic system 700 includes electronic controller 770. Electronic controller 770 includes additional logic stored in associated memory 774 for execution by processor 772. A robotic movement module 702 is included which controls the movements of a robotic arm 704. In the illustrated embodiment, robotic arm 704 includes a first arm segment 706 which is rotatable relative to a base 705 about a vertical axis. First arm segment 706 is moveably coupled to a second arm segment 708 through a first joint 710 whereat second arm segment 708 may be rotated relative to first arm segment 706 in a first direction. Second arm segment 708 is moveably coupled to a third arm segment 711 through a second joint 712 whereat third arm segment 711 may be rotated relative to second arm segment 708 in a second direction. Third arm segment 711 is moveably coupled to a fourth arm segment 714 through a third joint 716 whereat fourth arm segment 714 may be rotated relative to third arm segment 711 in a third direction and a rotary joint 718 whereby an orientation of fourth arm segment 714 relative to third arm segment 711 may be altered. Magnetic coupling device 10 is illustratively shown secured to the end of robotic arm 704. Any of the disclosed magnetic coupling devices may include a coupling interface to couple the magnetic coupling device to the end of robotic arm 704. Magnetic coupling device 10 is used to couple a workpiece 17 (not shown) to robotic arm 704. Although magnetic coupling device 10 is illustrated, any of themagnetic coupling devices described herein and any number of the magnetic coupling devices described herein may be used with robotic system 700.

[0160] In one embodiment, electronic controller 770 by processor 772 executing robotic movement module 702 moves robotic arm 704 to a first pose whereat magnetic coupling device 100 contacts the workpiece at a first location. Electronic controller 770 by processor 772 executing a magnetic coupler state module 776 instructs magnetic coupling device 10 to place magnetic coupling device 10 in one of the ON state, a partial ON state, or a hyper ON state to couple the workpiece to robotic system 700. Electronic controller 770 by processor 772 executing robotic movement module 702 moves the workpiece from the first location to a second, desired, spaced apart location. Once the workpiece is at the desired second position, electronic controller 770 by processor 772 executing magnetic coupler state module 76 may instruct magnetic device 10 to place magnetic coupling device 10 in the OFF state to decouple the workpiece from robotic system 700 and optionally to execute the degauss functionality. In one example, electronic controller 770 by processor 772 executing magnetic coupler state module 76 instructs magnetic coupling device 10 to sequentially place the magnetic coupling device 10 in a partial ON state to lift a ferromagnetic workpiece, after lifting the ferromagnetic workpiece by moving robotic arm 704 instructs magnetic coupling device 10 to place the magnetic coupling device in either a more powerful partial ON state, the ON state, or a hyper ON state to increase the holding force of magnetic coupling device 10 on ferromagnetic workpiece for subsequent movement by robotic arm 704, and after positioning the ferromagnetic workpiece in a desired location by further moving the robotic arm 704 instructs magnetic coupling device 10 to place magnetic coupling device 10 in the OFF state to decouple ferromagnetic workpiece from robotic system 700, and optionally run the degaussing functionality. Electronic controller 770 then repeats the process to couple, move, and decouple another workpiece.

[0161] The following are non-limiting examples of the present disclosure.

[0162] Example 1 . A magnetic coupling device for magnetically coupling to a ferromagnetic workpiece is provided. The magnetic coupling device comprising a switchable magnetic flux source and a plurality of pole portions. The switchable magnetic flux source being switchable between a plurality of states. The switchable magnetic flux source including at least one non-reversible permanent magnet having a north pole and a south pole and a first magnetic field strength and at least one reversible magnet. The plurality of pole portions including a first north pole portion positioned to be magnetically coupled with the north pole of the at least one non- reversible permanent magnet and a first south pole portion positioned to be magnetically coupled with the south pole of the at least one non-reversible permanent magnet. Each of the plurality of pole portions having a workpiece engagement interface having at least one workpiece engagement surface. The plurality of states includes (a) an OFF state wherein a north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non- reversible permanent magnet, a south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has a second magnetic field strength generally equal to the first magnetic field strength of the at least one non-reversible permanent magnet; (b) a first ON state wherein the north pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non- reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has a third magnetic field strength generally equal to or less than the first magnetic field strength of the at least one non-reversible permanent magnet; and (c) a second ON state wherein the north pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non- reversible permanent magnet, and the at least one reversible magnet has a fourthmagnetic field strength greater than the first magnetic field strength of the at least one non-reversible permanent magnet.

[0163] Example 2. The magnetic coupling device of Example 1 , wherein in the OFF state of the plurality of states a first resultant magnetic field strength at the workpiece engagement surfaces is incapable of moving the ferromagnetic workpiece from a first position to a second position.

[0164] Example s. The magnetic coupling device of Example 2, wherein in the second ON state of the plurality of states a second resultant magnetic field strength at the workpiece engagement surfaces is capable of moving the ferromagnetic workpiece from the first position to the second position.

[0165] Example 4. The magnetic coupling device of Example 2, wherein in the first ON state of the plurality of states a third resultant magnetic field strength at the workpiece engagement surfaces is capable of moving the ferromagnetic workpiece from the first position to the second position, the third resultant magnetic field strength at the workpiece engagement surfaces being less than the second resultant magnetic field strength at the workpiece engagement surfaces.

[0166] Example 5. The magnetic coupling device of any one of Examples 1 -4, further comprising a controller operatively coupled to the switchable magnetic flux source to control a current state of the plurality of states of the switchable magnetic flux source by controlling an orientation of the north pole and the south pole of the at least one reversible magnet and a magnitude of the magnetic field strength of the at least one reversible magnet.

[0167] Example 6. The magnetic coupling device of Example 5, further comprising a housing supporting the switchable magnetic flux source and the plurality of pole portions.

[0168] Example 7. The magnetic coupling device of Example 6, wherein the housing and the plurality of pole portions are integrally formed.

[0169] Example 8. The magnetic coupling device of Example 6, wherein the plurality of pole portions are removably coupled to the housing.

[0170] Example 9. The magnetic coupling device of any of Examples 6-8, wherein the controller is spaced apart from the housing such that the controller is not moveable with the housing.

[0171] Example 10. The magnetic coupling device of any of Examples 6-8, wherein the controller is supported by the housing such that the controller is moveable with the housing.

[0172] Example 11. The magnetic coupling device of any one of Examples 2- 10, wherein the plurality of states further includes at least two degaussing states to remove residual magnetism from the workpiece engagement interface of each of the plurality of pole portions. The at least two degaussing states including (d) a first degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has a fifth magnetic field strength less than the first magnetic field strength of the at least one non-reversible permanent magnet; and (e) a second degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has a sixth magnetic field strength greater than the first magnetic field strength of the at least one non-reversible permanent magnet.

[0173] Example 12. The magnetic coupling device of any one of Examples 2- 10, wherein the controller executes a degaussing sequence to remove residual magnetism from the workpiece engagement interface of each of the plurality of pole portions, the degaussing sequence including a plurality of degaussing states of the switchable magnetic flux source to generate an alternating magnetic field at theworkpiece engagement interface of each of the plurality of pole portions over a time period.

[0174] Example 13. The magnetic coupling device of Example 12, wherein the plurality of degaussing states includes (d) a first degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has a fifth magnetic field strength less than the first magnetic field strength of the at least one non-reversible permanent magnet; and (e) a second degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has a sixth magnetic field strength greater than the first magnetic field strength of the at least one non-reversible permanent magnet.

[0175] Example 14. The magnetic coupling device of Example 13, wherein the plurality of degaussing states includes (f) a third degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has a seventh magnetic field strength less than the first magnetic field strength of the at least one non-reversible permanent magnet, the seventh magnetic field strength being greater than the fifth magnetic field strength; and (g) a fourth degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversiblemagnet has an eighth magnetic field strength greater than the first magnetic field strength of the at least one non-reversible permanent magnet, the eighth magnetic field strength being less than the sixth magnetic field strength.

[0176] Example 15. The magnetic coupling device of Example 14, wherein the plurality of degaussing states includes (h) a fifth degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has a ninth magnetic field strength less than the first magnetic field strength of the at least one non-reversible permanent magnet, the ninth magnetic field strength being greater than the seventh magnetic field strength; and (i) a sixth degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has a tenth magnetic field strength greater than the first magnetic field strength of the at least one non-reversible permanent magnet, the tenth magnetic field strength being less than the eighth magnetic field strength.

[0177] Example 16. The magnetic coupling device of any one of Examples 12-15, wherein the degaussing sequence ends with the switchable magnetic flux source being in the OFF state.

[0178] Example 17. The magnetic coupling device of Example 15, wherein the degaussing sequence includes sequentially establishing the following states of the switchable magnetic flux source: one of the first degauss state and the second degauss state, the other of the first degauss state and the second degauss state, one of the third degauss state and the fourth degauss state, the other of the third degauss state and the fourth degauss state, one of the fifth degauss state and thesixth degauss state, the other of the fifth degauss state and the sixth degauss state, and the OFF state.

[0179] Example 18. The magnetic coupling device of any one of Examples 12-17, wherein the degaussing sequence is to be performed by the controller while the workpiece contact interfaces are in contact with the ferromagnetic workpiece.

[0180] Example 19. The magnetic coupling device of any of Examples 1 -18, wherein a magnetic mass of the at least one reversible magnet is more than double a magnetic mass of the at least one non-reversible permanent magnet.

[0181] Example 20. The magnetic coupling device of any of Examples 1 -18, wherein a magnetic mass of the at least one reversible magnet is more than triple a magnetic mass of the at least one non-reversible permanent magnet.

[0182]

[0183] Example 21. The magnetic coupling device of any of Examples 1 -18, wherein a magnetic mass of the at least one reversible magnet is more than four times a magnetic mass of the at least one non-reversible permanent magnet.

[0184] Example 22. The magnetic coupling device of any one of Examples 1- 21 , wherein the third magnetic field strength of the at least one reversible magnet is generally equal to the first magnetic field strength of the at least one non-reversible permanent magnet.

[0185] Example 23. The magnetic coupling device of any one of the preceding Examples, wherein the plurality of states further includes (d) a third ON state wherein the north pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has an eleventh magnetic field strength less than the third magnetic field strength of the at least one reversible magnet and less than the first magnetic field strength of the at least one non-reversible permanent magnet.

[0186] Example 24. The magnetic coupling device of any of the preceding Examples, wherein the at least one non-reversible permanent magnet includes a first number of non-reversible permanent magnets and the at least one reversible magnet includes a second number of reversible magnets.

[0187] Example 25. The magnetic coupling device of Example 24, wherein the first number equals the second number.

[0188] Example 26. The magnetic coupling device of Example 24, wherein the second number is greater than the first number.

[0189] Example 27. The magnetic coupling device of any one of Examples 24-26, wherein the first number is one.

[0190] Example 28. The magnetic coupling device of any one of Examples 24-27, wherein the first number of non-reversible permanent magnets and the second number of reversible magnets are positioned between an outer extent of the first north pole portion and an outer extent of the first south pole portion.

[0191] Example 29. The magnetic coupling device of any of the preceding Examples wherein the at least one reversible magnet and the at least one non- reversible permanent magnet are vertically stacked.

[0192] Example 30. The magnetic coupling device of any of the preceding Examples, wherein a first non-reversible permanent magnet of the at least one non- reversible permanent magnet has an active N-S pole pair defined by a first plane, a second plane of the first non-reversible permanent magnet is perpendicular to the first plane and parallel to a longitudinal centerline plane of a first reversible magnet of the at least one reversible magnet, the second plane intersects the first reversible magnet.

[0193] Example 31. The magnetic coupling device of Example 30 wherein the longitudinal centerline plane of the first reversible magnet intersects the first non- reversible permanent magnet.

[0194] Example 32. The magnetic coupling device of any of Examples 1 -29, wherein a first non-reversible permanent magnet of the at least one non-reversiblepermanent magnet has an active N-S pole pair defined by a first plane, a second plane of the first non-reversible permanent magnet is perpendicular to the first plane and parallel to a longitudinal centerline plane of a first reversible magnet of the at least one reversible magnet, the second plane is non-intersecting with the first reversible magnet.

[0195] Example 33. The magnetic coupling device of Example 32, wherein the second plane is non-intersecting with a second reversible magnet of the at least one reversible magnet.

[0196] Example 34. The magnetic coupling device of Example 33, wherein the first reversible magnet is on a first side of the second plane and the second reversible magnet is on a second side of the second plane, the second side of the second plane being opposite the first side of the second plane.

[0197] Example 35. The magnetic coupling device of any one of Examples 32-34, wherein the longitudinal centerline plane of the first reversible magnet intersects the first non-reversible permanent magnet.

[0198] Example 36. The magnetic coupling device of any of Examples 1 -23, wherein the at least one non-reversible permanent magnet includes a first number of non-reversible permanent magnets and the at least one reversible magnet includes a second number of reversible magnets and wherein the plurality of pole portions includes a third pole portion, and a first subset of the first number of non-reversible permanent magnets are positioned to be magnetically coupled with the first north pole portion and the first south pole portion and a second subset of the first number of non-reversible permanent magnets are positioned spaced apart from the first subset and to be magnetically coupled to the third pole portion and one of the first north pole portion and the first south pole portion.

[0199] Example 37. The magnetic coupling device of Example 36, wherein first subset of the first number of non-reversible permanent magnets and the second subset of the first number of non-reversible permanent magnets are supported by acommon pole plate that includes the first north pole portion, the first south pole portion, and the third pole portion.

[0200] Example 38. The magnetic coupling device of any one of Examples 36 and 37, wherein the first number equals the second number.

[0201] Example 39. The magnetic coupling device of any one of Examples 36-38, wherein a first one of the at least one non-reversible permanent magnet is rectilinear.

[0202] Example 40. The magnetic coupling device of any one of Examples 36-39, wherein a first one of the at least one reversible magnet is rectilinear.

[0203] Example 41. The magnetic coupling device of any one of Examples 36 and 37, wherein the second number is greater than the first number.

[0204] Example 42. The magnetic coupling device of any of the preceding Examples, wherein each of plurality of pole portions includes a plurality of projections separated by a plurality of recesses, the plurality of projections collectively forming a workpiece contact interface of the respective pole portion.

[0205] Example 43. The magnetic coupling device of any of the preceding Examples, wherein each of the plurality of pole portions are movably coupled to the housing.

[0206] Example 44. The magnetic coupling device of any one of Examples 1 - 42, wherein each of the plurality of pole portions are fixedly coupled to the housing.

[0207] Example 45. The magnetic coupling device of any one of Examples 1- 44, further comprising one or more sensors to determine a characteristic of a magnetic circuit present between the magnetic coupling device and the ferromagnetic workpiece to be coupled to the magnetic coupling device.

[0208] Example 46. The magnetic coupling device of Example 45, wherein the one or more sensors are supported by the housing and are spaced apart from the workpiece engagement interfaces of the plurality of pole portions.

[0209] Example 47. The magnetic coupling device of any one of Examples 1 - 46, wherein the at least one non-reversible magnet is an at least one rare earth permanent magnet.

[0210] Example 48. The magnetic coupling device of Example 47, wherein the at least one reversible magnet is an at least one electro-permanent magnet.

[0211] Example 49. The magnetic coupling device of any one of Examples 1 - 46, wherein the at least one reversible magnet is an at least one electro-permanent magnet.

[0212] Example 50. The magnetic coupling device of any one of Examples 1- 49, wherein the at least one reversible magnet has a plurality of set orientations for a north pole and a south pole and maintains a current orientation of the plurality of set orientations in the absence of an external characteristic.

[0213] Example 51. A magnetic coupling device for magnetically coupling to a ferromagnetic workpiece is provided. The magnetic coupling device, comprising a switchable magnetic flux source and a plurality of pole portions. The switchable magnetic flux source being switchable between a plurality of states. The switchable magnetic flux source including at least one non-reversible permanent magnet having a north pole and a south pole and a first magnetic field strength and at least one reversible magnet. The plurality of pole portions including a first north pole portion positioned to be magnetically coupled with the north pole of the at least one non- reversible permanent magnet and a first south pole portion positioned to be magnetically coupled with the south pole of the at least one non-reversible permanent magnet. Each of the plurality of pole portions having a workpiece engagement interface having at least one workpiece engagement surface. The plurality of states includes at least two degaussing states to remove residual magnetism from the workpiece engagement interface of each of the plurality of pole portions. The at least two degaussing states including (a) a first degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, the southpole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has a fifth magnetic field strength less than the first magnetic field strength of the at least one non-reversible permanent magnet; and (b) a second degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has a sixth magnetic field strength greater than the first magnetic field strength of the at least one non-reversible permanent magnet.

[0214] Example 52. The magnetic coupling device of Example 51 , further comprising a controller operatively coupled to the switchable magnetic flux source to control a current state of the plurality of states of the switchable magnetic flux source by controlling an orientation of the north pole and the south pole of the at least one reversible magnet and a magnitude of the magnetic field strength of the at least one reversible magnet.

[0215] Example 53. The magnetic coupling device of Example 52, further comprising a housing supporting the switchable magnetic flux source and the plurality of pole portions.

[0216] Example 54. The magnetic coupling device of Example 53, wherein the housing and the plurality of pole portions are integrally formed.

[0217] Example 55. The magnetic coupling device of Example 53, wherein the plurality of pole portions are removably coupled to the housing.

[0218] Example 56. The magnetic coupling device of any of Examples 53-55, wherein the controller is spaced apart from the housing such that the controller is not moveable with the housing.

[0219] Example 57. The magnetic coupling device of any of Examples 53-55, wherein the controller is supported by the housing such that the controller is moveable with the housing.

[0220] Example 58. The magnetic coupling device of any one of Examples 51-57, wherein the plurality of degaussing states includes (c) a third degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has a seventh magnetic field strength less than the first magnetic field strength of the at least one non-reversible permanent magnet, the seventh magnetic field strength being greater than the fifth magnetic field strength; and (d) a fourth degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has an eighth magnetic field strength greater than the first magnetic field strength of the at least one non-reversible permanent magnet, the eighth magnetic field strength being less than the sixth magnetic field strength.

[0221] Example 59. The magnetic coupling device of Example 58, wherein the plurality of degaussing states includes (e) a fifth degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has a ninth magnetic field strength less than the first magnetic field strength of the at least one non-reversible permanent magnet, the ninth magnetic field strength being greater than the seventh magnetic field strength; and (f) a sixth degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversiblemagnet has a tenth magnetic field strength greater than the first magnetic field strength of the at least one non-reversible permanent magnet, the tenth magnetic field strength being less than the eighth magnetic field strength.

[0222] Example 60. The magnetic coupling device of any one of Examples51-59, wherein subsequent to the at least two degaussing states the switchable magnetic flux source being in the OFF state.

[0223] Example 61. The magnetic coupling device of any one of Examples52-60, wherein the degaussing sequence is to be performed by the controller while the workpiece contact interfaces are in contact with the ferromagnetic workpiece.

[0224] Example 62. A magnetic coupling device for magnetically coupling to a ferromagnetic workpiece, comprising: a housing including at least one cradle; a switchable magnetic flux source supported by the housing, the switchable magnetic flux source being switchable between at least an OFF state and an ON state, the switchable magnetic flux source including at least one rare earth permanent magnet and at least one electro-permanent magnet; and a plurality of pole portions, each having a workpiece engagement interface having at least one workpiece engagement surface; wherein the at least one cradle of the housing receives the at least one electro-permanent magnet and supports the at least one electropermanent magnet in a spaced apart relationship relative to the at least one rare earth permanent magnet.

[0225] Example 63. The magnetic coupling device of Example 62, wherein the at least one cradle has an open end to receive the at least one electropermanent magnet and a support surface opposite the open end to support the at least one electro-permanent magnet.

[0226] Example 64. The magnetic coupling device of any one of Examples 62 and 63, wherein the at least one cradle is positioned above the at least one rare earth permanent magnet and the at least one rare earth permanent magnet is positioned vertically between the at least one workpiece engagement surface of afirst pole portion of the plurality of pole portions and the at least one electropermanent magnet.

[0227] Example 65. The magnetic coupling device of any one of Examples 62-64, wherein the at least one cradle includes a first cradle positioned to a first side of a first rare earth permanent magnet of the at least one rare earth permanent magnet and a second cradle positioned to a second side of the first rare earth permanent magnet, the second side opposite the first side.

[0228] Example 66. The magnetic coupling device of Example 65, wherein a first support surface of the first cradle supports a first end of a first electro-permanent magnet of the at least one electro-permanent magnet and a second support surface of the second cradle supports a second end of the first electro-permanent magnet, the second end of the first electro-permanent magnet being opposite the first end of the first electro-permanent magnet.

[0229] Example 67. The magnetic coupling device of Example 66, wherein the first rare earth permanent magnet has an active N-S pole pair defined by a first plane, a second plane of the first rare earth permanent magnet is perpendicular to the first plane and parallel to a longitudinal centerline plane of the first electropermanent magnet, the second plane intersects the first electro-permanent magnet.

[0230] Example 68. The magnetic coupling device of any one of Examples 66 and 67, wherein the longitudinal centerline plane of the first electro-permanent magnet intersects the first rare earth permanent magnet.

[0231] Example 69. The magnetic coupling device of any one of Examples 62-64, wherein the at least one cradle includes a first cradle positioned to a first side of a first rare earth permanent magnet of the at least one rare earth permanent magnet; a second cradle positioned to a second side of the first rare earth permanent magnet, the second side opposite the first side; a third cradle positioned to the first side of the first rare earth permanent magnet of the at least one rare earth permanent magnet; and a fourth cradle positioned to the second side of the first rare earth permanent magnet.

[0232] Example 70. The magnetic coupling device of Example 69, wherein a first support surface of the first cradle supports a first end of a first electro-permanent magnet of the at least one electro-permanent magnet and a second support surface of the second cradle supports a second end of the first electro-permanent magnet, the second end of the first electro-permanent magnet being opposite the first end of the first electro-permanent magnet and wherein a third support surface of the third cradle supports a first end of a second electro-permanent magnet of the at least one electro-permanent magnet and a fourth support surface of the fourth cradle supports a second end of the second electro-permanent magnet, the second end of the second electro-permanent magnet being opposite the first end of the second electropermanent magnet.

[0233] Example 71. The magnetic coupling device of Example 70, wherein the first rare earth permanent magnet has an active N-S pole pair defined by a first plane, a second plane of the first rare earth permanent magnet is perpendicular to the first plane and parallel to a longitudinal centerline plane of the first electropermanent magnet, the second plane is non-intersecting with the first electropermanent magnet.

[0234] Example 72. The magnetic coupling device of Example 71 , wherein the second plane is non-intersecting with the second electro-permanent magnet.

[0235] Example 73. The magnetic coupling device of Example 72, wherein the first electro-permanent magnet is on a first side of the second plane and the second electro-permanent magnet is on a second side of the second plane, the second side of the second plane being opposite the first side of the second plane.

[0236] Example 74. The magnetic coupling device of any one of Examples 71-73, wherein the longitudinal centerline plane of the first electro-permanent magnet intersects the first rare earth permanent magnet.

[0237] Example 75. The magnetic coupling device of any one of Examples 62-74, wherein the plurality of pole portions includes at least one north pole portion and at least one south pole portion.

[0238] Example 76. The magnetic coupling device of Example 75, wherein each of the at least one north pole portion and the at least one south pole portion includes a plurality of projections separated by a plurality of recesses, the plurality of projections collectively forming a workpiece contact interface of the respective at least one north pole portion and at least one south pole portion.

[0239] Example 77. The magnetic coupling device of any one of Examples 75 and 76, wherein each the at least one north pole portion and the at least one south pole portion are movably coupled to the housing.

[0240] Example 78. The magnetic coupling device of any one of Examples 75 and 76, wherein each the at least one north pole portion and the at least one south pole portion are fixedly coupled to the housing.

[0241] Example 79. The magnetic coupling device of any one of Examples 75 and 76, wherein each the at least one north pole portion and the at least one south pole portion are integrally formed as part of the housing.

[0242] Example 80. The magnetic coupling device of any one of Examples 62-79, further comprising one or more sensors to determine a characteristic of a magnetic circuit present between the magnetic coupling device and the ferromagnetic workpiece to be coupled to the magnetic coupling device.

[0243] Example 81. The magnetic coupling device of Example 80, wherein the one or more sensors are supported by the housing and are spaced apart from the workpiece engagement interfaces of the plurality of pole portions.

[0244] Various modifications and additions can be made to the exemplary embodiments discussed without departing from the scope of the present invention. For example, while the embodiments described above refer to particular features, the scope of this invention also includes embodiments having different combinations of features and embodiments that do not include all of the described features.Accordingly, the scope of the present invention is intended to embrace all such alternatives, modifications, and variations as fall within the scope of the claims, together with all equivalents thereof.

Claims

CLAIMS:1 . A magnetic coupling device for magnetically coupling to a ferromagnetic workpiece, comprising: a switchable magnetic flux source, the switchable magnetic flux source being switchable between a plurality of states, the switchable magnetic flux source including at least one non-reversible permanent magnet having a north pole and a south pole and a first magnetic field strength and at least one reversible magnet; and a plurality of pole portions including a first north pole portion positioned to be magnetically coupled with the north pole of the at least one non-reversible permanent magnet and a first south pole portion positioned to be magnetically coupled with the south pole of the at least one non-reversible permanent magnet, each of the plurality of pole portions having a workpiece engagement interface having at least one workpiece engagement surface, wherein the plurality of states includes(a) an OFF state wherein a north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non- reversible permanent magnet, a south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non- reversible permanent magnet, and the at least one reversible magnet has a second magnetic field strength generally equal to the first magnetic field strength of the at least one non-reversible permanent magnet;(b) a first ON state wherein the north pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non- reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non- reversible permanent magnet, and the at least one reversible magnet has athird magnetic field strength generally equal to or less than the first magnetic field strength of the at least one non-reversible permanent magnet; and(c) a second ON state wherein the north pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has a fourth magnetic field strength greater than the first magnetic field strength of the at least one non-reversible permanent magnet.

2. The magnetic coupling device of claim 1 , wherein in the OFF state of the plurality of states a first resultant magnetic field strength at the workpiece engagement surfaces is incapable of moving the ferromagnetic workpiece from a first position to a second position.

3. The magnetic coupling device of claim 2, wherein in the second ON state of the plurality of states a second resultant magnetic field strength at the workpiece engagement surfaces is capable of moving the ferromagnetic workpiece from the first position to the second position.

4. The magnetic coupling device of claim 2, wherein in the first ON state of the plurality of states a third resultant magnetic field strength at the workpiece engagement surfaces is capable of moving the ferromagnetic workpiece from the first position to the second position, the third resultant magnetic field strength at the workpiece engagement surfaces being less than the second resultant magnetic field strength at the workpiece engagement surfaces.

5. The magnetic coupling device of any one of claims 1 -4, further comprising a controller operatively coupled to the switchable magnetic flux source to control a current state of the plurality of states of the switchable magnetic flux source by controlling an orientation of the north pole and the south pole of the at least one reversible magnet and a magnitude of the magnetic field strength of the at least one reversible magnet.

6. The magnetic coupling device of claim 5, further comprising a housing supporting the switchable magnetic flux source and the plurality of pole portions.

7. The magnetic coupling device of claim 6, wherein the housing and the plurality of pole portions are integrally formed.

8. The magnetic coupling device of claim 6, wherein the plurality of pole portions are removably coupled to the housing.

9. The magnetic coupling device of any of claims 6-8, wherein the controller is spaced apart from the housing such that the controller is not moveable with the housing.

10. The magnetic coupling device of any of claims 6-8, wherein the controller is supported by the housing such that the controller is moveable with the housing.11 . The magnetic coupling device of any one of claims 2-10, wherein the plurality of states further includes at least two degaussing states to remove residual magnetism from the workpiece engagement interface of each of the plurality of pole portions, the at least two degaussing states including(d) a first degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversiblepermanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has a fifth magnetic field strength less than the first magnetic field strength of the at least one non-reversible permanent magnet; and(e) a second degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non- reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has a sixth magnetic field strength greater than the first magnetic field strength of the at least one non-reversible permanent magnet.

12. The magnetic coupling device of any one of claims 2-10, wherein the controller executes a degaussing sequence to remove residual magnetism from the workpiece engagement interface of each of the plurality of pole portions, the degaussing sequence including a plurality of degaussing states of the switchable magnetic flux source to generate an alternating magnetic field at the workpiece engagement interface of each of the plurality of pole portions over a time period.

13. The magnetic coupling device of claim 12, wherein the plurality of degaussing states includes(d) a first degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has a fifth magnetic field strength less than the first magnetic field strength of the at least one non-reversible permanent magnet; and(e) a second degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non- reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has a sixth magnetic field strength greater than the first magnetic field strength of the at least one non-reversible permanent magnet.

14. The magnetic coupling device of claim 13, wherein the plurality of degaussing states includes(f) a third degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has a seventh magnetic field strength less than the first magnetic field strength of the at least one non-reversible permanent magnet, the seventh magnetic field strength being greater than the fifth magnetic field strength; and(g) a fourth degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has an eighth magnetic field strength greater than the first magnetic field strength of the at least one non-reversible permanent magnet, the eighth magnetic field strength being less than the sixth magnetic field strength.

15. The magnetic coupling device of claim 14, wherein the plurality of degaussing states includes(h) a fifth degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has a ninth magnetic field strength less than the first magnetic field strength of the at least one non-reversible permanent magnet, the ninth magnetic field strength being greater than the seventh magnetic field strength; and(i) a sixth degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has a tenth magnetic field strength greater than the first magnetic field strength of the at least one non-reversible permanent magnet, the tenth magnetic field strength being less than the eighth magnetic field strength.

16. The magnetic coupling device of any one of claims 12-15, wherein the degaussing sequence ends with the switchable magnetic flux source being in the OFF state.

17. The magnetic coupling device of claim 15, wherein the degaussing sequence includes sequentially establishing the following states of the switchable magnetic flux source: one of the first degauss state and the second degauss state, the other of the first degauss state and the second degauss state, one of the third degauss state and the fourth degauss state, the other of the third degauss state and the fourth degauss state, one of the fifth degauss state and the sixth degauss state, the other of the fifth degauss state and the sixth degauss state, and the OFF state.

18. The magnetic coupling device of any one of claims 12-17, wherein the degaussing sequence is to be performed by the controller while the workpiece contact interfaces are in contact with the ferromagnetic workpiece.

19. The magnetic coupling device of any of claims 1 -18, wherein a magnetic mass of the at least one reversible magnet is more than double a magnetic mass of the at least one non-reversible permanent magnet.

20. The magnetic coupling device of any of claims 1 -18, wherein a magnetic mass of the at least one reversible magnet is more than triple a magnetic mass of the at least one non-reversible permanent magnet.21 . The magnetic coupling device of any of claims 1 -18, wherein a magnetic mass of the at least one reversible magnet is more than four times a magnetic mass of the at least one non-reversible permanent magnet.

22. The magnetic coupling device of any one of claims 1 -21 , wherein the third magnetic field strength of the at least one reversible magnet is generally equal to the first magnetic field strength of the at least one non-reversible permanent magnet.

23. The magnetic coupling device of any one of the preceding claims, wherein the plurality of states further includes (d) a third ON state wherein the north pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has an eleventh magnetic field strength less than the third magnetic field strength of the at least one reversible magnet and less than the first magnetic field strength of the at least one non-reversible permanent magnet.

24. The magnetic coupling device of any of the preceding claims, wherein the at least one non-reversible permanent magnet includes a first number of non-reversible permanent magnets and the at least one reversible magnet includes a second number of reversible magnets.

25. The magnetic coupling device of claim 24, wherein the first number equals the second number.

26. The magnetic coupling device of claim 24, wherein the second number is greater than the first number.

27. The magnetic coupling device of any one of claims 24-26, wherein the first number is one.

28. The magnetic coupling device of any one of claims 24-27, wherein the first number of non-reversible permanent magnets and the second number of reversible magnets are positioned between an outer extent of the first north pole portion and an outer extent of the first south pole portion.

29. The magnetic coupling device of any of the preceding claims wherein the at least one reversible magnet and the at least one non-reversible permanent magnet are vertically stacked.

30. The magnetic coupling device of any of the preceding claims, wherein a first non-reversible permanent magnet of the at least one non-reversible permanent magnet has an active N-S pole pair defined by a first plane, a second plane of the first non-reversible permanent magnet is perpendicular to the first plane and parallelto a longitudinal centerline plane of a first reversible magnet of the at least one reversible magnet, the second plane intersects the first reversible magnet.31 . The magnetic coupling device of claim 30 wherein the longitudinal centerline plane of the first reversible magnet intersects the first non-reversible permanent magnet.

32. The magnetic coupling device of any of claims 1-29, wherein a first non- reversible permanent magnet of the at least one non-reversible permanent magnet has an active N-S pole pair defined by a first plane, a second plane of the first non- reversible permanent magnet is perpendicular to the first plane and parallel to a longitudinal centerline plane of a first reversible magnet of the at least one reversible magnet, the second plane is non-intersecting with the first reversible magnet.

33. The magnetic coupling device of claim 32, wherein the second plane is nonintersecting with a second reversible magnet of the at least one reversible magnet.

34. The magnetic coupling device of claim 33, wherein the first reversible magnet is on a first side of the second plane and the second reversible magnet is on a second side of the second plane, the second side of the second plane being opposite the first side of the second plane.

35. The magnetic coupling device of any one of claims 32-34, wherein the longitudinal centerline plane of the first reversible magnet intersects the first non- reversible permanent magnet.

36. The magnetic coupling device of any of claims 1-23, wherein the at least one non-reversible permanent magnet includes a first number of non-reversible permanent magnets and the at least one reversible magnet includes a secondnumber of reversible magnets and wherein the plurality of pole portions includes a third pole portion, and a first subset of the first number of non-reversible permanent magnets are positioned to be magnetically coupled with the first north pole portion and the first south pole portion and a second subset of the first number of non- reversible permanent magnets are positioned spaced apart from the first subset and to be magnetically coupled to the third pole portion and one of the first north pole portion and the first south pole portion.

37. The magnetic coupling device of claim 36, wherein first subset of the first number of non-reversible permanent magnets and the second subset of the first number of non-reversible permanent magnets are supported by a common pole plate that includes the first north pole portion, the first south pole portion, and the third pole portion.

38. The magnetic coupling device of any one of claims 36 and 37, wherein the first number equals the second number.

39. The magnetic coupling device of any one of claims 36-38, wherein a first one of the at least one non-reversible permanent magnet is rectilinear.

40. The magnetic coupling device of any one of claims 36-39, wherein a first one of the at least one reversible magnet is rectilinear.41 . The magnetic coupling device of any one of claims 36 and 37, wherein the second number is greater than the first number.

42. The magnetic coupling device of any of the preceding claims, wherein each of plurality of pole portions includes a plurality of projections separated by a plurality of recesses, the plurality of projections collectively forming a workpiece contact interface of the respective pole portion.

43. The magnetic coupling device of any of the preceding claims, wherein each of the plurality of pole portions are movably coupled to the housing.

44. The magnetic coupling device of any one of claims 1 -42, wherein each of the plurality of pole portions are fixedly coupled to the housing.

45. The magnetic coupling device of any one of claims 1 -44, further comprising one or more sensors to determine a characteristic of a magnetic circuit present between the magnetic coupling device and the ferromagnetic workpiece to be coupled to the magnetic coupling device.

46. The magnetic coupling device of claim 45, wherein the one or more sensors are supported by the housing and are spaced apart from the workpiece engagement interfaces of the plurality of pole portions.

47. The magnetic coupling device of any one of claims 1 -46, wherein the at least one non-reversible magnet is an at least one rare earth permanent magnet.

48. The magnetic coupling device of claim 47, wherein the at least one reversible magnet is an at least one electro-permanent magnet.

49. The magnetic coupling device of any one of claims 1 -46, wherein the at least one reversible magnet is an at least one electro-permanent magnet.

50. The magnetic coupling device of any one of claims 1 -49, wherein the at least one reversible magnet has a plurality of set orientations for a north pole and a south pole and maintains a current orientation of the plurality of set orientations in the absence of an external characteristic.51 . A magnetic coupling device for magnetically coupling to a ferromagnetic workpiece, comprising: a switchable magnetic flux source, the switchable magnetic flux source being switchable between a plurality of states, the switchable magnetic flux source including at least one non-reversible permanent magnet having a north pole and a south pole and a first magnetic field strength and at least one reversible magnet; and a plurality of pole portions including a first north pole portion positioned to be magnetically coupled with the north pole of the at least one non-reversible permanent magnet and a first south pole portion positioned to be magnetically coupled with the south pole of the at least one non-reversible permanent magnet, each of the plurality of pole portions having a workpiece engagement interface having at least one workpiece engagement surface, wherein the plurality of states includes at least two degaussing states to remove residual magnetism from the workpiece engagement interface of each of the plurality of pole portions, the at least two degaussing states including(a) a first degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has a fifth magnetic field strength less than the first magnetic field strength of the at least one non-reversible permanent magnet; and(b) a second degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has a sixth magnetic field strength greater than the first magnetic field strength of the at least one non-reversible permanent magnet.

52. The magnetic coupling device of claim 51 , further comprising a controller operatively coupled to the switchable magnetic flux source to control a current state of the plurality of states of the switchable magnetic flux source by controlling an orientation of the north pole and the south pole of the at least one reversible magnet and a magnitude of the magnetic field strength of the at least one reversible magnet.

53. The magnetic coupling device of claim 52, further comprising a housing supporting the switchable magnetic flux source and the plurality of pole portions.

54. The magnetic coupling device of claim 53, wherein the housing and the plurality of pole portions are integrally formed.

55. The magnetic coupling device of claim 53, wherein the plurality of pole portions are removably coupled to the housing.

56. The magnetic coupling device of any of claims 53-55, wherein the controller is spaced apart from the housing such that the controller is not moveable with the housing.

57. The magnetic coupling device of any of claims 53-55, wherein the controller is supported by the housing such that the controller is moveable with the housing.

58. The magnetic coupling device of any one of claims 51 -57, wherein the plurality of degaussing states includes(c) a third degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has a seventh magnetic field strength less than the first magnetic field strength of the at least one non-reversible permanent magnet, the seventh magnetic field strength being greater than the fifth magnetic field strength; and(d) a fourth degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has an eighth magnetic field strength greater than the first magnetic field strength of the at least one non-reversible permanent magnet, the eighth magnetic field strength being less than the sixth magnetic field strength.

59. The magnetic coupling device of claim 58, wherein the plurality of degaussing states includes(e) a fifth degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has a ninth magnetic field strength less than the first magnetic field strength of the at least one non-reversible permanent magnet, the ninth magnetic field strength being greater than the seventh magnetic field strength; and(f) a sixth degauss state wherein the north pole of the at least one reversible magnet is magnetically coupled to the south pole of the at least one non-reversible permanent magnet, the south pole of the at least one reversible magnet is magnetically coupled to the north pole of the at least one non-reversible permanent magnet, and the at least one reversible magnet has a tenth magnetic field strength greater than the first magnetic field strength of the at least one non-reversible permanent magnet, the tenth magnetic field strength being less than the eighth magnetic field strength.

60. The magnetic coupling device of any one of claims 51 -59, wherein subsequent to the at least two degaussing states the switchable magnetic flux source being in the OFF state.61 . The magnetic coupling device of any one of claims 52-60, wherein the degaussing sequence is to be performed by the controller while the workpiece contact interfaces are in contact with the ferromagnetic workpiece.

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