Systems and methods for magnetic rotational coupling devices

Abstract

To provide a rotational coupling with high efficiency and no friction, which is sought for a long time and can be actuated under a high output condition.SOLUTION: Improved magnetic rotor assemblies are provided. In one embodiment, the magnetic rotor assembly includes two or more rotor disks. The rotor disks may each contain corresponding sets of permanent magnets, which may be circumferentially disposed around the disks. The disks then may be positioned near one another such that the disks are magnetically coupled. In certain instances, the N-poles of the permanent magnets may face one another. In other instances, the S-poles of the permanent magnets may face one another.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Patent Application No. 62 / 896,251, filed September 5, 2019, the disclosure of which is incorporated herein by reference for all purposes.

[0002] The present invention relates generally to rotary couplings, and more particularly to friction-reducing torque transmission components. [Background technology]

[0003] Mechanical machines convert and / or transfer energy through the use of fixed and moving parts that are interposed between a power source and a load or work to be done. The result is a kinetic chain of linkages, couplings, gears, and other such mechanical interfaces that are subject to frictional energy losses in the form of heat and sound. These and other such dissipative forces can significantly reduce the efficiency of a system, typically expressed as the ratio of power output to power input.

[0004] Various types of low friction couplings have been developed over the years, but such designs are deficient in many respects. For example, magnetic "gears" have been developed that feature a number of strong permanent magnets arranged circumferentially at regular angular intervals around the circumference. Such mechanical couplings have been successful in providing gear-like motion with little or no friction. However, their use of simple single layer magnets has proven to be suboptimal with respect to providing a strong, slip-free rotational coupling between elements at high rotational speeds and torques. Summary of the Invention [Problem to be solved by the invention]

[0005] Thus, there is a need for a system and method that overcomes these and other limitations of the prior art. For example, there has been a long-felt need for a highly efficient, frictionless rotary coupling capable of operating under high power conditions. [Means for solving the problem]

[0006] The present disclosure presents a new and innovative magnetic rotor assembly and a method for providing a magnetic rotor assembly. In a first aspect, a magnetic rotor assembly is provided that includes a first rotor disk and a second rotor disk. The first rotor disk may include a first disk and a set of first permanent magnets arranged circumferentially around the first disk such that the north poles face outward from the first surface of the first disk. The second rotor disk may include a second disk and a set of second permanent magnets arranged circumferentially around the disk such that the north poles face outward from the first surface of the second disk. The first surface of the first disk may face (face) the first surface of the second disk such that the first rotor disk and the second rotor disk are magnetically coupled to each other.

[0007] In a second aspect according to the first aspect, the first set of permanent magnets may be arranged circumferentially around the first disk with their south poles facing outward from the first face of the first disk, and the second set of permanent magnets may be arranged circumferentially around the second disk with their south poles facing outward from the first face of the second disk.

[0008] In a third aspect according to either the first or second aspect, the first side of the first disc is spaced from the first side of the second disc.

[0009] In a fourth embodiment according to any of the first to third embodiments, the first side of the first disc is spaced 0.125 to 0.635 cm from the first side of the second disc.

[0010] In a fifth aspect according to any of the first to fourth aspects, the first side of the first disc is in contact with the first side of the second disc.

[0011] In a sixth aspect according to any of the first to fifth aspects, each of the magnets of the first set of permanent magnets is a disc-shaped neodymium magnet fixed within a corresponding recess in the first disk.

[0012] In a seventh aspect according to any of the first to sixth aspects, the first set of permanent magnets and the second set of permanent magnets each comprise 12 rare earth magnets.

[0013] In an eighth embodiment according to any of the first through seventh embodiments, the rare earth magnet has a diameter of about 1 inch (about 2.54 cm).

[0014] In a ninth embodiment according to any of the first through eighth embodiments, the first disc body and the second disc each comprise graphite and are about 7 inches (about 17.78 cm) in diameter.

[0015] In a tenth embodiment according to any of the first through ninth embodiments, each of the permanent magnets is positioned about 1 / 8 inch (about 0.318 cm) from its respective disk. In an eleventh aspect, a method is provided that includes providing a first disk and a second disk, and positioning a first set of permanent magnets within the first disk such that the first set of permanent magnets are circumferentially disposed about the first disk. The method may also include positioning a second set of permanent magnets within the second disk such that the second set of permanent magnets are circumferentially disposed about the second disk. The method may further include positioning the first disk and the second disk such that the first set of permanent magnets oppose (face) the second set of permanent magnets such that the first disk and the second disk are magnetically coupled to form a magnetic rotor assembly.

[0016] The features and advantages described herein are not exhaustive, and many additional features and advantages will be apparent to those skilled in the art, particularly in view of the drawings and description.Furthermore, it should be noted that the language used herein has been selected primarily for ease of reading and instructional purposes, and not to limit the scope of the disclosed subject matter.

[0017] The present invention will now be described in conjunction with the accompanying drawings, in which like reference numbers refer to like elements and in which: [Brief description of the drawings]

[0018] [Figure 1] 1 is a diagrammatical illustration of a magnetic coupling assembly in accordance with an illustrative embodiment;

[0019] [Diagram 2] 1A-1C illustrate the insertion of magnets into a rotor disk according to various embodiments.

[0020] [Diagram 3] 1A-1D sequentially illustrate joining two magnetic rotor disks to form a magnetic rotor assembly according to one embodiment. [Figure 4] 1A-1D sequentially illustrate joining two magnetic rotor disks to form a magnetic rotor assembly according to one embodiment.

[0021] [Diagram 5] FIG. 5 is a partial perspective view of the magnetic rotor assembly shown in FIGS. 3 and 4.

[0022] [Figure 6] 1 is a flowchart illustrating a method of forming a magnetic coupling assembly in accordance with various embodiments. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0023] The following detailed description of the invention is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. Furthermore, there is no intention to be bound by the preceding background or any findings presented in the following detailed description.

[0024] Various embodiments of the present invention relate to an improved frictionless torque transfer device that employs a novel form of magnetic coupling rather than a mechanical coupling to reduce or substantially eliminate frictional power losses.

[0025] 1, a magnetic coupling assembly 100 according to an exemplary embodiment generally includes an input shaft 110 rigidly coupled to a substantially disk-shaped magnetic rotor assembly (or “input rotor assembly”) 131, which is magnetically coupled (as described in further detail below) to a first magnetic rotor assembly (or “output rotor assembly”) 132 and a second magnetic rotor assembly (or “output rotor assembly”) 133. The output rotor assemblies 132 and 133 are rigidly coupled to respective output shafts 121 and 122 such that rotation of the input shaft 110 results in corresponding rotation of the output shafts 121 and 122.

[0026] In this regard, while the example magnetic coupling assembly in FIG. 1 is shown in the context of a single input rotor assembly (131) driving two output rotor assemblies (132, 133), it will be understood that the invention is not so limited and that any given input rotor assembly may be magnetically coupled to any number of output rotor assemblies, including in some embodiments a single output rotor assembly.

[0027] It will also be understood that the various components depicted in Figure 1 are not necessarily drawn to scale. For example, while rotor assemblies 131, 132 and 133 are shown as having substantially the same diameter, in some embodiments the rotor assemblies are configured with different diameters (including different radial positions of the respective magnets) to achieve particular mechanical advantages and / or rotational speed ratios. For clarity, Figure 1 does not show various conventional mechanical components known in the art, such as bearings, shaft couplings, output loads (e.g., generators), input drives (e.g., electric motors), etc.

[0028] To achieve the desired magnetic coupling behavior, each pair of adjacent magnetically coupled rotor assemblies (e.g., input rotor assembly 131 and output rotor assembly 133) are positioned such that their circumferences overlap (in a direction perpendicular to their axis of rotation) by a distance d1 and are separated (in a direction parallel to their axis of rotation) by a distance d2 as shown. In one embodiment, d1 ranges from 1.5 to 2.5 cm (preferably about 2.0 cm) and d2 ranges from 0.125 to 0.635 cm (preferably about 0.380 cm). These dimensions may vary (and may be optimized analytically or empirically) depending on, among other things, the geometry of the rotor assemblies, as well as the strength, size, and distribution of the individual magnets.

[0029] In operation, by virtue of magnetic coupling, the output shafts 121 and 122 rotate in response to rotation of the input shaft, which may be driven, for example, by an electric motor or the like (not shown). Depending on the radial position (also referred to as the "effective diameter") of the circular array of magnets incorporated in each rotor assembly, the available torque and rotational speed (τo1, ωo1, τo2, ωo2) of each output shaft 121 and 122 can be calculated as a function of the applied torque and rotational speed (τin, ωin) of the input shaft 110.

[0030] For example, consider an embodiment in which the effective diameters of rotor assemblies 131, 132, and 133 are equal. In such a case, ωo1=ωo2=ωin, and the torque available at each output 121 and 122 is equal to half the torque of the input 110, i.e., τo1=τin / 2, τo2=τin / 2. Thus, considering the power provided by each shaft as the product of torque and rotational speed, the power available at outputs 121 and 122 is half the power of the input 110, minus losses. In accordance with the present invention, such losses are extremely low (indeed, even negligible) as a result of the non-contact, frictionless nature of the magnetic coupling between adjacent rotor assemblies, particularly compared to the substantial losses to friction and heat that occur between mechanical gears in conventional systems.

[0031] Having thus generally described an exemplary magnetically coupled assembly, an individual rotor assembly will now be described with reference to the flow chart of FIG. 6 in conjunction with FIGS. 2-5.

[0032] Referring first to the exemplary method 600 of Figure 6, a method of assembling a magnetically coupled system according to various embodiments generally includes providing a set of magnets (e.g., rare earth magnets such as N52 neodymium magnets) (step 601), inserting or otherwise incorporating some of the magnets into a first rotor disk (step 602), inserting or otherwise incorporating some of the magnets into a second rotor disk (step 603), opposing (facing) a pair of disks (e.g., with N-oriented faces adjacent to one another) and gradually rotating the disks until the disks attract each other and are magnetically secured together, thereby forming a single magnetic rotor assembly (step 604), connecting the magnetic rotor assembly to a shaft (step 605), and combining the magnetic rotor assembly with one or more other adjacent magnetic rotor assemblies to form a completed magnetically coupled assembly (step 606). Each of these steps will now be described in further detail.

[0033] Referring first to the exemplary rotor disk 200 shown in FIG. 2, assembly begins with procuring a set of magnets 250. In one embodiment, for example, each magnet 250 is a circular nickel-plated N52 type neodymium rare earth magnet having a 1.0 inch diameter and a 1 / 8 inch thickness. The magnets 250 are then secured to the rotor disk (or "disk body") 210 in a regular pattern circumferentially with their magnetic poles facing the same direction (e.g., all north poles pointing out of the page with respect to FIG. 2).

[0034] In one embodiment, rotor disk 210 is an aluminum, carbon fiber, or graphite disk (e.g., a 3D printed graphite disk) having an outer diameter D of 7.0 inches, a thickness of 3 / 16 inches (approximately 0.477 cm), and a central hole 214 having an inner diameter (e.g., ½ inch (approximately 1.27 cm)) configured to accept a shaft as described above.

[0035] Twelve recessed regions 212 are formed in the disk 210, each configured to tightly receive a corresponding magnet 250. The regions 212 thus exhibit 12-fold rotational symmetry and are arranged at regular 30 degree increments around the circumference. The magnets 250 may be secured within their corresponding recesses with a suitable adhesive, such as a UV-protected waterproof adhesive. In the illustrated embodiment, the magnets 250 are positioned 2 / 6 inch (about 0.85 cm) away from the circumference of the disk 210, with their centers spaced about ½ inch apart.

[0036] It will be understood that rotor disk 200 as shown in Figure 2 is not intended to be limiting in any way. Magnets 250 may have a variety of geometries (thickness, shape, etc.) and any number of such magnets (e.g., more or less than 12) may be secured to disk 210. Additionally, magnets may be positioned closer to or farther from the outer periphery of disk 210.

[0037] 3 and 4 sequentially illustrate the joining of two magnetic rotor disks to form a magnetic rotor assembly, according to one embodiment. More specifically, FIG. 3 illustrates that two assembled rotor disks 301 and 302 are brought together such that their inner faces (310, 320) each correspond to the north poles of the respective magnets, and their outer faces 311 and 321 oppositely correspond to the south poles of the respective magnets. In additional or alternative implementations, the rotor disks 301, 302 may be joined by bringing together the faces that correspond to the south poles of the respective magnets.

[0038] When the individual magnets on each face 310 and 320 are perfectly aligned N-to-N, the resulting repulsive forces prevent rotor disks 301 and 302 from magnetically attaching to one another. However, if the disks are rotated slightly (e.g., about 15 degrees) so that the magnets are staggered, the magnetic fields of the magnets are positioned such that the rotor disks attract one another and become firmly attached (FIG. 4).

[0039] FIG. 5 is a partial perspective view of a magnetic rotor assembly 500 as shown in FIGS. 3 and 4, showing the relative positions of the trapped magnets. It will be apparent that the regular circumferential spacing of the magnets around the circumference of the completed disk assembly will produce a similarly regular circumferential spatial modulation of the magnetic field, effectively forming a "magnetic gear" (with regular variations in magnetic field orientation and strength corresponding to the "teeth" of the gear). However, unlike mechanical gears, when disk assemblies are placed adjacent to one another as shown in FIG. 1, the result is a particularly effective form of rotational magnetic coupling that is both strong (i.e., adjacent disk assemblies are strongly magnetically coupled) and low friction (due to the non-contact nature of the coupling).

[0040] While the foregoing detailed description provides those skilled in the art with a convenient road map for implementing various embodiments of the present invention, it should be understood that the specific embodiments described above are examples only and are not intended to limit the scope, applicability, or configuration of the present invention in any way. To the contrary, various changes may be made in the function and arrangement of the described elements without departing from the scope of the present invention. As used herein, the term "exemplary" means "serving as an example, instance, or illustration." Any implementation described herein as "exemplary" should not necessarily be construed as preferred or advantageous over other implementations, nor is it intended to be construed as a model that must be replicated exactly.

Claims

1. a first rotor disk comprising a first disk and a first set of permanent magnets circumferentially disposed about the first disk with north poles facing outward from a first face of the first disk; a second rotor disk comprising a second disk and a second set of permanent magnets circumferentially disposed about the second disk with north poles facing outward from a first face of the second disk; wherein the first surface of the first disk faces the first surface of the second disk such that the first rotor disk and the second rotor disk are magnetically coupled to each other.

2. 2. The magnetic rotor assembly of claim 1, wherein said first surface of said first disk is spaced from said first surface of said second disk.

3. 3. The magnetic rotor assembly of claim 2, wherein said first surface of said first disk is spaced between 0.125 cm and 0.635 cm from said first surface of said second disk.

4. 2. The magnetic rotor assembly of claim 1, wherein said first surface of said first disk is in contact with said first surface of said second disk.

5. 2. The magnetic rotor assembly of claim 1, wherein each of said magnets of said first set of permanent magnets is a disc-shaped neodymium magnet secured within a corresponding recess in said first disk.

6. 2. The magnetic rotor assembly of claim 1, wherein said first set of permanent magnets and said second set of permanent magnets each comprise twelve rare earth magnets.

7. 7. The magnetic rotor assembly of claim 6, wherein said rare earth magnet has a diameter of approximately 1 inch (2.54 cm).

8. 2. The magnetic rotor assembly of claim 1, wherein said first disk body and said second disk each comprise graphite and are approximately 7 inches in diameter.

9. 2. The magnetic rotor assembly of claim 1, wherein each of said permanent magnets is positioned approximately 1 / 8 inch from said respective disk.

10. a first rotor disk comprising a first disk and a first set of permanent magnets circumferentially disposed about the first disk with their south poles facing outward from a first face of the first disk; a second rotor disk comprising a second disk and a second set of permanent magnets circumferentially disposed about the second disk with their south poles facing outward from a first face of the second disk; wherein the first surface of the first disk faces the first surface of the second disk such that the first rotor disk and the second rotor disk are magnetically coupled to each other.

11. 11. The magnetic rotor assembly of claim 10, wherein said first surface of said first disk is spaced from said first surface of said second disk.

12. 12. The magnetic rotor assembly of claim 11, wherein said first surface of said first disk is spaced between 0.125 cm and 0.635 cm from said first surface of said second disk.

13. 11. The magnetic rotor assembly of claim 10, wherein said first surface of said first disk is in contact with said first surface of said second disk.

14. 11. The magnetic rotor assembly of claim 10, wherein each of said magnets of said first set of permanent magnets is a disc-shaped neodymium magnet secured within a corresponding recess in said first disk.

15. The magnetic rotor assembly of claim 10 , wherein the first set of permanent magnets and the second set of permanent magnets each comprise twelve rare earth magnets.

16. 16. The magnetic rotor assembly of claim 15, wherein said rare earth magnet has a diameter of approximately 1 inch.

17. 11. The magnetic rotor assembly of claim 10, wherein said first disk body and said second disk each comprise graphite and are approximately 7 inches in diameter.

18. 11. The magnetic rotor assembly of claim 10, wherein each of said permanent magnets is positioned approximately 1 / 8 inch from said respective disk.

19. Providing a first disk and a second disk; positioning a first set of permanent magnets within the first disk such that the first set of permanent magnets are circumferentially disposed around the first disk; positioning a second set of permanent magnets within the second disk such that the second set of permanent magnets are circumferentially disposed around the second disk; positioning the first disk and the second disk such that the first set of permanent magnets faces the second set of permanent magnets such that the first disk and the second disk are magnetically coupled to form a magnetic rotor assembly; The method includes:

20. 20. The method of claim 19, wherein the first disk and the second disk are positioned such that at least one of: (i) the north poles of the first set of permanent magnets face the north poles of the second set of permanent magnets; and (ii) the south poles of the first set of permanent magnets face the south poles of the second set of permanent magnets.

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