Magnetic coupling device having a moving workpiece interface - Patents.com

Abstract

The magnetic coupling device may include a movable pole piece that may be retractable along a first direction and may be locked in position.

Description

[Technical field]

[0001] Related Applications This application is related to U.S. Provisional Patent Application No. 63 / 325,111, entitled "MAGNETIC COUPLING DEVICE WITH MOVABLE WORKPIECE INTERFACES," filed on March 29, 2022, and U.S. Provisional Patent Application No. 63 / 400,296, entitled "FLEXIBLE POLE SHOES FOR A MAGNETIC COUPLING DEVICE," filed on August 23, 2022, the disclosures of which are expressly incorporated by reference in their entireties into this specification.

[0002] Technical Field FIELD OF THE DISCLOSURE The present disclosure relates to magnetic coupling devices and, more particularly, to magnetic coupling devices having multiple moving workpiece interfaces.

[0003] background Magnetic coupling devices are known, and exemplary coupling devices are disclosed in U.S. Patent No. 7,012,495, U.S. Patent No. 8,878,639, and U.S. Patent Application Publication No. 20180311795.

[0004] overview 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 includes a housing, a switchable magnetic flux source supported by the housing, and a plurality of magnetic pole pieces. The switchable magnetic flux source is switchable between at least an off state and at least one of a partial on state and an on state. Each includes at least one workpiece interface having a workpiece engagement surface. The plurality of magnetic pole pieces includes a first magnetic pole piece including a first workpiece interface having a first workpiece engagement surface, and a second magnetic pole piece including a second workpiece interface having a second workpiece engagement surface. Each of the first magnetic pole piece and the second magnetic pole piece is movable relative to the housing when the switchable magnetic flux source is in the off state and is held relative to the housing when the switchable magnetic flux source is in at least one of the partial on state and the on state. The first engagement surface of the first pole piece maintains a first position relative to the housing when the switchable magnetic flux source is in an off state and is not in contact with the ferromagnetic workpiece regardless of the orientation of the housing, and the second engagement surface of the second pole piece maintains a second position relative to the housing when the switchable magnetic flux source is in an off state and is not in contact with the ferromagnetic workpiece regardless of the orientation of the housing.

[0005] In one example, each of the first pole piece and the second pole piece is constrained to be movable in a single degree of freedom relative to the housing.

[0006] In another example thereof, the first pole piece is translatable relative to the housing when the switchable magnetic flux source is in an off state.

[0007] In a further example thereof, the second pole piece is translatable relative to the housing when the switchable magnetic flux source is in an off state.

[0008] In yet another example thereof, the magnetic coupling device further comprises a first biasing means coupled to the housing and a second biasing means coupled to the housing. The first biasing means maintains the first engagement surface of the first pole piece in a first position relative to the housing when the switchable flux source is in an off state and not in contact with the ferromagnetic workpiece, regardless of the orientation of the housing. The second biasing means maintains the second engagement surface of the second pole piece in a second position relative to the housing when the switchable flux source is in an off state and not in contact with the ferromagnetic workpiece, regardless of the orientation of the housing. In that variation, the first biasing means is a first spring and the second biasing means is a second spring.

[0009] In yet another example thereof, the magnetic coupling device further comprises a first support coupled to the housing and supporting the first pole piece, and a second support coupled to the housing and supporting the second pole piece. The first support includes a first locking portion at least partially defining a first channel for receiving the first pole piece. The first locking portion is movable relative to the housing between an unlocked position in which the first pole piece is movable relative to the housing and a locked position in which the first pole piece is held relative to the housing. The second support includes a second locking portion at least partially defining a second channel for receiving the second pole piece. The second locking portion is movable relative to the housing between an unlocked position in which the second pole piece is movable relative to the housing and a locked position in which the second pole piece is held relative to the housing. In that variation, the first pole piece is translatable relative to the housing in a first direction and the first locking part of the first support is translatable from the unlocked position to the locked position along a second direction, the second direction being inclined relative to the first direction. In another variation, the first locking part is moved from the unlocked position to the locked position when the switchable flux source transitions from an off state to at least one of a partially on state and an on state. In a further variation, the magnetic coupling device further comprises a first biasing means supported by the first support and a second biasing means supported by the second support. The first biasing means maintains the first engagement surface of the first pole piece in a first position relative to the housing when the switchable flux source is in an off state and not in contact with the ferromagnetic workpiece, regardless of the orientation of the housing. The second biasing means maintains the second engagement surface of the second pole piece in a second position relative to the housing when the switchable flux source is in an off state and not in contact with the ferromagnetic workpiece, regardless of the orientation of the housing. In yet a further variation thereof, the first biasing means is a first spring and the second biasing means is a second spring. In yet another variation thereof, the first pole piece is retractable relative to the underside of the first support when the switchable flux source is in the off state and the second pole piece is retractable relative to the underside of the second support when the switchable flux source is in the off state.In yet another variation, the first limiter defines a maximum setback distance of the first pole piece relative to the underside of the first support and the second limiter defines a maximum setback distance of the second pole piece relative to the underside of the second support. In yet a further variation thereof, the first limiter includes a first portion carried by the first pole piece and a first stop surface on the first support and the second limiter includes a second portion carried by the second pole piece and a second stop surface on the second support.

[0010] In yet another example thereof, the switchable magnetic flux source is positioned between the first pole piece and the second pole piece.

[0011] In yet another example thereof, the switchable magnetic flux source is positioned vertically in line with the first pole piece and the second pole piece.

[0012] In yet a further example thereof, the switchable magnetic flux source includes at least one permanent magnet. In a variation thereof, the at least one permanent magnet includes an electro-permanent magnet. In another variation thereof, the at least one permanent magnet further includes a rare earth permanent magnet.

[0013] In yet a further example, the switchable magnetic flux source includes an electromagnet. In yet another example, the switchable magnetic flux source includes a platter having a plurality of permanent magnets and a plurality of pole pieces interleaved therebetween. In that variation, the plurality of permanent magnets and the plurality of pole pieces form a linear array. In another variation, the plurality of permanent magnets and the plurality of pole pieces form a circular array.

[0014] In yet a further example thereof, the switchable flux source includes a plurality of permanent magnets. In that variation, at least a first permanent magnet of the plurality of permanent magnets includes an electro-permanent magnet. In another variation, at least one of the plurality of permanent magnets is a rare earth magnet. In yet another variation, the plurality of permanent magnets includes a first permanent magnet and a second permanent magnet movable relative to the first permanent magnet. In yet a further variation, the second permanent magnet is rotatable relative to the first permanent magnet. In yet a further variation, each of the first permanent magnet and the second permanent magnet is positioned between the first pole portion and the second pole portion. In yet another variation, in an on state of the switchable flux source, a north pole of the second permanent magnet is substantially aligned with a north pole of the first permanent magnet, and in an off state of the switchable flux source, a south pole of the second permanent magnet is substantially aligned with a north pole of the first permanent magnet.

[0015] In yet a further example thereof, each of the first magnetic pole portion and the second magnetic pole portion are positioned on a first side of the switchable magnetic flux source and are, in at least one of the partial on state and the on state of the switchable magnetic flux source, a north magnetic pole portion of the magnetic coupling device and a south magnetic pole portion of the magnetic coupling device, respectively.

[0016] In yet a further example thereof, the first magnetic pole piece is positioned on a first side of the switchable magnetic flux source and the second magnetic pole piece is positioned on a second side of the switchable magnetic flux source, and in at least one of the partial on state and the on state of the switchable magnetic flux source, the first magnetic pole piece is a north magnetic pole piece of the magnetic coupling device and the second magnetic pole piece is a south magnetic pole piece of the magnetic coupling device.

[0017] In yet a further example thereof, the first pole piece is a first cylindrical pin having a first rounded end and the second pole piece is a second cylindrical pin having a second rounded end.

[0018] In yet a further example thereof, the magnetic coupling device further comprises at least one sensor for providing a characteristic of one or more of the plurality of movable pole pieces. In a variation thereof, the characteristic is a position of one or more of the plurality of movable pole pieces. In another variation thereof, the characteristic is a magnetic flux associated with one or more of the plurality of movable pole pieces.

[0019] In another example thereof, the magnetic coupling device further comprises a controller operably coupled to the switchable magnetic flux source and the at least one sensor, the controller configured to determine whether one or more of the plurality of movable magnetic pole pieces are spaced apart from the ferromagnetic workpiece and whether one or more of the plurality of movable magnetic pole pieces are in contact with the ferromagnetic workpiece based on a characteristic of one or more of the plurality of movable magnetic pole pieces. In that variation, the controller is configured to determine a characteristic of motion of one or more of the plurality of movable magnetic pole pieces. In another variation thereof, the characteristic of motion of one or more of the plurality of movable magnetic pole pieces is a position of one or more of the plurality of movable magnetic pole pieces relative to the housing. In yet another variation thereof, the first magnetic pole piece is retractable relative to the housing, and the characteristic of motion is when the first magnetic pole piece is fully retracted relative to the housing, and an end of the first magnetic pole piece remains extended from the housing when fully retracted.

[0020] In yet another example thereof, the partial on state is a first partial on state, wherein each of the first and second pole pieces is held relative to the housing when the switchable flux source is in the first partial on state, and the switchable flux source is further switchable to a second partial on state in which each of the first and second pole pieces is movable relative to the housing.

[0021] In yet another example thereof, the partial on state is a first partial on state, and when the switchable magnetic flux source is in the first partial on state, each of the first and second magnetic pole pieces is held relative to the housing, and the switchable magnetic flux source is further switchable to a second partial on state in which each of the first and second magnetic pole pieces is movable relative to the housing, and the controller monitors the magnetic flux while the switchable magnetic flux source is in the second partial on state to determine whether one or more of the plurality of movable magnetic pole pieces is spaced apart from the ferromagnetic workpiece.

[0022] In yet another example thereof, the partial on state is a first partial on state, and when the switchable magnetic flux source is in the first partial on state, each of the first and second magnetic pole pieces is held relative to the housing, and the switchable magnetic flux source is further switchable to a second partial on state in which each of the first and second magnetic pole pieces is movable relative to the housing, and the controller monitors the magnetic flux while the switchable magnetic flux source is in the second partial on state to determine whether one or more of the plurality of movable magnetic pole pieces is in contact with the ferromagnetic workpiece.

[0023] In still yet another example thereof, the partial on state is a first partial on state, and when the switchable flux source is in the first partial on state, each of the first and second pole pieces is held relative to the housing, and the switchable flux source is further switchable to a second partial on state in which each of the first and second pole pieces is movable relative to the housing, and the controller monitors the magnetic flux while the switchable flux source is in the second partial on state to determine the motion characteristics.

[0024] 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 includes a housing, a switchable magnetic flux source supported by the housing, a plurality of magnetic pole pieces, a plurality of biasing means, and a plurality of locking portions. The switchable magnetic flux source is switchable between at least an off state and at least one of a partial on state and an on state. The plurality of magnetic pole pieces each include at least one workpiece interface having a workpiece engagement surface. The plurality of biasing means bias the plurality of magnetic pole pieces to an extended position against a lower surface of the housing. The plurality of locking portions secure the plurality of magnetic pole pieces relative to the housing when the switchable magnetic flux source is in at least one of the partial on state and the on state. The plurality of magnetic pole pieces include a plurality of north magnetic pole pieces forming north magnetic poles of the magnetic coupling device when the switchable magnetic flux source is in at least one of the partial on state and the on state, and a plurality of south magnetic pole pieces forming south magnetic poles of the magnetic coupling device when the switchable magnetic flux source is in at least one of the partial on state and the on state. Each of the plurality of pole pieces is translatable relative to the housing along a respective axis when the switchable magnetic flux source is in an off state, and each includes a respective workpiece interface having a respective workpiece engaging surface.

[0025] In one example thereof, the magnetic coupling device further comprises at least one sensor for providing a characteristic of one or more of the plurality of magnetic pole pieces. In a variation thereof, the characteristic is a position of one or more of the plurality of magnetic pole pieces. In another variation thereof, the characteristic is a magnetic flux associated with one or more of the plurality of magnetic pole pieces.

[0026] In another example thereof, the magnetic coupling device further comprises a controller operably coupled to the switchable magnetic flux source and the at least one sensor, the controller configured to determine whether one or more of the plurality of magnetic pole pieces are spaced apart from the ferromagnetic workpiece and whether one or more of the plurality of magnetic pole pieces are in contact with the ferromagnetic workpiece based on a characteristic of one or more of the plurality of magnetic pole pieces. In that variation, the controller is configured to determine a characteristic of motion of one or more of the plurality of magnetic pole pieces. In another variation thereof, the characteristic of motion of one or more of the plurality of magnetic pole pieces is a position of one or more of the plurality of magnetic pole pieces relative to the housing. In a further variation thereof, the characteristic of motion is when a first magnetic pole piece of one or more of the plurality of magnetic pole pieces is fully retracted relative to the housing, and an end of the first magnetic pole piece remains extended from the housing when fully retracted.

[0027] In a further example thereof, the partial on state is a first partial on state, and when the switchable magnetic flux source is in the first partial on state, each of one or more of the plurality of magnetic pole portions is held relative to the housing, and the switchable magnetic flux source is further switchable to a second partial on state in which each of one or more of the plurality of magnetic pole portions is movable relative to the housing, and in the second partial on state, when the switchable magnetic flux source, the plurality of north magnetic pole portions still form north magnetic poles of the magnetic coupling device and the plurality of south magnetic pole portions still form south magnetic poles of the magnetic coupling device.

[0028] In yet a further example thereof, the partial on state is a first partial on state, and when the switchable magnetic flux source is in the first partial on state, each of one or more of the plurality of magnetic pole pieces is held relative to the housing, and the switchable magnetic flux source is further switchable to a second partial on state in which each of one or more of the plurality of magnetic pole pieces is movable relative to the housing, and in the second partial on state, when the switchable magnetic flux source, the plurality of north magnetic pole pieces still form north poles of the magnetic coupling device and the plurality of south magnetic pole pieces still form south poles of the magnetic coupling device, and the controller monitors the magnetic flux while the switchable magnetic flux source is in the second partial on state to determine whether one or more of the plurality of movable magnetic pole pieces are spaced apart from the ferromagnetic workpiece.

[0029] In yet a further example thereof, the partial on state is a first partial on state, and when the switchable magnetic flux source is in the first partial on state, each of one or more of the plurality of magnetic pole pieces is held relative to the housing, and the switchable magnetic flux source is further switchable to a second partial on state in which each of one or more of the plurality of magnetic pole pieces is movable relative to the housing, and in the second partial on state, when said switchable magnetic flux source, the plurality of north magnetic pole pieces still form north poles of the magnetic coupling device and the plurality of south magnetic pole pieces still form south poles of the magnetic coupling device, and the controller monitors the magnetic flux while the switchable magnetic flux source is in the second partial on state to determine whether one or more of the plurality of movable magnetic pole pieces are in contact with a ferromagnetic workpiece.

[0030] In yet a further example thereof, the partial on state is a first partial on state, and when the switchable magnetic flux source is in the first partial on state, each of one or more of the multiple magnetic pole portions is held relative to the housing, and the switchable magnetic flux source is further switchable to a second partial on state in which each of one or more of the multiple magnetic pole portions is movable relative to the housing, and in the second partial on state, when said switchable magnetic flux source, the multiple north magnetic pole portions still form north magnetic poles of the magnetic coupling device and the multiple south magnetic pole portions still form south magnetic poles of the magnetic coupling device, and the controller monitors the magnetic flux while the switchable magnetic flux source is in the second partial on state to determine the motion characteristics.

[0031] In yet another example thereof, the magnetic coupling device includes a proximity sensor supported by the housing and separated from the multiple pole pieces.

[0032] In yet another exemplary embodiment of the present disclosure, a magnetic coupling device for magnetically coupling to a ferromagnetic workpiece is provided. The magnetic coupling device includes a housing, a switchable magnetic flux source supported by the housing, and a plurality of magnetic pole pieces movably coupled to the housing. The switchable magnetic flux source is switchable between at least an off state and at least one of a partial on state and an on state. Each of the plurality of magnetic pole pieces includes at least one workpiece interface having a workpiece engagement surface. The plurality of magnetic pole pieces includes a first magnetic pole piece including a first workpiece interface having a first plurality of spaced apart protrusions that are moveable as a group relative to the housing when the switchable magnetic flux source is in the off state and that are held relative to the housing when the switchable magnetic flux source is in at least one of the partial on state and the on state, and a second magnetic pole piece including a second workpiece interface having a second plurality of spaced apart protrusions that are moveable as a group relative to the housing when the switchable magnetic flux source is in the off state and that are held relative to the housing when the switchable magnetic flux source is in at least one of the partial on state and the on state.

[0033] In one example, the first pole piece is movable relative to the lower surface of the housing in a first direction.

[0034] In another example thereof, the first pole piece is movable relative to the lower surface of the housing in only a first direction.

[0035] In a further example thereof, the first pole piece includes a plurality of elongated slots having a major axis along the first direction, and the magnetic coupling device further includes a plurality of couplers that couple the first pole piece to the housing and cooperate with the plurality of elongated slots to enable the first pole piece to move in the first direction.

[0036] In yet a further example thereof, the first plurality of protrusions includes a first protrusion, a second protrusion, and a third protrusion, and a first spacing between the first protrusion and the second protrusion is equal to a second spacing between the second protrusion and the third protrusion.

[0037] In yet another example thereof, the first plurality of protrusions includes a first protrusion, a second protrusion, and a third protrusion, and a first spacing between the first protrusion and the second protrusion is not equal to a second spacing between the second protrusion and the third protrusion.

[0038] In yet another exemplary embodiment of the present disclosure, a magnetic coupling device for magnetically coupling to a ferromagnetic workpiece is provided. The magnetic coupling device includes a housing, a switchable magnetic flux source supported by the housing, a plurality of magnetic pole pieces, and at least one coupler. The switchable magnetic flux source is switchable between at least an off state and at least one of a partial on state and an on state. The plurality of magnetic pole pieces includes a first magnetic pole piece movably coupled to the housing. The first magnetic pole piece includes at least one workpiece interface having a workpiece engagement surface. The first magnetic pole piece includes at least one elongated slot having a major axis along a first direction. The at least one coupler couples the first magnetic pole piece to the housing and cooperates with the at least one elongated slot to constrain movement of the first magnetic pole piece in the first direction relative to the housing. The first magnetic pole piece is movable relative to the housing when the switchable magnetic flux source is in the off state and is held relative to the housing when the switchable magnetic flux source is in at least one of the partial on state and the on state.

[0039] In one example, the at least one elongated slot of the first pole piece includes a first elongated slot and a second elongated slot, and the at least one coupler cooperates with both the first elongated slot and the second elongated slot to constrain movement of the first pole piece in a first direction relative to the housing.

[0040] In another example thereof, the at least one coupler includes a first coupler received in a first elongated slot of the at least one elongated slot and a second coupler received in a second elongated slot of the at least one elongated slot.

[0041] In yet another exemplary embodiment of the present disclosure, a magnetic coupling device for magnetically coupling to a ferromagnetic workpiece is provided, the magnetic coupling device including a housing, a switchable magnetic flux source supported by the housing and switchable between an off state, at least one of a first partially on state and an on state, and a second partially on state, a plurality of magnetic pole pieces each including at least one workpiece interface having a workpiece engagement surface, the plurality of magnetic pole pieces including a first magnetic pole piece including a first workpiece interface having a first workpiece engagement surface and a second magnetic pole piece including a second workpiece interface having a second workpiece engagement surface, each of the first magnetic pole piece and the second magnetic pole piece being movable relative to the housing when the switchable magnetic flux source is in one of the off state and the second partially on state. the switchable magnetic flux source being in at least one of a partial on state and an on state, a plurality of magnetic pole pieces held against the housing; at least one sensor for providing a characteristic of one or more of the plurality of movable magnetic pole pieces; and a controller operably coupled to the switchable magnetic flux source and the at least one sensor, the controller configured to determine whether one or more of the plurality of movable magnetic pole pieces are spaced apart from a ferromagnetic workpiece and whether one or more of the plurality of movable magnetic pole pieces are in contact with the ferromagnetic workpiece based on the characteristic of the one or more of the plurality of movable magnetic pole pieces.

[0042] In one example, the characteristic is the position of one or more of the plurality of movable pole pieces. In another example thereof, the property is a magnetic flux associated with one or more of the plurality of movable pole pieces.

[0043] In yet another example thereof, the controller is configured to determine a motion characteristic of one or more of the plurality of movable pole pieces. In that variation, the motion characteristic of one or more of the plurality of movable pole pieces is a position of one or more of the plurality of movable pole pieces relative to the housing. In another variation thereof, the first pole piece is retractable relative to the housing and the motion characteristic is when the first pole piece is fully retracted relative to the housing, and the workpiece engaging surface of the first pole piece remains extended from the housing when fully retracted.

[0044] In a further example thereof, the controller monitors the magnetic flux while the switchable magnetic flux source is in the second partial on state to determine the motion characteristic.

[0045] In yet a further example thereof, the controller monitors the magnetic flux while the switchable magnetic flux source is in the second partial on state to determine whether one or more of the plurality of movable magnetic pole pieces are spaced apart from the ferromagnetic workpiece.

[0046] In yet a further example thereof, the controller monitors the magnetic flux while the switchable magnetic flux source is in the second partial on state to determine whether one or more of the plurality of movable magnetic pole pieces are in contact with the ferromagnetic workpiece.

[0047] In yet a further example thereof, the first engagement surface of the first pole piece maintains a first position relative to the housing when the switchable magnetic flux source is in one of the off state and the second partially on state and is not in contact with the ferromagnetic workpiece, regardless of the orientation of the housing, and the second engagement surface of the second pole piece maintains a second position relative to the housing when the switchable magnetic flux source is in one of the off state and the second partially on state and is not in contact with the ferromagnetic workpiece, regardless of the orientation of the housing.

[0048] In yet a further example thereof, each of the first and second pole pieces is constrained to be movable in a single degree of freedom relative to the housing. In that variation, the first pole piece is translatable relative to the housing when the switchable flux source is in one of the off state and the second partially on state. In another variation thereof, the second pole piece is translatable relative to the housing when the switchable flux source is in one of the off state and the second partially on state.

[0049] In yet another example thereof, the magnetic coupling device further comprises a first biasing means coupled to the housing, the first biasing means configured to maintain the first engagement surface of the first pole piece in a first position relative to the housing when the switchable magnetic flux source is in one of the off state and the second partially on state and not in contact with the ferromagnetic workpiece, regardless of the orientation of the housing, and a second biasing means coupled to the housing, the second biasing means configured to maintain the second engagement surface of the second pole piece in a second position relative to the housing when the switchable magnetic flux source is in one of the off state and the second partially on state and not in contact with the ferromagnetic workpiece, regardless of the orientation of the housing. In that variation, the first biasing means is a first spring and the second biasing means is a second spring.

[0050] In yet another example thereof, the magnetic coupling device further comprises a first support coupled to the housing and supporting a first magnetic pole piece, the first support including a first locking portion at least partially defining a first channel for receiving the first magnetic pole piece, the first locking portion being movable relative to the housing between an unlocked position in which the first magnetic pole piece is movable relative to the housing and a locked position in which the first magnetic pole piece is held relative to the housing; and a second support coupled to the housing and supporting a second magnetic pole piece, the second support including a second locking portion at least partially defining a second channel for receiving the second magnetic pole piece, the second locking portion being movable relative to the housing between an unlocked position in which the second magnetic pole piece is movable relative to the housing and a locked position in which the second magnetic pole piece is held relative to the housing. In that variation, the first magnetic pole portion is translatable relative to the housing in a first direction and the first locking portion of the first support is translatable from an unlocked position to a locked position along a second direction, the second direction being inclined relative to the first direction.

[0051] In yet another example thereof, the switchable magnetic flux source is positioned between the first pole piece and the second pole piece.

[0052] In yet a further example thereof, the switchable flux source includes a plurality of permanent magnets. In that variation, at least a first permanent magnet of the plurality of permanent magnets includes an electro-permanent magnet. In another variation, at least one of the plurality of permanent magnets is a rare earth magnet. In a further variation, the plurality of permanent magnets includes a first permanent magnet and a second permanent magnet movable relative to the first permanent magnet. In a still further variation, the second permanent magnet is rotatable relative to the first permanent magnet. In yet a further variation, in an on state of the switchable flux source, a north pole of the second permanent magnet is substantially aligned with a north pole of the first permanent magnet, and in an off state of the switchable flux source, a south pole of the second permanent magnet is substantially aligned with a north pole of the first permanent magnet.

[0053] In yet a further example thereof, the first pole piece is a first cylindrical pin having a first rounded end and the second pole piece is a second cylindrical pin having a second rounded end.

[0054] In a further exemplary embodiment of the present disclosure, a method of coupling a magnetic coupling device to a ferromagnetic workpiece is provided, the method including a housing of the magnetic coupling device, a switchable magnetic flux source supported by the housing and switchable between an off state, at least one of a first partial on state and an on state, and a second partial on state, and a plurality of magnetic pole pieces, each of the plurality of magnetic pole pieces including at least one workpiece interface having a workpiece engagement surface, a first magnetic pole piece including the first workpiece interface having the first workpiece engagement surface and a second magnetic pole piece including the second workpiece interface having the second workpiece engagement surface, each of the first magnetic pole piece and the second magnetic pole piece being configured to be coupled to a ferromagnetic workpiece when the switchable magnetic flux source is in one of the off state and the second partial on state. the switchable magnetic flux source being movable relative to the housing when the magnetic coupling device is spaced apart from the ferromagnetic workpiece and being held relative to the housing when the switchable magnetic flux source is in at least one of a partial on state and an on state; configuring the switchable magnetic flux source to a second partial on state while the magnetic coupling device is spaced apart from the ferromagnetic workpiece; determining when at least one of the plurality of moveable magnetic pole pieces contacts the ferromagnetic workpiece; configuring the switchable magnetic flux source to one of the first partial on state and the on state after determining when at least one of the plurality of moveable magnetic pole pieces contacts the ferromagnetic workpiece; and lifting the ferromagnetic workpiece using the magnetic coupling device.

[0055] In one example, configuring the switchable magnetic flux source in one of the first partial on state and the on state includes configuring the switchable magnetic flux source in the first partial on state. The method further includes, after lifting the ferromagnetic workpiece with the magnetic coupling device, configuring the switchable magnetic coupling device in one of a third partial on state and the on state, the third partial on state increasing the magnetic flux through the ferromagnetic workpiece relative to the first partial on state and the second partial on state.

[0056] In yet another exemplary embodiment of the present disclosure, a method of coupling a magnetic coupling device to a ferromagnetic workpiece is provided that includes monitoring a position of at least one moveable pole piece of the magnetic coupling device relative to a housing of the magnetic coupling device, and magnetically coupling the magnetic coupling device to the ferromagnetic workpiece with a magnetic circuit sufficient to fix the moveable pole piece relative to the housing and lift the ferromagnetic workpiece with the magnetic coupling device as the moveable pole piece moves from a first position to a second position.

[0057] In yet another exemplary embodiment, a method of coupling a magnetic coupling device to a ferromagnetic workpiece is provided that includes moving the magnetic coupling device toward the ferromagnetic workpiece at a speed greater than a first speed, the magnetic coupling device having a plurality of movable magnetic pole pieces relative to a housing, detecting when a closest magnetic pole piece of the plurality of movable magnetic pole pieces of the magnetic coupling device is at a first separation from the ferromagnetic workpiece, and decelerating the speed of the magnetic coupling device toward the ferromagnetic workpiece to a second speed, the second speed being less than or equal to the first speed.

[0058] In one example, the method includes detecting when a plurality of movable magnetic pole pieces are in contact with a ferromagnetic workpiece, fixing the movable magnetic pole pieces relative to a housing, and magnetically coupling the magnetic coupling device to the ferromagnetic workpiece with a magnetic circuit sufficient to lift the ferromagnetic workpiece using the magnetic coupling device.

[0059] In yet 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 includes a housing, a switchable magnetic flux source supported by the housing, a plurality of magnetic pole pieces, at least one sensor supported by the housing, and a controller operably coupled to the switchable magnetic flux source and the at least one sensor. The switchable magnetic flux source is switchable between an off state, at least one of a first partial on state and an on state, and a second partial on state. Each of the plurality of magnetic pole pieces includes at least one workpiece interface having a workpiece engagement surface. The plurality of magnetic pole pieces includes a first magnetic pole piece including a first workpiece interface having a first workpiece engagement surface, and a second magnetic pole piece including a second workpiece interface having a second workpiece engagement surface. Each of the first magnetic pole piece and the second magnetic pole piece is movable relative to the housing when the switchable magnetic flux source is in one of the off state and the second partial on state, and is held relative to the housing when the switchable magnetic flux source is in at least one of the partial on state and the on state. Based on the at least one sensor, the controller is configured to determine a separation of the plurality of moveable pole pieces relative to the ferromagnetic workpiece.

[0060] In yet a further exemplary embodiment of the present disclosure, a robotic system is provided that includes a robotic arm having attached to its end a magnetic coupling device according to one or more aspects of the present disclosure.

[0061] Other aspects and optional and / or preferred embodiments will become apparent from the following description provided below with reference to the accompanying drawings.

[0062] BRIEF DESCRIPTION OF THE DRAWINGS The above and other features and advantages of the present disclosure, as well as the manner in which the same are accomplished, 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. [Brief description of the drawings]

[0063] [Figure 1] FIG. 2 is a representative diagram of an exemplary magnetic coupling device having movable pole pieces, each with a respective workpiece contact interface, spaced apart from a ferromagnetic workpiece. [Diagram 2] 2 illustrates the magnetic coupling device of FIG. 1 with the workpiece contact interface of the movable pole piece in contact with the ferromagnetic workpiece and the first pole piece at least partially recessed relative to the underside of the housing of the magnetic coupling device. [Figure 2A] 1A-1C show exemplary ends of a movable pole piece. [Figure 2B] 13A-13C show another exemplary end of the movable pole piece. [Figure 2C] 13A-13C show further exemplary ends of the movable pole piece including a compliance unit. [Diagram 3] FIG. 2 illustrates the magnetic coupling device of FIG. 1 with a sensing system. [Figure 4] 1 is a representative diagram of an exemplary magnetic coupling apparatus including a first exemplary switchable magnetic flux source having an actuator and an electronic controller operably coupled to the actuator. [Figure 4A] FIG. 2 is a representative diagram of another exemplary magnetic coupling apparatus including a first exemplary switchable magnetic flux source having an actuator and an electronic controller operably coupled to the actuator. [Figure 4B] FIG. 2 is an exploded perspective view of an exemplary platter having multiple permanent magnets and pole pieces. [Figure 4C] 4C is a perspective view of two examples of the platter of FIG. 4B. [Figure 4D] FIG. 4D is a bottom assembly view of the platter of FIG. 4C. [Figure 4E] FIG. 1 illustrates an exemplary lower portion of a housing to which pole pieces and movable pole pieces are coupled, each of the movable pole pieces having a respective workpiece contact interface, and an exemplary movable platter having multiple permanent magnets and pole pieces and spaced apart from the pole pieces of the housing; [Figure 4F]FIG. 4F shows the configuration of FIG. 4E with the movable platter positioned adjacent to the pole piece of the housing. [Diagram 5] FIG. 5 illustrates a stack of permanent magnets of a first exemplary switchable magnetic flux source having a first permanent magnet movable relative to a second permanent magnet, the stack of permanent magnets being oriented in the off state of the magnetic coupling device of FIG. [Figure 6] 5 illustrates the stack of permanent magnets oriented in a first on-state of the magnetic coupling device of FIG. 4, in which the north poles of the two permanent magnets are aligned. [Figure 7] 7 illustrates a stack of permanent magnets oriented in a second on state of the magnetic coupling device of FIG. 4, the second on state being a partial on state in which there is less magnetic flux available at the workpiece contact interface than in the first on state of FIG. 6. [Figure 8A] FIG. 13 is a representative diagram of an exemplary magnetic coupling arrangement in which the magnetic coupling arrangement includes a second exemplary magnetic flux source having a stack of permanent magnets having a first electro-permanent magnet and associated coil and a second permanent magnet. [Figure 8B] FIG. 2 is a representative diagram of an example magnetic coupling device including another example magnetic flux source having at least one movable permanent magnet coupled to an actuator. [Figure 8C] FIG. 8C illustrates the example magnetic coupling device of FIG. 8B with at least one movable permanent magnet in a lowered position. [Figure 8D] 1 is a representation of an exemplary magnetic coupling device including an electromagnet. [Figure 9] FIG. 1 illustrates an exemplary robot having an exemplary magnetic coupling device attached to the end of the robot's arm. [Figure 10] FIG. 2 is a first bottom perspective view of an exemplary magnetic coupling device. [Figure 11] 11 is a second top perspective view of the exemplary magnetic coupling device of FIG. 10. [Figure 12] 11 is a first side view of the example magnetic coupling device of FIG. 10. [Figure 13]11 is a second side view of the example magnetic coupling device of FIG. 10. [Figure 14] 11 is a bottom view of the exemplary magnetic coupling device of FIG. 10. [Figure 15] 11 is an exploded view of a base and a first support of the first and second movable pole pieces of the example magnetic coupling device of FIG. 10. [Figure 15A] 16 is an assembled view of the base, first support, and first and second movable pole pieces of FIG. 15 of the exemplary magnetic coupling device of FIG. 10. [Figure 16] 15 is an assembled view of the base, first support, and first and second movable pole pieces of the exemplary magnetic coupling device of FIG. 10 removed from the housing of the exemplary magnetic coupling device of FIG. 10. FIG. [Figure 17] A partial side cross-sectional view of the base, movable pole piece, and first support locking portion of the exemplary magnetic coupling device of Figure 10, taken through the center of the first pole piece of Figure 15, with the switchable magnetic flux source in an off state and the first pole piece movable in a first direction relative to the underside of the housing of the exemplary magnetic coupling device. [Figure 18] A partial side cross-sectional view of the base, movable pole piece, and locking portion of the first support of the exemplary magnetic coupling device of Figure 10, taken through the center of the first pole piece of Figure 15, where the first pole piece cannot move in a first direction relative to the underside of the housing of the exemplary magnetic coupling device due to the switchable magnetic flux source being in an on state and the locking portion moving in a second direction. [Figure 19] FIG. 11 illustrates the example robot of FIG. 9 with the example magnetic coupling device of FIG. 10 coupled to the end of its arm and positioned relative to a first stack of ferromagnetic parts, and with the switchable magnetic flux source of the example magnetic coupling device in an off state. [Figure 20] 20 shows the robot and magnetic coupling device of FIG. 19 contacting a first ferromagnetic component of a first stack of ferromagnetic components, with the switchable magnetic flux source of the magnetic coupling device in an off state and at least a portion of the multiple magnetic pole pieces retracted relative to the housing of the magnetic coupling device. [Figure 21]FIG. 21 illustrates the robot and magnetic coupling device of FIG. 20 with the switchable flux source of the magnetic coupling device in an on state and the first ferromagnetic part being lifted relative to the remaining first stack of ferromagnetic parts. [Figure 22] 1 is a partial side perspective view of another exemplary magnetic coupling device; [Figure 23] FIG. 23 is an exploded view of the magnetic coupling device of FIG. 22. [Figure 24] 24 is a cross-sectional view taken along line 24-24 of FIG. 22 with the movable pole shoe in a first raised position relative to the underside of the housing of the magnetic coupling device. [Diagram 25] FIG. 25 shows the view of FIG. 24 with the movable pole shoe in a second, lowered position relative to the underside of the housing of the magnetic coupling device. [Figure 26] FIG. 2 is a side view of a movable pole shoe of the magnetic coupling device. [Figure 27] FIG. 2 is a side view of the magnetic coupling device spaced from the workpiece. [Figure 28] FIG. 2 is a perspective view of a magnetic coupling device with the pole pieces fully extended and engaging a workpiece. [Figure 29] FIG. 2 is a perspective view of a magnetic coupling device with the pole pieces engaged in a partially wedged position on a workpiece; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0064] Detailed Description of the Drawings For the purposes of promoting an understanding of the principles of the present disclosure, reference is made to the embodiments illustrated in the drawings and the following description. The embodiments disclosed herein are not intended to be exhaustive or to limit the disclosure to the precise forms disclosed in the following detailed description. Rather, the embodiments have been chosen and described so that those skilled in the art can utilize their teachings. Thus, no limitation of the scope of the present disclosure is intended thereby. Corresponding reference characters indicate corresponding parts throughout the several views.

[0065] The terms "couple," "coupled," and "coupler," and variations thereof, are used to include both configurations in which two or more components are in direct physical contact, and arrangements in which two or more components are not in direct contact with each other (e.g., the components are "coupled" through at least a third component), but still cooperate or interact with each other.

[0066] In some cases, numerical terms such as first, second, third, and fourth are used throughout this disclosure and in the claims to refer to various components or features. Such use is not intended to indicate an ordering of the components or features. Rather, the numerical terms are used to aid the reader in identifying the components or features being referenced, and should not be narrowly construed as providing a particular ordering of the components or features.

[0067] 1, an exemplary magnetic coupling device 10 is shown. The magnetic coupling device 10 is configured to magnetically couple a ferromagnetic workpiece 12 having a contact surface 13. The magnetic coupling device 10 includes a housing 14, a switchable magnetic flux source 16, a north pole piece 18, and a south pole piece 20.

[0068] The north pole piece 18 includes a support 30 and a first movable pole piece 32. The support 30 may be coupled to the housing 14 or may be integrally formed with the housing 14. The support 30 may be a single component or multiple components assembled together. The first movable pole piece 32 includes a workpiece interface 34 having a workpiece engagement surface 36. In an embodiment, the first movable pole piece 32 is movable in a single degree of freedom relative to the support 30 and thus the housing 14. In the illustrated embodiment, the first movable pole piece 32 is translatable in directions 40 and 42 relative to a lower surface 44 of the housing 14 and a lower surface 46 of the north pole piece 18. In an embodiment, the first movable pole piece 32 is rotatable relative to the support 30 or the housing 14. In an embodiment, the first movable pole piece 32 is movable in multiple degrees of freedom relative to the support 30.

[0069] In the illustrated embodiment, the first movable pole piece 32 is shown as a cylindrical pin and the workpiece engagement surface 36 is shown as a spherical end surface of the cylindrical pin. The first movable pole piece 32 and the workpiece engagement surface 36 may have other suitable shapes. The workpiece engagement surface 36 may be flat, curved, contoured, have a plurality of spaced apart projections, or may have any other suitable shape for contacting the contact surface 13 of the ferromagnetic workpiece 12. The first movable pole piece 32, and therefore the workpiece engagement surface 36, are made from a ferromagnetic material to complete a magnetic circuit from the switchable magnetic flux source 16 through the ferromagnetic workpiece 12. Referring to FIG. 2A, an exemplary workpiece engagement surface 36 of the first movable pole piece 32 (which is also an exemplary shape of the workpiece engagement surface 56 of the first movable pole piece 52) is shown. In FIG. 2A, the workpiece engagement surface 36 is spherical in shape. 2B, another exemplary workpiece engagement surface 36 of the first movable pole piece 32 (also an exemplary shape of the workpiece engagement surface 56 of the first movable pole piece 52) is shown having a central flat region 37 and rounded corners 38. In an embodiment, the first movable pole piece 32 may include a compliance unit 60 (see FIG. 2C) including a support 62 and a spherical ball 64 rotatable within the support 62. The spherical ball 64 includes an engagement surface 66 for contacting the ferromagnetic workpiece 12. The engagement surface 66, like the workpiece engagement surface 36, may be flat, curved, contoured, have a plurality of spaced apart projections, or may have any other suitable shape for contacting the contact surface 13 of the ferromagnetic workpiece 12. Among other advantages, the inclusion of the compliance unit 60 is that the ball 64 can pivot to provide a larger surface area contact compared to the point contact of a cylindrical pin with a spherical end. In embodiments, the support 62 may be cylindrical and received by the support 30 and moveable relative to the housing 14 in the same manner as the first movable pole piece 32. Additionally, in embodiments, the first movable pole piece 32 or the support 62 may be other shapes, such as a hexagon, square, triangle, and other suitable shapes.By having a polygonal shape, the first movable pole piece 32 or support 62 may be received in a similarly sized polygonal opening and held in a known rotational orientation relative to the housing 14 .

[0070] The south pole piece 20 includes a support 50 and a first movable pole piece 52. The support 50 may be coupled to the housing 14 or may be integrally formed with the housing 14. The support 50 may be a single component or multiple components assembled together. The first movable pole piece 52 includes a workpiece interface 54 having a workpiece engagement surface 56. In an embodiment, the first movable pole piece 52 is movable in a single degree of freedom relative to the support 50 and thus the housing 14. In the illustrated embodiment, the first movable pole piece 52 is translatable in directions 40 and 42 relative to the lower surface 44 of the housing 14 and the lower surface 58 of the south pole piece 20. In an embodiment, the first movable pole piece 52 is rotatable relative to the support 50 or the housing 14. In an embodiment, the first movable pole piece 52 is movable in multiple degrees of freedom relative to the support 50.

[0071] In the illustrated embodiment, the first movable pole piece 52 is shown as a cylindrical pin and the workpiece engaging surface 56 is shown as a spherical end surface of the cylindrical pin. The first movable pole piece 52 and the workpiece engaging surface 56 may have other suitable shapes. The first movable pole piece 52, and therefore the workpiece engaging surface 56, are fabricated from a ferromagnetic material to complete a magnetic circuit from the switchable magnetic flux source 16 through the ferromagnetic workpiece 12.

[0072] The switchable magnetic flux source 16 of the magnetic coupling tool 10 is switchable between an off state, in which a magnetic circuit is formed within the housing 14, and an on state, in which a magnetic circuit is formed from the switchable magnetic flux source 16, through the workpiece interface 34 of the magnetic coupling tool 10, through the ferromagnetic workpiece 12, through the workpiece interface 54 of the magnetic coupling tool 10, and back to the switchable magnetic flux source 16. In an embodiment, the switchable magnetic flux source 16 may be disposed in at least one partial on state in which the strength of the magnetic circuit formed through the ferromagnetic workpiece 12 is greater than in the off state and less than in the on state.

[0073] The switchable magnetic flux source 16 may include multiple permanent magnets and is configurable to have at least one overall north magnetic pole portion and at least one overall south magnetic pole portion when in an on state. In an embodiment, the switchable magnetic flux source 16 includes at least one electro-permanent magnet that is switchable between an on state (having a north magnetic pole and a south magnetic pole) and an off state (not magnetized relative to an external object). Furthermore, the at least one electro-permanent magnet may be configured such that its magnetic poles are in a NS or SN orientation to allow the switchable magnetic flux source 16 to be configured in an on state and an off state. Additionally, the at least one electro-permanent magnet may be configured to have a varying magnetic strength that allows the device to be configured in a partial on state where the magnetic strength at the workpiece interfaces 34 and 54 is less than the on state and greater than the off state.

[0074] Referring to FIG. 8A, in an embodiment, the switchable magnetic flux source 16 includes at least one rare earth permanent magnet 70 and at least one electro-permanent magnet 72, the combination of which is switchable between an ON state (where the north pole of the electro-permanent magnet 72 is aligned with the north pole of the rare earth permanent magnet 70) with a magnetic strength at the workpiece interfaces 34 and 54, and an OFF state (as shown in FIG. 8) with a magnetic circuit formed inside the housing 14. Furthermore, the combination may be configured to have various magnetic strengths that allow the device to be configured in a partial ON state where the magnetic strength at the workpiece interfaces 34 and 54 is less than the ON state and greater than the OFF state. As shown in FIG. 8A, multiple coils 74 are wound around the electro-permanent magnet 72 and connected to a current source 76. By applying different currents to the coils 74, the magnetic pole orientation of the electro-permanent magnet 72 can be reversed and maintained without applying a current. Thus, the switchable magnetic flux source 16 can be switched between an OFF state and an ON state without physically moving the electro-permanent magnet 72 relative to the rare earth permanent magnet 70.

[0075] 4, in an embodiment, the switchable magnetic flux source 16 includes a plurality of rare earth permanent magnets, illustratively rare earth permanent magnet 80 and rare earth permanent magnet 82, the combination of which is switchable between an ON state (where the north pole of rare earth permanent magnet 82 is aligned with the north pole of rare earth permanent magnet 80, see FIG. 5) having a magnetic strength at the workpiece interfaces 34 and 54, and an OFF state (as shown in FIGS. 4 and 6) in which a magnetic circuit is formed inside the housing 14. As shown in FIG. 4, an actuator 84 is coupled to the rare earth permanent magnet 82 to rotate the rare earth permanent magnet 82 relative to the rare earth permanent magnet 80 about an axis 86 (see FIGS. 5-7). Additionally, the combination may be configured to have a variety of magnetic strengths that allow the device to be configured in a partial ON state in which the magnetic strength at the workpiece interfaces 34 and 54 is less than the ON state and greater than the OFF state (see FIG. 7). In an embodiment, the actuator 84 may be an electric actuator, such as a coil disposed around the rare earth permanent magnet 82, an electric / mechanical actuator, such as an electric motor and linkage or gear set, or a mechanical, pneumatic, hydraulic, manual actuator, or combinations thereof. An exemplary system including a coil for imparting rotation of a magnet is disclosed in U.S. Pat. No. 11,031,166, entitled "ELECTROMAGNET-SWITCHABLE PERMANENT MAGNET DEVICE," the entire disclosure of which is expressly incorporated herein by reference. Exemplary actuation systems are disclosed in U.S. Pat. No. 11,097,401, entitled "MAGNETIC COUPLING DEVICE WITH AT LEAST ONE OF A SENSOR ARRANGEMENT AND A DEGAUSS CAPABILITY," and U.S. Pat. No. 10,903,030, entitled "VARIABLE FIELD MAGNETIC COUPLERS AND METHODS FOR ENGAGING A FERROMAGNETIC WORKPIECE," the entire disclosures of which are expressly incorporated herein by reference.

[0076] Returning to FIG. 1 , the magnetic coupling device 10 further includes a first biasing means 90 coupled to the first movable pole piece 32 for biasing the first movable pole piece 32 in the direction 40 to the fully extended position depicted in FIG. 1 . A second biasing means 92 is coupled to the first movable pole piece 52 for biasing the first movable pole piece 52 in the direction 40 to the fully extended position. Exemplary biasing means include springs, pressurized fluid chambers, and other suitable devices for biasing the first movable pole piece 32 and the first movable pole piece 52 in the direction 40. Exemplary springs include compression springs, torsion springs, gas springs, pneumatic springs, and other suitable types of springs. The first movable pole piece 32 and the first movable pole piece 52 are biased to the fully extended position regardless of the orientation of the magnetic coupling device 10. 1 as being oriented vertically such that the first movable pole pieces 32 and 52 extend below the housing 14. The first movable pole pieces 32 and 52 remain fully extended relative to the housing 14 even if the magnetic coupling device 10 is rotated 90 degrees to the left or right, or even if it is turned upside down, due to the action of the first and second biasing means 90 and 92.

[0077] In an embodiment, in the fully extended position of the first movable pole piece 32 and the first movable pole piece 52, the apexes of the workpiece engaging surface 36 of the first movable pole piece 32 and the workpiece engaging surface 56 of the first movable pole piece 52 define a line that is parallel to the lower surface 44 of the housing 14. In an embodiment, in the fully extended position of the first movable pole piece 32 and the first movable pole piece 52, the apexes of the workpiece engaging surface 36 of the first movable pole piece 32 and the workpiece engaging surface 56 of the first movable pole piece 52 define a line that is inclined relative to the lower surface 44 of the housing 14. Although only a single first movable pole piece 32 and first movable pole piece 52 are shown in FIG. 1, in an embodiment, one or both of the north pole piece 18 and the south pole piece 20 include a plurality of first movable pole pieces 32 and first movable pole pieces 52. In the embodiment shown in Figures 10-21, the north pole piece 18 and the south pole piece 20 each include a plurality of movable pole pieces, illustratively each includes two movable pole pieces. In an embodiment, the movable pole piece is movable in a single degree of freedom, such as the movable pole pieces of the illustrated embodiment of Figures 10-21 being translatable in directions 40 and 42. In an embodiment, the movable pole piece is movable in multiple degrees of freedom. For example, the movable pole piece may have a first portion translatable in directions 40 and 42 and a second portion coupled to an end of the first portion that is rotatable relative to the first portion. The second portion may be a rocker that is rotatable relative to the first portion and may include a plurality of spaced engagement surfaces for contacting a workpiece. In an embodiment, the movable pole piece is translatable relative to the housing 14 as well as rotatable relative to the housing 14.

[0078] As shown in Figure 4, each of the first movable pole pieces 32 and 52 are positioned in a non-overlapping vertical arrangement with respect to the switchable flux source 16, where the switchable flux source 16 is positioned between the first movable pole pieces 32 and 52. In an embodiment, one or both of the first movable pole pieces 32 and 52 may be positioned in an overlapping vertical arrangement with respect to the switchable flux source 16, as shown in Figure 4A, where one or both of the first movable pole pieces 32 and 52 are within the vertical envelope of the switchable flux source 16. In the arrangement shown in Figure 4A, a lower portion of the housing 14 includes pole pieces for enabling the switchable flux source 16 to be magnetically coupled to the first movable pole pieces 32 and 52. In an embodiment, the movable pole piece 32, 52 is removably coupled to the housing 14. In an example, the pole piece in the housing includes a threaded recess and the movable pole piece includes a threaded stud that is received in the threaded recess.

[0079] In embodiments, the switchable magnetic flux source 16 of the magnetic coupling device 10 includes multiple north poles and multiple south poles. In these embodiments, one or more movable magnetic pole pieces are provided for each distinct north pole region of the magnetic coupling device 10 and each distinct south pole region of the magnetic coupling device 10. An exemplary switchable magnetic flux source 16 having multiple north poles and multiple south poles includes a four-pole magnet. Another exemplary switchable magnetic flux source 16 having multiple north poles and multiple south poles includes a platter configuration having multiple two-pole magnets. Exemplary platter configurations are disclosed in U.S. Pat. No. 7,161,451; U.S. Pat. No. 11,097,401, entitled "MAGNETIC COUPLING DEVICE WITH AT LEAST ONE OF A SENSOR ARRANGEMENT AND A DEGAUSS CAPABILITY"; U.S. Pat. No. 10,903,030, entitled "VARIABLE FIELD MAGNETIC COUPLERS AND METHODS FOR ENGAGING A FERROMAGNETIC WORKPIECE"; U.S. Provisional Patent Application No. 62 / 248,804, filed Oct. 30, 2015, entitled "MAGNETIC COUPLING DEVICE WITH A ROTARY ACTUATION SYSTEM"; and German Utility Model No. 20201600669, the entire disclosures of which are expressly incorporated herein by reference.

[0080] 4B-4D, an exemplary switchable magnetic flux source 400 is shown. The switchable magnetic flux source 400 is disposed within an iron-free version of the housing 14. Magnetic pole pieces may be provided on an underside of the housing 14 for contacting the ferromagnetic workpiece 12. Additionally, in an embodiment, the flexible pole shoes 32 and 52 may be magnetically coupled to the switchable magnetic flux source 400 as described herein.

[0081] The switchable permanent magnet assembly 400 includes an upper platter 412 and a lower platter 414 disposed within the housing 14. Each of the platters 412 and 414 includes a plurality of spaced apart permanent magnets 430 and a plurality of magnetic pole pieces 450 arranged in a circular array. Each of the plurality of spaced apart permanent magnets 430 is illustratively shown as a single permanent magnet, but may include a plurality of permanent magnets and / or at least one permanent magnet positioned within the housing. Exemplary platters are provided in U.S. Pat. No. 7,161,451, German Utility Model No. 202016006696, and U.S. Provisional Patent Application No. 62 / 248,804, entitled “MAGNETIC COUPLING DEVICE WITH A ROTARY ACTUATION SYSTEM,” filed on Oct. 30, 2015, Docket No. MTI-0007-01-US-E, the entire disclosures of which are expressly incorporated herein by reference.

[0082] Each permanent magnet 430 has a north pole side 432 and a south pole side 434. The permanent magnets 430 and pole pieces 450 of the platters 412 and 414 are each arranged to form a closed shape with one of the pole pieces 450 positioned between two of the permanent magnets 430. Furthermore, the permanent magnets 430 are arranged such that each of the two permanent magnets 430 that contact the pole pieces 450 between them contacts either their north pole side or their south pole side with the pole pieces 450. When the north pole sides of adjacent permanent magnets 430 contact the pole pieces 450, the pole pieces 450 are referred to as north pole pieces. When the south pole sides of adjacent permanent magnets 430 contact the pole pieces 450, the pole pieces 450 are referred to as south pole pieces. Upper platter 412 and lower platter 414 each include a permanent magnet 430 and a pole piece 450 arranged in a circular configuration.

[0083] In an embodiment, the lower platter 414 is held stationary relative to the housing 14 that contains it, and the upper platter 412 rotates relative to the lower platter 414. The upper platter 412 is rotatable in directions 490, 492 about a central axis 494 relative to the lower platter 414 to change the alignment of the permanent magnets 430 and pole pieces 450 of the upper platter 412 relative to the permanent magnets 430 and pole pieces 450 of the lower platter 414.

[0084] The switchable permanent magnet assembly 400 is considered to be in the on state when the south pole piece 450 of the lower platter 414 is aligned with the south pole piece 450 of the upper platter 412 and the north pole piece 450 of the lower platter 414 is aligned with the north pole piece 450 of the upper platter 412. In the on state, the workpiece is held by the switchable magnetic flux source 400 due to the completion of a magnetic circuit from the aligned north pole pieces 450 of the upper and lower platters 412, 414, through the workpiece to the aligned south pole pieces 450 of the upper and lower platters 412 and 414.

[0085] The switchable permanent magnet assembly 400 is considered to be in the off state when the south pole portion 450 of the lower platter 414 is aligned with the north pole portion 450 of the upper platter 412 and the north pole portion 450 of the lower platter 414 is aligned with the south pole portion 450 of the upper platter 412. In the off state, the workpiece is not held by the switchable magnetic flux source 400 due to the completion of a magnetic circuit in the upper platter 412 and lower platter 414 from the aligned north pole portion 450 of the upper platter 412 to the south pole portion 450 of the lower platter 414 and from the aligned north pole portion of the upper platter 412 to the south pole portion 450 of the lower platter 414.

[0086] The switchable permanent magnet assembly 400 is considered to be in a partially on state when the south pole portion 450 of the upper platter 412 partially overlaps the north pole portion 450 of the lower platter 414 and the north pole portion 450 of the upper platter 412 partially overlaps the south pole portion 450 of the lower platter 414. In the partially on state, the workpiece may be held by the magnetic flux source due to the completion of a magnetic circuit from the overlapping north pole portions 450 of the upper and lower platters 412, 414, through the workpiece 27 to the overlapping south pole portions 450 of the upper and lower platters 412, 414. Increasing the degree of overlap between the overlapping north pole pieces 450 of the upper platter 412 and the lower platter 414 and the overlapping south pole pieces 450 of the upper platter 412 and the lower platter 414 increases the strength of the magnetic circuit.

[0087] 4B, an upper platter 412 is shown. The upper platter 412 includes a cylindrical base component 420 having a central opening 422 and a plurality of radially extending openings 224. Each of the radially extending openings 224 is sized and shaped to receive a permanent magnet 430. Each permanent magnet 430 has a north side 432, a south side 434, a radially inwardly facing side 436, a radially outwardly facing side 238, a top 440, and a bottom.

[0088] As shown in FIG. 4C, the cylindrical base component 420 surrounds each of the north side 432, south side 434, radially inward facing side 136, and radially outward facing side 138 of the permanent magnet 430. In one embodiment, the opening 224 is not a through opening, but rather a stop-deep opening from the bottom surface of the cylindrical base component 420, so that the cylindrical base component 420 also surrounds the top 440 of the pole piece 450. In the illustrated embodiment, the cylindrical base component 420 is a single, integral component. In one embodiment, the cylindrical base component 420 is made of two or more components joined together. In an embodiment, the base component 420, and therefore the pole piece 450, are made from steel. Other suitable ferromagnetic materials may be used for the base component 420. The lower platter 414 is substantially identical to the upper platter 412. The upper platter 412 can be rotated relative to the lower platter 414 to place the switchable permanent magnet assembly 400 in an on state, a partially on state, or an off state.

[0089] 4D, the upper platter (not visible) and the lower platter 414 are arranged in an on state, with the south pole piece 450 of the upper platter 412 adjacent to the south pole piece 450 of the lower platter 414 and the north pole piece 450 of the upper platter 412 adjacent to the north pole piece 450 of the lower platter 414. A possible arrangement of the first movable pole piece 32 and the first movable pole piece 52 of the switchable magnetic flux source 400 is shown in FIG. 4D. In the first arrangement, the first pole piece 321 is disposed radially outward of the respective north pole piece 450 and the second pole piece 521 is disposed radially outward of the respective south pole piece 450. Each of the first pole piece 321 and the second pole piece 521 is magnetically coupled to the switchable magnetic flux source 400 through the housing 14 and, in an embodiment, through the supports 30, 50. In the second arrangement, the first pole piece 322 is disposed radially inward of the respective north pole piece 450 and the second pole piece 522 is disposed radially inward of the respective south pole piece 450. Each of the first pole piece 322 and the second pole piece 522 is magnetically coupled to the switchable magnetic flux source 400 through the housing 14 and, in an embodiment, through the supports 30, 50. In an embodiment, the supports 30 and 50 also form the respective pole pieces 450 of the lower platter 414. In a third arrangement, the first pole piece 321, the first pole piece 322, the second pole piece 521 and the second pole piece 522 are all included. In the on state, a workpiece 12, made of a ferromagnetic material, is held by the switchable magnetic flux source 400, including the upper platter 412 and the lower platter 414, due to the completion of a magnetic circuit from the aligned north pole piece 450 of the upper platter 412 and the lower platter 414, through one or both of the first pole piece 321 and the first pole piece 322, through one or both of the first pole piece 321 and the first pole piece 322, through one or both of the second pole piece 521 and the second pole piece 522, to the aligned south pole piece 450 of the upper platter 412 and the lower platter 414. The undersides of the first pole piece 321 and / or the first pole piece 322, depending on the arrangement, and the second pole piece 521 and / or the second pole piece 522, depending on the arrangement, form the workpiece contact interface.Additionally, sensors 100, 102 may be positioned adjacent to various north and south pole sections 450. In an embodiment, at least one of the north pole sections 450 and at least one of the south pole sections 450 have a sensor 100, 102 associated therewith to monitor leakage flux associated with the respective north pole section and the respective south pole section. As shown in FIG. 4D, a first sensor 100 may be positioned adjacent to the north pole section 450, such as directly above or radially outside the north pole section 450, and a second sensor 102 may be positioned adjacent to the south pole section 450, such as directly above or radially outside the south pole section 450. An electronic controller may perform a calibration run of the permanent magnet assembly 400 or any of the magnetic coupling devices disclosed herein to store sensor values ​​for determining an operating state of the device including the switchable magnetic flux source 400.

[0090] 2, the workpiece engaging surface 36 of the first movable pole piece 32 and the workpiece engaging surface 56 of the first movable pole piece 52 are both in contact with the contact surface 13 of the ferromagnetic workpiece 12. Each of the first movable pole piece 32 and the first movable pole piece 52 may be recessed into their respective supports 30 and supports 50. As shown in FIG. 2, the first movable pole piece 32 is recessed further relative to the support 30 than the first movable pole piece 52 is recessed relative to the support 50. This independent movement of the first movable pole piece 32 and the first movable pole piece 52 allows the magnetic coupling apparatus 10 to couple to different molded parts without having to swap the north pole piece 18 and the south pole piece 20.

[0091] 3, in an embodiment, the magnetic coupling tool 10 further includes a monitoring system 48 including one or more sensors that monitor when the workpiece engaging surface 36 of the first movable pole piece 32 and the workpiece engaging surface 56 of the first movable pole piece 52 contact the contact surface 13 of the ferromagnetic workpiece 12. An exemplary monitoring system includes a laser distance sensor attached to the magnetic coupling device 10, causing the magnetic coupling device 10 to stop at a pre-taught distance from the ferromagnetic workpiece 12. In another monitoring system, each of the first movable pole piece 32 and the first movable pole piece 52 includes a proximity sensor that measures the distance from the sensor to the top of the respective first movable pole piece 32 and first movable pole piece 52, and further advancement of the magnetic coupling device 10 in the direction 40 is stopped once all of the first movable pole piece 32 and first movable pole piece 52 have moved. In a further monitoring system, the travel distance of each of the first movable pole piece 32 and first movable pole piece 52 is measured. In yet another monitoring system, a force sensor is used to measure the force required to advance the magnetic coupling device 10 further in the direction 40. In an embodiment, the proximity sensor is supported by the housing 14 and separated from the moveable pole pieces 32, 52. Exemplary proximity sensors include ultrasonic sensors, laser range finders, inductive sensors, and other suitable devices for measuring distance.

[0092] Additionally, characteristics of the magnetic circuit formed between the magnetic coupling tool 10 and the ferromagnetic workpiece 12 can be used to evaluate proper placement of the magnetic coupling device 10 on the contact surface 13 of the ferromagnetic workpiece 12 when the switchable magnetic flux source 16 is in an ON state. As shown in FIG. 3, a first sensor 100 may be positioned proximate the north pole piece 18 and a second sensor 102 may be positioned proximate the south pole piece 20. Each of the first sensor 100 and the second sensor 102 may be a magnetic flux sensor. Additional types of sensors include temperature sensors used to compensate for temperature dependent drift of the magnetic flux sensors. Furthermore, the locations of the sensors 100 and 102 are exemplary and one or the sensors may be positioned in different locations including near or at the bottom ends of the north pole piece 18 and the south pole piece 20 and / or centrally above or below the switchable magnetic flux source 16. An exemplary sensing system is disclosed in U.S. Pat. No. 11,097,401, entitled "MAGNETIC COUPLING DEVICE WITH AT LEAST ONE OF A SENSOR ARRANGEMENT AND A DEGAUSS CAPABILITY," the entire disclosure of which is expressly incorporated herein by reference.

[0093] Each of the sensors 100 and 102 is operably coupled to an electronic controller 170. The electronic controller 170 includes at least one processor 172 and associated memory 174. The memory 174 includes magnetic coupling status logic 176, which is a logic control circuit that monitors the output of the sensors 100 and 102, or other sensors disclosed herein, to monitor one or more characteristics of the magnetic coupling apparatus 10 and / or one or more characteristics of the magnetic circuit formed between the magnetic coupling tool 10 and the ferromagnetic workpiece 12. The term "logic" as used herein includes software and / or firmware executed on one or more programmable processors, application specific integrated circuits, field programmable gate arrays, digital signal processors, hardwired logic, or combinations thereof. Thus, according to embodiments, the various logics may be implemented in any suitable manner and remain in accordance with the embodiments disclosed herein. A non-transitory machine-readable medium containing logic may further be considered to be embodied in any tangible form computer-readable carrier, such as a solid-state memory, a magnetic disk, and an optical disk, that contains a suitable set of computer instructions and data structures that cause a processor to perform the techniques described herein. The present disclosure contemplates other embodiments in which the electronic controller 170 is not microprocessor-based, but rather is configured to control the operation of the magnetic coupling device 10 based on one or more sets of hardwired instructions. Furthermore, the electronic controller 170 may be included in a single device or may be multiple devices that are netted or otherwise electrically connected together to provide the functionality described herein.

[0094] The electronic controller 170 can further receive input through one or more input devices 180. Exemplary input devices include buttons, switches, levers, dials, touch displays, soft keys, and communication modules. The electronic controller 170 can further provide output through one or more output devices 182. Exemplary output devices include visual indicators, audio indicators, and communication modules. Exemplary visual indicators include displays, lights, and other visual systems. Exemplary audio indicators include speakers and other suitable audio systems.

[0095] 8B and 8C, another exemplary magnetic coupling device 600 including a switchable magnetic flux source 16 is shown. With reference to FIG. 8B, a permanent magnet 80 is positioned in an upper portion of the housing 14, while in FIG. 8C, a rare earth permanent magnet 80 is positioned in a lower portion of the housing 14. In the arrangement shown in FIG. 8B, the switchable magnetic flux source 16 is in an OFF state. In the arrangement shown in FIG. 8C, the switchable magnetic flux source 16 is in an ON state. The permanent magnet 80 is moved between the positions shown in FIG. 8B and 8C by an actuator 84. The actuator 84 may be a mechanical actuator, such as one driven by an electric motor, a pneumatic actuator, a hydraulic actuator, or any other suitable device for positioning the rare earth permanent magnet 80. 8B, the housing 14 may include a ferromagnetic member or shunt 94 that forms a magnetic circuit with the rare earth permanent magnet 80 when the rare earth permanent magnet 80 is in the raised position to reduce stray magnetic flux reaching the first movable pole piece 32 and the first movable pole piece 52. In this embodiment, an upper portion of the housing 14 is non-ferromagnetic and a lower portion proximate the supports 30 and 50 is ferromagnetic.

[0096] 4E and 4F, there is shown a platter version of the magnetic coupling device 600. Figure 4E corresponds to Figure 8B with the device in the off state, and Figure 4F corresponds to Figure 8C with the device in the on state.

[0097] 4E, the rare earth permanent magnet 80 is replaced with a linear platter 610 having a plurality of permanent magnets 612 separated by a plurality of pole pieces 614 arranged in a linear array. The magnets are arranged such that like poles are adjacent to each pole piece 614, such that a first group of pole pieces 614 are south pole pieces and a second group of pole pieces 614 are north pole pieces. In an embodiment, each of the permanent magnets 612 and pole pieces 614 are linear, resulting in the linear platter 610 being linear.

[0098] A lower portion of the housing 14' is also shown. The housing 14' includes a plurality of magnetic pole pieces 616 and a plurality of non-ferromagnetic pieces 618 positioned between the magnetic pole pieces 616. The magnetic pole pieces 614 of the linear platter 610 are vertically aligned with the magnetic pole pieces 616 of the housing 14', and the magnets 612 are vertically aligned with the non-ferromagnetic pieces 618.

[0099] As the actuator 84 moves the linear platter 610 downward in the direction 40 to the position shown in FIG. 4F, the pole pieces 614 are magnetically coupled to the respective pole pieces 616 on which they are vertically positioned. The pole pieces 616 are each magnetically coupled to a respective moveable pole piece 32, 52 that contacts the ferromagnetic workpiece 12. Additionally, a first moveable pole piece 32 and a first moveable pole piece 52 may be included along the length of each pole piece 616. Further, while only three pole pieces 616 and corresponding moveable pole pieces 32, 52 are shown, in embodiments, additional pole pieces 616 and corresponding moveable pole pieces 32, 52 may be included and the linear platter 610 may similarly increase in number of permanent magnets 612 and pole pieces 614.

[0100] 8D, another exemplary magnetic coupling device 800 is shown. The magnetic coupling device 800 includes an electromagnet 802 instead of a permanent magnet, rare earth or electro-permanent magnet for the switchable magnetic flux source 16. When current is supplied to the electromagnet 802, the exemplary magnetic coupling device 800 is in an on state, and when the current is removed, the exemplary magnetic coupling device 800 is in an off state.

[0101] 9, there is shown an exemplary robotic system 700. Although the robotic system 700 is shown in FIG 9, the embodiments described therein may be applied to other types of machines (e.g., crane hoists, pick and place machines, etc.).

[0102] The robotic system 700 includes an electronic controller 770. The electronic controller 770 includes additional logic stored in an associated memory 774 for execution by a processor 772. A robotic motion module 702 is included that controls movement of a robotic arm 704. In the illustrated embodiment, the robotic arm 704 includes a first arm segment 706 that is rotatable relative to a base about a vertical axis. The first arm segment 706 is movably coupled to a second arm segment 708 through a first joint 710, where the second arm segment 708 can rotate in a first direction relative to the first arm segment 706. The second arm segment 708 is movably coupled to a third arm segment 711 through a second joint 712, where the third arm segment 711 can rotate in a second direction relative to the second arm segment 708. The third arm segment 711 is movably coupled to the fourth arm segment 714 through a third joint 716, where the fourth arm segment 714 can rotate in a third direction relative to the third arm segment 711 and at a rotational joint 718, thereby changing the orientation of the fourth arm segment 714 relative to the third arm segment 711. A magnetic coupling device 10 is illustratively shown secured to the end of the robot arm 704. The magnetic coupling device 10 is used to couple a workpiece 12 to the robot arm 704. Although a magnetic coupling device 10 is shown, any of the magnetic coupling devices described herein and any number of the magnetic coupling devices described herein may be used with the robot system 700.

[0103] In an embodiment, the electronic controller 770 executing the robot motion module 702 via a processor 772 moves the robot arm 704 to a first pose where the magnetic coupling device 10 contacts the workpiece at a first location. In an embodiment, the switchable magnetic flux source 16 of the magnetic coupling device 10 is in an OFF state and at least one of the magnetic coupling device 10 or the robot system 700 detects or determines that the movable pole shoe of the magnetic coupling device 10 is in contact with the ferromagnetic workpiece 12. The determination that the movable pole shoe of the magnetic coupling device 10 is in contact with the ferromagnetic workpiece 12 may result from a sensor of the magnetic coupling device 10, a sensor of the robot system 700, or a reading from a known position of the robot arm 704 of the robot system 700. The electronic controller 770 executing the magnetic coupler state module 776 via a processor 772 instructs the magnetic coupling device 10 to place the magnetic coupling device 10 in one of an ON state or a partial ON state to couple the workpiece 12 to the robot system 700. The electronic controller 770 executing the robot motion module 702 via a processor 772 moves the workpiece from the first location to a second desired spaced location. Once the workpiece is in the second desired position, the electronic controller 770 executing the magnetic coupler state module 76 via a processor 772 instructs the magnetic coupling device 10 to turn the magnetic coupling device 10 to an off state to decouple the workpiece from the robot system 700. In one example, the electronic controller 770 executing the magnetic coupler state module 776 via the processor 772 sequentially instructs the magnetic coupling device 10 to turn the magnetic coupling device 10 to a partial on state to lift the ferromagnetic workpiece 12, after lifting the ferromagnetic workpiece 12 by moving the robot arm 704, instructs the magnetic coupling device 10 to turn the magnetic coupling device 10 to an on state or another partial on state to increase the holding force of the magnetic coupling device 10 on the ferromagnetic workpiece 12, after positioning the ferromagnetic workpiece 12 at a desired location by further moving the robot arm 704, instructs the magnetic coupling device 10 to turn the magnetic coupling device 10 to an off state to decouple the ferromagnetic workpiece 12 from the robot system 700.In an embodiment, the electronic controller 770 also monitors readings from sensors of the magnetic coupling apparatus 10 and / or robotic system 700 once a ferromagnetic workpiece 12 has been moved from the stack to verify proper contact with each of the moveable pole pieces and the ferromagnetic workpiece 12 before further moving the ferromagnetic workpiece 12 with the robotic system 700. The electronic controller 770 then repeats the process of coupling, moving, and uncoupling another workpiece 12.

[0104] 10-21, an exemplary magnetic coupling device 200 is shown. With reference to FIG. 12, the magnetic coupling device 200 includes a housing 202, a switchable magnetic flux source 16 positioned within the housing 202, a north pole portion 204, and a south pole portion 206. Each of the housing 202 and the north pole portion 204 are identical. Each of the housing 202 and the north pole portion 204 are coupled to a respective base, i.e., base 208 and base 210, which are coupled to the housing 202. In an embodiment, one or both of the bases 208 and 210 are integrally formed with the south pole portion 206.

[0105] 15, there is shown an exploded view of the north pole piece 204 and base 208. The base 208 is coupled to the housing 202 using two fasteners 212 that are received in openings in the base 208 and screwed into threaded openings in the housing 202.

[0106] The north pole piece 204 comprises a support 220, a first pole piece 222 (the first pole piece of the south pole piece 206 is shown in the drawings as first pole piece 223), a second pole piece 224 (the second pole piece of the south pole piece 206 is shown in the drawings as second pole piece 225), a first biasing means, illustratively a first spring 226, a second biasing means, illustratively a second spring 228, a first limiter 230, and a second limiter 232. The first pole piece 222 includes a workpiece interface 234 having a workpiece engagement surface 236. The second pole piece 224 includes a workpiece interface 238 having a workpiece engagement surface 240. The first pole piece 222 further includes an opening 242 that receives the first limiter 230, and the second pole piece 224 further includes an opening 244 that receives the second limiter 232. An exemplary limiter is a dowel pin.

[0107] The support 220 includes a locking portion 250 and a housing 252. The locking portion 250 includes a first channel portion 254 and a second channel portion 256. The locking portion 250 is coupled to the base 208 but is movable relative to the base 208 in directions 258 and 260. Two dowel pins 262 are received in openings 264 in the base 208 and similar openings (not shown) in the locking portion 250. The dowel pins are made of a ferromagnetic material to attract the locking portion 250 toward the base 208 or the base 210 of the south pole portion 206 (see FIG. 12). A shoulder bolt 266 couples the locking portion 250 to the base 208 and allows the locking portion 250 to move relative to the base 208 in directions 258 and 260. The base 208 also includes a first channel portion 268 and a second channel portion 270. When the locking portion 250 is coupled to the base 208, the first channel portion 254 of the locking portion 250 and the first channel portion 268 of the base 208 cooperate to define a channel for the first pole portion 222, and the second channel portion 256 of the locking portion 250 and the second channel portion 270 of the base 208 cooperate to define a channel for the second pole portion 224.

[0108] The housing 252 of the support 220 is coupled to the locking portion 250 and moves together with the locking portion 250 in directions 258 and 260 relative to the base 208. The housing 252 includes a first recess 279 (see FIG. 15A) that receives the first pole portion 222, the first limiter 230, and the first spring 226, and a second recess 280 (see FIG. 15A) that receives the second pole portion 224, the second limiter 232, and the second spring 228. As shown in FIG. 15A, the second pole portion 224 can translate in directions 40 and 42 within the second recess 280. The first limiter 230 limits movement in direction 42 when the first limiter 230 contacts a stop surface 282 of the second recess 280 and limits movement in direction 40 when the first limiter 230 contacts a corresponding stop surface 284 (see FIGS. 15 and 16 ) on the top of the locking portion 250. The housing 252 is coupled to the locking portion 250 through a pair of dowel pins 286 and fasteners 288 that are received in openings 290 and threaded into threaded openings 292 of the locking portion 250.

[0109] 17, when the switchable flux source 16 is in the OFF state, the locking portion 250 of the north pole piece 204 is movable in a direction 258 and the locking portion 250 of the south pole piece 206 is movable in a direction 260, respectively. This provides a gap 285 (see FIG. 17) or at least a loose hold between the first pole piece 222 and the second pole piece 224 of the north pole piece 204 and the first pole piece 223 and the second pole piece 225 of the south pole piece 206, respectively, allowing each of the first pole piece 222, the first pole piece 223, the second pole piece 224, and the second pole piece 225 to move in the directions 40 and 42, respectively, relative to the underside 203 of the housing 202, independently of one another.

[0110] 18, when the switchable magnetic flux source 16 is in the on state, the locking portion 250 of the north pole piece 204 moves in a direction 260 towards the base 208 due to the locking portion 250 and the base 208 being made from a ferromagnetic material and the locking portion 250 being magnetically attracted to the switchable magnetic flux source 16. This movement in the direction 260 causes the locking portion 250 to clamp the first pole piece 222 and the second pole piece 224 in place (between the base 208 and the locking portion 250) and prevent or at least resist further movement in either of the directions 40 and 42. Similarly, the locking portion 250 of the south pole piece 206 moves in a direction 258 towards the base 210 due to the locking portion 250 and the base 210 being made from a ferromagnetic material and the locking portion 250 being magnetically attracted to the switchable magnetic flux source 16. This movement in direction 258 causes locking portion 250 to clamp first pole piece 223 and second pole piece 225 in place (between base 210 and locking portion 250) and prevent or at least resist further movement in either direction 40 or direction 42. This clamp holds each of first pole piece 222, first pole piece 223, second pole piece 224 and second pole piece 225 against underside 203 of housing 202. In an embodiment, magnetic coupling device 10 includes an additional or alternative system for holding the position of first pole piece 222, first pole piece 223, second pole piece 224 and second pole piece 225. For example, a mechanical actuator or fastener may be included to hold the respective locking portions 250 against the bases 208 and 210 to clamp the first pole piece 222, the first pole piece 223, the second pole piece 224, and the second pole piece 225 in place. Among other benefits of including a mechanical actuator is that the switchable magnetic flux source 16 can be switched to an off state and the positions of the first pole piece 222, the first pole piece 223, the second pole piece 224, and the second pole piece 225 are maintained. This allows the first pole piece 222, the first pole piece 223, the second pole piece 224, and the second pole piece 225 to remain in a repeatable position for rapid contact and transport of the next ferromagnetic workpiece 12 in the stack (see FIGS. 19-21).

[0111] 19-21, the magnetic coupling device 200 is coupled to a robot arm 704 of an exemplary robot system 700, and the operation of the magnetic coupling device 200 is shown. With reference to FIG. 19, the magnetic coupling device 200 is positioned above a stack of ferromagnetic workpieces 12, illustratively ferromagnetic workpieces 12A, ferromagnetic workpieces 12B, ferromagnetic workpieces 12C, and ferromagnetic workpieces 12D. The switchable magnetic flux source 16 of the magnetic coupling device 200 is in an off state, such that each of the first magnetic pole piece 222, the first magnetic pole piece 223, the second magnetic pole piece 224, and the second magnetic pole piece 225 are fully extended relative to the lower surface 203 of the housing 202 and can move in the direction 42 in the presence of an external force (e.g., pushing against the ferromagnetic workpiece 12A). 20, magnetic coupling device 200 is brought into contact with ferromagnetic workpiece 12A, with first pole piece 222 and second pole piece 224 each shown recessed a respective amount into support 220 (with first pole piece 223 and second pole piece 225 also recessed a respective amount). As shown, first pole piece 222 is positioned at a higher point on ferromagnetic workpiece 12A and is therefore recessed relative to second pole piece 224. At this point, the switchable magnetic flux source 16 is switched to an ON state, and the respective locking portions 250 clamp the first pole piece 222, the first pole piece 223, the second pole piece 224, and the second pole piece 225 in place, forming a magnetic circuit between the magnetic coupling device 200 and the ferromagnetic workpiece 12A through the first pole piece 222, the first pole piece 223, the second pole piece 224, and the second pole piece 225. Referring to FIG. 21, the ferromagnetic workpiece 12A may now be removed from the stack of remaining workpieces (ferromagnetic workpiece 12B, ferromagnetic workpiece 12C, ferromagnetic workpiece 12D). The robotic system 700 then moves the ferromagnetic workpiece 12A to a desired location and picks up the ferromagnetic workpiece 12B.

[0112] In an embodiment, one of the magnetic coupling device 10 and the robotic system 700 determines the position of each of the first pole piece 222, first pole piece 223, second pole piece 224, and second pole piece 225 relative to the housing 14 or relative to each other. This may be accomplished by sensors measuring the compression of the respective springs, sensors monitoring the separation of the top of each of the first pole piece 222, first pole piece 223, second pole piece 224, and second pole piece 225 from the top of the second recess 280 in the housing 252, optical sensors monitoring exterior markings of each of the first pole piece 222, first pole piece 223, second pole piece 224, and second pole piece 225, as well as other suitable sensor systems. By knowing the location of the engagement surfaces of each of the first pole piece 222, the first pole piece 223, the second pole piece 224, and the second pole piece 225, and knowing the shape of the parts 12 to be coupled, one of the magnetic coupling device 10 and the robotic system 700 can determine the location of the magnetic coupling device 10 on the parts 12. Using this knowledge, the positioning of the part 12, such as the orientation of the part 12, can be determined by the robotic system 700 and the robotic arm 704 can be actuated to position the part 12 in a desired location. Additionally, the use of sensors associated with one or more of the movable pole pieces 222, 223, 224, and / or 225 helps to provide a consistent force on the part 12, or a repeatable pick or positioning of the part 12, and the gripping force of the magnetic circuit from part 12 to part 12.

[0113] 22-26, there is shown another exemplary magnetic coupling device 300. The magnetic coupling device 300 includes a housing 202 and any one of the exemplary switchable magnetic flux sources disclosed herein.

[0114] The magnetic coupling device 300 includes a pair of pole shoes, one pole shoe 302 is shown in Figures 22-26. Pole shoe 302 serves as the north pole shoe of the magnetic coupling device 300, while a second pole shoe (not shown), identical to pole shoe 302, is mounted on the opposite side of the housing 202 and thus opposite the switchable magnetic flux source 16 located within the housing 202. The second pole shoe serves as the south pole of the magnetic coupling device 300. The second pole shoe is mounted to the housing 202 in the same manner as pole shoe 302.

[0115] 26, the pole shoe 302 includes a lower portion 304 having a plurality of protrusions 306 (two marked with reference numbers) each having a workpiece engagement surface 308 that interacts with the ferromagnetic workpiece 12. As shown in FIG. 26, the width of each of the protrusions 306 may be uniform across the lower portion 304 while the spacing may be variable. In an embodiment, the width of each of the protrusions 306 may be variable while the spacing between the protrusions 306 is one of uniform or variable. In an embodiment, the width of each of the protrusions 306 may be uniform while the spacing between the protrusions 306 is one of uniform or variable. Further details regarding exemplary projections and spacing of the pole shoes 302 are provided in U.S. Patent Application Serial No. 16 / 964,005, entitled "MAGNETIC LIFTING DEVICE HAVING POLE SHOES WITH SPACED APART PROJECTIONS," published as U.S. Patent Application Publication No. 20210031317, the entire disclosure of which is expressly incorporated herein by reference. Additionally, as disclosed in U.S. Patent Application Serial No. 16 / 964,005 and incorporated herein by reference, a resilient material can be disposed in the openings between the projections 306 and / or cover the workpiece engaging surface 308 to reduce potential chafing of the ferromagnetic workpiece 12 when in contact with the magnetic coupling device 300.

[0116] Further, as shown in FIG. 26, each of the projections 306 has a common length. In an embodiment, one or more of the projections 306 is longer relative to another projection 306 such that the workpiece engagement surfaces 308 are not coplanar. In an embodiment, each of the projections 306 has the same length, but each of the workpiece engagement surfaces 308 are not coplanar due to the pole shoe lower portion 304 being non-linear to match the contour of the intended ferromagnetic workpiece 12. In an embodiment, each of the workpiece engagement surfaces 308 of the projections 306 are not coplanar due to the pole shoe lower portion 304 being non-linear to match the contour of the intended ferromagnetic workpiece 12. Exemplary shapes of the lower portion 304 of the pole shoe 302 include linear, stepped, V-shaped, curved, and other suitable non-linear surfaces that may or may not include linear segments.

[0117] Although the illustrated embodiment includes a pole shoe 302 having a lower portion 304 with multiple protrusions 306, in embodiments, the lower portion 304 of each pole shoe 302 may be solid such that each defines a single workpiece engagement surface 308. Exemplary shapes for the lower portion 304 of the pole shoe 302 include linear, stepped, V-shaped, curved, and other suitable non-linear surfaces that may or may not include linear segments.

[0118] The pole shoe 302 further includes a number of interfaces 310 through which the pole shoe 302 is coupled to the housing 202. In the illustrated embodiment, two interfaces 310A and 310B are shown, however, in other embodiments, additional or fewer interfaces may be provided. In the illustrated embodiment, the number of interfaces 310 generally constrains the movement of the pole shoe 302 relative to the housing 202 along a single linear axis 320 (see Figures 24 and 25). In other embodiments, the number of interfaces 310 constrains the movement in a plane and / or provides for rotational movement of the pole shoe 302 relative to the housing 202. For example, if a single interface 310 is implemented, the pole shoe 302 may be capable of rotating relative to the housing 202 and, optionally, moving along a single linear axis, such as axis 320.

[0119] The exemplary interface 310 shown in FIG. 26 is an elongated slot 312 having a lower surface 314 and an upper surface 316. The pole shoe 302 is coupled to the housing 202 through a pair of couplings, illustratively fasteners, shoulder bolts 330. The shoulder bolts 330 include a threaded portion 332 that threads into an opening 334 in the housing 202 and a shoulder 336 that is positioned within each of the elongated slots 312. As shown in FIGS. 24 and 25, the elongated slots 312 are larger in diameter than the shoulder portions 336 of the shoulder bolts 330 along the major axis of the elongated slots 312. This allows the pole shoe 302 to move along a single linear axis 320 between a first position shown in FIG. 24 and a second position shown in FIG. 25 along the major axis of the elongated slots 312. In an embodiment, the width of each of the elongated slots 312 is slightly larger than the diameter of the shoulder 336 of the shoulder bolt 330, thereby constraining any movement of the pole shoe 302 along the housing 202 that is not along the single linear axis 320. In an embodiment, a single coupler, such as an extension retainer, may be received in each of the elongated slots 312A, 312B to couple the pole shoe 302 to the housing 202. In an embodiment, one or more of the elongated slots are deep blind holes that receive guides, such as pins, that constrain the movement of the pole shoe 302 relative to the housing 202, and thus couple the pole shoe 302 to the housing 202.

[0120] In FIG. 25, the pole shoe 302 is lowered relative to the underside 340 of the housing 202. In FIG. 24, the pole shoe 302 is raised relative to the underside 340 of the housing 202. In an embodiment, the pole shoe 302 can move between the positions shown in FIG. 24 and FIG. 25 and positions therebetween while the switchable magnetic flux source 16 is in an OFF state. When the switchable magnetic flux source 16 is in an ON state or a partial ON state with sufficient magnetic strength, the pole shoe 302 is held against the housing 202 by magnetic forces and no longer moves in the direction 320. In the ON state or a partial ON state with sufficient magnetic strength of the switchable magnetic flux source 16, the switchable magnetic flux source 16 is magnetically coupled to the ferromagnetic workpiece 12 through the housing 202 and a pair of pole shoes 302 (one shown), such that the magnetic coupling device 300 can lift and move the ferromagnetic workpiece 12 or hold the ferromagnetic workpiece 12 in place relative to another object.

[0121] Although not shown, in an embodiment, the magnetic coupling device 300 includes a biasing means for biasing the pole shoe 302 to the position of Figure 25. An exemplary biasing means includes a spring.

[0122] In an embodiment, the magnetic coupling tool 200 is positioned adjacent to the ferromagnetic workpiece 12, with the first pole piece 222, the first pole piece 223, the second pole piece 224, and the second pole piece 225 each extending downwardly in a fully extended position, and the switchable flux source 16 in a partially on state (FIG. 27). When in the partially on state, a magnetic circuit may be formed between the ferromagnetic workpiece 12 and the switchable flux source 16 through the housing 202, the base 208, the first pole piece 222, the second pole piece 224, the base 210, the first pole piece 223, and the second pole piece 225. Additionally, depending on the magnetic strength of the partial on state, the locking portion 250 does not clamp the first pole piece 222, the first pole piece 223, the second pole piece 224, and the second pole piece 225, thereby allowing the first pole piece 222, the first pole piece 223, the second pole piece 224, and the second pole piece 225 to continue to move in the directions 40, 42 relative to the base 208 and the base 210. In an embodiment, the partial on is up to 50% of the power of the on state. In an embodiment, the partial on is up to 40% of the power of the on state. In an embodiment, the partial on is up to 30% of the power of the on state.

[0123] At a first time, when the pole pieces 222, 223, 224, 225 are in a fully extended position, the switchable magnetic flux source 16 has a partial on state, and the first pole piece 222, the first pole piece 223, the second pole piece 224, and the second pole piece 225 are each spaced apart from the ferromagnetic workpiece 12, the electronic controller 170 may receive a first magnetic flux value from at least one of the sensors 100, 102. In embodiments in which the electronic controller 170 monitors one of the first sensor 100 and the second sensor 102, the electronic controller 170 may detect a change in the magnetic flux value as an indication that the pole pieces have contacted the ferromagnetic workpiece 12. In embodiments where the electronic controller 170 monitors both the first sensor 100 and the second sensor 102, the electronic controller 170 may sense a change in the magnetic flux value of each of the first sensor 100 and the second sensor 102 as an indication that one of the north pole pieces and one of the south pole pieces has contacted the ferromagnetic workpiece 12. In embodiments, a sensor, such as a magnetic flux sensor, may be associated with each of the first pole piece 222, the first pole piece 223, the second pole piece 224, and the second pole piece 225, and the electronic controller 170 may monitor each sensor for a change in the magnetic flux value as an indication that each of the first pole piece 222, the first pole piece 223, the second pole piece 224, and the second pole piece 225 has contacted the ferromagnetic workpiece 12. The electronic controller 170 may determine that the monitored sensor value indicates contact with the ferromagnetic workpiece 12 when the change in the sensor value exceeds a threshold amount. In alternative embodiments, other types of sensors may be used to determine when each of the first pole piece 222, the first pole piece 223, the second pole piece 224, and the second pole piece 225 contacts the ferromagnetic workpiece 12. Exemplary sensors include respective biasing means, illustratively spring-loaded strain sensors, that bias the first pole piece 222, the first pole piece 223, the second pole piece 224, and the second pole piece 225 in the direction 42.

[0124] 28, at a second time subsequent to the first time, the magnetic coupling tool 200 is repositioned (i.e., by the robot system 700) so that at least one of the first pole piece 222, the first pole piece 223, the second pole piece 224, and the second pole piece 225 contacts the contact surface 13 of the workpiece 12. When the magnetic coupling device 200 contacts the ferromagnetic workpiece 12 at the second time, the magnetic flux field changes and the electronic controller 170 receives a second magnetic flux value from at least one of the sensors 100, 102 that is different from the first magnetic flux value.

[0125] When the electronic controller 170 detects contact with the contact surface 13 of the ferromagnetic workpiece 12, the electronic controller 170 determines an additional distance that the magnetic coupling device 200 can be advanced toward the ferromagnetic workpiece 12 before one or more of the first pole piece 222, the first pole piece 223, the second pole piece 224, and the second pole piece 225 are fully retracted. In an embodiment, this additional distance is determined based on the stored values ​​for each of the first pole piece 222, the first pole piece 223, the second pole piece 224, and the second pole piece 225. Thus, the robotic system 700 can communicate to the electronic controller 770 an additional distance that the magnetic coupling device 200 can be advanced toward the ferromagnetic workpiece 12. In an example, the additional distance is 20 millimeters. Additionally, the sensors 100, 102 continue to monitor the magnetic flux as each of the first pole pieces 222, 223, 224, and 225 continues to be retracted into the housing 252. As each of the first pole pieces 222, 223, 224, and 225 retracts, the length of each of the first pole pieces 222, 223, 224, and 225 to the ferromagnetic workpiece 12 is shortened, increasing the magnetic circuit with the ferromagnetic workpiece 12. The sensors 100, 102 are able to detect this change in magnetic flux, which is a decrease in magnetic flux for the arrangement of the sensors 100, 102 of FIG. 3 as more magnetic flux is directed through the ferromagnetic workpiece 12. In an embodiment, the electronic controller 170 records the magnetic flux values ​​of the sensors 100, 102 associated with each first pole piece 222, first pole piece 223, second pole piece 224, and second pole piece 225 at full extension (contacting the ferromagnetic workpiece 12), full retraction (contacting the ferromagnetic workpiece 12), and optionally positions in between (contacting the ferromagnetic workpiece 12). Based on these stored values ​​and measurements, the electronic controller 170 can determine the retraction of each first pole piece 222, first pole piece 223, second pole piece 224, and second pole piece 225.Additionally, for a ferromagnetic workpiece 12 having an irregular shape, such as that shown in FIG. 19, the electronic controller 170 records a first set of values ​​of the sensors 100, 102 when each of the first pole piece 222, the first pole piece 223, the second pole piece 224, and the second pole piece 225 are in contact with the ferromagnetic workpiece 12 (due to the shape of the ferromagnetic workpiece 12, these values ​​are when one or more of the first pole piece 222, the first pole piece 223, the second pole piece 224, and the second pole piece 225 are at least partially retracted) and a second set of values ​​of the sensors 100, 102 when each of the first pole piece 222, the first pole piece 223, the second pole piece 224, and the second pole piece 225 are at an appropriate retracted depth. In an example, the appropriate retraction depth may be when a first of the first pole piece 222, the first pole piece 223, the second pole piece 224, and the second pole piece 225 are fully retracted. By storing the first set of values ​​and the second set of values, the electronic controller 170 may determine when each of the first pole piece 222, the first pole piece 223, the second pole piece 224, and the second pole piece 225 has contacted the ferromagnetic workpiece 12 and when each of the first pole piece 222, the first pole piece 223, the second pole piece 224, and the second pole piece 225 is positioned to lift the ferromagnetic workpiece 12. In an embodiment, the electronic controller 170 stores values ​​for different thicknesses of the ferromagnetic workpiece 12 and a predicted thickness of the ferromagnetic workpiece 12 is provided to the electronic controller 170 through the input device 180.

[0126] At a third time point following the second time point when the electronic controller 170 determines that each of the first pole pieces 222, 223, 224, and 225 have been compressed a predetermined amount based on the stored values, further advancement of the magnetic coupling device 200 is halted and the switchable flux source 16 is configured to increase the magnetic circuit by configuring the switchable flux source 16 to a higher partial on or on state that causes the housing 252 to clamp and hold each of the first pole pieces 222, 223, 224, and 225. In an embodiment, the electronic controller 170 initially configures the switchable magnetic flux source 16 to a first higher partial on state sufficient to remove the ferromagnetic workpiece 12 from the stack of workpieces 12, and a separate electronic controller 170 configures the switchable magnetic flux source 16 to a second higher partial on state, or on state, higher than the first partial on state.

[0127] In an embodiment, the electronic controller 170 may further be capable of determining the proximity of the workpiece engaging surfaces of the first pole piece 222, the first pole piece 223, the second pole piece 224, and the second pole piece 225 to the ferromagnetic workpiece 12 by monitoring the sensors 100, 102. The magnetic flux detected by the sensors 100, 102 for a given partial on or on state of the switchable magnetic flux source 16 changes as the workpiece engaging surfaces of the first pole piece 222, the first pole piece 223, the second pole piece 224, and the second pole piece 225 approach the ferromagnetic workpiece 12. Thus, the electronic controller 170 may store magnetic flux values ​​when one or more of the first magnetic pole portion 222, the first magnetic pole portion 223, the second magnetic pole portion 224, and the second magnetic pole portion 225 contact the ferromagnetic workpiece 12, as well as magnetic flux values ​​when each of the first magnetic pole portion 222, the first magnetic pole portion 223, the second magnetic pole portion 224, and the second magnetic pole portion 225 is spaced apart from the ferromagnetic workpiece 12 and the closest one of the first magnetic pole portion 222, the first magnetic pole portion 223, the second magnetic pole portion 224, and the second magnetic pole portion 225 is spaced apart a first distance. When the electronic controller 170 determines that the closest one of the first pole piece 222, the first pole piece 223, the second pole piece 224, and the second pole piece 225 is separated from the ferromagnetic workpiece 12 by a first distance, the magnetic coupling device 200 may change the configuration of the switchable magnetic flux source 16 or may alert the electronic controller 770 to change the speed of travel of the magnetic coupling device 200 toward the ferromagnetic workpiece 12. In an embodiment, the electronic controller 770 may control the speed of the magnetic coupling device 200 toward the ferromagnetic workpiece 12 to be greater than the first speed when the closest one of the first pole piece 222, the first pole piece 223, the second pole piece 224, and the second pole piece 225 is the first distance from the ferromagnetic workpiece 12 and to be less than or equal to the first speed when the closest one of the first pole piece 222, the first pole piece 223, the second pole piece 224, and the second pole piece 225 is the first distance from the ferromagnetic workpiece 12.

[0128] Working Example Example 1: 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 may include a housing, a switchable magnetic flux source supported by the housing, and a plurality of magnetic pole pieces. The switchable magnetic flux source may be switchable between at least an off state and at least one of a partial on state and an on state. Each of the plurality of magnetic pole pieces may include at least one workpiece interface having a workpiece engagement surface. The plurality of magnetic pole pieces may include a first magnetic pole piece including a first workpiece interface having a first workpiece engagement surface, and a second magnetic pole piece including a second workpiece interface having a second workpiece engagement surface. Each of the first magnetic pole piece and the second magnetic pole piece may be movable relative to the housing when the switchable magnetic flux source is in the off state and may be held relative to the housing when the switchable magnetic flux source is in at least one of the partial on state and the on state. The first engagement surface of the first pole piece can maintain a first position relative to the housing when the switchable magnetic flux source is in an off state and is not in contact with the ferromagnetic workpiece regardless of the orientation of the housing, and the second engagement surface of the second pole piece can maintain a second position relative to the housing when the switchable magnetic flux source is in an off state and is not in contact with the ferromagnetic workpiece regardless of the orientation of the housing.

[0129] Example 2: The magnetic coupling device of example 1, wherein each of the first pole piece and the second pole piece can be constrained to be movable in a single degree of freedom relative to the housing.

[0130] Example 3: A magnetic coupling device according to any one of Examples 1 and 2, wherein the first pole piece can be translatable relative to the housing when the switchable magnetic flux source is in an off state.

[0131] Example 4: A magnetic coupling device according to any one of Examples 1 to 3, wherein the second pole piece can be translatable relative to the housing when the switchable magnetic flux source is in an off state.

[0132] Example 5: The magnetic coupling device according to any one of Examples 1 to 4 may further include a first biasing means coupled to the housing and a second biasing means coupled to the housing. The first biasing means may maintain the first engagement surface of the first pole piece in a first position relative to the housing when the switchable flux source is in an off state and not in contact with the ferromagnetic workpiece, regardless of the orientation of the housing. The second biasing means may maintain the second engagement surface of the second pole piece in a second position relative to the housing when the switchable flux source is in an off state and not in contact with the ferromagnetic workpiece, regardless of the orientation of the housing.

[0133] Example 6: The magnetic coupling device of example 5, wherein the first biasing means can be a first spring and the second biasing means can be a second spring.

[0134] Example 7: The magnetic coupling device according to any one of Examples 1 to 4 may further include a first support coupled to the housing and supporting the first magnetic pole part, and a second support coupled to the housing and supporting the second magnetic pole part. The first support may include a first locking part at least partially defining a first channel for receiving the first magnetic pole part. The first locking part may be movable relative to the housing between an unlocked position in which the first magnetic pole part is movable relative to the housing, and a locked position in which the first magnetic pole part is held relative to the housing. The second support may include a second locking part at least partially defining a second channel for receiving the second magnetic pole part. The second locking part may be movable relative to the housing between an unlocked position in which the second magnetic pole part is movable relative to the housing, and a locked position in which the second magnetic pole part is held relative to the housing.

[0135] Example 8: A magnetic coupling device as described in Example 7, wherein the first magnetic pole portion may be translatable relative to the housing in a first direction, and the first locking portion of the first support may be translatable from an unlocked position to a locked position along a second direction, the second direction being inclined relative to the first direction.

[0136] Example 9: A magnetic coupling device as described in any of embodiments 7 and 8, wherein the first locking portion can be moved from the unlocked position to the locked position when the switchable magnetic flux source transitions from an off state to at least one of a partially on state and an on state.

[0137] Example 10: The magnetic coupling device according to any one of Examples 7 to 9 may further include a first biasing means supported by the first support and a second biasing means supported by the second support. The first biasing means may maintain the first engagement surface of the first pole piece in a first position relative to the housing when the switchable flux source is in an off state and not in contact with the ferromagnetic workpiece, regardless of the orientation of the housing. The second biasing means may maintain the second engagement surface of the second pole piece in a second position relative to the housing when the switchable flux source is in an off state and not in contact with the ferromagnetic workpiece, regardless of the orientation of the housing.

[0138] Example 11: The magnetic coupling device of example 10, wherein the first biasing means can be a first spring and the second biasing means can be a second spring.

[0139] Example 12: A magnetic coupling device described in any one of Examples 7 to 11, wherein the first magnetic pole portion can be retracted relative to the underside of the first support when the switchable magnetic flux source is in an off state, and the second magnetic pole portion can be retracted relative to the underside of the second support when the switchable magnetic flux source is in an off state.

[0140] Example 13: A magnetic coupling device described in any one of Examples 7 to 12, wherein the first limiter can determine a maximum setback distance of the first magnetic pole portion relative to the lower surface of the first support, and the second limiter can determine a maximum setback distance of the second magnetic pole portion relative to the lower surface of the second support.

[0141] Example 14: A magnetic coupling device as described in Example 13, wherein the first limiter may include a first portion carried by the first pole piece and a first stop surface on the first support, and the second limiter may include a second portion carried by the second pole piece and a second stop surface on the second support.

[0142] Example 15: A magnetic coupling device according to any one of Examples 1 to 14, wherein the switchable magnetic flux source can be positioned between the first magnetic pole piece and the second magnetic pole piece.

[0143] Example 16: A magnetic coupling device according to any one of Examples 1 to 14, wherein the switchable magnetic flux source is aligned with the first pole piece and the second pole piece in the vertical direction.

[0144] Example 17: A magnetic coupling device according to any of the preceding examples, wherein the switchable magnetic flux source includes at least one permanent magnet.

[0145] Example 18: The magnetic coupling device of example 17, wherein the at least one permanent magnet comprises an electro-permanent magnet.

[0146] Example 19: The magnetic coupling device of any one of Examples 17 and 18, wherein the at least one permanent magnet further comprises a rare earth permanent magnet.

[0147] Example 20: The magnetic coupling device of any one of Examples 1 to 16, wherein the switchable magnetic flux source includes an electromagnet.

[0148] Example 21: A magnetic coupling device according to any one of Examples 1 to 16, wherein the switchable magnetic flux source includes a platter having a plurality of permanent magnets and a plurality of magnetic pole pieces interleaved therebetween.

[0149] Example 22: A magnetic coupling device as described in Example 21, wherein the plurality of permanent magnets and the plurality of magnetic pole pieces form a linear array.

[0150] Example 23: A magnetic coupling device as described in Example 21, wherein the plurality of permanent magnets and the plurality of magnetic pole pieces form a circular array.

[0151] Example 24: A magnetic coupling device according to any one of Examples 1 to 23, wherein the switchable magnetic flux source can include a plurality of permanent magnets.

[0152] Example 25: The magnetic coupling device of Example 24, wherein at least a first permanent magnet of the plurality of permanent magnets can be an electro-permanent magnet.

[0153] Example 26: The magnetic coupling device of example 24, wherein at least a second permanent magnet of the plurality of permanent magnets can be a rare earth magnet.

[0154] Example 27: The magnetic coupling device of example 24, wherein the plurality of permanent magnets can include a first permanent magnet and a second permanent magnet movable relative to the first permanent magnet.

[0155] Example 28: The magnetic coupling device of example 27, wherein the second permanent magnet can be rotatable relative to the first permanent magnet.

[0156] Example 29: A magnetic coupling device as described in Example 28, wherein each of the first permanent magnet and the second permanent magnet can be positioned between the first magnetic pole piece and the second magnetic pole piece.

[0157] Example 30: A magnetic coupling device described in any one of Examples 27 to 29, wherein in an on state of the switchable flux source, the north pole of the second permanent magnet can be approximately aligned with the north pole of the first permanent magnet, and in an off state of the switchable flux source, the south pole of the second permanent magnet is approximately aligned with the north pole of the first permanent magnet.

[0158] Example 31: A magnetic coupling device described in any one of Examples 1 to 30, wherein each of the first magnetic pole portion and the second magnetic pole portion are positioned on a first side of the switchable magnetic flux source and are, in at least one of a partial on state and an on state of the switchable magnetic flux source, a north magnetic pole portion of the magnetic coupling device and a south magnetic pole portion of the magnetic coupling device, respectively.

[0159] Example 32: In yet a further example thereof, the first magnetic pole portion may be positioned on a first side of the switchable magnetic flux source and the second magnetic pole portion may be positioned on a second side of the switchable magnetic flux source, and in at least one of a partial on state and an on state of the switchable magnetic flux source, the first magnetic pole portion is a north magnetic pole portion of the magnetic coupling device and the second magnetic pole portion is a south magnetic pole portion of the magnetic coupling device, any one of Examples 1 to 30.

[0160] Example 33: A magnetic coupling device described in any one of Examples 1 to 32, wherein the first magnetic pole piece may be a first cylindrical pin that may optionally have a first rounded end, and the second magnetic pole piece may be a second cylindrical pin that may optionally have a second rounded end.

[0161] Example 34: A magnetic coupling device described in any one of Examples 1 to 33, which may further include at least one sensor for providing one or more characteristics of the plurality of movable magnetic pole portions.

[0162] Example 35: A magnetic coupling device as described in Example 34, wherein the characteristic is the position of one or more of the multiple movable magnetic pole pieces.

[0163] Example 36: A magnetic coupling device as described in Example 34, wherein the characteristic is a magnetic flux associated with one or more of the plurality of movable magnetic pole pieces.

[0164] Example 37: The magnetic coupling apparatus of Example 34 can further include a controller operably coupled to the switchable magnetic flux source and the at least one sensor. The controller can be configured to determine whether one or more of the plurality of movable pole pieces are spaced apart from the ferromagnetic workpiece and whether one or more of the plurality of movable pole pieces are in contact with the ferromagnetic workpiece based on a characteristic of one or more of the plurality of movable pole pieces.

[0165] Example 38: A magnetic coupling device as described in Example 37, wherein the controller can be configured to determine motion characteristics of one or more of the multiple movable magnetic pole pieces.

[0166] Example 39: A magnetic coupling device as described in Example 38, wherein the motion characteristic of one or more of the plurality of movable magnetic pole pieces can be a position of one or more of the plurality of movable magnetic pole pieces relative to the housing.

[0167] Example 40: The magnetic coupling device of example 39, wherein the first pole piece can be retractable relative to the housing and the motion characteristic can be when the first pole piece is fully retracted relative to the housing. An end of the first pole piece can remain extending from the housing when fully retracted.

[0168] Example 41: A magnetic coupling device described in any of Examples 1 to 40, wherein the partial on state is a first partial on state, and each of the first magnetic pole portion and the second magnetic pole portion is held relative to the housing when the switchable magnetic flux source is in the first partial on state, and the switchable magnetic flux source is further switchable to a second partial on state in which each of the first magnetic pole portion and the second magnetic pole portion is movable relative to the housing.

[0169] Example 42: In yet another example thereof, the partial on state is a first partial on state, and when the switchable magnetic flux source is in the first partial on state, each of the first and second magnetic pole pieces is held relative to the housing, and the switchable magnetic flux source is further switchable to a second partial on state in which each of the first and second magnetic pole pieces is movable relative to the housing, and the controller can monitor the magnetic flux while the switchable magnetic flux source is in the second partial on state to determine whether one or more of the plurality of movable magnetic pole pieces are spaced apart from the ferromagnetic workpiece.

[0170] Example 43: In yet another example thereof, the partial on state is a first partial on state, and when the switchable magnetic flux source is in the first partial on state, each of the first and second magnetic pole pieces is held relative to the housing, and the switchable magnetic flux source is further switchable to a second partial on state in which each of the first and second magnetic pole pieces is movable relative to the housing, and the controller can monitor the magnetic flux while the switchable magnetic flux source is in the second partial on state to determine whether one or more of the plurality of movable magnetic pole pieces is in contact with a ferromagnetic workpiece.

[0171] Example 44: In yet another example thereof, the partial on state is a first partial on state, and when the switchable magnetic flux source is in the first partial on state, each of the first magnetic pole portion and the second magnetic pole portion are held relative to the housing, and the switchable magnetic flux source is further switchable to a second partial on state in which each of the first magnetic pole portion and the second magnetic pole portion are movable relative to the housing, and the controller can monitor the magnetic flux while the switchable magnetic flux source is in the second partial on state to determine the motion characteristics.

[0172] Example 45: A magnetic coupling device according to any of the preceding examples, including a proximity sensor supported by the housing and separated from the plurality of magnetic pole pieces.

[0173] Example 46: 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 may include a housing, a switchable magnetic flux source supported by the housing, a plurality of magnetic pole pieces, a plurality of biasing means for biasing the plurality of magnetic pole pieces to an extended position relative to a lower surface of the housing, and a plurality of locking portions for fixing the plurality of magnetic pole pieces relative to the housing when the switchable magnetic flux source is in at least one of a partial on state and an on state. The switchable magnetic flux source may be switchable between at least an off state and at least one of a partial on state and an on state. Each of the plurality of magnetic pole pieces may include at least one workpiece interface having a workpiece engagement surface. The plurality of magnetic pole pieces may include a plurality of north magnetic pole pieces forming a north magnetic pole of the magnetic coupling device when the switchable magnetic flux source is in at least one of a partial on state and an on state, and a plurality of south magnetic pole pieces forming a south magnetic pole of the magnetic coupling device when the switchable magnetic flux source is in at least one of a partial on state and an on state. Each of the multiple pole pieces may be translatable relative to the housing along a respective axis when the switchable magnetic flux source is in an off state, and each may include a respective workpiece interface having a respective workpiece engaging surface.

[0174] Example 47: The magnetic coupling device of Example 46 can further comprise at least one sensor for providing a characteristic of one or more of the plurality of magnetic pole pieces.

[0175] Example 48: A magnetic coupling device as described in Example 47, wherein the characteristic can be the position of one or more of the multiple magnetic pole portions.

[0176] Example 49: A magnetic coupling device as described in Example 47, wherein the characteristic can be magnetic flux associated with one or more of the multiple magnetic pole portions.

[0177] Example 50: The magnetic coupling apparatus of Example 47 can further include a controller operably coupled to the switchable magnetic flux source and the at least one sensor. The controller can be configured to determine whether one or more of the plurality of magnetic pole pieces are spaced apart from the ferromagnetic workpiece and whether one or more of the plurality of magnetic pole pieces are in contact with the ferromagnetic workpiece based on a characteristic of one or more of the plurality of magnetic pole pieces.

[0178] Example 51: A magnetic coupling device as described in Example 50, wherein the controller can be configured to determine motion characteristics of one or more of the multiple magnetic pole pieces.

[0179] Example 52: A magnetic coupling device as described in Example 51, wherein the motion characteristic of one or more of the multiple magnetic pole portions can be a position of one or more of the multiple magnetic pole portions relative to the housing.

[0180] Example 53: The magnetic coupling device of example 52, wherein the motion characteristic can be when one or more first pole pieces of the plurality of pole pieces are fully retracted relative to the housing. An end of the first pole piece can remain extended from the housing when fully retracted.

[0181] Example 54: A magnetic coupling device described in any of Examples 46 to 53, wherein the partial on state is a first partial on state, and when the switchable magnetic flux source is in the first partial on state, each of one or more of the multiple magnetic pole portions is held relative to the housing, and the switchable magnetic flux source is further switchable to a second partial on state in which each of one or more of the multiple magnetic pole portions is movable relative to the housing, and in the second partial on state, when the switchable magnetic flux source, the multiple north magnetic pole portions still form north magnetic poles of the magnetic coupling device and the multiple south magnetic pole portions still form south magnetic poles of the magnetic coupling device.

[0182] Example 55: A magnetic coupling device as described in Example 50, wherein the partial on state is a first partial on state, and when the switchable magnetic flux source is in the first partial on state, each of one or more of the multiple magnetic pole portions is held relative to the housing, and the switchable magnetic flux source is further switchable to a second partial on state in which each of one or more of the multiple magnetic pole portions is movable relative to the housing, and in the second partial on state, when the switchable magnetic flux source, the multiple north magnetic pole portions still form north magnetic poles of the magnetic coupling device and the multiple south magnetic pole portions still form south magnetic poles of the magnetic coupling device, and the controller monitors the magnetic flux while the switchable magnetic flux source is in the second partial on state to determine whether one or more of the multiple movable magnetic pole portions are spaced apart from the ferromagnetic workpiece.

[0183] Example 56: A magnetic coupling device as described in any one of Examples 50 and 55, wherein the partial on state is a first partial on state, and when the switchable magnetic flux source is in the first partial on state, each of one or more of the multiple magnetic pole portions is held relative to the housing, and the switchable magnetic flux source is further switchable to a second partial on state in which each of one or more of the multiple magnetic pole portions is movable relative to the housing, and in the second partial on state, when the switchable magnetic flux source, the multiple north magnetic pole portions still form north magnetic poles of the magnetic coupling device and the multiple south magnetic pole portions still form south magnetic poles of the magnetic coupling device, and the controller monitors the magnetic flux while the switchable magnetic flux source is in the second partial on state to determine whether one or more of the multiple movable magnetic pole portions are in contact with a ferromagnetic workpiece.

[0184] Example 57: A magnetic coupling device as described in Example 50, wherein the partial on state is a first partial on state, and when the switchable magnetic flux source is in the first partial on state, each of one or more of the multiple magnetic pole portions is held relative to the housing, and the switchable magnetic flux source is further switchable to a second partial on state in which each of one or more of the multiple magnetic pole portions is movable relative to the housing, and in the second partial on state, when the switchable magnetic flux source, the multiple north magnetic pole portions still form north magnetic poles of the magnetic coupling device and the multiple south magnetic pole portions still form south magnetic poles of the magnetic coupling device, and the controller monitors the magnetic flux while the switchable magnetic flux source is in the second partial on state to determine motion characteristics.

[0185] Example 58: A magnetic coupling device for magnetically coupling to a ferromagnetic workpiece is provided. The magnetic coupling device includes a housing, a switchable magnetic flux source supported by the housing, and a plurality of magnetic pole pieces movably coupled to the housing. The switchable magnetic flux source may be switchable between at least an off state and at least one of a partial on state and an on state. Each of the plurality of magnetic pole pieces may include at least one workpiece interface having a workpiece engagement surface. The plurality of magnetic pole pieces may include a first magnetic pole piece including a first workpiece interface having a first plurality of spaced apart protrusions that are moveable as a group relative to the housing when the switchable magnetic flux source is in the off state and that are held relative to the housing when the switchable magnetic flux source is in at least one of the partial on state and the on state, and a second magnetic pole piece including a second workpiece interface having a second plurality of spaced apart protrusions that are moveable as a group relative to the housing when the switchable magnetic flux source is in the off state and that are held relative to the housing when the switchable magnetic flux source is in at least one of the partial on state and the on state.

[0186] Example 59: A magnetic coupling device as described in Example 58, wherein the first pole piece is movable relative to the underside of the housing in a first direction.

[0187] Example 60: A magnetic coupling device as described in Example 58, wherein the first pole piece is movable relative to the underside of the housing in only the first direction.

[0188] Example 61: A magnetic coupling device described in any of Examples 59 and 60, wherein the first pole piece can include a plurality of elongated slots having a major axis along the first direction, and the magnetic coupling device further includes a plurality of couplers capable of coupling the first pole piece to the housing and cooperating with the plurality of elongated slots to enable the first pole piece to move in the first direction.

[0189] Example 62: The magnetic coupling device of any of Examples 58-61, wherein the first plurality of protrusions can include a first protrusion, a second protrusion, and a third protrusion. A first spacing between the first protrusion and the second protrusion can be equal to a second spacing between the second protrusion and the third protrusion.

[0190] Example 63: The magnetic coupling device of any of Examples v to 61, wherein the first plurality of protrusions can include a first protrusion, a second protrusion, and a third protrusion. A first spacing between the first protrusion and the second protrusion is not equal to a second spacing between the second protrusion and the third protrusion.

[0191] Example 64: A magnetic coupling device for magnetically coupling to a ferromagnetic workpiece is provided. The magnetic coupling device may include a housing, a switchable magnetic flux source supported by the housing, a plurality of magnetic pole pieces, and at least one coupler. The switchable magnetic flux source may be switchable between at least an off state and at least one of a partial on state and an on state. The plurality of magnetic pole pieces may include a first magnetic pole piece movably coupled to the housing. The first magnetic pole piece may include at least one workpiece interface having a workpiece engagement surface. The first magnetic pole piece may include at least one elongated slot having a major axis along a first direction. The at least one coupler may couple the first magnetic pole piece to the housing and may cooperate with the at least one elongated slot to constrain movement of the first magnetic pole piece in the first direction relative to the housing. The first magnetic pole piece may be movable relative to the housing when the switchable magnetic flux source is in the off state and may be held relative to the housing when the switchable magnetic flux source is in at least one of the partial on state and the on state.

[0192] Example 65: The magnetic coupling device of Example 64, wherein the at least one elongated slot of the first pole piece can include a first elongated slot and a second elongated slot. The at least one coupler cooperates with both the first elongated slot and the second elongated slot to inhibit movement of the first pole piece in the first direction relative to the housing.

[0193] Example 66: A magnetic coupling device as described in Example 65, wherein the at least one coupler may include a first coupler received in a first elongated slot of the at least one elongated slot, and a second coupler received in a second elongated slot of the at least one elongated slot.

[0194] Example 67: In yet 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 include a housing; a switchable magnetic flux source supported by the housing and switchable between an off state, at least one of a first partial on state and an on state, and a second partial on state; a plurality of movable magnetic pole pieces each including at least one workpiece interface having a workpiece engagement surface, the plurality of movable magnetic pole pieces including a first pole piece including a first workpiece interface having a first workpiece engagement surface and a second pole piece including a second workpiece interface having a second workpiece engagement surface, each of the first pole piece and the second pole piece being movable relative to the housing when the switchable magnetic flux source is in one of the off state and the second partial on state and held relative to the housing when the switchable magnetic flux source is in at least one of the partial on state and the on state; at least one sensor for providing one or more characteristics of the plurality of movable magnetic pole pieces; and a controller operably coupled to the switchable magnetic flux source and the at least one sensor. The controller can be configured to determine whether one or more of the multiple movable magnetic pole pieces are spaced apart from the ferromagnetic workpiece and whether one or more of the multiple movable magnetic pole pieces are in contact with the ferromagnetic workpiece based on characteristics of one or more of the multiple movable magnetic pole pieces.

[0195] Example 68: The magnetic coupling device of claim 67, wherein the characteristic can be the position of one or more of the plurality of movable pole pieces.

[0196] Example 69: The magnetic coupling device of claim 67, wherein the characteristic may be magnetic flux associated with one or more of the plurality of movable pole pieces.

[0197] Example 70: The magnetic coupling device of claim 67, wherein the controller can be configured to determine motion characteristics of one or more of the plurality of moveable pole pieces.

[0198] Example 71: The magnetic coupling device of claim 70, wherein the motion characteristic of one or more of the plurality of movable pole pieces can be a position of one or more of the plurality of movable pole pieces relative to the housing.

[0199] Example 72: The magnetic coupling device of claim 71, wherein the first pole piece can be retractable relative to the housing, and the motion characteristic can be when the first pole piece is fully retracted relative to the housing, and a workpiece engaging surface of the first pole piece remains extending from the housing when fully retracted.

[0200] Example 73: A magnetic coupling device as described in any one of claims 70 to 72, wherein the controller is capable of monitoring the magnetic flux while the switchable magnetic flux source is in the second partial on state to determine the motion characteristics.

[0201] Example 74: A magnetic coupling device as described in any of claims 67 to 73, wherein the controller can monitor the magnetic flux while the switchable magnetic flux source is in the second partial on state to determine whether one or more of the plurality of movable magnetic pole pieces are spaced apart from the ferromagnetic workpiece.

[0202] Example 75: A magnetic coupling device as described in any of claims 67 to 74, wherein the controller is capable of monitoring the magnetic flux while the switchable magnetic flux source is in the second partial on state to determine whether one or more of the plurality of movable magnetic pole pieces are in contact with the ferromagnetic workpiece.

[0203] Example 76: A magnetic coupling device as described in any one of claims 67 to 75, wherein the first engagement surface of the first pole portion is capable of maintaining a first position relative to the housing when the switchable magnetic flux source is in one of an off state and a second partial on state and is not in contact with the ferromagnetic workpiece, regardless of the orientation of the housing, and the second engagement surface of the second pole portion maintains a second position relative to the housing when the switchable magnetic flux source is in one of an off state and a second partial on state and is not in contact with the ferromagnetic workpiece, regardless of the orientation of the housing.

[0204] Example 77: A magnetic coupling device as described in any one of claims 67 to 76, wherein each of the first pole piece and the second pole piece can be constrained to be movable with a single degree of freedom relative to the housing.

[0205] Example 78: The magnetic coupling device of claim 77, wherein the first pole piece can be translatable relative to the housing when the switchable magnetic flux source is in one of the off state and the second partially on state.

[0206] Example 79: A magnetic coupling device as described in any one of claims 77 and 78, wherein the second pole piece can be translatable relative to the housing when the switchable magnetic flux source is in one of the off state and the second partially on state.

[0207] Example 80: The magnetic coupling device described in any one of claims 67 to 79 may further comprise a first biasing means coupled to the housing, the first biasing means maintaining the first engagement surface of the first magnetic pole portion in a first position relative to the housing when the switchable magnetic flux source is in one of the off state and the second partial on state and is not in contact with the ferromagnetic workpiece, regardless of the orientation of the housing, and a second biasing means coupled to the housing, the second biasing means maintaining the second engagement surface of the second magnetic pole portion in a second position relative to the housing when the switchable magnetic flux source is in one of the off state and the second partial on state and is not in contact with the ferromagnetic workpiece, regardless of the orientation of the housing.

[0208] Example 81: The magnetic coupling device of claim 80, wherein the first biasing means is a first spring and the second biasing means is a second spring.

[0209] Example 82: The magnetic coupling device described in any one of claims 67 to 81 may further comprise a first support coupled to the housing and supporting a first magnetic pole portion, the first support including a first locking portion at least partially defining a first channel for receiving the first magnetic pole portion, the first locking portion being movable relative to the housing between an unlocked position in which the first magnetic pole portion is movable relative to the housing and a locked position in which the first magnetic pole portion is held relative to the housing, and a second support coupled to the housing and supporting a second magnetic pole portion, the second support including a second locking portion at least partially defining a second channel for receiving the second magnetic pole portion, the first locking portion being movable relative to the housing between an unlocked position in which the second magnetic pole portion is movable relative to the housing and a locked position in which the second magnetic pole portion is held relative to the housing.

[0210] Example 83: A magnetic coupling device as described in claim 82, wherein the first magnetic pole portion can be translatable relative to the housing in a first direction, and the first locking portion of the first support can be translatable from an unlocked position to a locked position along a second direction, the second direction being inclined relative to the first direction.

[0211] Example 84: A magnetic coupling device as described in any one of claims 67 to 83, wherein the switchable magnetic flux source can be positioned between the first pole piece and the second pole piece.

[0212] Example 85: A magnetic coupling device according to any one of claims 67 to 84, wherein the switchable magnetic flux source can include a plurality of permanent magnets.

[0213] Example 86: The magnetic coupling device of claim 85, wherein at least a first permanent magnet of the plurality of permanent magnets can be an electro-permanent magnet.

[0214] Example 87: The magnetic coupling device of claim 85, wherein at least a second permanent magnet of the plurality of permanent magnets can be a rare earth magnet.

[0215] Example 88: The magnetic coupling device of claim 87, wherein the plurality of permanent magnets can include a first permanent magnet and a second permanent magnet movable relative to the first permanent magnet.

[0216] Example 89: The magnetic coupling device of claim 88, wherein the second permanent magnet can be rotatable relative to the first permanent magnet.

[0217] Example 90: A magnetic coupling device as described in any one of claims 88 and 89, wherein in an on state of the switchable magnetic flux source, the north pole of the second permanent magnet can be approximately aligned with the north pole of the first permanent magnet, and in an off state of the switchable magnetic flux source, the south pole of the second permanent magnet is approximately aligned with the north pole of the first permanent magnet.

[0218] Example 91: A magnetic coupling device described in any one of claims 67 to 90, wherein the first magnetic pole piece may be a first cylindrical pin having a first rounded end and the second magnetic pole piece may be a second cylindrical pin having a second rounded end.

[0219] Example 92: In yet another exemplary embodiment of the present disclosure, a method for coupling a magnetic coupling device to a ferromagnetic workpiece is provided. The method can include providing a housing for the magnetic coupling device, a switchable magnetic flux source supported by the housing and switchable between an off state, at least one of a first partial on state and an on state, and a second partial on state, and a plurality of magnetic pole pieces. Each of the plurality of magnetic pole pieces can include at least one workpiece interface having a workpiece engagement surface. The plurality of magnetic pole pieces can include a first magnetic pole piece including a first workpiece interface having a first workpiece engagement surface, and a second magnetic pole piece including a second workpiece interface having a second workpiece engagement surface. Each of the first magnetic pole piece and the second magnetic pole piece can be movable relative to the housing when the switchable magnetic flux source is in one of the off state and the second partial on state, and can be held relative to the housing when the switchable magnetic flux source is in at least one of the partial on state and the on state. The method can further include configuring the switchable magnetic flux source to a second partial on state while the magnetic coupling device is spaced from the ferromagnetic workpiece, determining when at least one of the plurality of movable magnetic pole pieces contacts the ferromagnetic workpiece, configuring the switchable magnetic flux source to one of the first partial on state and the on state after determining when at least one of the plurality of movable magnetic pole pieces contacts the ferromagnetic workpiece, and lifting the ferromagnetic workpiece using the magnetic coupling device.

[0220] Example 93: The method of claim 92, wherein configuring the switchable magnetic flux source in one of the first partial on state and the on state includes configuring the switchable magnetic flux source in the first partial on state. The method can further include configuring the switchable magnetic coupling device in one of a third partial on state and the on state after lifting the ferromagnetic workpiece with the magnetic coupling device. The third partial on state increases the magnetic flux through the ferromagnetic workpiece relative to the first partial on state and the second partial on state.

[0221] Example 94: A method of coupling a magnetic coupling device to a ferromagnetic workpiece is provided, the method can include monitoring a position of at least one moveable pole piece of the magnetic coupling device relative to a housing of the magnetic coupling device, and magnetically coupling the magnetic coupling device to the ferromagnetic workpiece with a magnetic circuit sufficient to fix the moveable pole piece relative to the housing and lift the ferromagnetic workpiece with the magnetic coupling device as the moveable pole piece moves from a first position to a second position.

[0222] Example 95: A method of coupling a magnetic coupling device to a ferromagnetic workpiece is provided. The method can include moving the magnetic coupling device toward the ferromagnetic workpiece at a speed greater than a first speed, the magnetic coupling device having a plurality of movable pole pieces relative to a housing, detecting when a closest pole piece of the plurality of movable pole pieces of the magnetic coupling device is at a first separation from the ferromagnetic workpiece, and decreasing the speed of the magnetic coupling device toward the ferromagnetic workpiece to a second speed, the second speed being less than or equal to the first speed.

[0223] Example 96: The method described in Example 95 may further include detecting when the plurality of movable magnetic pole pieces are in contact with a ferromagnetic workpiece, fixing the movable magnetic pole pieces relative to the housing, and magnetically coupling the magnetic coupling device to the ferromagnetic workpiece with a magnetic circuit sufficient to lift the ferromagnetic workpiece using the magnetic coupling device.

[0224] Example 97: A magnetic coupling device for magnetically coupling to a ferromagnetic workpiece is provided. The magnetic coupling device includes a housing, a switchable magnetic flux source supported by the housing, a plurality of magnetic pole pieces, at least one sensor supported by the housing, and a controller operably coupled to the switchable magnetic flux source and the at least one sensor. The switchable magnetic flux source is switchable between an off state, at least one of a first partial on state and an on state, and a second partial on state. Each of the plurality of magnetic pole pieces includes at least one workpiece interface having a workpiece engagement surface. The plurality of magnetic pole pieces includes a first magnetic pole piece including a first workpiece interface having a first workpiece engagement surface, and a second magnetic pole piece including a second workpiece interface having a second workpiece engagement surface. Each of the first magnetic pole piece and the second magnetic pole piece is movable relative to the housing when the switchable magnetic flux source is in one of the off state and the second partial on state, and is held relative to the housing when the switchable magnetic flux source is in at least one of the partial on state and the on state. Based on the at least one sensor, the controller is configured to determine a separation of the plurality of moveable pole pieces relative to the ferromagnetic workpiece.

[0225] Example 98: A robotic system is provided, the robotic system including a robotic arm having a magnetic coupling device according to any one of Examples 1 to 91 attached to an end of the robotic arm.

[0226] Various modifications and additions can be made to the exemplary embodiments described without departing from the scope of the present invention. For example, while the above embodiments refer to certain features, the scope of the present 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 that fall within the scope of the claims, together with all equivalents thereof.

Claims

1. A magnetic coupling device for magnetically coupling to a ferromagnetic processed piece, Housing and A switchable flux source supported by the housing, wherein the switchable flux source is switchable between at least an off state, a partially on state and at least one of an on state, A plurality of pole portions, each including at least one workpiece interface having a workpiece engagement surface, wherein the plurality of pole portions includes a first pole portion including a first workpiece interface having a first workpiece engagement surface, and a second pole portion including a second workpiece interface having a second workpiece engagement surface, each of the first and second pole portions being movable relative to the housing when the switchable flux source is in the off state, and held relative to the housing when the switchable flux source is in at least one of the partially on and on states, the first engagement surface of the first pole portion maintains a first position relative to the housing when the switchable flux source is in the off state and not in contact with the ferromagnetic workpiece, regardless of the orientation of the housing, and the second engagement surface of the second pole portion maintains a second position relative to the housing when the switchable flux source is in the off state and not in contact with the ferromagnetic workpiece, regardless of the orientation of the housing. A magnetic coupling device equipped with the following features.

2. The magnetic coupling device according to claim 1, wherein each of the first and second magnetic pole portions is constrained to move with respect to the housing with a single degree of freedom.

3. The magnetic coupling device according to any one of claims 1-2, wherein the first magnetic pole portion is translationally translatable relative to the housing when the switchable magnetic flux source is in the off state.

4. The magnetic coupling device according to claim 3, wherein the second magnetic pole portion is translationally translatable relative to the housing when the switchable magnetic flux source is in the off state.

5. A first biasing means coupled to the housing, wherein the first biasing means maintains the first engagement surface of the first magnetic pole portion in the first position relative to the housing, regardless of the orientation of the housing, when the switchable magnetic flux source is in the off state and not in contact with the ferromagnetic processed piece. A second biasing means coupled to the housing, wherein the second biasing means maintains the second engagement surface of the second magnetic pole portion in the second position relative to the housing, regardless of the orientation of the housing, when the switchable magnetic flux source is in the off state and not in contact with the ferromagnetic processed piece. The magnetic coupling device according to claim 1, further comprising:

6. The magnetic coupling device according to claim 5, wherein the first biasing means is a first spring and the second biasing means is a second spring.

7. A first support body coupled to the housing and supporting the first pole portion, the first support body includes a first locking portion that at least partially defines a first channel for receiving the first pole portion, the first locking portion being movable relative to the housing between an unlocked position in which the first pole portion is movable relative to the housing and a locked position in which the first pole portion is held relative to the housing, A second support connected to the housing and supporting the second pole portion, the second support includes a second locking portion that at least partially defines a second channel for receiving the second pole portion, the second locking portion being movable relative to the housing between an unlocked position in which the second pole portion is movable relative to the housing and a locked position in which the second pole portion is held relative to the housing. The magnetic coupling device according to claim 1, further comprising:

8. The magnetic coupling device according to claim 7, wherein the first magnetic pole portion may be translationally movable with respect to the housing in a first direction, and the first locking portion of the first support is translationally movable along a second direction from the unlocked position to the locked position, and the second direction is inclined with respect to the first direction.

9. The magnetic coupling device according to any one of claims 7 and 8, wherein the first locking portion is moved from the unlocked position to the locked position when the switchable magnetic flux source transitions from the off state to at least one of the partially on state and the on state.

10. A first biasing means supported by the first support, the first biasing means maintains the first engagement surface of the first magnetic pole portion in the first position relative to the housing, regardless of the orientation of the housing, when the switchable flux source is in the off state and not in contact with the ferromagnetic processed piece. A second biasing means supported by the second support, wherein the second biasing means maintains the second engagement surface of the second magnetic pole portion in the second position relative to the housing, regardless of the orientation of the housing, when the switchable flux source is in the off state and not in contact with the ferromagnetic processed piece. The magnetic coupling device according to claim 7, further comprising:

11. The magnetic coupling device according to claim 10, wherein the first biasing means is a first spring and the second biasing means is a second spring.

12. The magnetic coupling device according to claim 7, wherein the first magnetic pole portion is retractable relative to the lower surface of the first support when the switchable magnetic flux source is in the off state, and the second magnetic pole portion is retractable relative to the lower surface of the second support when the switchable magnetic flux source is in the off state.

13. The magnetic coupling device according to claim 7, wherein a first limiter defines the maximum retraction distance of the first magnetic pole portion relative to the lower surface of the first support, and a second limiter defines the maximum retraction distance of the second magnetic pole portion relative to the lower surface of the second support.

14. The magnetic coupling device according to claim 13, wherein the first limiter includes a first portion supported by the first magnetic pole portion and a first stopping surface on the first support, and the second limiter includes a second portion supported by the second magnetic pole portion and a second stopping surface on the second support.

15. The magnetic coupling device according to claim 1, wherein the switchable magnetic flux source is positioned between the first magnetic pole portion and the second magnetic pole portion.

16. The magnetic coupling device according to claim 1, wherein the switchable magnetic flux source is positioned in a straight line with the first magnetic pole portion and the second magnetic pole portion in the vertical direction.

17. The magnetic coupling device according to claim 1, wherein the switchable magnetic flux source includes at least one permanent magnet.

18. The magnetic coupling device according to claim 17, wherein the at least one permanent magnet includes a permanent electromagnet.

19. The magnetic coupling device according to any one of claims 17 and 18, wherein the at least one permanent magnet further comprises a rare earth permanent magnet.

20. The magnetic coupling device according to claim 1, wherein the switchable magnetic flux source includes an electromagnet.

21. The magnetic coupling device according to claim 1, wherein the switchable magnetic flux source includes a platter having a plurality of permanent magnets and a plurality of magnetic pole portions arranged alternately between them.

22. The magnetic coupling device according to claim 21, wherein the plurality of permanent magnets and the plurality of magnetic pole portions form a linear array.

23. The magnetic coupling device according to claim 21, wherein the plurality of permanent magnets and the plurality of magnetic pole portions form a circular array.

24. The magnetic coupling device according to claim 1, wherein the switchable magnetic flux source includes a plurality of permanent magnets.

25. The magnetic coupling device according to claim 24, wherein at least one of the plurality of permanent magnets is a permanent electromagnet.

26. The magnetic coupling device according to claim 24, wherein at least the second permanent magnet among the plurality of permanent magnets is a rare earth magnet.

27. The magnetic coupling device according to claim 24, wherein the plurality of permanent magnets include a first permanent magnet and a second permanent magnet that is movable relative to the first permanent magnet.

28. The magnetic coupling device according to claim 27, wherein the second permanent magnet is rotatable with respect to the first permanent magnet.

29. The magnetic coupling device according to claim 28, wherein each of the first permanent magnet and the second permanent magnet is positioned between the first magnetic pole portion and the second magnetic pole portion.

30. A magnetic coupling device according to any one of claims 27 to 29, wherein in the ON state of the switchable magnetic flux source, the north magnetic pole of the second permanent magnet is substantially aligned with the north magnetic pole of the first permanent magnet, and in the OFF state of the switchable magnetic flux source, the south magnetic pole of the second permanent magnet is substantially aligned with the north magnetic pole of the first permanent magnet.

31. The magnetic coupling device according to claim 1, wherein each of the first magnetic pole portion and the second magnetic pole portion is located on the first side of the switchable magnetic flux source and is the north magnetic pole portion and the south magnetic pole portion of the magnetic coupling device, respectively, in at least one of the partially ON state and the ON state of the switchable magnetic flux source.

32. The magnetic coupling device according to claim 1, wherein the first magnetic pole portion is located on the first side of the switchable magnetic flux source, and the second magnetic pole portion may be located on the second side of the switchable magnetic flux source, and in at least one of the partially ON state and the ON state of the switchable magnetic flux source, the first magnetic pole portion is the north magnetic pole portion of the magnetic coupling device, and the second magnetic pole portion is the south magnetic pole portion of the magnetic coupling device.

33. The magnetic coupling device according to claim 1, wherein the first magnetic pole portion is a first cylindrical pin having a first rounded end, and the second magnetic pole portion is a second cylindrical pin having a second rounded end.

34. The magnetic coupling device according to claim 1, further comprising at least one sensor for providing the characteristics of one or more of the plurality of movable magnetic pole portions.

35. The magnetic coupling device according to claim 34, wherein the aforementioned characteristic is the position of one or more of the plurality of movable magnetic pole portions.

36. The magnetic coupling device according to claim 34, wherein the characteristic is a magnetic flux associated with one or more of the plurality of movable magnetic pole portions.

37. The magnetic coupling device according to claim 34, further comprising the switchable magnetic flux source and a controller operably coupled to at least one sensor, wherein the controller is configured to determine, based on the characteristics of one or more of the plurality of movable magnetic poles, whether one or more of the plurality of movable magnetic poles are separated from the ferromagnetic processed piece and whether one or more of the plurality of movable magnetic poles are in contact with the ferromagnetic processed piece.

38. The magnetic coupling device according to claim 37, wherein the controller is configured to determine the motion characteristics of one or more of the plurality of movable magnetic poles.

39. The magnetic coupling device according to claim 38, wherein the motion characteristics of one or more of the plurality of movable magnetic pole portions are the positions of one or more of the plurality of movable magnetic pole portions with respect to the housing.

40. The magnetic coupling device according to claim 39, wherein the first magnetic pole portion is retractable relative to the housing, the motion characteristic is when the first magnetic pole portion is fully retracted relative to the housing, and the end of the first magnetic pole portion remains extended from the housing when fully retracted.

41. The magnetic coupling device according to claim 1, wherein the partially on state is the first partially on state, and each of the first pole portion and the second pole portion is held relative to the housing when the switchable flux source is in the first partially on state, and the switchable flux source is further switchable to a second partially on state in which each of the first pole portion and the second pole portion is movable relative to the housing.

42. The magnetic coupling device according to claim 37, wherein the partial-on state is the first partial-on state, and when the switchable flux source is in the first partial-on state, each of the first pole portion and the second pole portion is held relative to the housing, and the switchable flux source is further switchable to a second partial-on state in which each of the first pole portion and the second pole portion is movable relative to the housing, and the controller monitors the magnetic flux while the switchable flux source is in the second partial-on state to determine whether one or more of the plurality of movable pole portions are separated from the ferromagnetic processed piece.

43. The magnetic coupling device according to any one of claims 37 and 42, wherein the partially on state is a first partially on state, and when the switchable flux source is in the first partially on state, each of the first pole portion and the second pole portion is held relative to the housing, and the switchable flux source is further switchable to a second partially on state in which each of the first pole portion and the second pole portion is movable relative to the housing, and the controller monitors the magnetic flux while the switchable flux source is in the second partially on state to determine whether one or more of the plurality of movable pole portions are in contact with the ferromagnetic processed piece.

44. The magnetic coupling device according to claim 38, wherein the partially on state is a first partially on state, and when the switchable flux source is in the first partially on state, each of the first pole portion and the second pole portion is held relative to the housing, and the switchable flux source is further switchable to a second partially on state in which each of the first pole portion and the second pole portion is movable relative to the housing, and the controller monitors the magnetic flux while the switchable flux source is in the second partially on state in order to determine the motion characteristics.

45. The magnetic coupling device according to claim 1, comprising a proximity sensor supported by the housing and separated from the plurality of magnetic pole portions.

46. A magnetic coupling device for magnetically coupling to a ferromagnetic processed piece, Housing and A switchable flux source supported by the housing, wherein the switchable flux source is switchable between at least an off state, a partially on state and at least one of an on state, A plurality of pole portions, each including at least one workpiece interface having a workpiece engagement surface, wherein the plurality of pole portions includes a plurality of north pole portions that form the north pole of the magnetic coupling device when the switchable flux source is in at least one of the partially on state and the on state, and a plurality of south pole portions that form the south pole of the magnetic coupling device when the switchable flux source is in at least one of the partially on state and the on state, each of the plurality of pole portions being translatable relative to the housing along its respective axis when the switchable flux source is in the off state, and each having its respective workpiece interface having its respective workpiece engagement surface, Multiple biasing means for biasing the plurality of magnetic pole portions to an extended position relative to the lower surface of the housing, When the switchable magnetic flux source is in the ON state, a plurality of locking parts secure the plurality of magnetic pole parts to the housing. A magnetic coupling device equipped with the following features.

47. The magnetic coupling device according to claim 46, further comprising at least one sensor for providing the characteristics of one or more of the plurality of magnetic pole portions.

48. The magnetic coupling device according to claim 47, wherein the aforementioned characteristic is the position of one or more of the plurality of magnetic pole portions.

49. The magnetic coupling device according to claim 47, wherein the characteristic is a magnetic flux associated with one or more of the plurality of magnetic pole portions.

50. The magnetic coupling device according to claim 47, further comprising the switchable magnetic flux source and a controller operably coupled to at least one sensor, wherein the controller is configured to determine, based on the characteristics of one or more of the plurality of magnetic pole portions, whether one or more of the plurality of magnetic pole portions are separated from the ferromagnetic processed piece and whether one or more of the plurality of magnetic pole portions are in contact with the ferromagnetic processed piece.

51. The magnetic coupling device according to claim 50, wherein the controller is configured to determine the motion characteristics of one or more of the plurality of magnetic pole portions.

52. The magnetic coupling device according to claim 51, wherein the motion characteristics of one or more of the plurality of magnetic pole portions are the positions of one or more of the plurality of magnetic pole portions with respect to the housing.

53. The motion characteristic is when one or more of the plurality of pole portions are fully retracted relative to the housing, and the end of the first pole portion remains extended from the housing when fully retracted, according to claim 52.

54. The magnetic coupling device according to any one of claims 46 to 53, wherein the partially on state is a first partially on state, and when the switchable flux source is in the first partially on state, one or more of the plurality of pole portions are held relative to the housing, and the switchable flux source is further switchable to a second partially on state in which one or more of the plurality of pole portions are movable relative to the housing, and in the second partially on state, the plurality of north pole portions still form the north pole of the magnetic coupling device, and the plurality of south pole portions still form the south pole of the magnetic coupling device.

55. The magnetic coupling device according to claim 50, wherein the partially on state is a first partially on state, and when the switchable flux source is in the first partially on state, one or more of the plurality of pole portions are held relative to the housing, and the switchable flux source is further switchable to a second partially on state in which one or more of the plurality of pole portions are movable relative to the housing, in the second partially on state, the plurality of north pole portions still form the north pole of the magnetic coupling device, the plurality of south pole portions still form the south pole of the magnetic coupling device, and the controller monitors the magnetic flux while the switchable flux source is in the second partially on state to determine whether one or more of the plurality of movable pole portions are separated from the ferromagnetic processed piece.

56. The magnetic coupling device according to any one of claims 50 and 55, wherein the partially on state is a first partially on state, and when the switchable flux source is in the first partially on state, one or more of the plurality of pole portions are held relative to the housing, and the switchable flux source is further switchable to a second partially on state in which one or more of the plurality of pole portions are movable relative to the housing, in the second partially on state, the plurality of north pole portions still form the north pole of the magnetic coupling device, the plurality of south pole portions still form the south pole of the magnetic coupling device, and the controller monitors the magnetic flux while the switchable flux source is in the second partially on state to determine whether one or more of the plurality of movable pole portions are in contact with the ferromagnetic processed piece.

57. The magnetic coupling device according to claim 50, wherein the partially on state is a first partially on state, and when the switchable flux source is in the first partially on state, one or more of the plurality of pole portions are held relative to the housing, and the switchable flux source is further switchable to a second partially on state in which one or more of the plurality of pole portions are movable relative to the housing, in the second partially on state, the plurality of north pole portions still form the north pole of the magnetic coupling device, the plurality of south pole portions still form the south pole of the magnetic coupling device, and the controller monitors the magnetic flux while the switchable flux source is in the second partially on state in order to determine the motion characteristics.

58. A magnetic coupling device for magnetically coupling to a ferromagnetic processed piece, Housing and A switchable flux source supported by the housing, wherein the switchable flux source is switchable between at least an off state, a partially on state and at least one of an on state, A plurality of pole portions movablely coupled to the housing, each of the plurality of pole portions including at least one workpiece interface having a workpiece engagement surface, the plurality of pole portions including a first pole portion including a first workpiece interface having a first plurality of separation protrusions which is movable relative to the housing as a group when the switchable flux source is in the off state and is held relative to the housing when the switchable flux source is in the partially on state and at least one of the on state, and a second pole portion including a second workpiece interface having a second plurality of separation protrusions which is movable relative to the housing as a group when the switchable flux source is in the off state and is held relative to the housing when the switchable flux source is in the partially on state and at least one of the on state A magnetic coupling device equipped with the following features.

59. The magnetic coupling device according to claim 58, wherein the first magnetic pole portion is movable with respect to the lower surface of the housing in a first direction.

60. The magnetic coupling device according to claim 58, wherein the first magnetic pole portion is movable with respect to the lower surface of the housing only in the first direction.

61. The magnetic coupling device according to any one of claims 59 and 60, wherein the first pole portion includes a plurality of elongated slots having a principal axis along the first direction, and the magnetic coupling device further comprises a plurality of couplers that couple the first pole portion to the housing and cooperate with the plurality of elongated slots to enable the first pole portion to move in the first direction.

62. The magnetic coupling device according to any one of claims 58 to 60, wherein the first plurality of protrusions include a first protrusion, a second protrusion, and a third protrusion, and the first distance between the first protrusion and the second protrusion is equal to the second distance between the second protrusion and the third protrusion.

63. The magnetic coupling device according to any one of claims 58 to 60, wherein the first plurality of protrusions include a first protrusion, a second protrusion, and a third protrusion, and the first distance between the first protrusion and the second protrusion is not equal to the second distance between the second protrusion and the third protrusion.

64. A magnetic coupling device for magnetically coupling to a ferromagnetic processed piece, Housing and A switchable flux source supported by the housing, wherein the switchable flux source is switchable between at least an off state, a partially on state and at least one of an on state, A plurality of pole portions, wherein the first pole portion is movably coupled to the housing, the first pole portion includes at least one workpiece interface having a workpiece engagement surface, and the first pole portion includes at least one elongated slot having a principal axis along a first direction, At least one coupler that couples the first pole portion to the housing and, in cooperation with at least one elongated slot, restrains the movement of the first pole portion in a first direction relative to the housing, wherein the first pole portion is movable relative to the housing when the switchable flux source is in the off state and is held relative to the housing when the switchable flux source is in at least one of the partially on state and the on state. A magnetic coupling device equipped with the following features.

65. The magnetic coupling device according to claim 64, wherein the at least one elongated slot of the first pole portion includes a first elongated slot and a second elongated slot, and the at least one coupler cooperates with both the first elongated slot and the second elongated slot to suppress the movement of the first pole portion in the first direction relative to the housing.

66. The magnetic coupling device according to claim 65, wherein the at least one coupler includes a first coupler that is received in a first elongated slot of the at least one elongated slot, and a second coupler that is received in a second elongated slot of the at least one elongated slot.

67. A magnetic coupling device for magnetically coupling to a ferromagnetic processed piece, Housing and A switchable flux source supported by the housing, which is switchable between an off state, at least one of a first partially on state and an on state, and a second partially on state, A plurality of pole portions, each including at least one workpiece interface having a workpiece engagement surface, wherein the plurality of pole portions includes a first pole portion including a first workpiece interface having a first workpiece engagement surface and a second pole portion including a second workpiece interface having a second workpiece engagement surface, each of the first pole portion and the second pole portion being movable relative to the housing when the switchable flux source is in either the off state or the second partially on state, and held relative to the housing when the switchable flux source is in at least one of the partially on state or the on state, A sensor for providing the characteristics of one or more of the plurality of movable magnetic pole portions, A controller operably coupled to the switchable magnetic flux source and the at least one sensor, wherein the controller is configured to determine, based on the characteristics of one or more of the plurality of movable magnetic poles, whether one or more of the plurality of movable magnetic poles are separated from the ferromagnetic processed piece, and whether one or more of the plurality of movable magnetic poles are in contact with the ferromagnetic processed piece. A magnetic coupling device equipped with the following features.

68. The magnetic coupling device according to claim 67, wherein the aforementioned characteristic is the position of one or more of the plurality of movable magnetic pole portions.

69. The magnetic coupling device according to claim 67, wherein the characteristic is a magnetic flux associated with one or more of the plurality of movable magnetic pole portions.

70. The magnetic coupling device according to claim 67, wherein the controller is configured to determine the motion characteristics of one or more of the plurality of movable magnetic poles.

71. The magnetic coupling device according to claim 70, wherein the motion characteristics of one or more of the plurality of movable magnetic pole portions are the positions of one or more of the plurality of movable magnetic pole portions with respect to the housing.

72. The magnetic coupling device according to claim 71, wherein the first magnetic pole portion is retractable relative to the housing, the motion characteristic is when the first magnetic pole portion is fully retracted relative to the housing, and the machined piece engaging surface of the first magnetic pole portion remains extended from the housing when fully retracted.

73. The magnetic coupling device according to any one of claims 70 to 72, wherein the controller monitors the magnetic flux while the switchable magnetic flux source is in the second partially ON state in order to determine the motion characteristics.

74. The magnetic coupling device according to any one of claims 67 to 72, wherein the controller monitors the magnetic flux while the switchable magnetic flux source is in the second partially ON state in order to determine whether one or more of the plurality of movable magnetic pole portions are separated from the ferromagnetic processed piece.

75. The magnetic coupling device according to any one of claims 67 to 72, wherein the controller monitors the magnetic flux while the switchable magnetic flux source is in the second partially ON state in order to determine whether one or more of the plurality of movable magnetic pole portions are in contact with the ferromagnetic processed piece.

76. The magnetic coupling device according to any one of claims 67 to 72, wherein the first engagement surface of the first magnetic pole portion maintains a first position relative to the housing when the switchable magnetic flux source is in either the off state or the second partially on state and is not in contact with the ferromagnetic processed piece, regardless of the orientation of the housing, and the second engagement surface of the second magnetic pole portion maintains a second position relative to the housing when the switchable magnetic flux source is in either the off state or the second partially on state and is not in contact with the ferromagnetic processed piece, regardless of the orientation of the housing.

77. The magnetic coupling device according to any one of claims 67 to 72, wherein each of the first and second magnetic pole portions is constrained to move with respect to the housing with a single degree of freedom.

78. The magnetic coupling device according to claim 77, wherein the first magnetic pole portion is translationally translatable relative to the housing when the switchable magnetic flux source is in either the off state or the second partially on state.

79. The magnetic coupling device according to claim 77, wherein the second magnetic pole portion is translationally translatable relative to the housing when the switchable magnetic flux source is in either the off state or the second partially on state.

80. A first biasing means coupled to the housing, wherein the first biasing means maintains the first engagement surface of the first magnetic pole portion in the first position relative to the housing when the switchable flux source is in either the off state or the second partially on state and is not in contact with the ferromagnetic processed piece, regardless of the orientation of the housing. A second biasing means coupled to the housing, wherein the second biasing means maintains the second engagement surface of the second magnetic pole portion in the second position relative to the housing when the switchable flux source is in either the off state or the second partially on state and is not in contact with the ferromagnetic processed piece, regardless of the orientation of the housing. A magnetic coupling device according to any one of claims 67 to 72, further comprising:

81. The magnetic coupling device according to claim 80, wherein the first biasing means is a first spring and the second biasing means is a second spring.

82. A first support body coupled to the housing and supporting the first pole portion, the first support body includes a first locking portion that at least partially defines a first channel for receiving the first pole portion, the first locking portion being movable relative to the housing between an unlocked position in which the first pole portion is movable relative to the housing and a locked position in which the first pole portion is held relative to the housing, A second support connected to the housing and supporting the second pole portion, the second support includes a second locking portion that at least partially defines a second channel for receiving the second pole portion, the second locking portion being movable relative to the housing between an unlocked position in which the second pole portion is movable relative to the housing and a locked position in which the second pole portion is held relative to the housing. A magnetic coupling device according to any one of claims 67 to 72, further comprising:

83. The magnetic coupling device according to claim 82, wherein the first magnetic pole portion may be translationally movable with respect to the housing in a first direction, and the first locking portion of the first support is translationally movable along a second direction from the unlocked position to the locked position, and the second direction is inclined with respect to the first direction.

84. The magnetic coupling device according to any one of claims 67 to 72, wherein the switchable magnetic flux source is positioned between the first magnetic pole portion and the second magnetic pole portion.

85. The magnetic coupling device according to any one of claims 67 to 72, wherein the switchable magnetic flux source includes a plurality of permanent magnets.

86. The magnetic coupling device according to claim 85, wherein at least one of the plurality of permanent magnets is a permanent electromagnet.

87. The magnetic coupling device according to claim 85, wherein at least the second permanent magnet among the plurality of permanent magnets is a rare earth magnet.

88. The magnetic coupling device according to claim 87, wherein the plurality of permanent magnets include a first permanent magnet and a second permanent magnet that is movable relative to the first permanent magnet.

89. The magnetic coupling device according to claim 88, wherein the second permanent magnet is rotatable with respect to the first permanent magnet.

90. The magnetic coupling device according to claim 88, wherein in the ON state of the switchable magnetic flux source, the north magnetic pole of the second permanent magnet is substantially aligned with the north magnetic pole of the first permanent magnet, and in the OFF state of the switchable magnetic flux source, the south magnetic pole of the second permanent magnet is substantially aligned with the north magnetic pole of the first permanent magnet.

91. The magnetic coupling device according to any one of claims 67 to 72, wherein the first magnetic pole portion is a first cylindrical pin having a first rounded end, and the second magnetic pole portion is a second cylindrical pin having a second rounded end.

92. A method for coupling a magnetic coupling device to a ferromagnetic processed piece, The present invention provides a housing for a magnetic coupling device, a switchable flux source supported by the housing and switchable between an off state, a first partially on state and an on state, and a second partially on state, and a plurality of pole portions, each of which includes at least one workpiece interface having a workpiece engagement surface, and the plurality of pole portions includes a first pole portion including a first workpiece interface having a first workpiece engagement surface, and a second pole portion including a second workpiece interface having a second workpiece engagement surface, each of which is movable relative to the housing when the switchable flux source is in either the off state or the second partially on state, and is held relative to the housing when the switchable flux source is in either the partially on state or the on state. The magnetic coupling device is separated from the ferromagnetic processed piece while the switchable magnetic flux source is configured to the second partially ON state, Determining when at least one of the plurality of movable magnetic pole portions contacts the ferromagnetic processed piece, After determining when at least one of the plurality of movable magnetic pole portions contacts the ferromagnetic processed piece, the switchable magnetic flux source is configured to either the first partially ON state or the ON state. Using the magnetic coupling device, the ferromagnetic processed piece is lifted. Methods that include...

93. Configuring the switchable flux source to either the first partially on state or the on state includes configuring the switchable flux source to the first partially on state, and the method is The method according to claim 92, further comprising lifting the ferromagnetic processed piece using the magnetic coupling device, and then configuring the switchable magnetic coupling device to either a third partially ON state or an ON state, wherein the third partially ON state increases the magnetic flux passing through the ferromagnetic processed piece compared to the first partially ON state and the second partially ON state.

94. A method for coupling a magnetic coupling device to a ferromagnetic processed piece, To monitor the position of at least one movable magnetic pole portion of the magnetic coupling device relative to the housing of the magnetic coupling device, When the movable magnetic pole portion moves from the first position to the second position, the movable magnetic pole portion is fixed to the housing, and the magnetic coupling device is magnetically coupled to the ferromagnetic processed piece using a magnetic circuit sufficient to lift the ferromagnetic processed piece using the magnetic coupling device. Methods that include...

95. A method for coupling a magnetic coupling device to a ferromagnetic processed piece, Moving the magnetic coupling device toward the ferromagnetic processed piece at a speed exceeding a first speed, wherein the magnetic coupling device has a plurality of movable magnetic poles relative to the housing, To detect that the nearest magnetic pole among the multiple movable magnetic poles of the magnetic coupling device is in a first separation from the ferromagnetic processed piece, The method involves reducing the speed of the magnetic coupling device toward the ferromagnetic processed piece to a second speed, wherein the second speed is less than or equal to the first speed. Methods that include...

96. The detection of when the plurality of movable magnetic poles are in contact with the ferromagnetic processed piece, The movable magnetic pole portion is fixed to the housing, The magnetic coupling device is magnetically coupled to the ferromagnetic processed piece using a magnetic circuit sufficient to lift the ferromagnetic processed piece using the magnetic coupling device. The method according to claim 95, further comprising:

97. A magnetic coupling device for magnetically coupling to a ferromagnetic processed piece, Housing and A switchable flux source supported by the housing, wherein the switchable flux source is switchable between an off state, at least one of a first partially on state and an on state, and a second partially on state. A plurality of pole portions, each including at least one workpiece interface having a workpiece engagement surface, wherein the plurality of pole portions includes a first pole portion including a first workpiece interface having a first workpiece engagement surface, and a second pole portion including a second workpiece interface having a second workpiece engagement surface, each of the first pole portion and the second pole portion being movable relative to the housing when the switchable flux source is in either the off state or the second partially on state, and held relative to the housing when the switchable flux source is in at least one of the partially on state or the on state, At least one sensor supported by the housing, A controller operably coupled to the switchable flux source and the at least one sensor, wherein the controller is configured to determine the separation of the plurality of movable magnetic poles from the ferromagnetic processed piece based on the at least one sensor. A magnetic coupling device equipped with the following features.

98. A robotic system comprising a robotic arm having a magnetic coupling device according to any one of claims 1, 46, 58, 64, or 67 attached to the end of the robotic arm.

99. A magnetic coupling device for magnetically coupling to a ferromagnetic processed piece, Housing and A switchable magnetic flux source supported by the housing and switchable between multiple states, A plurality of movable pole portions, each including at least one workpiece interface having a workpiece engagement surface, wherein the plurality of movable pole portions include a first subset of a north pole portion and a second subset of a south pole portion, and each of the plurality of movable pole portions is movable relative to the housing, A sensor for providing the characteristics of one or more of the plurality of movable magnetic pole portions, A controller operably coupled to the switchable flux source and the at least one sensor, wherein the controller is configured to determine the position of each of the first subsets of the north pole portions of the plurality of movable pole portions and each of the second subsets of the south pole portions of the plurality of movable pole portions based on the characteristics of one or more of the plurality of movable pole portions, and the controller determines the location of the magnetic coupling device on the ferromagnetic material based on the position of each of the first subsets of the north pole portions of the plurality of movable pole portions and each of the second subsets of the south pole portions of the plurality of movable pole portions and the known shape of the ferromagnetic material, and A magnetic coupling device equipped with the following features.

100. A robot system comprising a robot arm and a magnetic coupling device according to claim 99, which is attached to the end of the robot arm.

101. The robot system according to claim 100, wherein the robot system is configured to operate to position the ferromagnetic workpiece at a desired position based on the determined location of the magnetic coupling device on the ferromagnetic workpiece.

102. A robotic system for magnetically coupling to a ferromagnetic processed piece, The base and, A robotic arm having multiple movable arm segments, A magnetic coupling device coupled to the end of the robot arm, the magnetic coupling device includes a plurality of workpiece interfaces and a switchable magnetic flux source having a first state in which a first magnetic flux in the plurality of workpiece interfaces is insufficient to lift the ferromagnetic workpiece, and a second state in which a second magnetic flux in the plurality of workpiece interfaces is sufficient to lift the ferromagnetic workpiece. Multiple sensors are movable by the aforementioned robot arm, A controller operably coupled to the switchable magnetic flux source and the plurality of sensors, wherein the controller is configured to determine the position of the magnetic coupling device on the ferromagnetic processed piece based on the plurality of sensors and the known shape of the ferromagnetic processed piece, and to actuate the robot arm to position the ferromagnetic processed piece in a desired orientation based on the determined position of the magnetic coupling device on the ferromagnetic processed piece, and A robotic system equipped with [the necessary components].

103. The robot system according to claim 102, wherein the magnetic coupling device includes a housing and a plurality of magnetic pole portions, the first magnetic pole portion of the plurality of magnetic pole portions includes a first workpiece interface of the plurality of workpiece interfaces, and the second magnetic pole portion of the plurality of magnetic pole portions includes a second workpiece interface of the plurality of workpiece interfaces.

104. The robot system according to claim 103, wherein the first magnetic pole portion and the second magnetic pole portion are each independently movable relative to the housing.

105. The robot system according to claim 103, wherein the first magnetic pole portion is the north magnetic pole portion, the second magnetic pole portion is the south magnetic pole portion, and the switchable magnetic flux source is positioned between the first magnetic pole portion and the second magnetic pole portion.

106. A magnetic coupling device for magnetically coupling to a ferromagnetic processed piece, Housing and Multiple workpiece interfaces supported by the housing, A switchable magnetic flux source supported by the housing, the switchable magnetic flux source having a first state in which a first magnetic flux at the plurality of workpiece interfaces is insufficient to lift the ferromagnetic workpiece, and a second state in which a second magnetic flux at the plurality of workpiece interfaces is sufficient to lift the ferromagnetic workpiece, Multiple sensors supported by the housing, A controller operably coupled to the switchable magnetic flux source and the plurality of sensors, wherein the controller is configured to determine the position of the magnetic coupling device on the ferromagnetic processed piece based on the plurality of sensors and the known shapes of the ferromagnetic processed piece, and A magnetic coupling device equipped with the following features.

107. The robot system according to claim 106, wherein the magnetic coupling device includes a plurality of magnetic pole portions, the first magnetic pole portion of the plurality of magnetic pole portions includes the first processing piece interface of the plurality of processing piece interfaces, and the second magnetic pole portion of the plurality of magnetic pole portions includes the second processing piece interface of the plurality of processing piece interfaces.

108. The robot system according to claim 107, wherein the first magnetic pole portion and the second magnetic pole portion are each independently movable relative to the housing.

109. The robot system according to claim 107, wherein the first magnetic pole portion is the north magnetic pole portion, the second magnetic pole portion is the south magnetic pole portion, and the switchable magnetic flux source is positioned between the first magnetic pole portion and the second magnetic pole portion.

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