Permanent Electromagnet Array

Abstract

To provide an apparatus and a method for attracting ferrous objects with a programmable permanent electromagnet array.SOLUTION: A permanent electromagnet array 300 includes one or more of a plurality of parallel-arranged permanent electromagnets 140A, 140B having a common length and a planar pole piece 234 coupled to a first end of the plurality of permanent electromagnets, each of which includes a first end and a second end opposite the first end.SELECTED DRAWING: Figure 3A

Description

[Technical Field]

[0001] This application claims priority from U.S. Provisional Patent Application No. 62 / 849,204 (Docket No. ASP0011PV), entitled "Permanent Electromagnet," filed May 17, 2019, which is incorporated herein by reference for all purposes.

[0002] This application is directed to apparatus and methods relating to permanent electromagnets. In particular, this application is directed to an apparatus and method for attracting ferrous objects using a programmable permanent electromagnet array. [Background technology]

[0003] A magnet is a material or object that generates a magnetic field. This field is invisible but is responsible for a magnet's most notable property: its ability to attract other ferromagnetic materials, such as iron. A permanent magnet is an object made of a magnetically rigid material that can be magnetized to generate its own persistent magnetic field. Materials that can be magnetized are also materials that are strongly attracted to magnets and are called ferromagnetic. These include the elements iron, nickel, and cobalt, some alloys of rare earth metals, and some natural minerals, such as lodestone. Ferromagnetic materials are the only materials that are strongly attracted to magnets to be generally considered magnetic; all other substances respond weakly to magnetic fields through one of several other types of magnetism.

[0004] Ferromagnetic materials can be divided into magnetically "soft" materials, such as annealed iron, which can be magnetized but do not tend to remain magnetized, and magnetically "hard" materials, which tend to remain magnetized. Permanent magnets are made from "hard" ferromagnetic materials, such as alnico, aluminum, nickel, and cobalt alloys, neodymium alloys with other rare earth elements, and ferrites, which undergo special processing in strong magnetic fields during manufacturing to align their internal microcrystalline structure and make demagnetization extremely difficult. To demagnetize a saturated magnet, a certain magnetic field must be applied. This threshold depends on the coercivity of the respective material; "hard" materials have high coercivity, while "soft" materials have low coercivity. A magnet's overall strength is measured by its BH product. The strength of local magnetization of a material is measured by its magnetizability.

[0005] An electromagnet consists of a coil of wire that acts as a magnet when an electric current flows through it and ceases to be a magnet when the current stops. The coil is often wound around a core of a "soft" ferromagnetic material such as mild steel, thereby significantly increasing the magnetic field it generates. Summary of the Invention [Means for solving the problem]

[0006] The present application aims to solve the disadvantages of the prior art. According to an embodiment of the present application, a permanent electromagnet array can be provided. The permanent electromagnet array includes a plurality of permanent electromagnets of a common length arranged in parallel and a planar magnetic pole piece coupled to a first end of the plurality of permanent electromagnets. Each permanent electromagnet includes a first end and a second end opposite the first end.

[0007] According to another embodiment of the present application, there is provided a permanent electromagnet array including a plurality of pole pieces and a plurality of permanent electromagnets of a common length, each permanent electromagnet including a first and a second end, the permanent electromagnet being linearly disposed end to end between a pair of pole pieces and coupled to the pair of pole pieces.

[0008] According to yet another embodiment of the present application, an apparatus may be provided. The apparatus includes one or more of an electric permanent coil configured to provide current pulses, an energy storage device, an H-bridge driver circuit coupled to the electric permanent coil and the energy storage device, and a control circuit coupled to a switching element. The H-bridge driver circuit includes a switching element including an insulated-gate thyristor configured to receive the current pulses from the energy storage device and selectively drive the current pulses in a first direction or a second direction opposite the first direction relative to the electric permanent coil. The control circuit is configured to select between the first and second directions. A gate drive voltage for each switching element is optically isolated between the control circuit and the switching element. [Brief explanation of the drawings]

[0009] [Figure 1A] FIG. 1 illustrates a hard magnetic core according to the prior art. [Figure 1B] FIG. 1 is a diagram showing a current-carrying coil winding according to the prior art. [Figure 1C] 1 shows a permanent electromagnet charged by a single polarity current pulse passing through a coil according to the prior art; [Figure 1D] 1 shows a permanent electromagnet demagnetized by an AC pulse passing through the coil according to the prior art; [Figure 1E] FIG. 1 illustrates magnetic flux neutralized by a current in a coil according to the prior art. [Figure 1F] FIG. 1 illustrates the net magnetic flux reduction according to the prior art. [Figure 1G] FIG. 1 illustrates a permanent electromagnet demagnetized according to an embodiment of the present application. [Figure 2A] FIG. 1 shows a simple electromagnet according to the prior art. [Figure 2B] FIG. 1 illustrates a simple energized electromagnet according to the prior art. [Figure 2C] FIG. 1 illustrates a zero current biased electromagnet according to the prior art. [Figure 2D] FIG. 1 illustrates a biased electromagnet with magnetic flux cancellation according to the prior art. [Figure 2E] FIG. 1 shows a hard magnet and a semi-hard magnet with aligned poles according to the prior art. [Figure 2F] FIG. 1 shows a hard magnet and a semi-hard magnet with opposite poles according to the prior art. [Figure 2G] 1 shows a permanent electromagnet charged by a current pulse according to the prior art; [Figure 2H] 1 shows a permanent electromagnet demagnetized by alternating pulses according to the prior art; [Figure 3A] FIG. 1 illustrates an array of side-by-side permanent electromagnets with alternating polarity for short-range attractive forces, according to an embodiment of the present application. [Figure 3B] FIG. 1 illustrates an array of side-by-side permanent electromagnets with matching polarity for longer range attractive forces, according to an embodiment of the present application. [Figure 3C] FIG. 1 illustrates a demagnetized aligned permanent electromagnet array according to an embodiment of the present application. [Figure 3D] FIG. 1 is a magnetic flux diagram of short-range attractive forces according to an embodiment of the present application. [Figure 3E] FIG. 10 is a magnetic flux diagram for a longer range attractive force according to an embodiment of the present application. [Figure 4A] FIG. 1 illustrates an end-on-end permanent electromagnet array for short-range attractive forces, according to an embodiment of the present application. [Figure 4B] FIG. 10 illustrates an end-on-end permanent electromagnet array for longer range attraction, according to an embodiment of the present application. [Figure 4C] FIG. 1 illustrates a demagnetized end-on-end permanent electromagnet array according to an embodiment of the present application. [Figure 4D] FIG. 1 is a magnetic flux diagram of short-range attractive forces according to an embodiment of the present application. [Figure 4E] FIG. 10 is a magnetic flux diagram for a longer range attractive force according to an embodiment of the present application. [Figure 5A] FIG. 1 is a block diagram of a current pulse driver according to an embodiment of the present application. [Figure 5B] FIG. 1 is a block diagram illustrating a current pulse driver charging stage according to an embodiment of the present application. [Figure 5C] FIG. 10 is a block diagram illustrating discharging a capacitor of a permanent electromagnet array in a forward direction through a coil according to an embodiment of the present application. [Figure 5D] FIG. 10 is a block diagram illustrating discharging a capacitor of a permanent electromagnet array in a reverse direction through a coil, according to an embodiment of the present application. [Figure 5E] FIG. 1 is a first block diagram of a permanent electromagnet array current pulse driver with multiple coils according to an embodiment of the present application. [Figure 5F] FIG. 10 is a second block diagram of a permanent electromagnet array current pulse driver with multiple coils according to an embodiment of the present application. [Figure 6A] FIG. 10 is a magnetization diagram using repeated current pulses according to an embodiment of the present application. [Figure 6B] FIG. 10 is a demagnetization diagram using alternating single current pulses according to an embodiment of the present application. [Figure 6C] FIG. 10 illustrates exemplary magnetization timing according to an embodiment of the present application. [Figure 6D] 1A-1C are magnetization diagrams showing both hard and semi-hard magnetic materials according to examples of the present application. [Figure 6E] FIG. 2 is a magnetization diagram of a soft magnetic material according to an embodiment of the present application. [Figure 7A] FIG. 1 illustrates a permanent electromagnet array with serpentine layered coils, according to an embodiment of the present application. [Figure 7B] FIG. 10 illustrates a detail of a uniform serpentine coil layer according to an embodiment of the present application. [Figure 7C] FIG. 10 illustrates details of an odd number of serpentine coil layers according to an embodiment of the present application. [Figure 7D] FIG. 10 illustrates details of a spiral coil layer interconnection according to an embodiment of the present application. [Figure 7E] FIG. 2 illustrates details of a spiral coil layer according to an embodiment of the present application. [Figure 7F] FIG. 1 illustrates a top view of a permanent electromagnet array for high force and short range attractive force, according to an embodiment of the present application. [Figure 7G]FIG. 1 illustrates a top view of a permanent electromagnet array for lower force and longer range attractive force, according to an embodiment of the present application. [Figure 7H] FIG. 2 illustrates a top view of a demagnetized permanent electromagnet array, according to an embodiment of the present application. [Figure 8A] FIG. 1 illustrates an end-on-end two-dimensional permanent electromagnet array polarized for short-range attractive forces, according to an embodiment of the present application. [Figure 8B] FIG. 1 illustrates a side view of an end-on-end permanent electromagnet array and magnetic flux lines according to an embodiment of the present application. [Figure 8C] FIG. 1 illustrates an end-on-end two-dimensional permanent electromagnet array polarized for longer range attractive forces, according to an embodiment of the present application. [Figure 8D] FIG. 10 illustrates a side view of an end-on-end permanent electromagnet array programmed for longer range attractive forces and magnetic flux lines, according to an embodiment of the present application. [Figure 9A] 1 is a flowchart illustrating a first coil magnetization process according to an embodiment of the present application. [Figure 9B] 10 is a flowchart illustrating a second coil magnetization process according to an embodiment of the present application. [Figure 10] 1 is a flowchart illustrating a coil demagnetization process according to an embodiment of the present application. [Figure 11A] FIG. 10 illustrates a side view of a magnetometer installation for a side-by-side array, according to an embodiment of the present application. [Figure 11B] FIG. 1 illustrates a bottom view of a magnetometer installation according to an embodiment of the present application. [Figure 11C] FIG. 1 illustrates a side view of a thickness mode magnetic flux sensor for an end-to-end array, according to an embodiment of the present application. DETAILED DESCRIPTION OF THE INVENTION

[0010] The permanent electromagnet array of the present application is described in detail below and can be used in three distinct states.

[0011] Demagnetization - The permanent electromagnet array can be turned off by demagnetizing the permanent electromagnets. The result is that there are no magnetic poles at all: no north or south, no attractive or repulsive forces at all.

[0012] Short Distance, High Grip - In this configuration, all magnetic flux lines follow a short, concentrated path through the target's ferromagnetic material to the adjacent pole of opposite polarity. Almost all of the magnetic flux passes through the target material, maximizing grip.

[0013] Longer Distance, Lower Grip Force - An array of similar poles (e.g., North-North-North) does not create a concentrated "short circuit" for the magnetic field lines to follow, so they take a longer path out and around, as with a conventional bar magnet. Because the field lines are not concentrated in an area, the amount of magnetic flux that can flow through an object at long distances is a fraction of the total magnetic flux, but it can reach much farther than a short-distance configuration and therefore begin to affect objects at longer distances.

[0014] There is a need for permanent electromagnets that can be switched between short-range and long-range modes of attraction. Furthermore, permanent electromagnet arrays offer many advantages over the current state-of-the-art, as discussed below.

[0015] First, two or more permanent electromagnets can be combined in the volume of a single pole piece and magnet combination. This doubled magnetic flux density advantage is maintained even as the size of the permanent electromagnet array increases. A permanent electromagnet array provides an increased total attractive force per unit of volume and weight compared to a single permanent electromagnet. The attractive force between a polarized permanent electromagnet and a ferrous surface acts to attract the magnet and ferrous surface together.

[0016] Second, the permanent electromagnet array can be electrically switched to shift between being optimized for short-range attraction and being optimized for long-range attraction by changing the polarity of one or more permanent electromagnets in the array. The polarization of a permanent electromagnet is defined by a north and a south pole, with magnetic flux traveling from south to north.

[0017] Third, permanent electromagnet arrays can be fabricated at any scale that allows for a linear increase in the total attractive force.

[0018] Fourth, even when the disclosed permanent electromagnet arrays expand in one or two dimensions, the array assembly does not require additional thickness in the direction of attraction, thus saving weight and size over inferior approaches such as those shown in the following Figures 2A through 2G, which require simultaneous scaling in three dimensions.

[0019] Fifth, permanent electromagnet arrays continue to exhibit the same beneficial properties as individual permanent electromagnets: a) they can be polarized in either of two magnetic configurations, b) they can be completely demagnetized, allowing the attracted iron mass to detach from the permanent electromagnet array and move freely, and c) the polarization state of the permanent electromagnets can be maintained without the need for additional current beyond the initial polarization or demagnetization pulse.

[0020] Other advantages and differentiations are shown in the following diagram and accompanying description.

[0021] Referring now to FIG. 1A, a diagram illustrating a prior art hard magnetic core 100 is shown. FIG. 1A shows a perspective view of a cylindrical magnetic core 104 made from a combination of magnetically hard materials, including Alnico, and rare earths, including neodymium or samarium-cobalt. The magnet is a magnetically hard magnetic core polarized with a magnetic charge. The magnetic core 108 is not necessarily cylindrical, but for consistency in this application, it is generally depicted as a cylindrical core. For example, the magnetic core 104 could also have many possible prismatic shapes. The magnetic core 104 has magnetic properties as shown in FIG. 6D.

[0022] The magnetized magnet core 104 has a north pole 116 and a south pole 120 and an associated magnetic field. The magnetic field can be visualized using magnetic flux lines 108, also called magnetic field lines. The magnetic flux lines 108 represent the path of the magnetic flux. Magnetic flux is the net number of magnetic flux or field lines 108 passing through a surface; that is, the number passing in one direction minus the number passing in the opposite direction. In the associated figures, for clarity, only one magnetic flux line 108 is shown for each magnetic field. It should be understood that any number of magnetic flux lines 108 may actually be present, and that a single magnetic flux line 108 can represent any number of magnetic flux lines 108.

[0023] All magnetic flux lines 108 associated with a magnetized magnet core 104 (compared to a demagnetized magnet core 104, which has no magnetic flux lines 108) have a common magnetic flux direction 112. Within the magnet core 104 itself, the magnetic flux direction 112 travels from the south pole 120 to the north pole 116. Away from the magnet core 104, the same magnetic flux lines 108 travel in opposite directions (i.e., shown in either a clockwise or counterclockwise direction) such that the magnetic flux directions 112 of the same magnetic flux lines 108 are consistent.

[0024] Referring now to FIG. 1B, a diagram illustrating an energized coil winding 130 according to the prior art is shown. FIG. 1B illustrates an electrical coil 134 that may be formed from wire (e.g., copper wire), from a partial magnetic loop (FIGS. 7A-7C), or from layers with conductive traces or interconnected traces on stacked circuit boards (FIGS. 7D and 7E). Coil 134 is further illustrated with a current flowing in the direction of arrow 138. According to the right-hand rule known to those skilled in the art, the illustrated current generates magnetic flux field lines 108 in the illustrated direction 112. In further figures, where an arrow indicates the direction of current flow in coil 134, it should be understood that there is an equal current exiting the other lead of coil 134, even if not shown in the figure.

[0025] 1C, a diagram illustrating a permanent electromagnet being charged by a unipolar current pulse passed through a coil 140, in accordance with the prior art, is shown. FIG. 1C shows a magnetically rigid core 104 inserted into an electric coil 140 that is energized by a powerful discharge pulse 144 and the resulting magnetic polarization of the magnetic core 104. Furthermore, the resulting polarization lines and magnetic flux lines 108 remain after the electric pulse 144 is completed. The result is a charged permanent electromagnet 140.

[0026] Referring now to Figure 1D, there is shown a diagram illustrating a permanent electromagnet that has been demagnetized by AC pulses passed through coil 150, in accordance with the prior art. Figure 1D shows the permanent electromagnet receiving a train of demagnetizing AC pulses 154, thereby demagnetizing the magnetic polarity of core 104 and resulting in no useful magnetic flux lines.

[0027] Referring now to FIG. 1E, a diagram illustrating magnetic flux neutralized by current in a coil 160, according to the prior art, is shown. FIG. 1E shows a permanent magnet core 104 disposed inside a coil 134 carrying a continuous current 164, which generates a coil-induced magnetic flux that is directly opposite the polarity of the permanent magnet, but not strong enough to reverse the magnet's polarity. The resulting permanent magnet 160 will attract ferrous materials when the current is zero. However, as shown in FIG. IF, a continuous current 164 must be applied to counteract the magnet's magnetic field. Eventually, the net magnetic flux of the combination is reduced to a value close enough to zero to eject ferrous objects.

[0028] Referring now to Figure 1F, a diagram illustrating the reduction of net magnetic flux 170 according to the prior art is shown. Figure 1F shows how the magnetic flux 174 of the permanent magnet 160 can be gradually neutralized by increasing the coil current 178 until the net magnetic flux 174 of the magnet and coil combination 160 becomes zero.

[0029] Referring now to Figure 1G, a diagram illustrating a permanent electromagnet that has been demagnetized 180 is shown, according to an embodiment of the present application. Figure 1G shows the magnet core 104 and coil 134 in the demagnetized 180 state. Therefore, the magnet and coil have no magnetic field 184, and no magnetic flux lines 108 are shown. In this state, the demagnetized permanent electromagnet 180 does not exert a magnetic force on other objects.

[0030] Referring now to FIG. 2A, a diagram illustrating a simple electromagnet 200 according to the prior art is shown. FIGS. 2A-2H illustrate prior art permanent electromagnet configurations that are actually used to attract ferrous objects. However, all of these configurations perform less well than the embodiments disclosed herein. FIG. 2A illustrates a magnetically soft yoke 208 with one end inserted into the coil 134. This configuration comprises a typical electromagnet. As shown, with no current flowing, the electromagnet generates no magnetic flux, thereby showing no attraction to the ferrous mass or ferromagnetic surface 204. The ferrous mass or ferromagnetic surface 204 is made from an iron alloy that is attracted to magnets.

[0031] Referring now to FIG. 2B, a diagram illustrating a simple energized electromagnet 220 according to the prior art is shown. FIG. 2B shows a current 164 passing through a magnetically soft yoke 208 and a ferromagnetic surface 204, which is attracted in a direction that reduces two air gaps 224 (one is shown for clarity) that the magnetic flux lines 108 must cross. The strength of the magnetic attraction increases as the air gap decreases and is greatest when the electromagnet 220 is in direct contact with the ferromagnetic surface 204. During product and industrial use, the electromagnet 220 must remain powered with a constantly flowing current 164 to maintain its magnetic attraction to the ferromagnetic surface 204.

[0032] Referring now to Figure 2C, a diagram illustrating a prior art electromagnet biased with zero current 230 is shown. Figure 2C shows a magnetically charged permanent electromagnet 230 paired with a soft iron pole piece 234. The ferromagnetic surface 204 is attracted even with zero current 238. The pole piece or yoke is a magnetically soft iron material with the magnetic properties illustrated and described with reference to Figure 6E and is attached to one or more poles of the permanent electromagnet to provide a low reluctance path for magnetic flux to flow through the magnetic circuit.

[0033] Referring now to Figure 2D, a diagram illustrating a biased electromagnet with magnetic flux cancellation 240 is shown in accordance with the prior art. Figure 2D shows a permanent electromagnet 240 with a coil current 244 flowing in a direction that creates an opposing magnetic flux direction from the permanent magnet. At a certain level of current 244, shown in Figure 1F, the opposing magnetic flux in the coil 134 neutralizes the magnet's magnetic flux, resulting in no magnetic attraction.

[0034] Referring now to FIG. 2E, a diagram illustrating a hard magnet and a semi-hard magnet with aligned poles 250 according to the prior art is shown. FIG. 2E illustrates a permanent electromagnet configuration 250 requiring magnets of two different material types attached by pole pieces at opposite ends 234A, 234B. Inside the coil 134 is an Alnico magnet 254A, which is less magnetically hard than the neodymium alloy magnet 254B on the left, and may be of rare earth construction. The magnetic properties of the two types of magnets are shown in FIG. 6D. When a pulse of current is applied in the direction 144 shown in FIG. 2E, both magnets 254A, 254B adopt matching polarities, and the combined magnetic flux passing through the ferromagnetic surface 204 is correspondingly strong.

[0035] Referring now to Figure 2F, a diagram illustrating hard and semi-hard magnets with poles on opposite sides 260 is shown in accordance with the prior art. Figure 2F shows the same permanent electromagnet assembly as shown in Figure 2E, but with a current pulse 144 initiated in the opposite direction. This reverses the polarity of the permanent electromagnets, effectively shorting out the magnetic flux from the magnetically hard neodymium magnet 254B on the left. Because no magnetic flux remains across the air gap 224, there is no attraction with the ferromagnetic surface 204.

[0036] Referring now to Figure 2G, a diagram is shown illustrating a permanent electromagnet being charged by a current pulse 270, in accordance with the prior art. Figure 2G shows a magnetically charged permanent electromagnet and pole piece 234 shown attracting a ferromagnetic surface 204. This is considered the state of the art existing immediately prior to applicant's inventive step beginning with Figure 3.

[0037] Referring now to FIG. 2H, a diagram illustrating a permanent electromagnet demagnetized by alternating pulses 280 in accordance with the prior art is shown. FIG. 2H illustrates the same assembly as shown in FIG. 2G, but with alternating demagnetization pulses 154 applied to the electric permanent coil 134, thus eliminating the attraction to the ferromagnetic surface 204. A disadvantage of FIGS. 2G and 2H is the need to have long pole pieces 234 to efficiently transfer magnetic flux to and through the ferromagnetic surface 204. The disadvantage of having long pole pieces 234 is that their resistance to magnetic flux is slight, resulting in greater leakage of magnetic flux to the opposing pole of the permanent electromagnet, resulting in a lower level of magnetic flux traveling through the ferromagnetic surface 204 and, therefore, a lower level of magnetic attraction to the surface 204. The long pole pieces 234, in effect, disadvantageously reduce the strength of the magnetic attraction and increase the weight of the permanent electromagnet design.

[0038] Referring now to FIG. 3A, a diagram illustrating a side-by-side permanent electromagnet array with alternating polarity for short-range attractive force 300 according to an embodiment of the present application is shown. FIGS. 3A-3E illustrate one configuration of a preferred embodiment of the present application. FIG. 3A shows two side-by-side permanent electromagnets 140A, 140B coupled to a two-piece permanent electromagnet array 300 via a common pole piece 234. Compared to FIG. 2G, because two permanent electromagnets 140A, 140B are used, the density of the magnetic flux lines and the attractive force to the ferromagnetic surface 204 are approximately twice as great as the magnets in FIG. 2G. This alternating magnetic pole configuration is optimized for short-range attractive force. Attachment of the magnet core to the pole piece 234 in all permanent electromagnet arrays can be achieved by a combination or separate attachment mechanisms of magnetic attraction, solder bonding, and adhesive bonding.

[0039] Each permanent electromagnet includes a magnetically hard material portion and a conductor helically wound around the hard material portion, the conductor including one or more stacked layers of wire, each layer including one of a plurality of planar full loops of conductive trace bonded to an insulator film around each hard material portion and a plurality of planar and serpentine half loops of conductive trace bonded to an insulator film around each hard material portion.

[0040] Referring now to FIG. 3B, a diagram illustrates a side-by-side permanent electromagnet array with matching polarities for longer-range attractive forces 320, according to an embodiment of the present application. FIG. 3B illustrates the same side-by-side permanent electromagnets as FIG. 3A, but here, the permanent electromagnets 140A and 140B are polarized in the same S-direction by the current pulses 144A and 144B shown. In this magnetic configuration, the magnetic flux lines from the permanent electromagnet array are spread out further, providing better long-range attractive performance than the alternating-polarity permanent electromagnet array 300 configuration shown in FIG. 3A. In contrast, at short distances, when the array is polarized as in FIG. 3B, the magnetic flux lines must pass through a larger total air gap 244 around the bodies of the permanent electromagnets 140A and 140B, reducing the short-range magnetic flux and attractive forces, resulting in a lower attractive force than the configuration in FIG. 3A. Therefore, a permanent electromagnet that can switch between short-range and long-range attractive modes is needed.

[0041] 3C, a diagram illustrating a demagnetized side-by-side permanent electromagnet array 340, according to an embodiment of the present application, is shown. FIG. 3C shows both permanent electromagnets 140A, 140B being demagnetized by alternating demagnetizing currents 154A, 154B, thereby rendering the permanent electromagnet array 340 free of magnetic flux lines that engage with, and thereby attract, the ferromagnetic surface 204.

[0042] Referring now to Figure 3D, there is shown a magnetic flux diagram of a short-range attractive force 350, according to an embodiment of the present application. Figure 3D shows a one-dimensional four-permanent electromagnet array with alternating north poles 116 and south poles 120 optimized for short-range, high-force attractive forces.

[0043] A short-range attractive force is defined herein as occurring at a distance of the air gap 224 from contact to the maximum separation distance. The nominal attractive distance D2 358 for alternately polarized magnets is equal to D1 354, the distance between the magnet centers. The maximum separation distance for short-range attractive force is distance D2 358, where D2 358 is equal to or less than the distance D1 354 between the central axes of the permanent electromagnets 140. In one example, the short-range attractive force may be up to approximately 0.4 centimeters from contact. In the illustrated configuration, the permanent electromagnet array 350 exerts a short-range attractive force 304 on the ferromagnetic surface 204. To achieve the short-range object attraction configuration, each permanent electromagnet 140 is oppositely charged relative to its nearest neighboring permanent electromagnet 140. This is also shown in FIG. 7F for a 2×4 magnet configuration of an exemplary permanent electromagnet array. Every first, third, fifth, etc. magnet core 104 in the first row, and every second, fourth, sixth, etc. magnet core 104 in the second row, is charged with its north pole 116 facing the ferrous object surface 204. Every second, fourth, sixth, etc. magnet core 104 in the first row, and every first, third, fifth, etc. magnet core 104 in the second row, is charged with its south pole 120 facing the ferromagnetic surface 204. This alternating pattern of polarity of the magnet cores 104 provides a maximum number of magnetic flux lines 108, with a correspondingly short return path, thus limiting the range of attraction to the ferromagnetic surface 204. The magnetic flux direction 112 is from the south pole 120 to the north pole 116, and because adjacent magnet cores 104 are oppositely polarized, the magnetic flux return path is very short.

[0044] Referring now to Figure 3E, there is shown a magnetic flux diagram of a longer range attractive force 360 ​​according to an embodiment of the present application. Figure 3E shows a one-dimensional four permanent electromagnet array, where each permanent electromagnet 140 in a row has the same polarization direction, forming an array optimized for a longer range attractive force.

[0045] Longer-range attractive forces are generally defined herein as the short-range attractive force distance to the maximum separation distance. The nominal attractive force distance D2 368 for the long-range attractive force configuration is D3 364, which is equal to the dimension across the permanent electromagnet array 360. The maximum separation distance for longer-range attractive forces is distance D2 368, where D2 368 is equal to or less than distance D3 364, which is equal to the dimension across the permanent electromagnet array 360. In one example, the longer-range attractive force may be from about 0.4 centimeters to about 4 centimeters. In the illustrated configuration, the permanent electromagnet array 360 exerts a longer-range attractive force 308 on the ferromagnetic surface 204. To achieve the longer-range object attraction configuration, each magnet 104 is identically charged to its immediately adjacent magnets 104. This is also illustrated in FIG. 7G for an exemplary 2×4 permanent electromagnet array 300 configuration. All of the magnet cores 104 in the first and second rows are charged with their north poles 116 facing the ferromagnetic surfaces 204. This uniform pattern of charge on the magnet cores 104 provides the longest magnetic flux lines 108 from the multiple magnet cores 104, with a correspondingly long return path. Because the magnetic flux direction 112 is from the south pole 120 to the north pole 116 and adjacent magnet cores 104 are similarly polarized, the magnetic flux return path is longer than in the short-range attraction configuration of Figures 3A and 3D.

[0046] Referring now to Figure 4A, a diagram illustrating an end-on-end permanent electromagnet array for short-range attraction 400 is shown, according to an embodiment of the present application. Figures 4A-4E show another configuration of a preferred embodiment of the present application, in which two or more permanent electromagnets 140 are mounted end to end with pole pieces 234 interspersing the permanent electromagnets 140 and covering the ends of each array.

[0047] Figure 4A shows an end-on-end permanent electromagnet array. Due to the alternating polarity of the magnets as shown, the permanent electromagnet array 400 is optimized for high attractive forces over short distances.

[0048] Referring now to Figure 4B, a diagram illustrating an end-on-end permanent electromagnet array for longer-range attractive forces 420 is shown, according to an embodiment of the present application. Figure 4B shows the same end-on-end arrangement as shown in Figure 4A, but with the polarities of the permanent electromagnets aligned in the same direction. In this arrangement, the longer magnetic flux path length of the permanent electromagnet array is optimized for longer-range attractive forces.

[0049] 4C, a diagram illustrating a demagnetized end-on-end permanent electromagnet array 440 is shown, according to an embodiment of the present application. FIG. 4C shows an end-on-end arrangement of permanent electromagnets in a demagnetized state, where there is no attractive force on the ferromagnetic surface 204.

[0050] Referring now to Figure 4D, a magnetic flux diagram of short-range attractive force 450 is shown, according to an embodiment of the present application. Figure 4D shows a four-member permanent electromagnet array with alternating north and south poles optimized for short-range attractive force 304. The embodiment shown in Figure 4D has the same goal of optimized short-range attractive force as the embodiments shown in Figures 3A and 3D, but achieves this with a different permanent electromagnet 140 and pole piece 234 configuration.

[0051] Referring now to Figure 4E, a magnetic flux diagram of a longer range attractive force 460 is shown, according to an embodiment of the present application. Figure 4E shows a four-member permanent electromagnet array with stacked serial magnet polarities, as shown. This arrangement is optimized for a longer range attractive force 308.

[0052] Referring now to FIG. 5A, a block diagram of a current pulse driver 500 is shown, according to an embodiment of the present application. FIG. 5A illustrates an H-bridge current pulse driver circuit in which, upon command, a current pulse is sent forward or backward through a permanent electromagnet coil 524. An H-bridge configuration of semiconductor switches is a preferred configuration for passing current in either direction through a load by selecting an open or closed switch. It is understood that the permanent electromagnet 140 includes a magnetic core 104 and a coil 134, although the magnetic core 104 is not shown for clarity to better illustrate the current pulse generation circuitry, rather than the magnetic field and polarity.

[0053] The current pulse driver 500 may include a charger 508, an energy storage device (shown as a capacitor 512), a control circuit 516, and one or more switches (shown as a thyristor H-bridge 504). More thyristor H-bridges 504 may include more coils 524 (each coil 524 may be associated with one permanent electromagnet 140). In other embodiments, a thyristor H-bridge 504 may not be used, and instead, a hardware switch or actuator, a MOSFET, or an IGBT may be used to provide the switching function. While only one coil 524 is shown in FIGS. 5A-5F, it should be understood that a permanent electromagnet array of the present application requires at least two permanent electromagnets, and therefore at least two coils 524. A single coil 524 is shown simply to clarify the components required for charging and discharging purposes in FIGS. 5A-5D, while FIGS. 5E and 5F present a more accurate view of the permanent electromagnet array.

[0054] Charger 508 may be a power supply that functions to charge capacitor 512 as directed by charger enable / disable signal 544 from control circuit 516. In a preferred embodiment, charger 508 may be a switching DC power supply, such as a buck-boost power supply. In other embodiments, charger 508 may be a different form of power supply, including a linear power supply or a different type of switching power supply.

[0055] The capacitor 512 can be charged to a predetermined voltage by a charger 508. The manner in which it is discharged through the multiple switches or thyristor H-bridge 504 can determine the polarity (or lack of polarity in the case of a demagnetized permanent electromagnet 140, as shown in FIGS. 3C and 4C) of each permanent electromagnet 140. In a preferred embodiment, the capacitor 512 can be a 50 uF capacitor. Each thyristor H-bridge 504 can include one coil 524 (and magnet core 104) and four switches 528, 532, 536, and 540. To control whether current flows through the coil 524 and the direction of the current, the switches are opened and closed in pairs, which affects the polarity of the permanent electromagnet 140. The switches 528 and 540 can be opened and closed simultaneously, and the switches 532 and 536 can be opened and closed simultaneously. The operation of the switches is described in more detail with respect to FIGS. 5B-5F.

[0056] The control circuit 516 receives commands 520 and, in response, controls charger enable / disable 544 to the charger 508 and switches 528, 532, 536, and 540, respectively. The commands 520 may be commands from a computer, a computer application, a user-selected graphical user application (GUI) associated with the computer, or hardware switches output from a user-activated control. The commands 520 may specify several actions to be taken by the current pulse driver 500, including enabling short-range attraction, enabling long-range attraction, and demagnetizing the permanent electromagnet 140. Other commands 520 may be utilized, including, but not limited to, specifying the voltage level to which the charger 508 should charge the capacitor 512, specifying the operation of a particular thyristor H-bridge 504, or specifying the open or closed positions of particular switches 528, 532, 536, and 540. The control circuitry 516 can be implemented as any form of known control function including processor / memory, microcontroller, field programmable gate array (FPGA), programmable logic, state machine, pure hardware, or any combination of hardware / software / applications.

[0057] Alternatively, an H-bridge current pulse driver may include an electrically permanent coil configured to provide current pulses, an energy storage device, an H-bridge drive circuit coupled to the electrically permanent coil and the energy storage device, and a control circuit coupled to the switching elements. The H-bridge driver circuit includes switching elements including insulated-gate thyristors configured to receive current pulses from the energy storage device and selectively drive the current pulses through the electrically permanent coil in a first direction or a second direction opposite the first direction. The control circuit is configured to select between the first and second directions. The gate drive voltage of each switching element is optically isolated between the control circuit and the switching elements.

[0058] 5B, a block diagram illustrating a current pulse driver charging phase of a permanent electromagnet 550 is shown, according to an embodiment of the present application. FIG. 5B shows an H-bridge current pulse driver circuit during the charging phase of the storage capacitor 512.

[0059] The charging stage 550 can be used in connection with changing the operating mode of the current pulse driver 500 (e.g., from short-range attraction to long-range attraction, or from long-range attraction to short-range attraction), or as one of many charging steps (FIG. 10) required for the degaussing process.

[0060] For the charging phase 550, the control circuit 516 receives a command 520 specifying a new operating mode or a charge capacitor command 554. In one embodiment, the charge capacitor command 554 may specify a voltage level to charge the capacitor 512. The control circuit 516 then enables the charger 556, and the charger 508 charges the capacitor 558. In one embodiment, the charger enable signal 556 may be timed by the control circuit 516 to charge the capacitor 558 to the desired voltage. In another embodiment, the charger 508 may charge the capacitor 558 to the desired voltage in response to receiving a charger enable 556 indication of any duration. During this phase, all switches 528, 532, 536, and 540 of all thyristor H-bridges 504 are open because a closed switch may prevent the capacitor 512 from charging.

[0061] Referring now to FIG. 5C, a block diagram illustrating forward discharging of a permanent electromagnet capacitor through coil 560 is shown, according to an embodiment of the present application. FIG. 5C shows energy storage capacitor 512 discharging a current pulse through switches 1 and 4 in the forward direction of coil 524. The discharge steps of FIG. 5C and FIG. 5D show the steps where permanent electromagnet 140 is actually polarized to program permanent electromagnet array 300 for short-range attraction, long-range attraction, or demagnetization. The steps shown in FIG. 5C are performed after the steps shown in FIG. 5B.

[0062] The discharge sequence for programming the magnetic state into the permanent electromagnet array has the following important characteristics: It should be readily apparent to one skilled in the art that the magnitudes of the values ​​listed will vary depending on design-specific conditions and component selection. The individual discharges of the capacitors are a very fast process (discharge times of 25 to 100 microseconds) Capacitors discharge at very high currents (over 250 amps) Discharging capacitors from very high voltages (over 250 volts)

[0063] The permanent electromagnet array 300 utilizes one or more thyristor H-bridges 504 to control the direction of current to program the permanent electromagnets 140 into a given state. Depending on which switches 528, 532, 536, and 540 are open and which switches are closed, current flows in one of two directions through the permanent electromagnet coil windings 524, thus programming the corresponding permanent electromagnets 140 (not shown for clarity) into one of two magnetic states (NS or SN). The thyristors 504 may be chosen for their significantly higher power and energy handling characteristics compared to MOSFETs or IGBTs. Once the thyristors 504 are fired / triggered, they allow current to continue flowing until the flow drops to nearly zero, meaning that the entire capacitor 512 must discharge for any given command to reprogram the permanent electromagnets 140. Because MOSFETs cannot handle large amounts of power, more MOSFETs may be required to perform the task. However, MOSFETs are advantageously more efficient and controllable than thyristors 504 (e.g., the discharge of capacitor 512 can be modulated to provide fine current control). While this is not a major advantage for permanent electromagnet array 300 attraction devices that are only attempting to program a single magnetic state into a given permanent electromagnet 140, it could theoretically be more useful if permanent electromagnet array technology were incorporated into some form of electric motor optimized for high torque per unit power, operating at moderate rotational or linear speeds, but not necessarily constantly energized to maintain zero speed torque.

[0064] Control circuit 516 receives enable forward current via coil command 562. In one embodiment, command 562 may specify which of switches 528, 532, 536, 540 to open or close. In another embodiment, control circuit 516 may determine switch states 528, 532, 536, 540 after receiving enable forward current via coil command 562. In response to receiving enable forward current via coil command 562, control circuit 516 first provides charger disable 566 to charger 508, thereby stopping charger 508 from continuing to charge capacitor 512. In one embodiment, charger disable 566 results in charger 508 being disconnected from an input AC or DC power source (not shown), possibly including one or more battery cells.

[0065] After disabling the charging of capacitor 512, control circuit 516 directs thyristor H-bridge 504 to close switches S1 and S4 564 (and to leave switches S2 532 and S3 536 open). The same switch activation / deactivation is provided to any other thyristor H-bridges 504 that may be present in permanent electromagnet array 300. Closing S1 528 and S4 540 causes capacitor 512 to discharge through both switches S1 528, S4 540, resulting in a forward current through coil 524 and a change in the magnetization of the corresponding permanent electromagnet 140.

[0066] Referring now to FIG. 5D, a block diagram illustrating discharging the capacitor of a permanent electromagnet in the reverse direction through coil 570 is shown, according to an embodiment of the present application. FIG. 5D shows energy storage capacitor 512 discharging current pulse 578 through switches 2 and 3 in the reverse direction of coil 524. The discharging steps of FIGS. 5C and 5D provide the steps where permanent electromagnet 140 is actually polarized to program permanent electromagnet array 300 for short-range attraction, long-range attraction, or demagnetization. The steps shown in FIG. 5D are performed after the steps shown in FIG. 5B (charging capacitor 512).

[0067] Control circuit 516 receives enable reverse current via coil command 572. In one embodiment, command 572 specifies which of switches 528, 532, 536, 540 to open or close. In another embodiment, control circuit 516 determines switch states 528, 532, 536, 540 after receiving enable reverse current via coil command 572. In response to receiving enable forward current via coil command 572, control circuit 516 first provides charger disable 576 to charger 508, which stops charger 508 from continuing to charge capacitor 512. In one embodiment, charger disable 576 results in charger 508 being disconnected from an input AC or DC power source (not shown), possibly including one or more battery cells.

[0068] After disabling the charging of capacitor 512, control circuit 516 directs thyristor H-bridge 504 to close switches S2 and S3 574 (and to leave switches S1 528 and S4 540 open). The same switch activation / deactivation is provided to any other thyristor H-bridges 504 that may be present in current pulse driver 500. Closing S2 and S3 causes capacitor 512 to discharge through both switches S2 532, S3 536, resulting in a reverse current through coil 524 and a corresponding change in magnetization of permanent electromagnet 140.

[0069] Referring now to FIG. 5E, a first block diagram of a permanent electromagnet current pulse driver with multiple coils 580 is shown, according to an embodiment of the present application. There are multiple thyristor H-bridges 504, identified herein as thyristor H-bridge A 504A through thyristor H-bridge N 504N. Each thyristor H-bridge 504 includes switches S1 528, S2 532, S3 536, and S4 540. Thyristor H-bridge A 504A includes switches S1A 528A, S2A 532A, S3A 536A, and S4A 540A. Thyristor H-bridge N 504N includes switches S1N 528N, S2N 532N, S3N 536N, and S4N 540N. Any number of thyristor H-bridges 504 may be present in the current pulse driver 500, 580, and a separate switch control 548 may be provided for each thyristor H-bridge 504. The control circuit 516 provides switch control A 548A to thyristor H-bridge A 504A and switch control N 548N to thyristor H-bridge N 504N.

[0070] Multiple thyristor H-bridges 504 are present for the current pulse driver 580, but the switch control 548 may differ depending on the mode of operation. For a short-range attraction configuration, some coils 524 may use forward current to program the north pole 116 in one direction, and other coils 524 may use reverse current to program the north pole 116 in the opposite direction. For a longer-range attraction configuration, all coils 524 may use forward current to program the north pole 116 in the same direction.

[0071] 5F, there is shown a second block diagram of a permanent electromagnet current pulse driver with multiple coils 584, according to an embodiment of the present application. FIG. 5F shows an H-bridge circuit in which multiple permanent electromagnet coils 524 can have current pulses directed to the coils 524 in either an electrical series or electrical parallel configuration, or individually.

[0072] FIG. 5F shows a preferred embodiment in which multiple thyristor H-bridges are present, although only a complete thyristor H-bridge 504 is required. Additional half-thyristor H-bridges 586 can be provided for each additional coil 524. For clarity, only the last (Nth) half-thyristor H-bridge 586, including coil 524N and switches 532N and 540N, is shown. Any number of half-thyristor H-bridges 586 can be present in current pulse driver 584, and individual switch controls 548 can be provided for each thyristor H-bridge 504 or half-thyristor H-bridge 586. Control circuit 516 provides switch control A 548A to thyristor H-bridge A 504A and switch control N 548N to half-thyristor H-bridge N 586. The embodiment shown in FIG. 5F does not require switches 528 and 536 for the 1 / 2 thyristor H-bridge 586, which significantly reduces the number of switches required.

[0073] The permanent electromagnet array includes an energy storage device configured to supply current pulses to the plurality of permanent electromagnets to polarize the permanent electromagnets, and an H-bridge coil drive circuit coupled to the energy storage device and configured to selectively route the current pulses to the permanent electromagnets in one of a first direction and a second direction opposite the first direction. The polarity of the permanent electromagnets is determined by the first direction and the second direction. In one embodiment, the H-bridge coil drive circuit is configured to polarize each permanent electromagnet in an opposite direction to its nearest neighboring permanent electromagnet in response to the received current pulse. In another embodiment, the H-bridge coil drive circuit is configured to polarize each permanent electromagnet in the same direction as its nearest neighboring permanent electromagnet in response to the received current pulse. In yet another embodiment, the H-bridge coil drive circuit is configured to depolarize each permanent electromagnet, such that the plurality of permanent electromagnets are configured not to provide an attractive force to a ferrous surface.

[0074] Referring now to FIG. 6A, a magnetization diagram using repetitive current pulses 600 is shown, according to an embodiment of the present application. While the present application includes embodiments in which only a single current pulse 144 is used to magnetize the permanent electromagnets 140, in practice, three or four single-polarity current pulses 144 are typically used to fully polarize the permanent electromagnets 140 in an array. FIG. 6A shows an embodiment in which four current pulses 144 are used in sequence, using a common magnetization direction 606 or 608. Magnetization direction A 606 generates a coil current in a positive direction 610 relative to the coil 524. In these cases, all four pulses are applied to magnetization direction A 606 for a period 604. Each of these current 602 pulses charges the capacitor 512 to a level 612 and then discharges 616 from the capacitor 512 via the switching network and the coil 524. There is a capacitor charging period 614 between the current pulses 144.

[0075] 6B, a demagnetization diagram using alternating single current pulses 620 is shown, according to an embodiment of the present application. To demagnetize the permanent electromagnets 140, decreasing alternating pulses 144 are used to fully depolarize the permanent electromagnets 140 in the array. Depolarization refers to applying an alternating current to a permanent electromagnet to reduce or eliminate its magnetic polarity. The number of pulses to sufficiently depolarize the permanent electromagnets 140 so that the attached iron mass or ferromagnetic surface 204 is released is typically between 10 and 40 alternating pulses 144 of decreasing polarity.

[0076] In the illustrated example, a first current 602 pulse is applied to the permanent electromagnet 140 in a demagnetizing direction A 624, generating a coil current in the one or more coils 524 in a positive direction 610. Next, a second current 602 pulse is applied to the permanent electromagnet 140 in a demagnetizing direction B 628, generating a coil current in the one or more coils 524 in a negative direction 630. Typically, this second current pulse 144 is applied using the same (albeit negative) current 602 value. Next, a third current pulse 144, with a lower current 602 value than the first current pulse 144, is applied to the permanent electromagnet 140 in a demagnetizing direction A 625, generating a coil current in the one or more coils 524 in the positive direction 610. Next, a fourth current pulse 144 having a lower current 602 value than the second current pulse 144 is applied to the permanent electromagnet 140 in a demagnetizing direction B 628, generating a coil current in a negative direction 630 in one or more coils 524. This sequence of alternating pulses continues to decrease the current 602 level until the coils 524 are demagnetized.

[0077] 6C, a diagram illustrating exemplary magnetization timing 640 is shown, according to an embodiment of the present application. In a preferred embodiment, each current pulse 144 may have a pulse width 642 of approximately 50 μs in duration, with approximately 50 milliseconds between pulses 644. As the amplitude of the current pulses 144 decreases (demagnetization, per FIG. 6B), in some embodiments, the time between pulses 644 used to charge capacitor 512 may correspondingly decrease. It should be understood that the timing between particular pulses 642 and 644 is highly design dependent, may be a function of circuit values, and may differ from that shown in FIG. 6C.

[0078] Referring now to FIG. 6D, a magnetization diagram showing both hard and semi-hard magnetic materials 650 is shown, according to an embodiment of the present application. A magnetically hard material, such as neodymium (NdFeB), is compared to a slightly less hard material, such as AlNiCo (aluminum / nickel / cobalt). In FIG. 6D, the vertical axis is magnetic flux density in tesla, and the horizontal axis is magnetic field strength in amperes / meter. Hard magnetic materials are materials such as AlNiCo (aluminum / nickel / cobalt) and neodymium (NdFeB), which are used to manufacture the magnetic core 104 material. For low reluctance applications, such as short-range attraction modes where the element is already in close physical contact with the low reluctance circuit, there should be negligible difference in the grip strength of AlNiCo and NdFeB. For longer-range attraction, the energy density of neodymium magnets may be advantageous.

[0079] In either case, as the applied magnetic field strength supplied by the current pulse 144 through the permanent electromagnet coils 134, 524 increases in a positive direction, the coercive magnetic flux density 654 increases in a positive direction and does not decrease as the current decreases. This remains so until the applied magnetic field from the reverse current pulse 144 becomes sufficiently negative, reversing the magnetic core's coercive magnetic field to negative, where it remains negative until the external magnetic field is again pulsed sufficiently positive. As those skilled in the art will appreciate, in addition to applying high current pulses 144 to the permanent electromagnet coils 134, 524 to reverse the polarization of the permanent electromagnet 140 positively or negatively, applying a series of decreasing alternating current pulses 144 will reduce the magnetic flux of the permanent electromagnet to zero.

[0080] Referring now to FIG. 6E, a magnetization diagram of a soft magnetic material 670 according to an embodiment of the present application is shown. Soft magnetic materials may include iron, cobalt, nickel, and alloys such as Hyperco, Permalloy, magnetic steel, and amorphous metal alloy materials. As described herein, soft magnetic materials are used to fabricate pole pieces 234. FIG. 6E shows the magnetic flux density 654 of the magnetically soft material as a function of the externally applied magnetic field strength 658 resulting from current passing through a surrounding coil such as that shown in FIG. 2B featuring a magnetically soft yoke 208. Magnetically soft materials are used for all pole pieces 234 used in permanent electromagnet arrays because they do not retain magnetization and can therefore efficiently conduct magnetic flux from the permanent electromagnets 140 in the array into the air gap 224 and through the ferromagnetic surface 204.

[0081] Referring now to FIG. 7A, a diagram illustrating a permanent electromagnet array 700 according to an embodiment of the present application is shown. FIG. 7A shows an exploded view 700 of a 34-member permanent electromagnet array with windings formed from layered serpentine conductor traces 716 on an insulator film layer 720. The serpentine winding arrangement is designed to generate only alternating polarity patterns of magnetization in the side-by-side permanent electromagnet array used for short-range attraction. The winding design serves the purpose of excellent short-range attraction. The serpentine pattern windings provide exceptional magnetic flux strength in the array because the conductor packing density is higher than can be achieved with round wire windings.

[0082] The serpentine winding can be fabricated from alternating even 704 and odd 708 patterned conductor paths 716 on the insulating film layer 720. In a usage example, current can flow inward from terminal 2 732B through the top pad of the top layer 736 to the even layer 704, then travel the serpentine path on the even layer, and then exit from the bottom terminal soldered to the top terminal on the odd layer 708. The pairs and interconnects 728 on the odd 708 and even 704 layers continue to be stacked with their solder pads connected together, forming a continuous current circuit from one layer to the next. Finally, after passing through the stack 724 of layers 704, 708, the current reaches the bottom layer 740, where the opposite terminal 1 732A is attached. The bottom layer 740 is then routed to terminal 1 732A. Each layer 704, 708 in the stack of layers 724 includes a hole 712 for each of the magnet cores 104 to pass through.

[0083] The insulating film 720 is provided to prevent shorting between the coil layers 724. This can be achieved using flexible printed circuit fabrication, in which conductive traces 716 are etched from copper-plated thin-film plastic, such as polyamide, leaving copper coil layers in the desired winding pattern and intimately bonded to the polyamide insulating film 720. In other embodiments, other PCB insulating materials and conductors are possible. Other forms of manufacturing mats can be used without departing from the spirit of the disclosed embodiments. In one embodiment, the magnet core 104 can be approximately 3.2 mm wide by 6.4 mm long. However, any practical size and shape can be used based on final requirements.

[0084] Referring now to FIG. 7B, a diagram illustrating a detail 704 of a uniform serpentine coil layer according to an embodiment of the present application is shown. FIG. 7B shows details of the conductor wiring traces 716 and insulators 720 on the even layers 704 of the coil circuit layer. A current trace begins at the top solder pad 750A and meanders around each successive magnetic core 104, each making a half turn, until it reaches the bottom solder pad 754A. This current flows clockwise and counterclockwise around each AC magnetic core 104 in the array. Thus, when conducted, the current pulse 144 subsequently magnetizes each magnetic core 104 in an alternating polarity sequence. The current traveling through the layers of the serpentine circuit sequentially adds successive half turns 758 of magnetic flux to each magnetic core 104. For example, a current flowing in a clockwise direction makes a half turn around one of the magnet cores 104 on an even layer 704, and then follows a serpentine path on the next odd layer 708, which carries the same current in a clockwise half turn direction, under a half turn in the same direction from the previous layer.

[0085] 7C, a diagram illustrating details of an odd serpentine coil layer 708 is shown, according to an embodiment of the present application. Figure 7C shows details of conductor wiring traces 716 and insulators 720 on an odd coil circuit layer 708. The features and operation of odd layer 708 are as described with respect to even coil layer 704 of Figure 7B, but instead includes bottom solder pads 754B and top solder pads 750B.

[0086] Referring now to FIG. 7D , a diagram illustrating spiral coil layer interconnection details 760 is shown, according to an embodiment of the present application. FIG. 7D illustrates layers of circular coil links electrically connected from one layer to the next, with the circular links and connections together forming a spiral current path 768 above and below magnetic core 104. In practice, using the same printed circuit technology used to create spiral coil 764, certain coils can be connected in series or parallel to operate together at one time. For example, when coils 1, 2, 3, and 4 are connected in series or parallel and pulsed with current 144, they may generate one polarity for magnetic cores 1, 2, 3, and 4. Similarly, when coils 5, 6, 7, and 8 are electrically connected in series or parallel and pulsed with current 144, they may also adopt a common polarity for magnetic cores 5, 6, 7, and 8.

[0087] In effect, if cores 1, 2, 3, and 4 are magnetically polarized oppositely to cores 5, 6, 7, and 8, the resulting permanent electromagnet array is programmed into a short-range attractive mode. This mode is shown in Figure 7F. Furthermore, if cores 1, 2, 3, and 4 are magnetically polarized identically to cores 5, 6, 7, and 8, the permanent electromagnet array is programmed into a longer-range attractive mode. This mode is shown in Figure 7G.

[0088] Thus, the spiral winding method 768 allows a single permanent electromagnet array to be programmed for either short-range or long-range attractive forces. Finally, introducing a decreasing chain of AC pulses 144 to each series- or parallel-connected coil (FIG. 6B) demagnetizes the array, resulting in no attractive force. This mode is shown in FIG. 7H.

[0089] 7E, a diagram illustrating a spiral coil layer detail 770 is shown, according to an embodiment of the present application. FIG. 7E illustrates an etched conductor layer interconnected over another conductor layer to provide an interconnected spiral coil with terminal 1 732A and terminal 2 732B.

[0090] Referring now to FIG. 7F, a diagram illustrating a top view of a permanent electromagnet array for high force and short-range attraction 780 is shown, according to an embodiment of the present application. FIG. 7F shows a top view of a permanent electromagnet array 784. An exemplary 2x4 configuration is shown, with two rows of four magnet cores 104 each. The high force / short-range attraction configuration utilizes oppositely polarized permanent electromagnets 140 to facilitate a short magnetic flux return path. In the first or top row, the first and third magnet cores 104 have north poles 116 facing the ferrous object surface 204, and the second and fourth magnet cores 104 have south poles 120 facing the ferrous object surface 204. In the second or bottom row, the second and fourth magnet cores 104 have north poles 116 facing the ferrous object surface 204, and the first and third magnet cores 104 have south poles 120 facing the ferrous object surface 204.

[0091] Referring now to FIG. 7G, a diagram illustrating a top view of a permanent electromagnet array for lower force and longer range attraction 786, according to an embodiment of the present application, is shown. FIG. 7G illustrates a top view of a permanent electromagnet array 788. An exemplary 2X4 configuration is shown, with two rows of four magnet cores 104 each. The lower force / longer range attraction configuration utilizes similarly polarized permanent electromagnets 140 to facilitate a long magnetic flux return path. In both rows, all magnet cores 104 have their north poles 116 facing the ferrous object surface 204.

[0092] Referring now to Figure 7H, a diagram illustrating a top view of a demagnetized permanent electromagnet array 790 is shown, according to an embodiment of the present application. An exemplary 2x4 configuration is shown, with two rows of four magnet cores 104 each. Unlike the configurations shown in Figures 7F and 7G, all magnet cores 104 in Figure 1C are demagnetized 794 and have no polar orientation (i.e., no north poles 116 or south poles 120).

[0093] Referring now to FIG. 8A, a diagram illustrating a top view of an end-on-end two-dimensional permanent electromagnet array polarized for short-range attractive forces 800 is shown, according to an embodiment of the present application.

[0094] Figure 8A is a top view of an eight-member, end-on-end, two-dimensional permanent electromagnet array. The array shown is polarized in the alternating north-south pattern shown, optimizing this configuration for short-range attractive forces. In this example, the short distance is nominally equal to the distance between polarity changes in the length of one permanent electromagnet.

[0095] Note that the end-on-end configuration can be implemented in a variety of ways. It can be implemented as a linear or partially / fully curved array, as shown in Figures 4A / 4B, or as a close-in configuration, as shown in Figure 8A. The closed configuration does not need to have a defined beginning or end point, as in linear or curved arrays, and can be implemented as a geometric or non-geometric shape. Figure 8A shows a "square" embodiment with a pole piece 234 between a pair of permanent electromagnets 140.

[0096] Referring now to FIG. 8B, a diagram illustrating a side view of an end-on-end two-dimensional permanent electromagnet array and magnetic flux lines 810 is shown, according to an embodiment of the present application. FIG. 8B depicts a side view of the permanent electromagnet array 800 of FIG. 8A. From the side, only three of the nine magnetic pole pieces 234 are visible, identified as magnetic pole pieces 234A, 234B, and 234C, and the two permanent electromagnets 140 are identified as permanent electromagnet 140A and permanent electromagnet 140B. Each permanent electromagnet 140 has its own magnetic flux direction 112, traveling from the south pole 120 to the north pole 116.

[0097] Referring now to FIG. 8C, a diagram illustrating a top view of an end-on-end two-dimensional permanent electromagnet array polarized for longer-range attractive forces 820 is shown, according to an embodiment of the present application. FIG. 8C illustrates an end-on-end permanent electromagnet array 820 in which two strings of four permanent electromagnets 140 are each polarized in the same direction from left to right. Thus, the right-most pole piece 234 is the north pole 116 on the north-most side of the array, and the left-most pole piece 234 is the south pole 120 on the south-most side of the array. FIG. 8C is tilted at 45 degrees to provide the corresponding edge view of FIG. 8D.

[0098] Referring now to Figure 8D, a diagram is shown illustrating a side view of an end-on-end two-dimensional permanent electromagnet array programmed for longer range attractive forces and magnetic flux lines 830, according to an embodiment of the present application. Figure 8D shows an edge view of Figure 8C, illustrating the long magnetic flux lines that optimize this configuration for long range attractive forces. The long range is nominally defined as the distance between the north pole 116 and south pole 120 of the end-on-end magnet array.

[0099] In practice, half of the permanent electromagnet coils are electrically connected as one group in series or parallel, and the other half are connected separately in series or parallel. Thus, each group can have its own dedicated H-bridge driver, which is an electronic device as shown and described with reference to FIGS. 5A-5F. The H-bridge driver provides magnetizing and demagnetizing current pulses as shown and described with reference to FIGS. 6A-6C. In this case, when the two groups of windings are polarized in opposite directions, the array is optimized for short-range attraction. When the two groups are polarized in the same direction, the array is optimized for long-range attraction. In the edge view 830, five pole pieces 234 are visible: pole pieces 234A, 234B, and 234C. Between each pair of pole pieces 234, four permanent electromagnets 140 are visible.

[0100] Referring now to FIG. 9A, a flowchart illustrating a first coil magnetization process 900 according to an embodiment of the present application is shown. The first embodiment magnetizes a permanent electromagnet array in a single charge cycle and refers to the charge pulse states shown in FIGS. 5A-5F. In one embodiment, the permanent electromagnet array includes a plurality of parallel-arranged permanent electromagnets of a common length and a planar pole piece coupled to a first end of the plurality of permanent electromagnets. Each permanent electromagnet includes a first end and a second end opposite the first end. In a second embodiment, the permanent electromagnet array includes a plurality of pole pieces and a plurality of permanent electromagnets of a common length. Each permanent electromagnet includes a first and second end, and the permanent electromagnet is linearly arranged end-to-end between a pair of pole pieces and coupled to the pair of pole pieces. The flow begins at block 904.

[0101] At block 904, all of the permanent electromagnets 140 are in a pre-existing state. The pre-existing state may include a high force / short attractive force state, a lower force / longer attractive force state, or a demagnetized state. The flow proceeds to block 908.

[0102] At block 908, the control circuit 516 receives a command 520 to generate a (different) desired magnetic state.

[0103] At block 912, the control circuit 516 defines the necessary switch states 528, 532, 536, 540 for all coils 524 and permanent electromagnets 140 from the command 520. The flow proceeds to block 916.

[0104] In block 916, the control circuit 516 enables the charger 508 to charge the capacitor 512. The flow proceeds to block 920.

[0105] In block 920, the charger 508 charges the capacitor 512. The flow proceeds to decision block 924.

[0106] At decision block 924, control circuit 516 determines whether capacitor 512 is fully charged. If capacitor 512 is fully charged, flow continues to block 928. If capacitor 512 is not fully charged, flow instead continues to block 920 to continue charging capacitor 512.

[0107] At block 928, capacitor 512 is charged and control circuit 516 disables charger 508. Flow proceeds to block 932.

[0108] At block 932, the control circuit 516 sets the switch states 528, 532, 536, 540 to the required switch states 528, 532, 536, 540 defined at block 912. The flow proceeds to block 936.

[0109] At block 936, the capacitor 512 discharges through the closed switches that correspond to the required switch states 528, 532, 536, 540. The flow proceeds to block 940.

[0110] The permanent electromagnet array generates the desired magnetic state at block 940. The flow ends at block 940.

[0111] Referring now to FIG. 9B, a flow chart illustrating a second coil magnetization process 950 according to an embodiment of the present application is shown. The second embodiment magnetizes a permanent electromagnet array with a series of charging cycles. FIG. 9B illustrates a process for optimizing the magnetization of the permanent electromagnet array through repeated discharge of a storage capacitor 512 into magnetizing current pulses 144 that occur until the desired magnetic state is created. This state may be when a specific number of magnetizing pulses, such as the four current pulses 144 shown in FIG. 6A, are used. Otherwise, the current pulses 144 may be continued until the desired field strength is achieved, as measured by using the magnetic flux sensor output from a unit such as that shown in FIGS. 11A and 11C. The flow begins at block 954.

[0112] At block 954, all of the permanent electromagnets 140 are in a pre-existing state. The pre-existing state may include a high force / short range attractive state, a low force / long range attractive state, or a demagnetized state. The flow proceeds to block 958.

[0113] At block 958, the control circuit 516 receives a command 520 to generate a (different) desired magnetic state. The flow proceeds to block 962.

[0114] At block 962, the control circuit 516 defines the required switch states 528, 532, 536, 540 for all coils 524 from the command 520. The flow proceeds to block 966.

[0115] In block 966, the control circuit 516 enables the charger 508 to charge the capacitor 512. The flow proceeds to block 970.

[0116] At block 970, the charger 508 charges the capacitor 512. Each successive charging cycle according to Figures 5B-5C or 5B-5D charges the capacitor 512 to a successively higher level. The charging sequence is repeated until the permanent electromagnet 140 is fully magnetized. In one embodiment, the permanent electromagnet 140 may be fully magnetized when the permanent electromagnet 140 has an attractive force greater than a predetermined level. Flow proceeds to decision block 974.

[0117] At decision block 974, control circuit 516 determines whether capacitor 512 is fully charged. If capacitor 512 is fully charged, flow continues to block 978. If capacitor 512 is not fully charged, flow instead continues to block 970 to continue charging capacitor 512.

[0118] At block 978, capacitor 512 is charged and control circuit 516 disables charger 508. Flow proceeds to block 982.

[0119] At block 982, the control circuit 516 sets the switch states 528, 532, 536, 540 to the required switch states 528, 532, 536, 540 defined at block 962. The flow proceeds to block 986.

[0120] At block 986, the capacitor 512 discharges through the closed switches that correspond to the required switch states 528, 532, 536, 540. Flow proceeds to decision block 990.

[0121] At decision block 990, the control circuit 516 determines whether more discharge cycles of the capacitor 512 are needed. More discharge cycles are needed if the permanent electromagnet 140 is not yet fully magnetized or if the predetermined number of magnetization cycles (blocks 966-986) have not yet been completed. If more discharge cycles are needed, flow proceeds to block 966 to recharge the capacitor 512. If no more discharge cycles are needed, flow proceeds instead to block 994.

[0122] The permanent electromagnet array generates the desired magnetic state at block 994. The flow ends at block 994.

[0123] Referring now to FIG. 10 , a flow chart illustrating a coil demagnetization process 1000 is shown, according to an embodiment of the present application. The demagnetization process deactivates the permanent electromagnet array in a sequence of successively decreasing charge cycles. FIG. 10 illustrates the process of demagnetizing the permanent electromagnet array. The number of discharge cycles required can be a number such as 10 or 20, or can be based on how many current pulses 144 are needed to reduce the magnetometer reading from FIG. 11A or FIG. 11C to a sufficiently low value. The flow begins at block 1004.

[0124] At block 1004, all permanent electromagnet coils 524 are in a pre-existing state. The pre-existing state may include a high force / short range attractive state or a low force / long range attractive state. The flow proceeds to block 1008.

[0125] At block 1008, the control circuit 516 receives a command 520 to demagnetize the permanent electromagnet 140. The flow proceeds to block 1012.

[0126] At block 1012, the control circuit 516 obtains the required capacitor 512 voltages and switch states 528, 532, 536, 540 for all coils 524 from the command 520. The flow proceeds to block 1016.

[0127] At block 1016, the control circuit 516 enables the charger 508 to charge the capacitor 512. The flow proceeds to block 1020.

[0128] At block 1020, the charger 508 charges the capacitor 512. According to FIG. 6B, the charger 508 charges the capacitor 512 to successively lower voltages. The charging sequence is repeated until the permanent electromagnet 140 is demagnetized. In one embodiment, the permanent electromagnet array may be demagnetized if the permanent electromagnet array has a net zero attractive force. In another embodiment, the permanent electromagnet array may be demagnetized if the permanent electromagnet array has a net attractive force below a predetermined level. Flow proceeds to decision block 1024.

[0129] At decision block 1024, control circuit 516 determines whether capacitor 512 has reached the desired voltage. For degaussing operations, capacitor 512 is successively charged to a lower voltage with each or every other charging operation, rather than being fully charged at each step. If capacitor 512 has reached the desired voltage, flow proceeds to block 1028. If capacitor 512 has not reached the desired voltage, flow instead proceeds to block 1020 to continue charging capacitor 512.

[0130] At block 1028, capacitor 512 is charged to the desired voltage and control circuit 516 disables charger 508. Flow proceeds to block 1032.

[0131] At block 1032, the control circuit 516 sets the switch states 528, 532, 536, 540 to the required switch states 528, 532, 536, 540 defined at block 1012. The flow proceeds to block 1036.

[0132] At block 1036, the capacitor 512 discharges through the closed switches that correspond to the required switch states 528, 532, 536, 540. The flow proceeds to decision block 1040.

[0133] At decision block 1040, the control circuit 516 determines whether more discharge cycles are needed. If the permanent electromagnet 140 has not yet been demagnetized, or if the predetermined number of demagnetization cycles (blocks 1016-1036) have not yet been completed, more discharge cycles are needed. If more discharge cycles are needed, flow proceeds to block 1016 to recharge the capacitor 512. If more discharge cycles are not needed, flow proceeds instead to block 1044.

[0134] At block 1044, the permanent electromagnet array is demagnetized, completing the demagnetization process. The flow ends at block 1044.

[0135] 11A, a diagram is shown illustrating a side view of a magnetometer installation 1100, according to an embodiment of the present application. The magnetometer is often based on a Hall Effect sensor that measures magnetic flux flowing through a sensor (magnetometer) 1104. It is attached to the back side of a planar pole piece 234 and is aligned with one or more permanent electromagnets 140 of a permanent electromagnet array.

[0136] 11A shows a magnetometer installation for a side-by-side permanent electromagnet array. In this configuration, a portion of the magnetic flux entering and exiting each individual permanent electromagnet 140 in the array is diverted by a machined circular groove or flux diverting slot 1112 in the pole piece 234, for example, by conducting a portion of the magnetic flux from each individual permanent electromagnet 140 through the magnetometer yoke 1104 and back to the pole piece 234. By knowing the amount of magnetic flux passing through one of the permanent electromagnets 140, one can estimate the magnetic flux passing through the entire array when the entire array is approximately the same distance from the ferromagnetic surface 204.

[0137] By measuring the magnetic flux flowing through the sensor 1104, the processor or control circuitry 516 can optimize different functions.

[0138] 1. Energize and Discharge - By knowing the state of the permanent electromagnet and by measuring the magnetic flux, the control circuit 516 can select the appropriate charging voltage for the capacitor 512 to achieve the state change command 520. This can help prevent overshooting or undershooting the desired state when performing a degauss cycle. The signal from the sensor 1104 can be an analog voltage output, a radio signal, an optical signal, etc. that is fed to the control circuit 516.

[0139] 2. Object Sensing—An activated permanent electromagnet 140 in strong, intimate contact with a ferrous object surface 204 may have a high total magnetic flux due to the low magnetic reluctance of the circuit. If the ferrous object 204 does not make good contact or is not present at all, the magnetic flux must fight through a high-reluctance air or vacuum gap to complete the magnetic circuit, significantly reducing the total magnetic flux. Thus, if the permanent electromagnet 140 is activated and the measured magnetic flux is much lower than expected, it may be an indicator that there is not good contact with the ferromagnetic surface 204. This is particularly useful for automated processes where there may not be a human operator present to visually confirm that there may not be good contact.

[0140] In one example, the permanent electromagnet array may include a groove on a back surface of a pole piece opposite the plurality of permanent electromagnets, a magnetic flux sensor attached to the back surface within the enclosed area, and an iron cap attached to the pole piece opposite the magnetic flux sensor and outside the groove. The groove surrounds an area corresponding to the one or more permanent electromagnets. A portion of the magnetic flux flowing through the one or more permanent electromagnets flows through the magnetic flux sensor, and in response, the magnetic flux sensor is configured to provide a proximity indication reflecting the distance between the permanent electromagnet array and the iron surface.

[0141] In another example, the permanent electromagnet array can include a magnetic flux sensor mounted between an end of the permanent electromagnet and a pole piece, the magnetic flux sensor configured to provide a proximity indication reflecting the distance between the permanent electromagnet array and a ferrous surface.

[0142] 11B, a diagram illustrating a bottom view of a magnetometer installation 1120 is shown, according to an embodiment of the present application. FIG. 11B illustrates the positional relationship between the magnet 112, the magnetometer 1104, and the flux bypass slot 1112.

[0143] 11B shows a bottom view of the magnetometer 1104 mounting, showing the coaxial positioning of the permanent electromagnet core, magnetometer 1104, and flux diversion slot 1112. The return path yoke is not shown in this view, but overlaps the diameter of the diversion slot 1112.

[0144] Referring now to FIG. 11C , a diagram illustrating a side view of a thickness-mode magnetic flux sensor in an end-on-end array 1130 is shown, according to an embodiment of the present application. FIG. 11C illustrates how a thickness-mode magnetic flux sensor 1104 may be mounted to measure magnetic flux flowing through one arm of the end-on-end magnetic array. The magnetic flux sensor 1104 is an electronic device that outputs a voltage signal proportional to the magnetic flux traveling through the sensor, based on (for example) the Hall effect or the flux gate effect. A thickness-mode magnetic flux sensor is a magnetic flux sensor that measures magnetic flux through a thickness. When the permanent electromagnet array is substantially parallel to the ferrous surface 204, the output of one magnetic flux sensor 1104 can indicate the magnetic flux strength and attractive force of the entire array. The magnetic flux travels through the permanent electromagnet array, the pole piece 234, the air gap 224, the ferromagnetic surface 204, and the thickness-mode magnetic flux sensor 1104, forming a magnetic circuit.

[0145] In effect, the use of a magnetic flux sensor 1104 with a permanent electromagnet array allows a user to determine whether the array is magnetically attached to a surface (high magnetic flux through the sensor 1104), or whether it is attracted to but not connected to the ferrous surface 204 (moderate magnetic flux), or whether it is far away from the ferrous surface 204 (low magnetic flux).

[0146] Finally, those skilled in the art should appreciate that they may readily use the conception and specific examples disclosed as a basis for designing or modifying other structures for carrying out the same purposes of the present application without departing from the spirit and scope of the application as defined by the appended claims.

[0147] It will be readily understood that the components of the present application, as generally described and illustrated in the figures herein, could be arranged and designed in a wide variety of different configurations. Thus, the detailed description of the embodiments is not intended to limit the scope of the application, as claimed, but merely represents selected illustrative examples of the application.

[0148] Those skilled in the art will readily recognize that applications such as those described above may be implemented with steps in a different order and / or with hardware elements in different configurations than those specifically disclosed. Accordingly, while the application has been described based on these preferred embodiments, it will be apparent to those skilled in the art that certain modifications, variations, and alternative constructions are apparent while remaining within the spirit and scope of the application. Accordingly, reference should be made to the claims to determine the scope and scope of the application.

[0149] While preferred embodiments of the present application have been described, it should be understood that the described embodiments are exemplary only, and that the scope of the application, when considering the full range of equivalents and modifications (e.g., protocols, hardware devices, software platforms, etc.), should be defined solely by the appended claims.

Claims

1. an array of permanent electromagnets, each permanent electromagnet constructed from a magnetically hard material having a common length, each permanent electromagnet including a first end and a second end opposite the first end; a planar pole piece coupled to the first end of the plurality of permanent electromagnets; a plurality of first serpentine coil layers, each first serpentine coil layer including a plurality of first holes, each first hole operable to receive one of the permanent electromagnets, each first serpentine layer further including a conductive trace operable to provide one half-turn coil around each of the permanent electromagnets and to conduct current around the half-turn coil of the permanent electromagnets; a plurality of second serpentine coil layers, each second serpentine coil layer including a plurality of second holes, each second hole operable to receive one of the permanent electromagnets corresponding to one of the first holes of the first serpentine coil layer, each second serpentine layer further including a conductive trace operable to provide one half-turn coil around each of the permanent electromagnets to conduct current around the half-turn coil of the permanent electromagnet; the plurality of first serpentine coil layers are interstitched and electrically coupled with the plurality of second serpentine coil layers to provide a full rotation coil around the permanent electromagnet with the half rotation coil of the first serpentine coil layer and the half rotation coil of the second serpentine coil layer.

2. each of the conductive traces of the first and second serpentine coil layers being bonded to an insulating film; The system of claim 1 .

3. the magnetically hard material portion comprises at least one of alnico, neodymium, or samarium cobalt; The system of claim 1 .

4. the planar pole piece comprises at least one of Hyperco, Permalloy, electrical steel, or an amorphous metal alloy material; The system of claim 1 .

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