System and method for magnetic rotational coupling device

Abstract

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

Description

Technical Field

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

[0002] The present invention generally relates to a rotary coupling device, and more particularly to a friction - reducing torque - transmitting component.

Background Art

[0003] Mechanical machines convert and / or transmit energy by using fixed and movable components intervening between a power source and a load or work to be performed. As a result, a kinematic chain of link mechanisms, couplings, gears, and other such mechanical interfaces that are susceptible to frictional energy losses in the form of heat and sound occurs. Such other dissipative forces can significantly reduce the efficiency of the system, typically expressed as the ratio of output to input.

[0004] Over the years, various types of low - friction couplings have been developed, but such designs are inadequate in many respects. For example, magnetic “gears” have been developed that feature a number of powerful permanent magnets circumferentially arranged at regular angular intervals around the outer circumference. Such mechanical couplings have succeeded in providing a motion similar to that of a gear with little or no friction. However, the use of their simple single - layer magnets has been found not to be optimal with respect to providing a strong and non - slipping rotary coupling between elements at high rotational speeds and torques.

Summary of the Invention

Problems to be Solved by the Invention

[0005] Therefore, there is a need for systems and methods that overcome the aforementioned and other limitations of the prior art. For example, there has long been a demand for highly efficient, frictionless rotary couplings that can operate under high-power conditions. [Means for solving the problem]

[0006] This disclosure presents novel and innovative magnetic rotor assemblies and methods for providing magnetic rotor assemblies. In a first aspect, a magnetic rotor assembly is provided, comprising a first rotor disk and a second rotor disk. The first rotor disk may comprise a first disk and a set of first permanent magnets circumferentially arranged around the first disk such that their north poles face outward from a first surface of the first disk. The second rotor disk may comprise a second disk and a set of second permanent magnets circumferentially arranged around the disk such that their north poles face outward from a first surface of the second disk. The first surface of the first disk may face the first surface of the second disk so that the first rotor disk and the second rotor disk are magnetically coupled to each other.

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

[0008] In a third embodiment according to either the first or second embodiment, the first surface of the first disk is separated from the first surface of the second disk.

[0009] In a fourth embodiment according to any of the first to third embodiments, the first surface of the first disk is separated from the first surface of the second disk by 0.125 to 0.635 cm.

[0010] In a fifth embodiment according to any of the first to fourth embodiments, the first surface of the first disk is in contact with the first surface of the second disk.

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

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

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

[0014] In the ninth embodiment according to any of the first to eighth embodiments, the first disk body and the second disk each contain graphite and have a diameter of approximately 7 inches (approximately 17.78 cm).

[0015] In the tenth embodiment, according to any of the first to ninth embodiments, each permanent magnet is positioned approximately 1 / 8 inch (approximately 0.318 cm) away from its respective disk. An eleventh embodiment provides a method comprising supplying a first disk and a second disk, and positioning a set of first permanent magnets within the first disk such that the set of first permanent magnets is circumferentially arranged around the first disk. This method may also include positioning a set of second permanent magnets within the second disk such that the set of second permanent magnets is circumferentially arranged around the second disk. This method may further include positioning the first disk and the second disk such that the set of first permanent magnets faces the set of second permanent magnets such that the first disk and the second disk are magnetically coupled to form a magnetic rotor assembly.

[0016] The features and advantages described in this specification are not exhaustive, and in particular, many additional features and advantages will be apparent to those skilled in the art upon considering the drawings and the description. Further, it should be noted that the language used herein has been selected primarily for readability and for the purpose of instruction, and is not intended to limit the scope of the disclosed subject matter.

[0017] The present invention will now be described in conjunction with the accompanying drawings, in which like reference numerals denote like elements.

Brief Description of the Drawings

[0018] [[ID=...]] [Figure 1] It is a schematic diagram of a magnetic coupling assembly according to an exemplary embodiment.

[0019] [Figure 2] It is a diagram showing the insertion of magnets into a rotor disk according to various embodiments.

[0020] [Figure 3] It is a diagram sequentially showing the joining of two magnetic rotor disks for forming a magnetic rotor assembly according to one embodiment. [Figure 4] It is a diagram sequentially showing the joining of two magnetic rotor disks for forming a magnetic rotor assembly according to one embodiment.

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

[0022] [Figure 6] It is a flowchart showing a method of forming a magnetic coupling assembly according to various embodiments.

Modes for Carrying Out the Invention

[0023] The following detailed description of the invention is merely exemplary in nature and is not intended to limit the invention or its application and uses. Further, there is no intention to be bound by the views presented in the foregoing background art or the following detailed description.

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

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

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

[0027] It should also be understood that the various components shown in Figure 1 are not necessarily drawn to scale. For example, rotor assemblies 131, 132, and 133 are shown as having substantially the same diameter, but in some embodiments, the rotor assemblies are made up of different diameters (including different radial positions of each magnet) to achieve certain mechanical advantages and / or rotational speed ratios. For clarity, Figure 1 does not show various conventional mechanical components well known in the art, such as bearings, shaft couplings, output loads (e.g., generators), and input drive units (e.g., electric motors).

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

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

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

[0031] Having outlined an example of a magnetic coupling assembly, we will now describe the individual rotor assemblies by referring to the flowchart in Figure 6, in conjunction with Figures 2 to 5.

[0032] Referring first to the exemplary method 600 in Figure 6, methods for assembling a magnetic coupling system according to various embodiments generally include: supplying a set of magnets (e.g., rare earth magnets such as N52 neodymium magnets) (step 601); inserting or otherwise incorporating some of those magnets into a first rotor disk (step 602); inserting or otherwise incorporating some of the magnets into a second rotor disk (step 603); facing a pair of disks opposite each other (e.g., with N-oriented surfaces adjacent to each other) and gradually rotating the disks until they attract each other and are magnetically fixed, thereby forming a single magnetic rotor assembly (step 604); connecting the magnetic rotor assembly to an axis (step 605); and combining the magnetic rotor assembly with one or more other adjacent magnetic rotor assemblies to form a completed magnetic coupling assembly (step 606). Each of these steps will now be described in more detail.

[0033] First, referring to the exemplary rotor disk 200 shown in Figure 2, assembly begins with the step of procuring a set of magnets 250. In one embodiment, for example, each magnet 250 is a circular nickel-plated N52 type neodymium rare-earth magnet having a diameter of 1.0 inch and a thickness of 1 / 8 inch. The magnets 250 are then fixed to the rotor disk (or “disk body”) 210 in a regular pattern circumferentially, such that their magnetic poles face in the same direction (for example, all north poles face outwards relative to the page in Figure 2).

[0034] In one embodiment, the rotor disk 210 is an aluminum, carbon fiber, or graphite disk (e.g., a 3D printed graphite disk) having an outer diameter D of 7.0 inches, a thickness of 3 / 16 inch (approximately 0.477 cm), and a central hole 214 having an inner diameter (e.g., 1 / 2 inch (approximately 1.27 cm)) configured to receive the shaft as described above.

[0035] Twelve recessed regions 212 are formed within the disk 210, each configured to receive a corresponding magnet 250 without gaps. Thus, the regions 212 exhibit 12-fold rotational symmetry and are arranged in regular 30-degree increments around the outer periphery. The magnets 250 can be fixed within their corresponding recesses with a suitable adhesive, such as a UV-protective waterproof adhesive. In the illustrated embodiment, the magnets 250 are positioned 2 / 6 inch (approximately 0.85 cm) away from the outer periphery of the disk 210, with their centers approximately 1 / 2 inch apart.

[0036] It will be understood that the rotor disk 200 shown in Figure 2 is not intended to be limiting in any respect. The magnets 250 may have various geometric shapes (thickness, shape, etc.), and any number of such magnets (e.g., more than 12 or less than 12) can be fixed to the disk 210. In addition, the magnets may be positioned closer to or further away from the outer circumference of the disk 210.

[0037] Figures 3 and 4 sequentially show the joining of two magnetic rotor disks to form a magnetic rotor assembly according to one embodiment. More specifically, Figure 3 shows that two assembled rotor disks 301 and 302 are joined so that their inner surfaces (310, 320) correspond to the north poles of their respective magnets, and their outer surfaces 311 and 321 correspond to their south poles. In additional or alternative configurations, the rotor disks 301 and 302 may be joined by aligning the surfaces corresponding to the south poles of their respective magnets.

[0038] When the individual magnets on each surface 310 and 320 are perfectly aligned N to N, the resulting repulsive force prevents the rotor disks 301 and 302 from magnetically adhering to each other. However, if the disks are rotated slightly (e.g., about 15 degrees) so that the magnets are staggered, the magnetic fields of the magnets are positioned so that the rotor disks attract each other and adhere firmly (Figure 4).

[0039] Figure 5 is a partial perspective view of the magnetic rotor assembly 500 as shown in Figures 3 and 4, showing the relative positions of the confined magnets. It will be clear that the regular circumferential spacing of the magnets around the outer circumference of the completed disk assembly produces similarly regular circumferential spatial modulation of the magnetic field, effectively forming a “magnetic gear” (with regular fluctuations in the direction and intensity of the magnetic field corresponding to the “teeth” of the gear). However, unlike mechanical gears, when the disk assemblies are arranged adjacent to each other as shown in Figure 1, the result is a particularly effective form of rotational magnetic coupling that is both strong (i.e., adjacent disk assemblies are strongly magnetically coupled) and low friction (due to the non-contact nature of the coupling).

[0040] While the detailed description above provides a convenient roadmap for those skilled in the art to implement various embodiments of the invention, it should be understood that the specific embodiments described above are merely examples and are not intended to limit in any way the scope, applicability, or configuration of the invention. On the contrary, various modifications can be made to the function and arrangement of the elements described without departing from the scope of the invention. As used herein, the term “exemplary” means “serving as an example, case, or illustration.” Any implementation described herein as “exemplary” should not necessarily be construed as preferable or advantageous to other implementations, nor is it intended to be construed as a model that must be replicated in the same way.

Claims

1. A first rotor assembly and a second rotor assembly, wherein each of the first rotor assembly and the second rotor assembly is A first rotor disk comprising a first disk and a first plurality of permanent magnets arranged circumferentially around the outer circumference of the first disk, wherein the first polarity of each of the first plurality of permanent magnets faces outward from the first side surface of the first disk, A second rotor disk comprising a second disk and a plurality of second permanent magnets arranged circumferentially around the outer circumference of the second disk, wherein the first polarity of each of the plurality of second permanent magnets faces outward from the first side surface of the second disk, A first rotor assembly and a second rotor assembly, A device equipped with, In each of the first rotor assembly and the second rotor assembly, The first side surface of the first disk is in contact with the first side surface of the second disk, The first disk and the second disk are rotated so as to shift their relative positions, so that the first plurality of permanent magnets and the second plurality of permanent magnets are arranged alternately. The device further, A first shaft is fixedly coupled to the first rotor assembly and positioned to rotate the first rotor assembly in a first plane, A second shaft is fixedly coupled to the second rotor assembly and is positioned to rotate the second rotor assembly in a second plane different from the first plane, It is equipped with, The first plane is separated from the second plane by a predetermined distance, so that the first rotor assembly is magnetically coupled to the second rotor assembly but not mechanically coupled. A device characterized by the following features.

2. The first disk and the second disk of the first rotor assembly have a first diameter. The apparatus according to claim 1, wherein the first disk and the second disk of the second rotor assembly have a second diameter different from the first diameter.

3. The apparatus according to claim 1, wherein the first rotor assembly overlaps the second rotor assembly by a distance between 1.5 cm and 2.5 cm in a direction perpendicular to the respective rotation axes of the first rotor assembly and the second rotor assembly.

4. The apparatus according to claim 1, wherein the predetermined distance is between 0.125 cm and 0.635 cm in a direction parallel to the respective rotation axes of the first rotor assembly and the second rotor assembly.

5. Similar to the first rotor assembly and the second rotor assembly, A third rotor assembly, A first rotor disk comprising the first disk and a plurality of first permanent magnets arranged circumferentially around the outer circumference of the first disk, wherein the first polarity of each of the plurality of first permanent magnets faces outward from the first side surface of the first disk, The second rotor disk comprises the second disk and a plurality of second permanent magnets arranged circumferentially around the outer circumference of the second disk, wherein the first polarity of each of the plurality of second permanent magnets faces outward from the first side surface of the second disk, Includes, The first side surface of the first disk is in contact with the first side surface of the second disk, A third rotor assembly in which the first disk and the second disk are rotated so as to shift their relative positions, so that the first plurality of permanent magnets and the second plurality of permanent magnets are arranged alternately. A device further comprising, moreover, The device in question, A third shaft is fixedly coupled to the third rotor assembly and positioned to rotate the third rotor assembly in a third plane different from the second plane. It is equipped with, The apparatus according to claim 1, wherein the second plane is separated from the third plane by a second predetermined distance, so that the second rotor assembly is magnetically coupled to the third rotor assembly but not mechanically coupled.

6. The apparatus according to claim 1, wherein the first disk and the second disk are made of graphite.

7. Each permanent magnet in the first plurality of permanent magnets is positioned around the first disk at a predetermined arc-shaped distance from adjacent permanent magnets in the first plurality of permanent magnets. Each permanent magnet in the second plurality of permanent magnets is positioned around the second disk at a predetermined arc-shaped distance from adjacent permanent magnets in the second plurality of permanent magnets. The apparatus according to claim 1, wherein the first plurality of permanent magnets and the second plurality of permanent magnets are arranged alternately, causing the first disk to be shifted relative to the second disk by half of the predetermined arc-shaped distance.

8. Each permanent magnet in the first plurality of permanent magnets and the second plurality of permanent magnets has a first diameter, Each of the first disk and the second disk has a second diameter, The apparatus according to claim 1, wherein the first diameter is approximately one-seventh of the second diameter.

9. The first rotor assembly is configured such that the first plurality of permanent magnets are arranged at a first radial distance with respect to the first axis. The second rotor assembly is configured such that the second plurality of permanent magnets are arranged at a second radial distance with respect to the second axis. The apparatus according to claim 1, wherein the first radial distance is different from the second radial distance.

10. The second surface of the second rotor assembly overlaps the first surface of the first rotor assembly by a first distance, The second plane is separated from the first plane by a second distance, The first distance is between 0.125 cm and 0.635 cm. The apparatus according to claim 1, wherein the second distance is between 1.5 cm and 2.5 cm.

11. The first rotor assembly is coupled to the second rotor assembly magnetically rather than mechanically; A step of applying rotation to a first shaft that is fixedly connected to the first rotor assembly, The steps include transmitting the rotation to the second rotor assembly via a magnetic coupling between the first rotor assembly and the second rotor assembly through a gap separating the first rotor assembly from the second rotor assembly, A method for magnetic coupling, including, Each of the first rotor assembly and the second rotor assembly is, A first rotor disk comprising a first disk and a first plurality of magnets arranged circumferentially around the outer circumference of the first disk, wherein the first polarity of each permanent magnet of the first plurality of magnets faces outward from the first side surface of the first disk, A second rotor disk comprising a second disk and a plurality of second magnets arranged circumferentially around the outer circumference of the second disk, wherein the first polarity of each permanent magnet of the plurality of second magnets faces outward from the first side surface of the second disk, Includes, The first side surface of the first disk is in contact with the first side surface of the second disk, A method characterized in that the first disk and the second disk are rotated so as to shift their relative positions, so that the first plurality of magnets and the second plurality of magnets are arranged alternately.

12. The method according to claim 11, wherein the rotation is applied to the first axis at a first angular velocity and transmitted to the second axis connected to the second rotor assembly at a second angular velocity different from the first angular velocity, via the first rotor assembly configured to have a plurality of first magnets positioned at a first radial position with respect to the first axis and the second rotor assembly configured to have a plurality of second magnets positioned at a second radial position with respect to the second axis.

13. The method according to claim 11, wherein the first shaft is connected at a first end to the first rotor assembly and at a second end opposite to the first end to an input source that supplies the rotation.

14. The method according to claim 11, wherein the second rotor assembly is connected to an output load via a second shaft.

15. The steps include: coupling the second rotor assembly to the third rotor assembly magnetically rather than mechanically; The steps include transmitting the rotation to the third rotor assembly via a second magnetic coupling between the second rotor assembly and the third rotor assembly, through a second gap that separates the second rotor assembly from the third rotor assembly, The method according to claim 11, further comprising:

Images