Electro-Permanent Magnet Layout for Thin Low-Cost Anchoring
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Solution Overview
Problem
Magnetic apparatuses of the electro-permanent type face challenges in reducing production costs without increasing geometric sizes, particularly thickness, while maintaining equal magnetic anchoring force.
Innovation Solution
The design incorporates larger surface area polar units within the same thickness by arranging multiple polar units in a matrix configuration, using a combination of magnetic cores with different coercive values and a control unit to manage magnetic flows, allowing for reduced number of polar units without compromising magnetic force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the anchoring surface of each polar unit is increased to reduce production costs, then the number of polar units is reduced and processing time is shortened, but the geometric sizes and thickness of the magnetic apparatus increase
Solution Approach 1:
The patent implements nesting by placing first and second magnetic cores within a coil assembly, where the magnetic cores are positioned inside the coil structure. This nested arrangement allows multiple functional elements to occupy overlapping spatial volumes, enabling the polar units to generate sufficient magnetic force without increasing the overall thickness of the apparatus.
Solution Approach 2:
The patent transitions from a two-dimensional arrangement of polar units to a three-dimensional configuration by stacking magnetic cores and coil assemblies in layers. This dimensional change allows the system to achieve the required magnetic anchoring force through vertical stacking rather than horizontal expansion, thereby maintaining reduced thickness while lowering production costs through fewer polar units.
2Ease of manufacture
If the number of polar units is reduced to lower production costs, then processing time is reduced, but the magnetic anchoring force may be compromised
Solution Approach 1:
The patent employs composite magnetic structures by combining first and second magnetic cores with different material properties within the same polar unit. These composite magnetic assemblies, when positioned within the coil, generate enhanced magnetic fields that compensate for the reduced number of polar units, thereby maintaining the required magnetic anchoring force while reducing production costs.
Solution Approach 2:
The patent utilizes parameter changes by varying the coercive values and magnetic properties of different core materials in the composite structure. By selecting materials with specific magnetic characteristics and adjusting their arrangement within the coil assembly, the system optimizes magnetic field generation to achieve sufficient anchoring force with fewer polar units.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in a lower-cost magnetic apparatus with unaltered thickness, achieving the same magnetic anchoring force with fewer polar units, optimizing production costs and operational efficiency.
Implementation Method 1
a coil (30) positioned externally to and at the first magnetic core (40)
Implementation Method 2
a first magnetic core (40) with a first coercive value... a plurality of second magnetic cores (90A, 90B), each having its own coercive value which is different from the first coercive value
Data Source
AI summary
A magnetic apparatus for anchoring ferrous elements may include a support structure housing a plurality of polar units. The support structure has first and second sides at opposite surfaces. The polar units may include: a coil having a support and a conductive element wound on the support; a first magnetic core with a first coercive value, generating a first magnetic flow oriented in a first magnetic direction; and a plurality of second magnetic cores, each having its own coercive value different from the first coercive value. A first part of the second magnetic cores generates a second magnetic flow oriented in a second magnetic direction. A second part of the second magnetic cores generates a third magnetic flow oriented in a third magnetic direction. The third magnetic direction is parallel or antiparallel to the first magnetic direction and has a different direction with respect to the second magnetic direction.