Electromagnet With Ferromagnetic Side Panels For Tubular Load Handling
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Solution Overview
Problem
Conventional electromagnets used for moving tubular members and bundles of tubes suffer from laterally dispersed magnetic fields, leading to precision issues during load movement, repulsive forces between adjacent tubes, and high specific pressure on the load, making precise and automatic movement challenging.
Innovation Solution
The electromagnet design features two aligned E-shaped yokes with ferromagnetic side panels that are magnetically insulated from the cores, short-circuiting the lateral magnetic flux and directing it towards the polar shoes, thereby eliminating lateral dispersion and optimizing the magnetic field distribution for precise load movement and reduced surface contact pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If conventional electromagnets with inverted U or E-shaped polar yokes are used, then the magnetic attractive force is sufficient to move tubular members, but the laterally dispersed magnetic field causes lateral deviations and positioning inaccuracies
Solution Approach 1:
The electromagnet is divided into multiple independent pole pieces (at least three poles: first, second, and third poles) instead of a single continuous polar yoke. Each pole piece can be independently controlled, allowing selective activation to minimize lateral magnetic flux dispersion while maintaining sufficient attractive force for moving tubular members.
Solution Approach 2:
Different regions of the electromagnet have different magnetic properties - the pole pieces have high magnetic permeability to concentrate flux, while non-magnetic materials are used in lateral regions to prevent flux dispersion. The magnetic field distribution is optimized locally at each pole face to ensure precise positioning without lateral deviations.
2Use of energy by moving object
If the electromagnet is fed through adjustment systems to generate minimum operational magnetomotive force, then energy consumption is reduced, but lateral deviations still occur due to dispersed field
Solution Approach 1:
By segmenting the electromagnet into independent poles, the system can activate only the necessary poles for each positioning task, reducing overall energy consumption while maintaining precise positioning control through selective pole activation patterns.
Solution Approach 2:
The electromagnet system dynamically adjusts which poles are active based on the positioning requirements, allowing minimum operational magnetomotive force to be applied only where needed, thereby reducing energy consumption while preventing lateral deviations through optimized pole configuration.
3Force
If electromagnets are arranged longitudinally on bundles of tubes, then the magnetic attractive force is effective, but repulsive forces between adjacent tubes deform containment strappings
Solution Approach 1:
The magnetic field is segmented into distinct pole regions that create alternating polarity patterns across the bundle width. This segmentation ensures that adjacent tubes experience alternating attractive and repulsive forces from different poles, preventing the uniform repulsive forces that would otherwise deform the containment strappings.
Solution Approach 2:
Instead of having uniform polarity across the electromagnet face, the invention inverts the polarity pattern by creating alternating North and South poles. This inversion transforms the harmful uniform repulsive forces into a balanced pattern where repulsive forces between tubes are counteracted by attractive forces from adjacent poles, protecting the strappings from deformation.
4Force
If the active surface area of the electromagnet is limited to 50% or less of the plan surface area, then the magnetic force concentration is high, but the specific pressure on the load surface becomes excessively high and may damage small-thickness members
Solution Approach 1:
The magnetic force is segmented across multiple pole pieces distributed over the electromagnet surface. This segmentation allows the total magnetic force to be distributed over a larger effective area, reducing the specific pressure on any single point of the load surface while maintaining sufficient force concentration through optimized pole geometry and spacing.
Solution Approach 2:
The invention transitions from a single-plane active surface to a three-dimensional pole configuration where magnetic flux is distributed through multiple poles at different spatial positions. This dimensional change increases the effective contact area with the load while maintaining force concentration through vertical flux paths, thereby reducing surface pressure on delicate members.
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 design allows for precise and automatic movement of loads without lateral deviations, reduces the risk of strapping deformation, and decreases the likelihood of load surface damage, enabling efficient and accurate positioning and handling of tubular members and bundles.
Implementation Method 1
ferromagnetic side panels that are magnetically insulated from the cores, short-circuiting the lateral magnetic flux and directing it towards the polar shoes
Implementation Method 2
2 solenoids (4) wound on 2 cores (3), received in suitable recesses, buried in insulating resins and preferably manufactured from copper wire strips
Implementation Method 3
the combination of the great weight of the electromagnets with the magnetic attractive force distributed over a limited surface
Data Source
Figure 1a~1f
Figure 2~3
Figure 4~5
AI summary
The invention relates to a novel electromagnet (1) for moving tubular members in which the flux lines (2) extend only downwards in the direction of the load whereas the laterally dispersed magnetic field is substantially absent. The polar yoke of such an electromagnet (1) has two North polarity cores (3) on which two solenoids (4) are wound, protected on the bottom by annular baffles (5) made from non-magnetic material, and side panels (10) made from ferromagnetic material extend along both sides and pass next to the two cores (3) magnetically connecting the three South polarity poles, the side panels (10) being magnetically insulated from the two cores (3). The thickness of the side panels (10) is sized such that they are suitable to short-circuit the whole lateral flux preventing the dispersion thereof and conveying it completely towards the polar shoes (7) of the three poles and into the material to be magnetized thus actively contributing to the lifting of the latter.