Electromagnetic Array Using Radially Polarized Magnets
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Solution Overview
Problem
Existing electromagnetic actuator designs require significant amounts of expensive and limited permanent magnet material and heavy flux conducting material, which increases size, cost, and eddy current losses, necessitating a more efficient integration of components to achieve similar performance with reduced material usage.
Innovation Solution
The design incorporates radially polarized permanent magnets providing bias flux across axial gaps to combine with axial coil flux, integrated into a compact and lighter array structure, using fewer permanent magnets and flux conducting materials, with coils embedded in stationary components for improved cooling and a magnet assembly that moves relative to coil assemblies via linear bearings and springs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a monolithic electromagnetic actuator design is used, then the structure is simple and robust, but the amount of permanent magnet material and flux conducting material required is large, increasing weight, cost, and size
Solution Approach 1:
The actuator is divided into modular components including a magnet assembly with multiple permanent magnets arranged in specific patterns, separate coil assemblies, and distinct flux conducting structures. This segmentation allows each component to be optimized independently while reducing the total amount of permanent magnet material needed compared to a monolithic design.
Solution Approach 2:
The design employs nested flux conducting structures where inner flux conductors are positioned within outer flux conductors, creating efficient magnetic flux paths. This nesting arrangement reduces the overall volume of flux conducting material required while maintaining effective magnetic coupling between the magnet assembly and coil assemblies.
2Quantity of substance
If thick permanent magnets are used to establish bias flux, then the magnetic circuit is simpler, but the amount of permanent magnet material increases, raising cost and reducing supply availability
Solution Approach 1:
Instead of using thick permanent magnets, the design employs multiple thinner permanent magnets arranged in specific configurations (e.g., alternating polarity patterns). This segmentation achieves the required bias flux density while using less total permanent magnet material, and the modular arrangement simplifies manufacturing and assembly.
Solution Approach 2:
The permanent magnets are strategically positioned to create localized high-flux regions where needed, with varying magnet thicknesses and polarities optimized for specific magnetic circuit requirements. This local optimization allows efficient flux distribution throughout the actuator without requiring uniformly thick magnets.
3Force
If large amounts of flux conducting material are used, then the magnetic circuit performance is improved, but the weight increases and eddy current losses require lamination
Solution Approach 1:
The flux conducting structure uses nested concentric rings or cylindrical structures where inner flux conductors are positioned within outer flux conductors. This nesting creates efficient magnetic flux paths with minimal material, reducing the total volume and weight of flux conducting material while maintaining effective flux conduction capability.
Solution Approach 2:
The design transitions from planar flux conducting structures to three-dimensional nested cylindrical or spherical arrangements, creating efficient flux paths through the radial and axial dimensions. This dimensional optimization reduces the amount of material needed compared to traditional planar configurations.
4Ease of manufacture
If coils are mounted separately from flux conductors, then assembly is easier, but the overall device size and complexity increase
Solution Approach 1:
The coil assemblies are integrated with the flux conducting structures by embedding coils within or mounting them directly to the flux conducting rings or cylindrical structures. This merging reduces the number of separate components and simplifies assembly while maintaining electrical and magnetic isolation where needed.
Solution Approach 2:
The flux conducting structures serve multiple functions: they conduct magnetic flux, provide mechanical support for the coils, and act as structural elements of the actuator housing. This multi-functionality reduces the need for separate components, simplifying assembly while maintaining design flexibility.
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 configuration achieves the same performance as monolithic actuators while minimizing material usage, enhancing coil cooling and generating linear and reversible inertial forces, with reduced material costs and size, and improved thermal conductivity.
Implementation Method 1
radially polarized permanent magnets providing bias flux across axial gaps to combine with axial coil flux to linearize flux output
Implementation Method 2
The combination of bias flux and coil flux cancels in one gap, and adds in the other gap, producing a net force on an inertial mass
Implementation Method 3
uses a current conducting coil to drive magnetic flux across the same axial air gaps
Implementation Method 4
linear bearings that slidably mount the magnet assembly to the stationary shafts
Implementation Method 5
springs between the magnet assembly and the lower assembly; and springs between the magnet assembly and the upper assembly
Data Source
AI summary
An electromagnetic inertial force generator is provided, which includes radially polarized permanent magnets providing bias flux across axial gaps to combine with axial coil flux to linearize flux output. An array of components is integrated into a single structure that is more compact and lighter than a monolithic force generator, providing the same level of performance while using less permanent magnet material.