Magnetic Coupling Sensing and Degaussing for Ferromagnetic Workpieces
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Solution Overview
Problem
Magnetic coupling devices used in robotics and industrial automation face challenges in providing real-time feedback on the status of ferromagnetic workpieces and ensuring proper magnetic retention, positioning, and degaussing functionality, which are essential for safe handling and processing.
Innovation Solution
A magnetic coupling tool equipped with a switchable magnetic flux source, magnetic field sensors, and a logic control circuit that determines operating states such as magnetic flux presence, workpiece proximity, and orientation, along with degaussing capabilities to manage residual magnetism, integrated into a robotic system for precise control and handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If magnetic coupling devices are used to secure ferromagnetic workpieces, then workpiece retention and handling capability are improved, but residual magnetism remains on the workpiece after release which can interfere with subsequent processing
Solution Approach 1:
The patent applies periodic action through degaussing cycles that use alternating magnetic fields to progressively reduce residual magnetism on workpieces. The system performs repeated on-off cycling of magnetic flux with decreasing amplitude to eliminate harmful residual magnetism after workpiece handling, transforming the static residual magnetism problem into a dynamic elimination process.
2Loss of information
If sensors are added to provide real-time feedback on magnetic coupling status, then monitoring and control capability are improved, but device complexity increases
Solution Approach 1:
The patent implements multi-functionality by integrating sensors that serve multiple purposes: detecting workpiece presence, monitoring magnetic coupling status, determining workpiece orientation, and providing feedback for degaussing control. This universal sensing approach reduces overall system complexity compared to having separate dedicated sensors for each function.
Solution Approach 2:
The patent combines sensing and control functions into an integrated system where magnetic field sensors are merged with the magnetic flux source and control circuitry. This consolidation allows the same magnetic field to be used both for workpiece handling and for sensing, reducing the number of separate components needed.
3Object-generated harmful factors
If degaussing capability is integrated into the magnetic coupling device, then residual magnetism removal is improved, but device complexity and energy consumption increase
Solution Approach 1:
The patent merges the degaussing function with the existing magnetic coupling system by using the same magnetic flux source for both workpiece retention and degaussing operations. The control system switches between holding mode and degaussing mode, eliminating the need for separate degaussing hardware and reducing overall device complexity.
Solution Approach 2:
The degaussing function is implemented through periodic on-off cycling of the magnetic flux with decreasing amplitude. This periodic action allows the system to eliminate residual magnetism using the existing magnetic source without requiring continuous energy input or additional complex hardware.
4Manufacturing precision
If precise positioning and orientation control are implemented using sensors, then workpiece handling accuracy is improved, but measurement and detection difficulty increases
Solution Approach 1:
The patent implements feedback control by using magnetic field sensors to continuously monitor workpiece position and orientation, then adjusting the magnetic flux distribution to achieve desired positioning. The control system processes sensor signals and provides real-time adjustments, creating a closed-loop system that improves measurement effectiveness through active control.
Solution Approach 2:
The patent replaces mechanical positioning and sensing systems with magnetic field-based detection and control. Instead of using mechanical encoders, cameras, or physical contact sensors, the system uses magnetic field distribution patterns to determine workpiece position and orientation, simplifying the detection mechanism.
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
Enables real-time monitoring and control of magnetic coupling processes, ensuring safe and efficient handling of ferromagnetic workpieces by providing accurate feedback on retention and positioning, and effectively removing residual magnetism, thus enhancing operational reliability and workpiece quality.
Implementation Method 1
A first magnetic field sensor of the plurality of magnetic field sensors positioned to monitor a first magnetic flux associated with the first workpiece engagement surface and a second magnetic field sensor of the plurality of magnetic field sensors positioned to monitor a second magnetic flux associated with the second workpiece engagement surface
Implementation Method 2
devices which use magnetic fields in order to attract and/or secure a ferromagnetic target to a working face of the device
Implementation Method 3
These sources include electromagnets, electro-permanent magnets, switchable permanent magnet units or arrangements
Implementation Method 4
a logic control circuit configured to perform a degaussing cycle with the plurality of electrical windings
Data Source
AI summary
Magnetic coupling devices are disclosed having magnetic field sensors. The magnetic coupling device may include degaussing coils wrapped about pole extension shoes of the magnetic coupling device.