Flux-Directed Magnet Assemblies for Back-Iron-Free Magnetic Gearing
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Solution Overview
Problem
Existing electric machines face limitations in achieving high power and torque densities due to the weight and saturation of back iron, manufacturing complexity, and high costs associated with Halbach arrays, which hinder their widespread use in applications requiring improved efficiency and reduced size.
Innovation Solution
The integration of discrete Flux-Directed Magnetic (FDM) assemblies, comprising opposing flux-channeled magnetic segments, eliminates the need for back iron by optimizing flux direction through radial channels, utilizing permanent magnets or superconducting coils to achieve higher flux densities and torque densities without the manufacturing complexities of conventional Halbach arrays.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If back iron is used in conventional electric machines, then structural support and flux path are provided, but weight increases and flux density is limited due to saturation
Solution Approach 1:
The patent removes the back iron component entirely from the machine structure. Instead of using conventional back iron to provide structural support and flux paths, the invention employs discrete flux-directed magnet assemblies that self-support and create flux channels through their geometric arrangement and magnetic properties, eliminating the need for heavy back iron and thereby increasing power density.
Solution Approach 2:
The discrete magnet assemblies serve multiple functions simultaneously: they provide the magnetic flux generation, create flux-directed channels, provide structural support, and eliminate the need for separate back iron components. This multi-functionality allows the machine to achieve high power density without the weight penalty of conventional back iron structures.
2Power
If Halbach arrays are used to achieve high flux density, then power density improves, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent divides the magnetic structure into discrete, modular magnet assemblies that can be independently manufactured and then assembled. Each assembly contains magnets arranged to create flux-directed channels, but the modular nature allows for simplified manufacturing compared to monolithic Halbach arrays. The segments can be produced using conventional magnetization techniques and assembled through straightforward mechanical attachment.
Solution Approach 2:
The invention changes the geometric parameters and arrangement of the magnet assemblies to achieve flux direction control without requiring the complex continuous gradient magnetization of Halbach arrays. By using discrete assemblies with specific geometries and spacing, the patent achieves comparable flux density and torque performance through simpler manufacturing parameters.
3Power
If superconducting coils are used to generate high flux density, then power density increases, but cryogenic systems and quench protection complexity increase
Solution Approach 1:
The patent employs conventional permanent magnets with finite but sufficient flux density characteristics rather than expensive superconducting coils. The permanent magnets provide adequate flux density for high power density applications without requiring cryogenic cooling systems, quench protection, or other complex infrastructure associated with superconducting technology.
Solution Approach 2:
The invention replaces the complex cryogenic and electrical control systems required for superconducting coils with a purely magnetic field generation approach using permanent magnets. This substitution eliminates the need for mechanical cooling systems, temperature control, and quench detection/protection mechanisms while achieving sufficient flux density for high power density.
4Ease of manufacture
If conventional magnet assemblies are used, then manufacturing is simpler, but flux direction control and power density are limited
Solution Approach 1:
The patent implements flux direction control at the local level within each discrete magnet assembly. Each assembly is designed with specific magnet orientations and geometries to create localized flux channels that direct flux along desired paths. This local optimization of flux direction in each assembly contributes to overall high power density while maintaining manufacturing simplicity through modular design.
Solution Approach 2:
The invention introduces a new dimension of flux control through the spatial arrangement and geometric configuration of discrete magnet assemblies. By controlling the three-dimensional positioning, orientation, and spacing of the assemblies, the patent achieves superior flux direction control and power density that conventional two-dimensional magnet arrangements cannot provide, while maintaining manufacturing simplicity.
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 enables cost-effective synchronous machines with significantly improved power and torque densities, reduced magnetization losses, and enhanced efficiency, suitable for high RPM operations with reduced mechanical complexity and cost.
Implementation Method 1
optimizing flux direction through radial channels
Implementation Method 2
utilizing permanent magnets or superconducting coils to achieve higher flux densities
Implementation Method 3
utilizing permanent magnets or superconducting coils to achieve higher flux densities
Implementation Method 4
integrate magnetic gear boxes with single or dual rotor machines
Data Source
AI summary
A magnetic array for use in a synchronous electrical machine or a magnetic gear box, comprising a plurality of discrete magnetic segments. When individual ones of the segments are spaced away from influence of ferromagnetic material, such as prior to placement in the array, each includes a pole having the same maximum field strength. Each segment is positioned in a sequence along a circumferential array with changes in field orientation by which the field of each segment is spatially rotated relative to the field of a next segment in the sequence. Each segment is positioned in sufficient proximity to the next segment in the sequence to enable the fields to interact with one another and effect flux channeling.