Halbach Magnet Assembly Using Ferromagnetic Pins
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Solution Overview
Problem
Existing Halbach arrays require adhesives or mechanical means to secure adjacent magnets, increasing manufacturing costs and complexity, and reducing the operational lifetime due to potential adhesive failure. Additionally, handling larger magnets poses safety concerns during assembly.
Innovation Solution
The use of ferromagnetic pins positioned within cavities in adjacent magnets in a Halbach array to connect them, reducing or eliminating repelling magnetic forces and eliminating the need for adhesives or mechanical fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesives are used to secure adjacent magnets in a Halbach array, then the magnets can be joined together, but the manufacturing cost and complexity increase, and the operational lifetime is reduced due to potential adhesive failure
Solution Approach 1:
The patent replaces the chemical bonding system (adhesives) with a magnetic bonding system. Ferromagnetic pins are inserted through cavities in adjacent magnets, creating magnetic attraction forces that secure the magnets together without requiring adhesives. This substitution eliminates the complexity of adhesive application and curing processes while improving reliability by removing the failure mode associated with adhesive degradation over time.
2Strength
If adhesives are used to secure adjacent magnets in a Halbach array, then the magnets can be joined together, but the operational lifetime is reduced due to potential adhesive failure
Solution Approach 1:
The patent replaces the chemical bonding system (adhesives) with a magnetic bonding system. Ferromagnetic pins are inserted through cavities in adjacent magnets, creating magnetic attraction forces that secure the magnets together without requiring adhesives. This substitution eliminates the complexity of adhesive application and curing processes while improving reliability by removing the failure mode associated with adhesive degradation over time.
3Strength
If adhesives are used to secure adjacent magnets in a Halbach array, then the magnets can be joined together, but safety concerns arise during handling and assembly
Solution Approach 1:
The patent implements preliminary action by pre-drilling cavities through the magnets before assembly. These cavities are designed to receive ferromagnetic pins that will be inserted during assembly. By preparing the cavities in advance, the assembly process becomes simpler and safer, as the magnets can be aligned and secured using the pins without requiring complex adhesive application procedures or handling of large adhesive-covered surfaces.
4Device complexity
If ferromagnetic pins are used to connect adjacent magnets, then adhesives and mechanical fasteners are eliminated, but cavities must be formed in the magnets to accommodate the pins
Solution Approach 1:
The patent applies segmentation by dividing each magnet into regions separated by cavities. These cavities are strategically positioned to accommodate ferromagnetic pins that will connect adjacent magnets. The segmentation allows the magnetic bonding force to be concentrated at specific points through the pins, rather than requiring uniform bonding across entire magnet surfaces. This approach simplifies the overall assembly process while maintaining structural integrity.
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 solution reduces manufacturing costs and complexity by eliminating the need for adhesives and mechanical fasteners, while extending the operational lifetime of the Halbach array by preventing adhesive failure. It also enhances safety during assembly by reducing the need to handle large magnets with adhesives.
Implementation Method 1
The at least one ferromagnetic pin has a size, a shape, and a magnetic permeability that facilitate a magnetic force between the first surface and the second surface in the third direction inducing a magnetic flux path through the at least one ferromagnetic pin
Implementation Method 2
at least one ferromagnetic pin positioned within the at least one first cavity and the at least one second cavity to connect the first magnet and the second magnet
Implementation Method 3
In a Halbach array, permanent magnets are arranged such that a magnetic field density on one side of the array is substantially greater than that on the other side of the array
Implementation Method 4
Adjacent magnets in a Halbach array experience opposing magnetic forces. These forces produce a torque about a point of rotation in the magnets
Data Source
AI summary
A magnetic assembly includes a plurality of magnets arranged in a Halbach array. The plurality of magnets includes a first magnet and a second magnet positioned adjacent the first magnet, the first magnet having a first surface and the second magnet having a second surface adjacent the first surface. A first cavity is defined in the first surface and a second cavity is defined in the second surface. The magnetic assembly also includes a ferromagnetic pin positioned within the first cavity and the second cavity. The ferromagnetic pin has a size, a shape, and a magnetic permeability that facilitate a magnetic force between the first surface and the second surface inducing a magnetic flux path through the ferromagnetic pin.