Halbach Magnet Assembly Using Ferromagnetic Pins to Reduce Repulsion
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Solution Overview
Problem
Permanent magnetic assemblies in Halbach arrays face challenges due to repelling magnetic forces between adjacent magnets, which require adhesives for securing, increasing manufacturing complexity and reducing operational lifetime, and pose safety concerns during assembly.
Innovation Solution
Incorporating ferromagnetic pins of specific size, shape, and magnetic permeability within cavities of adjacent magnets to reduce or eliminate repelling forces, allowing for adhesive-free assembly and maintaining magnetic field strength, with the pins positioned to facilitate a magnetic flux path that induces a net attracting force or reduces repelling forces to less than 5 newtons.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesives are used to secure magnets together in a Halbach array, then the magnets can be held together against repelling forces, but the manufacturing cost and complexity increase
Solution Approach 1:
The patent replaces the chemical bonding mechanism (adhesives) with a magnetic field-based solution. Ferromagnetic pins are inserted through cavities in adjacent magnets, creating magnetic flux paths that generate attractive forces to counteract the repelling forces between magnets. This substitution eliminates the need for adhesives and their associated manufacturing complexity while maintaining the holding strength.
Solution Approach 2:
The ferromagnetic pins act as intermediaries between adjacent magnets. These pins provide a magnetic flux path that mediates the interaction between magnets with opposing polarities, enabling magnetic attraction through the pin material. This intermediary approach allows the magnetic assembly to hold together without direct magnet-to-magnet contact or chemical bonding.
2Strength
If adhesives are used to secure magnets together, then the magnets can be held together, but the operating lifetime is reduced due to adhesive failure
Solution Approach 1:
The patent replaces chemical bonding (adhesives) with magnetic field-based holding. The ferromagnetic pins create magnetic flux paths that generate continuous attractive forces, eliminating the degradation and failure modes associated with adhesive materials over time. This magnetic-based solution provides long-term reliability without the aging issues of chemical bonds.
3Force
If larger magnets are assembled into an array, then the magnetic field strength increases, but personnel safety concerns increase during handling and assembly
Solution Approach 1:
The ferromagnetic pins are pre-positioned in cavities within each magnet before assembly. This preliminary preparation allows magnets to be handled and positioned more safely, as the pins are already in place to provide magnetic attraction once assembled, reducing the risk of uncontrolled movement during the assembly process of larger, more powerful magnets.
4Force
If ferromagnetic pins are inserted through cavities in magnets, then repelling forces are reduced or eliminated, but cavities must be formed in the magnets
Solution Approach 1:
The patent divides each magnet into segments with cavities that accommodate ferromagnetic pins. This segmentation allows the pins to be inserted through specific pathways, creating magnetic flux paths that reduce repelling forces. The cavities are strategically positioned to minimize impact on overall magnetic field strength while enabling the pin insertion 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
This solution reduces manufacturing costs and complexity, extends the operational lifetime of Halbach arrays by eliminating the need for adhesives and minimizing magnetic field strength reduction, while ensuring safe handling and assembly of larger magnets.
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
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 such that an apparent magnetic force in the third direction between the first surface and the adjacent second surface is one of i) a repelling force less than 5 newtons (N) and ii) an attracting force
Data Source
AI summary
A magnetic assembly includes magnets arranged in a Halbach array. The magnets include a first magnet and a second magnet positioned adjacent the first magnet. The first magnet and the second magnet have adjacent surfaces. A cavity is formed in the each of the adjacent surfaces and is aligned with the cavity formed in the adjacent surface of the adjacent magnet. The magnetic assembly also includes a ferromagnetic pin positioned within the aligning cavities to connect the first magnet and the second magnet. 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 such that an apparent magnetic force between the first surface and the second surface is one of i) a repelling force less than 5 newtons (N) and ii) an attracting force.