Hysteresis Coupling for Variable Torque Control
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Solution Overview
Problem
Magnetic couplings used in cleaning heads for tanks face issues with missed coupling and slip due to high speed rotation, leading to potential damage and inability to vary torque transfer, making them unsuitable for applications requiring variable torque and speed.
Innovation Solution
A hysteresis coupling with a magnetic inductor in the liquid space drives a hysteresis part connected to the gear input shaft, allowing for reliable torque transfer at startup and continuous, variable torque adjustment through electromagnets or permanent magnets, with energy dissipation as heat during slip.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If permanent magnets are used in magnetic coupling, then the coupling structure is simple and maintenance-free, but the coupling slips at high speed rotation and cannot transfer sufficient starting torque
Solution Approach 1:
The patent changes the magnetic coupling mechanism from permanent magnets to electromagnets, allowing dynamic control of magnetic field strength. This enables the coupling to adapt its torque transfer capability based on operating conditions, particularly providing sufficient starting torque while maintaining reliable operation at high speeds.
Solution Approach 2:
The invention introduces dynamic control of the magnetic coupling through variable electromagnetic fields. The electromagnets can adjust their field strength in real-time, transforming the static coupling characteristic into a dynamic one that can respond to changing load and speed conditions, preventing slip and ensuring reliable torque transfer.
2Power
If magnetic coupling is designed for high starting torque, then the coupling can accelerate the turbine, but the coupling slips when load torque exceeds maximum torque
Solution Approach 1:
The patent implements feedback control through the electromagnetic coupling system. The electromagnets respond to load conditions by adjusting their magnetic field strength, providing feedback that maintains reliable torque transfer. When load torque increases, the system can increase magnetic field strength to prevent slip, ensuring continuous and reliable operation.
3Stability of the object's composition
If synchronous magnetic coupling is used, then the coupling parts move together, but there is no possibility of variable torque transfer or speed variation
Solution Approach 1:
The invention transforms the static synchronous coupling into a dynamic system using electromagnets. The electromagnetic field strength can be varied to allow both synchronous operation and controlled slip, enabling variable torque transfer and speed control while maintaining the fundamental coupling function.
Solution Approach 2:
The patent uses parameter changes in the electromagnetic field to achieve both synchronous coupling and variable torque transfer. By adjusting the current in the electromagnets, the system can operate in synchronous mode for stable coupling or allow controlled slip for variable speed and torque applications.
4Reliability
If the coupling maximum torque is considerably greater than starting torque, then the system can start reliably, but errors or impurities cause load torque to exceed maximum torque resulting in slip
Solution Approach 1:
The electromagnetic coupling provides dynamic torque capacity that can adapt to varying load conditions. Unlike fixed permanent magnet couplings, the electromagnets can increase their field strength in response to increased load torque caused by errors or impurities, maintaining reliable operation without slip.
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
The hysteresis coupling ensures stable torque transfer at startup and allows for variable speed control, reducing the risk of damage and enabling effective cleaning with 'soft' slip, suitable for environments with inflammable or explosive vapors.
Implementation Method 1
the rotation of the turbine is transferred to the gear in the gear housing via a hysteresis coupling comprising a magnetic inductor in the liquid space which is driven by the turbine, and which drives a hysteresis part which is mounted in the gear housing, and which is connected with the input shaft of the gear
Data Source
AI summary
When, according to the invention, a cleaning head is provided with a hysteresis coupling (9, 11) between the turbine (3) and the gear in the gear housing (13), the gear will remain separated from the turbine and not be subjected to liquid impact. The hysteresis coupling (9, 11) may be adjusted using electromagnets (9) as an inductor, which allows control/regulation of the rotating movements of the cleaning head to achieve the best possible cleaning pattern.