Magnetic Coupler Disc With Segmented Magnet Rows
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Solution Overview
Problem
Existing mechanical couplings for rotating shafts suffer from energy loss due to friction, leading to inefficiencies and potential material breakdown from heat generation during high-speed operation.
Innovation Solution
A magnetic coupler system comprising a disc with circumferentially spaced magnets arranged in multiple rows, where the outward and inward poles of each magnet are oriented to create a magnetic field that allows for frictionless rotation between two discs, with the inner row reinforcing the outer row's magnetic field.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If mechanical connections (belts, chains, gears) are used to couple rotating shafts, then rotational coupling is achieved, but energy loss occurs due to friction
Solution Approach 1:
The patent replaces the mechanical connection system (belts, chains, gears) with a magnetic coupling system. Magnets are arranged on both shafts to create magnetic fields that couple the shafts together, eliminating physical contact and friction-based energy losses while maintaining rotational coupling and reliability.
Solution Approach 2:
The patent introduces magnetic fields as an intermediary between the two rotating shafts. Instead of direct mechanical contact, the magnetic field acts as a mediator to transmit rotational motion and torque from one shaft to the other, eliminating friction and associated energy losses.
2Temperature
If mechanical connections are used to couple rotating shafts, then rotational coupling is achieved, but heat generation occurs leading to material breakdown
Solution Approach 1:
The patent replaces friction-based mechanical connections with a magnetic coupling system. By using magnetic fields to transmit torque without physical contact, the system eliminates the heat generation that occurs in mechanical connections, preventing thermal degradation and material breakdown.
Solution Approach 2:
The patent converts the potentially harmful effect of friction (heat generation) into a benefit by eliminating friction entirely through magnetic coupling. The magnetic field interaction provides the necessary coupling force without the harmful side effect of heat generation, thereby protecting material strength.
3Force
If magnets are arranged in multiple rows on the disc, then magnetic field reinforcement is achieved, but device complexity increases
Solution Approach 1:
The patent segments the magnetic coupling system into multiple rows of magnets on each disc. This segmentation allows the magnetic field to be reinforced through the combined effect of multiple magnet rows, increasing the coupling force while maintaining a systematic and manufacturable structure.
Solution Approach 2:
The patent combines multiple rows of magnets on each disc to create a reinforced magnetic field. The inner and outer rows of magnets work together synergistically, merging their magnetic fields to produce a stronger overall coupling effect between the two shafts.
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 magnetic coupler system achieves efficient energy transfer without frictional losses, reducing the risk of material damage and improving operational reliability by utilizing magnetic attraction and repulsion for rotational synchronization.
Implementation Method 1
A plurality of circumferentially-spaced magnets is provided around a face of the disc such that one pole from each magnet faces outwardly from the disc while the other pole for each magnet faces inwardly towards its axis of rotation
Implementation Method 2
rotation of one disc rotatably drives the second disc due to the coactions (attraction and repulsion) of the magnetic fields
Data Source
AI summary
A rotatable magnetic coupler includes disc carrying, circumferentially spaced magnets arranged in rows on a first side of the disc. The magnets are oriented such that one pole of a first magnetic polarity from each magnet faces outwardly from the disc rotation axis while the other pole of a second magnetic polarity for each magnet faces inwardly toward the axis of rotation. The inner row magnets are preferably of lesser height than the outer row magnets to intensify a virtual gear-coupling effect in the magnetic field lines. A magnetic coupling is formed when two such couplers are rotatably mounted sufficiently close to one another that their magnetic fields are coupled together, such that rotation of one coupler rotatably drives the second coupler.