Non-Contact Magnetic Coupler With Halbach Rotor Alignment
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Solution Overview
Problem
Existing food processing appliances face challenges in efficiently transferring rotational drive force to processing tools without direct contact, leading to potential slippage and energy loss, especially when using small brushless permanent magnet motors.
Innovation Solution
A non-contact magnetic coupler system utilizing a Halbach configuration for the drive and follower rotors, which maintains rotational alignment through a magnetic field gap, eliminating the need for a back iron and allowing for a compact design, thereby enhancing torque retention and reducing wear and tear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If a non-contact magnetic coupler system is used to transfer rotational drive force, then wear and tear is reduced and alignment is maintained, but torque retention and energy transfer efficiency deteriorate due to potential slippage
Solution Approach 1:
The patent replaces the traditional mechanical contact-based drive system with a magnetic field-based non-contact coupling system. The magnetic coupler uses magnetic attraction and repulsion forces between magnets in the drive rotor and follower rotor to transfer rotational force without physical contact, eliminating mechanical wear while maintaining efficient torque transfer through magnetic field coupling.
Solution Approach 2:
The magnetic field acts as an intermediary between the drive rotor and follower rotor, transferring rotational energy without direct contact. The magnetic coupler creates a magnetic flux path that bridges the gap between the two rotors, enabling force transmission through the magnetic field medium while preventing mechanical wear and slippage.
2Duration of action of stationary object
If a magnetic coupler with gap between drive and follower rotors is used, then wear is eliminated, but torque retention deteriorates compared to direct contact systems
Solution Approach 1:
The patent optimizes critical parameters including the gap distance between drive and follower rotors, magnet strength and configuration, and magnetic field density to achieve effective torque transfer across the non-contact gap. By carefully controlling these parameters, the system maintains high torque retention while preserving the wear-free benefits of non-contact operation.
Solution Approach 2:
The magnetic coupler system employs composite magnetic structures combining different magnet materials and configurations (including Halbach arrays) to maximize magnetic field strength and coupling efficiency across the gap, thereby maintaining high torque retention without requiring direct physical contact between components.
3Force
If Halbach configuration is used for magnets in drive and follower rotors, then torque retention is enhanced and compact design is achieved, but manufacturing complexity increases
Solution Approach 1:
The magnetic coupler system divides the magnetic structure into discrete magnet segments arranged in Halbach configurations on both the drive rotor and follower rotor. This segmentation allows for modular manufacturing, where individual magnet arrays can be produced separately and then assembled, reducing overall manufacturing complexity while maintaining the torque-enhancing benefits of the Halbach configuration.
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 effectively transfers rotational force to the processing tool with high torque retention, minimizing slippage and energy loss, and extending the lifespan of the appliance and processing assembly by maintaining alignment from 0 rpm to 5,000 rpm without direct contact.
Implementation Method 1
A magnetic coupler has a drive rotor that selectively transfers the rotational drive force to the follower rotor. At least one of the drive and follower rotors includes a magnet configuration that directs a respective magnetic field in a direction of a gap defined between the drive and follower rotors.
Implementation Method 2
The outer portion of the magnetic coupler includes a plurality of magnets that are oriented in a Halbach configuration that magnetically engages with the inner portion within the gap.
Implementation Method 3
The outer portion of the magnetic coupler includes a plurality of magnets that are oriented in a Halbach configuration that magnetically engages with the inner portion within the gap.
Data Source
AI summary
A food processing appliance includes a container having a rotational processing assembly that includes an inner portion of a magnetic coupler. A base has a drive system for providing a rotational drive force. A drive rotor selectively transfers the rotational drive force to the magnetic coupler. The drive rotor includes a plurality of drive-magnetic members that form an outer portion of the magnetic coupler. The inner portion and outer portions of the magnetic coupler selectively and magnetically engage to form an engaged position. The engaged position is further defined by the inner portion being completely separated from the outer portion to define a gap therebetween.