Compact Magnetic Coupling Assembly with Adjustable Air Gaps
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Solution Overview
Problem
Existing magnetic coupling assemblies are often bulky, require additional support, and suffer from high maintenance costs, leading to vibration issues and reduced efficiency in transferring torque between shafts.
Innovation Solution
A compact magnetic coupling assembly with a central magnet rotor and two rotatable inductor rotors, adjustable via a positioning mechanism, which allows for precise control of air gaps and torque transfer without additional support, reducing vibrations and maintenance needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a traditional magnetic coupling assembly with two magnet rotors and two inductor rotors is used, then torque transfer capability is achieved, but the assembly becomes bulky and requires additional support structures
Solution Approach 1:
The patent merges the two magnet rotors into a single central magnet rotor that is shared by both inductor rotors. This consolidation reduces the number of magnetic components from four (two magnet rotors and two inductor rotors) to three (one central magnet rotor and two inductor rotors), thereby reducing assembly bulk while maintaining torque transfer capability through optimized magnetic flux paths
Solution Approach 2:
The central magnet rotor is positioned axially between the two inductor rotors, creating a nested configuration where the central magnet rotor is surrounded by the two inductor rotors on opposite sides. This nested arrangement maximizes space utilization and reduces the overall axial length of the assembly compared to traditional configurations
2Stability of the object's composition
If additional support structures are added to the magnetic coupling assembly, then structural stability is improved, but maintenance costs and complexity increase
Solution Approach 1:
The central magnet rotor serves multiple functions simultaneously: it generates magnetic flux for both inductor rotors, provides structural support for the entire assembly, and acts as the rotational element for torque transfer. This multi-functionality eliminates the need for separate support structures, reducing device complexity while maintaining structural stability
Solution Approach 2:
The magnetic coupling assembly is designed to be self-supporting through the central magnet rotor, which inherently provides the necessary structural stability without requiring external support mechanisms. The magnetic forces and mechanical structure are integrated such that the system supports itself, reducing maintenance needs
3Ease of manufacture
If the axial distances between magnet rotor and inductor rotors are fixed, then manufacturing is simplified, but torque control and speed adjustment capabilities are reduced
Solution Approach 1:
The patent incorporates a positioning mechanism that enables dynamic adjustment of the axial distances between the central magnet rotor and the two inductor rotors. This dynamic capability allows the air gaps to be varied during operation, providing torque control and speed adjustment while the positioning mechanism maintains precise control over the relative positions
4Weight of moving object
If a compact design with reduced weight is used, then critical frequency issues are reduced, but torque transfer capability may be compromised
Solution Approach 1:
The patent employs permanent magnets with high energy products (such as NdFeB or SmCo) that provide high magnetic flux density in a reduced volume and weight. This use of high-performance magnetic materials allows the compact central magnet rotor design to maintain adequate torque transfer capability while significantly reducing the overall weight and volume of the assembly
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 solution provides efficient torque transfer, reduced vibrations, and lower maintenance costs by using a lightweight, compact design that adjusts air gaps to control speed and torque, enhancing versatility and reliability.
Implementation Method 1
a rotatable central magnet rotor comprising a set of permanent magnets, the central magnet rotor connected to the second rotary hub and arranged centrally between the first and second rotatable inductor rotor in order to transfer torque between the magnet rotor and the inductor rotors
Implementation Method 2
a positioning mechanism coupled to the first and second rotatable inductor rotors and configured to selectively move the inductor rotors to adjust the axial distances between the magnet rotor and the respective inductor rotors
Data Source
Figure 1
Figure 2
Figure 3A~3C
AI summary
The invention relates to an adjustable magnetic coupling assembly for coupling of a first rotary shaft and a second rotary shaft, the magnetic coupling assembly comprising a first and second rotary hub connectable to the first shaft and second shaft, respectively and a central shaft, a first and a second rotatable inductor rotor connected to the central shaft, the inductor rotors being configured to be rotated by the central shaft and to be movable in axial direction along the central shaft by a positioning mechanism and a rotatable central magnet rotor connected to the second rotary hub and arranged centrally between the first and second rotatable inductor rotor. The assembly further comprises a positioning mechanism coupled to the first and second rotatable inductor rotors and configured to selectively move the inductor rotors to adjust the axial distances between the magnet rotor and the respective inductor rotor.