Magnetic Coupling Assembly with Adjustable Air Gap
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Solution Overview
Problem
Existing magnetic coupling assemblies face challenges such as inability to adjust air gaps during operation, high rotating mass leading to increased wear, and stringent alignment requirements, especially at high rotation velocities, along with inefficiencies in cooling and maintenance.
Innovation Solution
A magnetic coupling assembly with a stationary housing, rotatable sleeve, and displacement elements that allow for axial displacement of inductor rotors relative to the magnet rotor, enabling gap adjustment without stopping the assembly, and a passive cooling mechanism using channels within the inductor rotor for ambient air flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the entire adjustment mechanism co-rotates with the rotation of the conductor disc, then the adjustment can be made during operation, but the rotating mass becomes relatively high and the assembly is prone to increased wear due to considerable centrifugal forces
Solution Approach 1:
The adjustment mechanism is segmented into a stationary adjustment element (sleeve with threads) and a rotating conductor disc. The sleeve remains stationary while the conductor disc rotates, allowing adjustment without co-rotation. This segmentation reduces the rotating mass and centrifugal forces while maintaining adjustment capability during operation.
Solution Approach 2:
A stationary sleeve with threaded surfaces acts as an intermediary between the rotating conductor disc and the stationary housing. The threaded engagement allows the stationary sleeve to control the axial position of the rotating conductor disc without itself rotating, enabling adjustment during operation while minimizing rotating mass.
2Stability of the object's composition
If all parts of the coupling assembly are connected to each other and to both the drive shaft and load shaft, then the assembly forms one unit, but severe requirements are placed on the accuracy of the alignment of the drive shaft relative to the load shaft
Solution Approach 1:
The conductor discs are extracted from the unified assembly structure and allowed to rotate independently on their own bearings. This separation allows the drive shaft and load shaft to be less precisely aligned, as the independent rotating discs accommodate minor misalignments without compromising the overall assembly stability.
Solution Approach 2:
The coupling assembly transitions from a static unified structure to a dynamic structure where conductor discs rotate independently on bearings. This dynamic configuration allows the system to accommodate shaft misalignment while maintaining assembly stability, reducing manufacturing precision requirements.
3Reliability
If the adjustment mechanism is stationary relative to the housing, then the rotating mass is reduced and wear is minimized, but the adjustment of the air gap cannot be accomplished when the coupling assembly is in operation
Solution Approach 1:
A stationary threaded sleeve acts as an intermediary that enables adjustment during operation without requiring the adjustment mechanism itself to rotate. The sleeve engages with the rotating conductor disc through threaded surfaces, allowing the stationary sleeve to control the axial position of the rotating disc, thus maintaining both reliability and operational adjustability.
Solution Approach 2:
The traditional mechanical co-rotating adjustment mechanism is replaced with a threaded engagement system. Instead of the adjustment element co-rotating with the conductor disc, a stationary threaded sleeve engages with the rotating disc, substituting a simple rotational adjustment with a threaded mechanical engagement that allows adjustment during rotation.
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 allows for adjustable torque transmission, reduced wear, improved cooling efficiency, and lower maintenance costs, while maintaining operational stability and accuracy even at high speeds.
Implementation Method 1
the sleeve comprises threaded outer surfaces of opposite threading engaged by the first and second displacement elements so as to displace the first displacement element and the first rotatable inductor rotor connected thereto in a first axial direction and the second displacement element and the second rotatable inductor rotor connected thereto in a second axial direction, opposite the first axial direction, upon rotation of the sleeve relative to the displacement elements
Implementation Method 2
Rotation of the first or second shaft results in rotation of the other shaft by magnetic action without there being any direct mechanical connection between the first and seconds shafts. More specifically, torque may be transferred between the magnet rotor and the inductor rotors and thereby between the first and second shaft via Lenz's law
Implementation Method 3
torque may be transferred between the magnet rotor and the inductor rotors and thereby between the first and second shaft via Lenz's law
Implementation Method 4
a passive cooling mechanism using channels within the inductor rotor for ambient air flow
Data Source
AI summary
A magnetic coupling assembly for coupling of a first rotary shaft and a second rotary shaft. The magnetic coupling assembly includes a first and second rotary hub, a sleeve, coaxial with the first rotary hub and arranged to be rotatable with respect to the first rotary hub, a first and second displacement element threadingly connected to the sleeve, and a first and a second rotatable inductor rotor arranged to co-rotate with the rotation of the first rotary hub. The first and second rotatable inductor rotors are connected to the first and second displacement element, respectively, and rotatable central magnet rotor. The sleeve includes threaded outer surfaces of opposite threading engaged by the first and second displacement elements so as to displace the first and second displacement elements in opposite directions.