Magnetic Coupling Assembly Axial Alignment Mechanism
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Solution Overview
Problem
Magnetic coupling assemblies face challenges in axial alignment during installation due to high magnetic forces and the need for precise air gap dimensions, making it difficult to achieve proper alignment without labor-intensive adjustments, especially in vertical installations.
Innovation Solution
A magnetic coupling assembly with axially movable hub parts and a connector unit allows for precise control and adjustment of air gaps between the magnet rotor and inductor rotors, enabling easy and reliable alignment without moving the drive or load shaft, using a combination of hub movement and adjustable spacers to set and maintain equal air gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If magnetic coupling assemblies use defined spacing between magnet rotor and conductors for proper functioning, then torque transmission efficiency is improved, but installation difficulty increases due to high magnetic forces and labor-intensive axial alignment
Solution Approach 1:
The invention introduces adjustable positioning mechanisms that allow the air gaps between the magnet rotor and conductors to be dynamically adjusted during installation and operation. This enables the coupling to adapt to varying conditions while maintaining optimal spacing for torque transmission, resolving the contradiction between efficiency and installation ease.
Solution Approach 2:
The invention allows changing the air gap parameters (distances between magnet rotor and conductors) to optimize performance. By providing adjustable positioning, the system can modify these parameters during installation to overcome high magnetic forces and achieve proper alignment without excessive labor, while maintaining the defined spacing needed for efficient torque transmission.
2Reliability
If magnetic coupling assemblies require precise axial alignment of rotors during installation, then coupling performance is improved, but installation time and labor increase significantly
Solution Approach 1:
The invention incorporates preliminary positioning features and adjustable mechanisms that facilitate axial alignment during installation. These features allow installers to more easily achieve the precise rotor alignment needed for coupling performance, reducing the time and labor required compared to traditional fixed-position installations.
Solution Approach 2:
The adjustable positioning mechanisms enable dynamic adjustment of rotor positions during installation, allowing installers to achieve precise axial alignment more efficiently. This dynamic capability reduces the time and effort needed to reach the required alignment precision for optimal coupling performance.
3Ease of manufacture
If magnetic coupling assemblies use fixed air gap dimensions, then manufacturing is simplified, but adaptability to varying load conditions and thermal expansion decreases
Solution Approach 1:
The invention introduces adjustable positioning mechanisms that allow air gap dimensions to be modified during installation and operation. This enables the coupling to adapt to varying load conditions and thermal expansion effects, overcoming the limitation of fixed dimensions while maintaining relatively simple manufacturing processes for the base components.
Solution Approach 2:
The invention allows changing the air gap parameters to adapt to different operating conditions. The adjustable mechanisms enable modification of these parameters in response to varying load requirements and thermal effects, providing versatility while keeping the base manufacturing process relatively simple.
4Adaptability or versatility
If magnetic coupling assemblies allow adjustment of air gaps during operation, then adaptability to varying conditions is improved, but device complexity increases
Solution Approach 1:
The invention implements adjustable positioning mechanisms that enable air gap modification during operation to adapt to varying conditions. While this adds some complexity, the mechanisms are designed to be integrated into the existing coupling structure, minimizing the increase in overall device complexity while achieving the desired adaptability.
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
Facilitates easy and accurate axial alignment, allowing for adjustments to air gaps during installation and operation, improving coupling performance by enabling equalization of air gaps under varying conditions, reducing labor and reinstallation efforts, and enhancing energy efficiency by adapting to load conditions.
Implementation Method 1
A magnetic coupling assembly may comprise one or more magnet rotors, with each magnet rotor having a respective set of permanent magnets. Each magnet rotor of the known magnetic coupling assembly is associated with at least one electromagnetic inductor rotor spaced apart from the magnet rotor. Torque may be transferred from the first shaft to the second shaft, with the speed of the load shaft reduced with respect to the speed of the drive shaft, without the drive shaft being in contact with the load shaft.
Implementation Method 2
Each magnet rotor of the known magnetic coupling assembly is associated with at least one electromagnetic inductor rotor spaced apart from the magnet rotor
Implementation Method 3
In practice the axial alignment of a magnetic coupling in the installation phase is a difficult task and is labor intensive, for instance because of the magnetic attraction between the elements of the coupling
Data Source
AI summary
The invention relates to a magnetic coupling assembly for associating a first rotatable shaft to a second rotatable shaft, the magnetic coupling assembly comprising:—a rotatable first hub to be connected to the first rotatable shaft, the first hub comprising a magnet rotor comprising a plurality of permanent magnets;—a rotatable second hub to be connected to the second rotatable shaft, the second hub comprising a conductor housing comprising at least one conductor positioned at a distance from a side of the magnet rotor facing the second rotatable shaft; wherein at least one of the second hub and first hub comprises an inner hub part and an outer hub part, wherein the hub parts are configured to allow the outer hub part to be axially movable over the inner hub part to adjust the axial position of the at least one conductor relative to the magnet rotor.