Magnetic Gear Unit with Intermediate Pole Carrier
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Solution Overview
Problem
Existing gear units are complex, prone to wear, and inefficient due to electrical lines and coils, limiting their compactness and reliability, especially at high speeds.
Innovation Solution
The gear unit design incorporates magnetizable intermediate poles between outer and inner poles, magnetized by permanently magnetized pole carriers, eliminating the need for electrical lines and coils, allowing for a simpler, more compact, and wear-free power transmission with adjustable torque handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If electrical lines and coils are used in the intermediate pole carrier, then power transmission can be achieved, but the device complexity and losses increase
Solution Approach 1:
The patent replaces the electrical system (coils and electrical lines) with a magnetic system using permanently magnetized poles. The intermediate poles are magnetized by these permanent magnets, eliminating the need for electrical connections and coils in the intermediate pole carrier, thus reducing device complexity while maintaining power transmission capability through magnetic field interaction
Solution Approach 2:
The patent extracts and removes the electrical lines and coils from the intermediate pole carrier design. By eliminating these components entirely and relying solely on magnetic induction from permanently magnetized poles, the design achieves simpler construction without electrical losses or connection complexities
2Power
If electrical lines and coils are used in the intermediate pole carrier, then power transmission can be achieved, but energy losses occur
Solution Approach 1:
The patent substitutes electrical power transmission through coils with magnetic power transmission through permanently magnetized poles. This eliminates resistive losses in electrical lines and energy consumption in coils, achieving wear-free and loss-free power transmission through magnetic field interaction alone
3Device complexity
If the pole bodies are not secured by a support structure, then the construction is simpler, but the stability at high speeds deteriorates
Solution Approach 1:
The patent uses a support bandage with support fibers as a flexible restraining structure to secure the pole bodies. This thin-film-like support structure provides the necessary stability at high speeds while maintaining a compact design with small radial thickness, balancing construction simplicity with operational stability
4Volume of moving object
If the intermediate pole carrier is designed with seated pole bodies, then the structure is more compact, but the manufacturing complexity increases
Solution Approach 1:
The patent implements a nested structure where pole bodies are seated within the intermediate pole carrier and secured by an outer support bandage. This nested arrangement achieves compact construction with small radial thickness while using standardized components that can be manufactured separately and assembled, balancing compactness with manufacturing feasibility
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
This design results in a robust, compact, and efficient gear unit with clear rotational behavior, enabling uninterrupted power transmission and stable operation at high speeds without electrical losses or wear, optimizing field distribution and torque transmission.
Implementation Method 1
the intermediate poles generating a magnetic field through magnetic induction and coils energized thereby, which magnetic field interacts with the outer poles and the inner poles
Implementation Method 2
the magnetizable material of the intermediate poles can be magnetized by permanently magnetized poles of at least one of the outer and inner pole carriers
Data Source
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AI summary
The unit has outer, inner and intermediate pole supports (10, 40, 30) with respective poles, where one of the supports is stationarily arranged, other support is coupled with a drive element and the third one of the supports is coupled with an output element. Each of intermediate poles (32-1, 32-4, 32-5) has a pole body made of a magnetic material, extending between an outside lying pole head facing the outer pole support and an inside lying pole head facing the inner pole support. The material is magnetizable by permanently magnetized poles of one of the outer and inner pole supports.