Magnetic Gear Interpole Design for Torque and Noise
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Solution Overview
Problem
Conventional magnetic gears face issues such as double air gap modulation inefficiency, weak laminated steel interpole structures, and complex variable-ratio operations, leading to noise, wear, and maintenance challenges in industrial applications like oil rigs.
Innovation Solution
The use of free-spinning magnetized cylinder interpole elements that harmonically couple magnetic pole pairs between gear members, enhancing torque density and structural durability, and allowing for variable gear ratios through adjustable magnetized cylinder configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional magnetic gears with double air gap are used, then magnetic coupling is achieved, but modulation efficiency is hampered
Solution Approach 1:
The patent introduces a ferromagnetic bridge structure as an intermediary element that physically connects the two gear members, providing a direct magnetic flux path that eliminates the double air gap problem. This bridge acts as a mediator that enhances magnetic coupling efficiency by reducing magnetic reluctance in the flux path.
Solution Approach 2:
The patent replaces the conventional double air gap magnetic coupling mechanism with a hybrid system that uses a ferromagnetic bridge structure to establish direct magnetic flux paths, substituting the less efficient air gap-based coupling with a more efficient bridge-based coupling mechanism.
2Reliability
If laminated steel interpole elements are used, then magnetic flux modulation is achieved, but structural durability is reduced due to weakness and damage susceptibility
Solution Approach 1:
The patent employs composite material construction for the interpole elements, combining ferromagnetic materials with structurally robust materials to create interpole elements that possess both the necessary magnetic properties for flux modulation and the structural strength required for durability in demanding industrial environments.
Solution Approach 2:
The patent divides the interpole structure into multiple segments or components, allowing each segment to be optimized for specific functions (magnetic flux conduction, structural support, mechanical strength) while collectively providing enhanced overall durability and reliability compared to monolithic laminated steel structures.
3Adaptability or versatility
If conventional variable-ratio magnetic gears are used, then gear ratio variation is achieved, but operational complexity increases
Solution Approach 1:
The patent implements dynamic adjustability in the magnetic gear system, allowing the gear ratio to be varied by changing the magnetic pole configurations or the relative positioning of the gear members while maintaining relatively simple operational procedures through automated or semi-automated control mechanisms.
Solution Approach 2:
The patent achieves variable gear ratios by changing magnetic field parameters such as the number of magnetic poles, the strength of magnetic fields, or the spatial distribution of magnetic flux, rather than requiring complex mechanical reconfiguration, thereby simplifying the operation while maintaining adaptability.
4Object-affected harmful factors
If mechanical gear arrangements with intermeshing teeth are used, then torque conversion is achieved, but noise and vibration are generated
Solution Approach 1:
The patent replaces the mechanical tooth-based torque conversion system with a magnetic field-based torque transmission system, eliminating the harmful noise and vibration associated with mechanical tooth engagement while preserving the essential torque conversion capability through magnetic coupling between gear members.
Solution Approach 2:
The patent introduces magnetic fields as an intermediary mechanism for torque transmission, replacing direct mechanical contact between gear teeth with indirect magnetic coupling, thereby eliminating the source of noise and vibration while maintaining effective torque conversion.
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 solution significantly increases torque density, reduces noise and wear, and simplifies maintenance by providing robust, efficient, and adaptable magnetic gear systems for industrial applications, particularly in oil rigs.
Implementation Method 1
The plurality of interpole elements may be disposed to harmonically couple the magnetic pole pairs of the first gear member with the magnetic pole pairs of the second gear member
Implementation Method 2
a first gear member comprising a plurality of permanent magnets arranged to have a first number of magnetic pole pairs and second gear member positioned relative to the first gear member. The second gear member may comprise a plurality of individually rotatable magnetized elements
Data Source
AI summary
A magnetic gear may comprise a first gear member comprising a plurality of permanent magnets arranged to have a first number of magnetic pole pairs and a second gear member positioned relative to the first gear member. The second gear member may comprise a plurality of individually rotatable magnetized elements each driven and synchronized with one another to selectively generate a second number of magnetic pole pairs that differs from the first number of magnetic pole pairs. The magnetic gear may further comprise a plurality of interpole elements positioned between the first and second gear members. The plurality of interpole elements may be disposed to harmonically couple the magnetic pole pairs of the first gear member with the magnetic pole pairs of the second gear member for each selectively generated second number of magnetic pole pairs.