Magnetic Level Coupling Circuit for Stronger Hold and Safer Assembly
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Solution Overview
Problem
Existing levels struggle with efficient magnetic coupling to magnetic workpieces, particularly due to the brittleness of rare-earth magnets and the need for direct contact during assembly, which can damage the magnets and reduce the magnetic coupling force.
Innovation Solution
The use of magnetic circuits with low reluctance materials, such as steel sleeves, to guide and focus the magnetic field, combined with rare-earth magnets positioned to maximize magnetic coupling force, and a press-fit assembly that avoids direct contact with the magnets during installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If rare-earth magnets are used to provide strong magnetic coupling force, then magnetic coupling force is improved, but the magnets become brittle and prone to damage during assembly
Solution Approach 1:
A recess is provided in the level body that receives the rare-earth magnet, serving as an intermediary structure that protects the brittle magnet from direct contact and damage during assembly while still allowing the magnet to provide sufficient magnetic coupling force through the recess walls
Solution Approach 2:
The recess structure is designed beforehand to cushion and protect the rare-earth magnet from impact and damage during the assembly process, preventing direct contact between the magnet and external forces that could cause brittleness-related failure
2Force
If magnetic coupling elements are positioned close to the base surface to maximize coupling force, then magnetic coupling force is improved, but the magnetic material quantity increases
Solution Approach 1:
The magnetic circuit structure is designed with specific local qualities - the magnetic circuit material is positioned strategically to guide and concentrate the magnetic field from the rare-earth magnet toward the base surface, maximizing coupling force efficiency while minimizing the total quantity of magnetic material required
3Ease of manufacture
If direct contact assembly is used to install magnetic components, then assembly simplicity is improved, but the brittle magnets are damaged
Solution Approach 1:
The recess acts as an intermediary structure during assembly, allowing the magnetic component to be installed without direct contact between the brittle magnet and the assembly tools or surfaces, thereby maintaining magnet integrity while keeping the assembly process simple
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
Enhances magnetic coupling force, reduces the need for excessive magnetic material, and protects rare-earth magnets from damage during assembly, ensuring secure attachment to magnetic workpieces.
Implementation Method 1
a magnetic coupling element located to direct a magnetic coupling field through or beyond a surface of the tool
Implementation Method 2
magnetic circuit including a magnet located adjacent to at least one metallic structure
Data Source
AI summary
A tool, such as a level, including one or more magnetic coupling device is provided. The magnetic coupling device may be a magnetic circuit including metal components surrounding a magnet, such as a permanent rare-earth magnet.