Magnetic Wheel Coupling for Safer Assisted Load Carriages

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Solution Overview

Problem

Existing assisted thrust systems for moving loads on carriages are complex and expensive, with a risk of autonomous movement if the operator loses grip, posing safety hazards and requiring complicated control mechanisms.

Innovation Solution

A simple and cost-effective assisted thrust system using magnetic coupling between gearmotors and wheels, which reduces the effort required to move loads by generating torque only when the operator exerts force, ensuring the carriage cannot move autonomously without operator input, thus enhancing safety and ease of use.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If motors are applied directly to the axle of the wheels to provide sufficient power to move the carriage, then the carriage can be moved without operator intervention, but the motor torque and power requirements become very high, making the system expensive

Engineering Contradiction:

Improveautonomous movement capabilityVSAvoidmotor power requirements

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

A magnetic coupling device acts as an intermediary between the motor and the wheel axle. The motor drives a first magnetic rotor, which magnetically couples to a second magnetic rotor on the wheel axle through a gear reducer unit, enabling power transmission without direct mechanical connection and reducing the motor's torque requirements

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces direct mechanical coupling with magnetic coupling. The magnetic coupling device uses magnetic fields instead of direct mechanical shafts and gears to transmit rotational force from the motor to the wheel, simplifying the mechanical structure and reducing the motor power needed

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If complex control mechanisms with multiple switches are used to assist the operator in all movement steps, then the carriage can be precisely controlled, but the handling becomes complicated

Engineering Contradiction:

Improvecontrol precisionVSAvoidhandling simplicity

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent extracts and eliminates unnecessary control switches from the system. Instead of requiring multiple switches for start/stop, mode selection, and direction control, the system uses a simplified control mechanism where the operator's natural pushing or pulling action on the grip directly controls the motor activation and direction

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The control system operates automatically based on the operator's physical interaction with the carriage. When the operator pushes or pulls the grip, the system self-activates the motor in the appropriate direction without requiring the operator to manually switch modes or select directions

Inventive Principle:

Principle #25Self-service

3Productivity

If the motor provides sufficient power to move the carriage autonomously, then the carriage can operate without operator thrust, but it poses a safety hazard if the operator loses grip

Engineering Contradiction:

Improveautonomous operationVSAvoidsafety hazard

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The magnetic coupling device is designed so that the motor cannot directly drive the wheel without operator input. The magnetic coupling allows the motor to rotate the wheel only when the operator is applying force to the carriage, preventing autonomous movement that could cause safety hazards

Inventive Principle:

Principle #9Preliminary anti-action

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 system significantly reduces operator effort, eliminates the risk of autonomous carriage movement, and simplifies control operations, making it safer and more user-friendly while avoiding complex and costly mechanisms.

Implementation Method 1

Motion is transmitted to the wheel (9, 10) by a magnetic coupling device, which comprises a first disc (22, 32), which is inserted with clearance into a first seat (45, 46) obtained in the drive wheel (9, 10), so as to be able to rotate with respect to the drive wheel (9, 10); and a second disc (23, 33), which is inserted with clearance into a second seat (24, 34) obtained in the drive wheel (9, 10) in a position opposite the first seat (45, 46), so as to be able to rotate with respect to the drive wheel (9, 10)

Methodology Applied

Scientific EffectMagnetic coupling: Magnetism

Implementation Method 2

a first gear reducer unit (15), the outlet shaft (17) of which is connected to the wheel (9, 10)

Methodology Applied

Scientific EffectGear reduction: Gear

Data Source

PatentUS11753059B2Assisted thrust system for carriages or for loads in general moved on wheels

Publication Date: 2023.09.12 RATIONAL PRODUCTION SRL

AI summary

An assisted thrust system for a carriage provided with wheels that includes a base to which a first directional wheel and a second directional wheel are fixed that are connected to the base so as to be able to rotate around a respective axis perpendicular to the base; to the base a first drive wheel and a second drive wheel are further fixed that are rotated by at least one gearmotor unit, which drives the first drive wheel by a first magnetic coupling device and the second drive wheel by a second magnetic coupling device.