Permanent Magnet Magnetiser Passage for Precise Field Control
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Solution Overview
Problem
Permanent magnet based magnetisers lack precision due to undesired magnetic field effects, while electric coil based magnetisers are expensive, power-intensive, and pose safety risks in high-volume magnetisation processes.
Innovation Solution
A permanent magnet based magnetiser design with a uniform passage and a diverging portion that reduces undesired magnetic field effects, featuring a circular array of shaped permanent magnets forming a Halbach array, and an optional insert with high magnetic permeability to enhance field uniformity and control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by stationary object
If permanent magnet based magnetisers are used, then operational cost and power consumption are reduced, but manufacturing precision and magnetic field precision deteriorate due to undesired magnetic field effects
Solution Approach 1:
The passage is segmented into three distinct zones: a first portion with permanent magnets providing the main magnetic field, a second intermediate portion with reduced or zero magnetic field strength, and a third portion for field control. This segmentation allows the magnetic field to be spatially differentiated, enabling precise magnetisation in the first portion while minimizing unwanted field effects at the outlet, thus resolving the contradiction between using permanent magnets for low power consumption and maintaining magnetic field precision.
Solution Approach 2:
A second permanent magnet or magnetic shielding material is introduced as an intermediary element in the second portion of the passage. This intermediary component actively counteracts or controls the magnetic field in the intermediate zone, preventing undesired magnetic field effects from propagating to the outlet while maintaining the benefits of permanent magnet operation. This mediator enables precise magnetic field control without requiring high power consumption.
2Manufacturing precision
If electric coil based magnetisers are used, then magnetic field precision is improved, but device complexity, power consumption, and operational cost increase
Solution Approach 1:
The invention replaces the complex electric coil-based magnetic field control system with a simplified permanent magnet-based system. By using permanently magnetized materials arranged in specific configurations within different portions of the passage, the system achieves precise magnetic field control without requiring complex electrical circuits, power supplies, or active control mechanisms, thus reducing device complexity while maintaining manufacturing precision.
Solution Approach 2:
The magnetic field parameters (strength, distribution, and control) are changed by using permanent magnets with specific magnetization strengths and orientations in different portions of the passage. Instead of dynamically adjusting electrical current to control the magnetic field, the invention uses fixed permanent magnet configurations that provide the desired field characteristics, thereby simplifying the device while maintaining precision.
3Productivity
If multiple electric coil based magnets are used for high-volume magnetisation, then productivity is improved, but power consumption, operational cost, and heat generation increase significantly
Solution Approach 1:
Multiple permanent magnet assemblies are merged into a single integrated magnetiser device with multiple passages or a multi-zone passage. This allows simultaneous magnetisation of multiple objects or sequential processing without requiring multiple independent electric coil systems. The combined permanent magnet structure provides the magnetic field for all zones, significantly reducing total power consumption and operational cost while maintaining high productivity through parallel or sequential processing capabilities.
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 design provides a precise and controlled magnetic field with reduced z-component effects at the inlet and outlet, minimizing unwanted magnetic influences and operational costs, while ensuring safety and efficiency in magnetising multiple objects simultaneously.
Implementation Method 1
a permanent magnet assembly arranged outside the passage to provide a magnetic field passing through the passage
Implementation Method 2
the average angle (B) of the normal vector of the opposing surfaces of the diverging portion to a longitudinal centre axis of the passage is greater than 45 degrees
Data Source
AI summary
A magnetizer including a housing, a passage arranged inside the housing, and a permanent magnet assembly arranged outside the passage to provide a magnetic field passing through the passage. The housing defines an inlet to the passage and an outlet from the passage such that an object to be magnetised can be inserted into the passage via the inlet in the housing and removed via the outlet in the housing. The passage includes a uniform portion where opposing surfaces of the permanent magnet assembly are arranged a uniform distance apart along the length of the uniform portion and a diverging portion arranged between one end of the uniform portion of the passage and the outlet of the housing.