Modular Magnetic Bearing Sector Assembly
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Solution Overview
Problem
The manual assembly of magnetic bearings is labor-intensive and costly, particularly for high production volumes, limiting the efficiency and scalability of manufacturing processes.
Innovation Solution
A modular magnetic bearing design with actuator and sensor sub-assemblies comprising multiple sectors, allowing for automated assembly and larger bobbin sizes, which simplifies and accelerates the manufacturing process while increasing load capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual assembly methods are used for magnetic bearings, then manufacturing flexibility and adaptability are maintained, but labor time and manufacturing cost increase significantly
Solution Approach 1:
The magnetic bearing is divided into multiple independent sectors (typically 3-4 sectors) that can be manufactured separately and then assembled. Each sector contains its own magnetic coils and structural elements. This segmentation enables parallel manufacturing of multiple sectors simultaneously, reducing total production time and allowing automated assembly processes while maintaining design flexibility.
2Productivity
If manual assembly methods are used for magnetic bearings, then assembly flexibility is maintained, but productivity and production volume scalability are limited
Solution Approach 1:
By dividing the magnetic bearing into standardized modular sectors, the invention enables automated assembly lines to efficiently manufacture multiple units in parallel. Each sector can be pre-assembled and tested independently, then quickly combined with other sectors and components using automated fastening systems, dramatically increasing production volume capability.
Solution Approach 2:
Magnetic coils are pre-wound around bobbin structures before final assembly into the magnetic bearing sectors. This preliminary preparation of critical components allows for standardized, repeatable assembly processes that can be automated, reducing on-site assembly complexity and enabling higher productivity.
3Strength
If smaller single laminations are used, then manufacturing precision is maintained, but bobbin size is limited and load capacity decreases
Solution Approach 1:
The magnetic bearing structure is segmented into multiple sectors that are assembled together to form the complete circular structure. Each sector can use smaller, precisely manufactured lamination stacks, but when assembled together they create the equivalent of a large-diameter bobbin structure, achieving both manufacturing precision and high load capacity.
Solution Approach 2:
Multiple smaller lamination stacks from different sectors are merged together through precise alignment and fastening to create the functional equivalent of a large single lamination structure. This combining approach allows each small sector to be manufactured with high precision using standard manufacturing capabilities, while the assembled structure achieves the load capacity of a much larger component.
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 modular design reduces labor time and costs, enables faster production, and enhances the feasibility of high-volume manufacturing by automating the assembly of magnetic bearings, improving their load capacity and manufacturing efficiency.
Implementation Method 1
The actuators, formed by electromagnets, are designed to support and position a rotating device, such as a rotating shaft
Implementation Method 2
The actuators, formed by electromagnets, are designed to support and position a rotating device
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention concerns a magnetic bearing (1), adapted to equip a rotary apparatus. The magnetic bearing (1) comprises: an actuator sub-assembly (2) provided with a magnetic base (10) and at least three actuator bobbins (20) mounted on the magnetic base (10), and a sensor sub-assembly (4) provided with at least three magnetic sensors (30) associated with the actuator bobbins (20). At least one sub-assembly (2 ; 4) amidst the actuator sub-assembly (2) and the sensor sub-assembly (4) comprises at least three sectors (11) mounted together. Each sector (11) includes at least one actuator bobbin (20) when the sector (11) belongs to the actuator sub-assembly (2), or at least one magnetic sensor (30) when the sector belongs to the sensor sub-assembly (4). The invention also concerns a rotary apparatus comprising such a magnetic bearing (1) and a method for manufacturing such a magnetic bearing (1).