Clamp Assembly Using Pulsed Coils to Magnetize Permanent Magnets
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Solution Overview
Problem
Existing electromagnetic clamping systems require high energy consumption and cooling systems due to the continuous application of high currents to achieve hundreds of pounds of clamping force, leading to inefficiencies and potential overheating during long clamping cycles.
Innovation Solution
A clamp assembly utilizing a plurality of magnet devices with permanent magnets and coils that can be selectively magnetized and demagnetized using a controller, along with keepers to provide a flux path, allowing for pulsing of coil currents to achieve clamping and release of force efficiently, reducing overall power consumption and eliminating the need for cooling systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If high current is applied constantly to electromagnets to achieve hundreds of pounds of clamping force, then sufficient clamping force is obtained, but total energy usage becomes extremely high
Solution Approach 1:
The patent applies periodic pulsed current to the coils instead of continuous current. The controller delivers current in short bursts to magnetize the permanent magnets only when clamping force is needed, then stops current flow while maintaining the magnetic field. This periodic action dramatically reduces energy consumption while maintaining the required clamping force during operation.
Solution Approach 2:
The patent replaces traditional electromagnets that require continuous high current with a hybrid system using permanent magnets activated by pulsed coils. The permanent magnets provide the holding field without continuous power, substituting the need for continuous electrical energy input while maintaining the same mechanical clamping force output.
2Force
If high current is applied constantly during long clamping cycles, then sufficient clamping force is maintained, but the electromagnets overheat requiring cooling systems
Solution Approach 1:
By applying current in short periodic pulses rather than continuously, the electromagnets (coils) have sufficient time to cool between pulses. This periodic on-off cycling prevents heat accumulation that would occur with continuous current application, eliminating the need for cooling systems during long clamping cycles.
Solution Approach 2:
The patent extracts the cooling system requirement by removing the continuous current application. The periodic pulsing of current eliminates the heat generation problem, so the harmful thermal effect is taken out of the system entirely, making cooling systems unnecessary.
3Force
If large electromagnets and high currents are used to obtain hundreds of pounds of clamping force, then sufficient force is achieved, but the system complexity increases due to required cooling systems
Solution Approach 1:
The periodic pulsed current operation eliminates heat buildup, which removes the entire cooling system subsystem. This simplification of the device architecture directly reduces complexity while maintaining the required clamping force capability throughout long operational cycles.
Solution Approach 2:
The patent substitutes the complex continuous electromagnet system with a simpler permanent magnet system activated by pulsed coils. This replacement eliminates the need for cooling infrastructure, reducing overall system complexity while achieving the same force output.
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 solution achieves a high clamping force with significantly reduced energy consumption and eliminates the need for cooling systems, as the coil currents are applied in short pulses rather than continuously, resulting in a more efficient and effective clamping process.
Implementation Method 1
When the electromagnets are actuated, they create a magnetic field whose flux lines flow through the plate
Implementation Method 2
each magnet device including a permanent magnet and a coil surrounding the permanent magnet; and a controller for pulsing the coils to selectively magnetize and demagnetize the permanent magnets
Implementation Method 3
the keeper also providing a flux path between the permanent magnets
Data Source
Figure 1
Figure 2~3
Figure 4A~4B
AI summary
A clamp assembly comprises a first clamp including a plurality of magnet devices. Each magnet device includes a permanent magnet and a coil surrounding the permanent magnet. The clamp assembly further comprises a controller for pulsing the coils to selectively magnetize and demagnetize the permanent magnets.