Double-Walled Split Can Structure for Leakage Detection and Low Loss

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Solution Overview

Problem

Existing split cans for magnetic clutches have high production costs and significant wall thickness, leading to increased transmission and eddy current losses, as well as thermal mismatch and heating issues due to the gap between inner and outer walls.

Innovation Solution

The split can is designed with an integrally connected inner and outer wall via a plurality of webs, produced using additive methods like the powder bed method, allowing for a thinner, more stable, and thermally compensated structure, with optional double-walled configurations and openings for medium introduction and monitoring sensors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a double-walled split can is produced by arranging two separately produced split cans one inside the other, then damage detection capability is improved, but production cost and wall thickness increase

Engineering Contradiction:

Improvedamage detection capabilityVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent merges the inner and outer split can walls into a single integrally produced component using additive manufacturing technology. This eliminates the need for separate production and assembly of two independent split cans, thereby reducing production cost while maintaining the double-walled structure for damage detection capability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent replaces the traditional mechanical assembly approach (arranging two separately produced split cans one inside the other) with an additive manufacturing process. This substitution enables integral production of the double-walled structure, reducing both production cost and wall thickness while preserving the monitoring gap for damage detection.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If a double-walled split can is produced by arranging two separately produced split cans one inside the other, then damage detection capability is improved, but wall thickness increases

Engineering Contradiction:

Improvedamage detection capabilityVSAvoidwall thickness

Core Design Contradiction:

ReliabilityVSLength of stationary object

Solution Approach 1:

The patent replaces the traditional mechanical assembly approach with additive manufacturing, enabling precise control of wall thickness. The additive process allows the inner and outer walls to be produced integrally with optimized thickness parameters, reducing overall wall thickness while maintaining the monitoring gap necessary for damage detection capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If sheet metal material is used for the split can, then production cost is reduced, but eddy current losses increase due to larger wall thickness

Engineering Contradiction:

Improveproduction costVSAvoideddy current losses

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The patent uses additive manufacturing to produce the split can with precisely controlled, reduced wall thickness. This enables the use of sheet metal material (lower cost) while minimizing eddy current losses through the thinned wall structure, as the additive process allows optimization of material distribution and thickness to reduce energy losses.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Temperature

If thermal paste is arranged in the gap between inner and outer walls, then thermal expansion mismatch is counteracted, but device complexity increases

Engineering Contradiction:

Improvethermal expansion controlVSAvoidassembly complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent replaces the complex assembly process of applying thermal paste between two separately produced split cans with an additive manufacturing process. The integral production method inherently manages thermal expansion through the designed web structure and monitoring gap, eliminating the need for thermal paste application and significantly reducing assembly complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

This design improves torque transmission and thermal behavior by reducing material thickness, minimizing eddy current losses, and enabling homogeneous thermal expansion, while allowing for efficient cooling or heating and damage detection through monitoring sensors.

Implementation Method 1

the webs are arranged between the inner wall and outer wall (3, 4) and are integrally connected to the inner wall and outer wall (3, 4)... a thermal compensation between the inner wall and the outer wall is achieved... the inner wall and the outer wall can thereby become heated or to thermally expand in a comparatively homogeneous manner

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

there is arranged between the walls a gap which is continuously monitored by monitoring sensors and consequently it is possible to detect damage to the split can

Methodology Applied

Scientific EffectDamage detection through gap monitoring:

Implementation Method 3

This is possible in particular by using additive production methods, such as, for example, the powder bed method

Methodology Applied

Scientific EffectAdditive manufacturing (powder bed method): 3D Printing

Data Source

PatentUS12142986B2Split can

Publication Date: 2024.11.12 KSB SE & CO KGAA

AI summary

A split can for a magnetic coupling includes a cylindrical jacket region and a base region connected to a first end of the jacket region. The jacket region has an inner wall and an outer wall enclosing the inner wall. The inner wall and the outer wall are spaced apart from each other in the radial direction by a gap, with the inner wall being integrally joined to the outer wall by a plurality of webs. The gap may be provided with a control medium which may be monitored to detect changes in one or more characteristics of the control medium indicative of split can leakage.