Switchable Magnetic Coupling for Barrier-Isolated Power Transfer
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Solution Overview
Problem
Existing magnetic coupling devices lack flexibility in controlling magnetic flux strength and efficiency in coupling with ferromagnetic workpieces, particularly in varying environmental conditions and operational demands.
Innovation Solution
A magnetic coupling device with a switchable magnetic flux source comprising permanent magnets and ferromagnetic cores, allowing for adjustable magnetic states, including ON, OFF, and partial ON states, facilitated by actuators and sensors for precise control and monitoring, enabling variable magnetic flux levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If magnetic coupling devices are used to connect rotating components across a barrier, then power and motion can be transmitted without penetrating the barrier, but the device complexity increases due to multiple magnetic components and alignment requirements
Solution Approach 1:
The patent implements nesting by placing the second magnet inside the bore of the first magnet, creating a compact dual-magnet assembly. This nested configuration allows both magnets to work together to generate the magnetic coupling field while maintaining a compact structure that fits within the drive shaft constraints, thus transmitting power across the barrier without compromising device simplicity
Solution Approach 2:
The patent introduces a non-magnetic barrier (such as a ceramic or polymer layer) as an intermediary between the two magnets. This intermediary allows magnetic flux to pass through while physically separating the magnets, enabling power transmission without direct contact or penetration of the barrier, thus maintaining barrier integrity while enabling functional coupling
2Reliability
If the distance between magnets is increased to accommodate a barrier, then the barrier can be effectively isolated, but the magnetic coupling strength decreases
Solution Approach 1:
By nesting the second magnet within the bore of the first magnet, the patent minimizes the effective distance between the magnetic centers while still accommodating the barrier. This nested arrangement allows the magnets to maintain strong coupling despite the presence of the barrier, as the magnetic flux path remains short and direct through the barrier material
Solution Approach 2:
The patent employs composite construction by combining magnetic materials (the magnets themselves) with non-magnetic barrier materials (ceramic, polymer, or air gap) in a layered composite structure. This composite approach allows the system to benefit from both the magnetic coupling strength of the magnets and the isolation properties of the barrier material, maintaining force transmission while ensuring barrier integrity
3Power
If a dual-magnet system is used to maintain coupling across a barrier, then power transmission is maintained, but the manufacturing precision requirements increase due to alignment constraints
Solution Approach 1:
The nested configuration of the second magnet within the bore of the first magnet provides inherent alignment guidance. The bore of the first magnet acts as a mechanical guide that constrains the position and orientation of the second magnet, ensuring proper alignment during assembly without requiring high-precision machining or complex alignment procedures, thus maintaining power transmission while reducing manufacturing precision requirements
Solution Approach 2:
The patent creates a magnetically equipotential arrangement by positioning the magnets in opposition across the barrier with their magnetic axes aligned. This equipotential configuration ensures that the magnetic flux distributes evenly across the barrier surface, reducing sensitivity to minor misalignments and maintaining consistent power transmission even with variations in manufacturing tolerances
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 device provides efficient and adaptable magnetic coupling with ferromagnetic workpieces, enhancing operational flexibility and performance across different conditions.
Implementation Method 1
a magnetic coupling device (400) having a first magnet (410, 420) and a second magnet (410, 420)
Implementation Method 2
the first magnet (410, 420) and the second magnet (410, 420) are arranged to face each other with the barrier (430) therebetween
Data Source
Figure 1~2
Figure 3
Figure 4A~4B
AI summary
Magnetic coupling devices are disclosed. The magnetic coupling devices may include at least one permanent magnet and at least one ferromagnetic core. The at least one permanent magnet may surround the at least one ferromagnetic core.