Variable-Flux Magnetic Couplers for Ferromagnetic Workpiece Handling
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Solution Overview
Problem
Existing magnetic couplers lack the ability to dynamically adjust the magnetic flux to efficiently lift and transport ferromagnetic workpieces, limiting their versatility and effectiveness in various applications.
Innovation Solution
A magnetic coupling device with a housing, workpiece contact interfaces, a first permanent magnet, a second permanent magnet that is moveable relative to the first, an actuator to move the second magnet, and an electronic controller to position the second magnet in multiple states, thereby adjusting the magnetic flux to suit different lifting and transport requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a magnetic coupler uses fixed permanent magnets, then the structure is simple and reliable, but the magnetic flux cannot be adjusted dynamically
Solution Approach 1:
The patent applies the dynamics principle by making the magnetic coupler's flux output adjustable through multiple permanent magnet assemblies that can be independently positioned. Each magnet assembly can be moved between different locations to dynamically change the magnetic flux density at the workpiece contact surface, transforming a static magnetic system into a dynamic one that adapts to different lifting requirements.
Solution Approach 2:
The patent segments the magnetic coupler into multiple independent permanent magnet assemblies, where each assembly can be controlled separately. This segmentation allows selective activation and positioning of individual magnet assemblies, enabling precise control over the total magnetic flux output while maintaining structural modularity and reducing overall system complexity.
2Adaptability or versatility
If multiple permanent magnet assemblies are used to provide variable magnetic flux, then the adaptability improves, but the device complexity increases
Solution Approach 1:
The patent implements universality by designing multiple permanent magnet assemblies that can perform the same lifting function but with varying flux contributions. Each magnet assembly is structurally identical and can be positioned in different locations or activated selectively, allowing the system to achieve multiple flux levels using standardized components, thereby reducing design complexity despite having multiple assemblies.
Solution Approach 2:
The patent applies local quality by enabling selective activation and positioning of individual magnet assemblies based on specific operational requirements. Different regions of the coupler can be activated independently to provide locally optimized magnetic flux distribution, allowing the system to adapt to different workpiece sizes, weights, and contact areas without requiring complete redesign of the entire magnet system.
3Productivity
If the second permanent magnet is moved to provide different flux levels, then the productivity improves, but the control system complexity increases
Solution Approach 1:
The patent applies self-service by utilizing the inherent magnetic properties of permanent magnets and their natural interaction with ferromagnetic workpieces. The system leverages the passive magnetic field generation capability of permanent magnets, requiring minimal active control compared to electromagnet systems. The actuators simply position the magnets, and the magnetic coupling occurs automatically through material properties rather than requiring continuous active control.
Solution Approach 2:
The patent replaces complex electromagnetic control systems with simpler mechanical positioning of permanent magnets. Instead of using powerful electromagnets with complex current control circuits, the system uses mechanically positioned permanent magnets where the magnetic field strength is determined by position rather than electrical input, significantly simplifying the control architecture while maintaining high productivity.
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 can provide multiple levels of magnetic flux, allowing it to lift and transport ferromagnetic workpieces efficiently, and can be configured for various applications, including destacking and handling multiple types of ferromagnetic materials.
Implementation Method 1
one or more permanent magnet(s) that is (are) rotatable relative to one or more stationary permanent magnet(s), in order to generate and shunt a magnetic field
Implementation Method 2
magnetic coupler... adapted to contact the ferromagnetic workpiece
Implementation Method 3
provide a first level of magnetic flux available to the ferromagnetic workpiece... provide a second level of magnetic flux... provide a third level of magnetic flux
Data Source
AI summary
Magnetic coupling devices are disclosed which may be configured in at least three states. The various states may be provided through one or more of altering a position of a permanent magnet relative to another permanent magnet and altering a current level in a coil surrounding a permanent magnet.