Variable Magnetic Coupler With Switchable Flux States
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Solution Overview
Problem
Current magnetic couplers lack the ability to dynamically adjust magnetic flux levels for efficient lifting and handling of ferromagnetic workpieces, often requiring multiple devices or complex setups to achieve desired magnetic states.
Innovation Solution
A magnetic coupling device with a housing, multiple workplace contact interfaces, and two permanent magnets with an actuator and electronic controller to adjust the position of the second magnet relative to the first, allowing for three distinct magnetic flux states: insufficient, sufficient, and enhanced lifting capabilities, monitored by sensors for precise control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a magnetic coupler uses fixed permanent magnets to provide lifting force, then the lifting capability is sufficient for heavy workpieces, but the device cannot be easily switched off or adjusted for different workpiece types
Solution Approach 1:
The patent implements a rotatable permanent magnet that can be positioned in different orientations (0° for on-state, 90° for off-state, intermediate angles for partial states) to dynamically adjust the magnetic flux available at the workpiece contact interface. This rotational mechanism allows the magnetic coupler to transition between multiple operational states, providing both strong lifting capability when needed and the ability to easily switch off or adjust for different workpiece types.
2Force
If multiple permanent magnets are used to provide sufficient magnetic flux for lifting, then the lifting capability increases, but the device complexity and size increase
Solution Approach 1:
The magnetic coupler is divided into two functional components: a stationary permanent magnet that provides a constant magnetic field, and a rotatable permanent magnet that can be positioned to either contribute to or cancel the magnetic flux at the workpiece interface. This segmentation allows the system to achieve multiple flux levels (on, off, partial states) using a single rotational degree of freedom rather than requiring multiple independent magnet assemblies, thereby reducing structural complexity.
3Force
If a magnetic coupler is designed to provide high magnetic flux for lifting heavy workpieces, then the lifting capability is sufficient, but the device cannot be used for lighter workpieces requiring lower magnetic flux
Solution Approach 1:
The patent changes the operational parameter of magnetic flux availability by rotating the second permanent magnet to different angular positions. When rotated to 0°, the magnet contributes maximum flux for heavy workpieces. When rotated to 90°, it provides minimal or zero flux for light workpieces or when lifting is not needed. Intermediate angles provide partial flux levels, enabling the same device to handle a wide range of workpiece weights and applications.
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
Enables efficient and controlled lifting and handling of ferromagnetic workpieces by dynamically adjusting magnetic flux, improving handling precision and versatility across different workpiece types.
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 to magnetically couple to a ferromagnetic workpiece
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.