PERMANENT MAGNET COUPLING AND TRANSMISSION

This application is a continuation-in-part of my copending application Serial No. 08/065,867 filed May 21, 1993.

Technical Field

The present invention relates to magnetic couplers utilizing rotary electroconductive plates and rotary discs containing permanent magnets. When used herein "magnetic couplers" is intended to include magnetic clutches and magnetic brakes.

Background of the Invention

When a non-ferrous electroconductive plate is rotated between two fixed discs containing permanent magnets ("magnetic disc") arranged so that opposing magnets on the discs are of opposite polarity, eddy currents are generated in the rotating plate resulting in magnetic friction between the electroconductive plate and the magnetic discs. Such an arrangement incorporated as a resistance applying means on an exercise bike is disclosed in U.S. Patent No. 4,826,150. The amount of the drag resulting from the magnetic friction in such a device may be varied by adjusting the relative positions of the magnetic discs between a position in which magnets of opposite polarity are positioned directly opposite one another (maximum magnetic friction) to a position in which magnets of like polarity are positioned directly opposite one another (no magnetic friction) . Magnetic friction can also be varied by adjusting the air gaps between the electroconductive plate and the magnetic discs; increasing the gaps decreases the magnetic friction.

It is to be understood that the operation of a load applying device in which a non-ferrous

electroconductive plate (copper plate, for example) is rotated relative to an adjacent magnetic disc, is different from the operation of a magnetic coupling device in which a ferrous plate is rotated relative to an adjacent magnetic disc in that in the latter instance there is a relatively strong axial attraction between the ferrous plate and the magnetic disc which is not present in the other instance between the non-ferrous electroconductive plate and the magnetic disc. It has been found that when a copper plate is rotated relative to a co-axial adjacent magnetic disc which is free to rotate and move axially, the magnetic disc will repel and rotate with the copper plate, moving toward the copper plate axially as the rotational speed builds up, but will not normally contact the copper plate. The axial thrust developed between the copper plate and the magnetic disc is proportional to their speed difference. However, when the adjacent rotating plate is ferrous rather than copper, the magnetic plate will move directly into contact with the magnetic plate while stationary or rotating if permitted to do so. This operating distinction is significant in the operation of the present invention.

When a magnetic disc is free to rotate between and independently of a pair of adjacent non-ferrous electroconductive plates which are mounted for rotation on a rotary axis coaxial with the rotary axis of the magnetic disc, and the magnetic disc is driven, for example, relative to the electroconductive plates, the plates initially tend to axially repel away from the magnetic disc as the plates' rotational speed increases and the slip between them decreases. The axial repulsion will then decrease, and the copper plates will eventually move axially toward the magnetic disc, ordinarily maintaining a small air gap which is usually at least about 3mm. This is not true when ferrous plates are used instead of non- ferrous electroconductive plates adjacent to the magnetic disc.

In all instances herebefore known to applicant in which a non-ferrous electroconductive plate has been used in association with a magnetic disc for a coupling function, the plate has either been positioned between two magnetic discs as in the previously mentioned U.S. Patent No. 4,826,150, or has been placed between a disc containing a permanent magnet and a yoke element engaging the disc so as to be magnetized. The latter arrangement is utilized in the speed governor disclosed in U.S. Patent No. 4,826,150.

To applicant's knowledge the prior art has failed to recognize the advantages to be gained in magnetic couplers by arranging a magnetic disc between two adjacent non-ferrous electroconductive plates. The present invention aims to provide improved couplers incorporating this superior arrangement.

Smtι-ma*rγ of the Invention

The practice of the present invention involves the combination of magnetic disc means, electroconductive means, and mounting means for mounting the magnetic disc means and electroconductive means on respective rotary shafts, one of the shafts being a powered input shaft and the other being an output shaft. In some of the embodiments of the invention the input and output shafts are coaxial, and in others the shafts are in offset parallel relationship. The electroconductive means preferably includes a pair of spaced electroconductive plates which are preferably copper, but may be aluminum or other non-ferrous material with a suitable electroconductive characteristic. The electroconductive means can also advantageously comprise a pair of spaced laminated plates each of which has a non-ferrous electroconductive plate (copper, for example) backed by a ferrous plate. Such a laminated plate has been found to be normally more efficient than a non-backed electroconductive plate. The magnetic disc means

comprises a disc having a plurality of permanent magnets inserted therein. In some embodiments the magnetic disc means includes a second magnetic disc matching the other disc and coaxial therewith. The magnetic drag between a magnetic disc and a non-ferrous electroconductive plate for a given air gap therebetween can be increased by increasing the diameter of the plate, by laminating the plate, by backing the plate with a ferrous plate, and by increasing the number and/or strength of the permanent magnets in the magnetic disc. These variables, once set in the design of a coupler, are permanent as respects a given coupler. Hence, the potential variable during operation of the coupler is the air gap. In some embodiments the two electroconductive plates are coupled together to rotate as a unit mounted on the input or output shaft and with the magnetic disc means mounted on the other shaft. In an alternative arrangement the magnetic disc means operates as an idler between the electroconductive plates, and these plates are mounted one on the input shaft and the other on the output shaft. Also, in some embodiments spring biasing is used so that the air gap is initially relatively narrow, but may increased by magnetic repulsion when rotation of the output shaft is stopped as a consequence for example, of bearing seizure. In still another embodiment the air gap is remotely controlled.

The rotary axes of the magnetic disc and electroconductive plates in the coupler can be in parallel offset relation rather than being coaxial. This offset relationship provides a magnetic coupling having a predetermined speed differential between the input and output shaft.

Brief Description of the Drawinσs

Figure 1 is a vertical sectional view through a first embodiment of coupler taken longitudinally of the

rotary axis and with the input and output shaft shown in longitudinal side elevation;

Figure 2 through 5 show second, third, fourth, and fifth embodiments taken in the same manner as Figure 1;

Figure 5A is a transverse sectional of the fifth embodiment taken as indicated by line 5A-5A in Figure 5;

Figure 6 is a vertical sectional view of a sixth embodiment taken in the same manner as Figure 1, and with the input and output shafts offset from one another;

Figure 6A is a transverse sectional view taken as indicted by line 6A-6A in Figure 6;

Figure 6B is a transverse sectional view taken like Figure 6A and illustrating a further embodiment; Figure 7 illustrates a magnetic disc unit in elevation and is taken as indicted by line 7-7 in Figure 1.

Figure 8, 9 and 10 illustrate three alternative arrangements of permanent magnets on a magnetic disc viewed as in Figure 7.

Figure 11 is a further embodiment taken in the same manner as Figure 1.

Detailed Description of the Invention Referring to the magnetic coupler embodiment of

Figure 1, input and output shafts 8-9 are coaxial and non- ferrous electroconductive plates 10-10' are connected together at their periphery by a connecting ring 12 held in place by bolts 14. The plates 10-10' are preferably copper plates or laminated copper plates. Plate 10 has an outer hub 16 secured thereto as by bolts 18, and this hub has a keyway fitting over a key 19 in turn fitting into a keyway at the outer end portion of the input shaft 8. A set screw 20 fixes the position of the plate 10 along the shaft 8. The other electroconductive plate 10' has a center opening 21 for the free passage of the output shaft 9. This shaft has a keyway receiving a key 22 which fits

into a keyway presented by the hub 23 of a magnetic disc 24 containing permanent magnets 25. In this coupler embodiment the air gaps 26-27 between the magnetic disc 12 and the electroconductive plates 10-10' are fixed in width.

When the input shaft 8 is rotated about its longitudinal rotary axis, thereby rotating the electroconductive plates 10-10', the magnetic disc 12 responsively picks up speed by way of magnetic friction between the magnetic disc and both of the plates 10-10'. Since there is no physical connection between the shafts 8-9, slippage can occur therebetween, thereby protecting the input shaft and related drive mechanism from over¬ loading caused by locking of the output shaft 9 due, for example, to freezing of a bearing thereon.

In the second embodiment of the invention (Fig. 2) the magnetic disc means comprises a pair of magnetic discs I2a-12a' having opposed hubs 28-28' slidably mounted on splines 30 provided on the output shaft 9. The hubs 28-28' are biased apart by compression springs 31 connected at their ends to the hubs. With this arrangement the air gaps 26-27 between the magnetic discs 12a-12a' and the electroconductive plates 10-10' are initially relatively narrow. Then responsive to acceleration of the input shaft 8 from a rest state, magnetic forces determine the minimum air gap between the magnetic discs 12a-12a' and the electroconductive plates 10-10', and the output shaft is driven by magnetic friction at substantially the same speed as the input shaft. If the output shaft seizes, thereby causing slippage to occur between the electroconductive plates 10- 10' and the magnetic discs 12a-12a', the air gaps 26-27 responsively widen as a consequence of resulting repulsion of the permanent magnets in the discs 12a-12a' relative to the electroconductive plates 10'. This repulsion acts counter to the bias of the compression springs 31.

In the third embodiment (Fig. 3), the electroconductive plates 10-10' are provided with hubs 32- 32' secured thereto by a plurality of bolts 33-33'. The hubs 32-32' have a keyway fitting over respective keys 34- 34', in turn fitting keyways at the opposing end portions of the input and output shafts 8-9. The input shaft 8 projects beyond the plate 10 to receive a bushing 36 in the hub of a magnetic disc 24'. This bushing 36 is free to rotate on the input shaft. Hence, the bushing and magnetic disc 24' comprise an idler rotor assembly permitting the disc 24' to rotate relative to the input shaft 8 and electroconductive plate 10. Adequate spacing is provided between the plates 10-10' to leave space for air gaps 26-27 between the plates and the magnetic disc 24'.

In operation of the third embodiment rotation of the input shaft 8 results in magnetic friction between the electroconductive plate 10 and the magnetic disc 24', and the resulting rotation of the magnetic disc causes rotation of the output shaft 9 by way of magnetic friction between the disc 24' and electroconductive plate 10'. If the output shaft 9 seizes, the coupler permits the magnetic idler disc 24' and plate 10' to turn relative to the input shaft 8 and relative to one another. In the fourth embodiment (Figure 4) the electroconductive plate 10 is connected to the input shaft 8 in the same manner as in the first embodiment, but is not connected to the other electroconductive plate 10'. The latter has a hub 38 slide-mounted on splines 40 provided by the output shaft 9 and is biased by a compression spring 42 toward the input shaft 8. A collar 43 is fixed by a set screw 44 on the output shaft 9 to serve as a seat for the spring 42. Also slide-mounted on the splines 40 is a bearing unit 46 mounted in a magnetic disc 24" so that the latter is an idler. The splined end portion of the output shaft 9 projects into close proximity with the input shaft 8.

When the fourth embodiment is in operation by rotation of the input shaft 8, the magnetic disc 24" is attracted to the electroconductive plate 10 and slides on the output shaft 9 while commencing rotation responsive to magnetic friction. The magnetic disc 24" self establishes a minimum air gap from the plate 10. As the disc 24" builds up speed to that of the plate 10, magnetic attraction and magnetic friction between the disc 24" and the electroconductive plate 10' causes the plate 10' to rotate and to slide with the disc 24" toward the other plate 10. If the output shaft 9 seizes, thereby stopping rotation of the electroconductive plate 10', the resulting repulsion between the disc 24" and the plate 10' because of the sudden difference in their relative speeds forces the plate 10' away from the magnetic disc in opposition to the spring 42 which remains free to rotate with the other plate 10.

When a magnetic disc is an idler journaled on a hub which is free to slide as a floater coaxially between two coaxial electroconductive plates, one of which is motor-driven and the other of which is connected to a load, the magnetic disc normally occupies a position midway between the electroconductive plates when the rotational speed of the plates is equal. However, if the air gap between the magnetic disc and the motor-driven electroconductive plate or the load-connected electroconductive plate is too great, the load-connected electroconductive plate will not be driven at the same speed as the motor-driven plate due to slippage of the motor-driven plate relative to the magnetic disc. It has been found that in this situation the magnetic disc normally drifts toward the load-connected electroconductive plate such that the air gap between the magnetic disc and the motor-driven plate is larger than the gap between the magnetic disc and the load-connected plate. If the sum of the air gaps is then gradually decreased, thereby decreasing the gap between the motor-

driven electroconductive plate and the magnetic disc, the rotational slippage therebetween decreases and the speed of the magnetic disc and the load-connected plate responsively increases. The air gap between the magnetic disc and the motor-driven electroconductive plate will remain larger than the gap between the magnetic disc and the load-connected magnetic plate.

The described discovered phenomena can be utilized as a clutch type of coupler for gradually applying a load to a motor after the motor is at full speed as will now be explained by reference to a fifth embodiment (Figure 5) . In this embodiment the input shaft 8 is extended beyond the electroconductive plate 10 and functions as a journal for a bushing 58 in a magnetic disc 59 thereby free to rotate as an idler independently of the input shaft 8 and the plate 10. Electroconductive plate 10 has a hub 60 slide-mounted on splines 61 on the output shaft 9 so that the plate 10' is coupled to the output shaft, but is free to slide therealong. A circumferentially grooved collar 62 is mounted by a throw- out bearing 64 on the output shaft 9 so that the collar 62 is free to slide along the output shaft without rotating. A yoke member 66 interfits with the circumferential groove 63 in the collar 62 and is swing-mounted at its opposite end by a pivot pin 68 on a mounting block 70. Movement of the yoke member 66 to responsively slide the collar 62 on the output shaft 9 is controlled by a servo motor 70 having a threaded shaft 71 extending through a nut 72 which has a pin 73 extending through a slot 74 in the arm of the yoke member. By this arrangement the electroconductive plate 10' can have a slide range between a no-load transfer position in which the air gap between the magnetic disc and plate 10' is so large that the plate 10' remains at rest when the input shaft 8' is turning at full speed, and a near full-load transfer position in which said air gap is small enough for full-speed driving of the load-connected electroconductive plate 10' via the

magnetic disc. In this range there can be controlled slippage of the load-connected plate 10' relative to the plate 10 and magnetic disc to provide speed adjustment of the load while the driving motor operates at constant speed.

As an alternative to the arrangement illustrated in Figure 5, the output shaft 9 can become the input shaft and vice versa. Also, as another alternative, the magnetic disc 59 can be mounted as an idler on an extension of the output shaft 9 rather than on an extension of the input shaft 8.

The sixth embodiment (Figures 6, 6A) illustrates an example in which the input shaft 8 and output shaft 9 are not coaxial. In this embodiment two pairs of bearings 70-70' and 71-71' are mounted in a housing 72 for receiving the shafts 8-9. A magnetic disc unit 74 is fitted by a key 75 on the output shaft 9, and the electroconductive plates 10-10' together with a spacer 76 are fitted by a key 77 on the input shaft 8. With this arrangement the plates 10-10' partly overlap the magnetic disc 74 and rotation of the input shaft 8 causes rotation of the output shaft 9 by way of magnetic friction between the magnetic disc 74 and electroconductive plates 10-10'. However, because in the illustrated example, the plates 10-10' are larger in diameter than the disc 74, the output shaft 9 will rotate proportionately faster similar to meshed gears having different pitch diameters. It will be appreciated, as shown in Figure 6B that a second output shaft 9' can be provided which is coupled to another magnetic disc 74' which is partly overlapped by the electroconductive plates 10-10'.

The permanent magnets used in the magnetic disc units are preferably of the rare earth type, and namely, the lanthonides such as samarium cobalt and neodymium iron boron. These magnets have magnetic properties exceeding the arnico and ceramic types. The magnets may be rectangular or circular in cross-section, for example, and

are bonded into complementing openings provided in a disc which may be plastic, metal or ceramic. The magnets are arranged symmetrically with adjacent magnets arranged so that they present opposite poles on each side of the disc. The magnets can also be stacked end for end, positive pole opposite negative pole, in the disc openings.

Figure 7 illustrates the magnetic disc example in Figure 1 in which four evenly spaced rectangular openings 80 are provided in the disc 24 to receive four sets of permanent magnets 25. Each set comprises two side-by-side stacks of rectangular magnets with three magnets per stack. The pairs in each set have their poles arranged oppositely from one another, i.e., one pair has its poles arranged in a N-S-N-S-N-S order from one face of the disc to the other face, whereas the adjoining pair has its poles arranged in a S-N-S-N-S-N order. Preferably, the magnets project a short distance beyond the faces of the disc.

The Figure 7 example of magnetic disc was successfully used in a Figure 5 coupling, for example, in experiments in which a 5 hp. synchronous motor, 3600 rpm, was used to drive a centrifugal pump. The electroconductive plates were copper, inches thick, with an 8 inch diameter, and the magnetic disc was of the same diameter and had a thickness of 1-1/8". The permanent magnets were each 1x2 inches, and inch thick, stacked in threes so that each magnet projected 3/16 inches beyond a respective face of the disc.

Figure 8 illustrates an alternative magnetic disc example utilizing rectangular permanent magnets 25 arranged with alternating north-south poles in equally spaced relation in a circular pattern in rectangular openings 180 in a disc 124. Figure 9 illustrates a similar arrangement with circular permanent magnets 125 mounted in circular holes 280 in a disc 224. Figure 10 shows a further example in which side-by-side permanent

magnet sectors 225 are arranged in a ring on each side of a disc 324.

Figure 11 shows a preferred magnetic coupler similar to that illustrated in Figure 3, but in which the non-ferrous electroconductive plates lθa-10'a (copper, for example) have been backed by steel plates 11-11' attached thereto in any suitable manner such, for example, as by rivets. Hub members 32a-32'a are bolt connected to the steel plates 11-11' and receive tapered end plugs 81-81' which are attached to the shafts 8-9 by keys 34-34'. The end plugs 81-81' are connected to the hub members 32a-32'a in any suitable manner. Force-fitted into the hub member 32a is a steel tube 21 which projects through the plates 10-11 as a stub shaft toward the plate 10' to slidably receive a bushing in the hub of a magnetic disc 24 containing permanent magnets 25.

It has been found that a copper plate backed by a steel plate is more efficient in the practice of this invention for the electroconductive plates than when a copper plate, or laminated copper plate is used, as previously described. For example, plates 10-10' which are 0.25 inches thick can be used in conjunction with steel backing plates 11-11' which are 0.50 inches thick, and obtain results superior to use of copper or laminated copper plates which are 0.50 inches thick. The thickness of the steel backing plates 11-11' is selected for rigidity when subjected to the magnetic forces encountered when rotating and does not affect the coupling efficiency. When the steel backing plates are used the flux density in the copper plates lθa-10'a is increased during operation of the coupler. Air gaps 26-27 are maintained between the magnetic disc 24 and the copper plates 10-10' when they are rotating even though there is axial attraction between the steel backing plates 11-11' and the magnets 25 when the coupling components are stationary.

It is preferred to back the electroconductive plates in all of the embodiments with steel backing plates as described with respect to the Figure 11 embodiment.

From the foregoing it will be appreciated that, although specific embodiments of the invention have been described herein for purposes of illustration, various modifications may be made without deviating from the spirit and scope of the invention. Accordingly, the invention is not limited except as by the appended claims.