A magnetic coupling is a component which transfers torque from one shaft to another using a magnetic field, rather than a physical mechanical connection. They are also known as magnetic drive couplings, magnetic shaft couplings, or magnetic disc couplings.
Magnetic couplings allow a physical separation between input and output shafts, precluding the use of shaft seals, which eventually wear out and fail from the sliding of two surfaces against each another. Magnetic couplings are also used for ease of maintenance on systems that require precise alignment, since they allow a greater off-axis error between the motor and driven shaft than physical couplings.
Magnetic couplings are most often used for liquid pumps, propeller systems, mine motors, conveyor belt motors and kiln elevators.
Some diver propulsion vehicles and remotely operated underwater vehicles use magnetic couplings to transfer torque from the electric motor to the prop. Magnetic gearing is also being explored for use in utility-scale wind turbines as a means of enhancing reliability. [1] The magnetic coupling has several advantages over a traditional stuffing box. [2] [3]
Some aquariums use magnetic drive pumps, which have a magnetic coupling between the motor on the dry side of an aquarium wall and the propeller or impeller in the water on the other side of the wall. [4] This coupling features two face-to-face magnetized disks: the driving magnet on the dry side, and the driven magnet on the underwater side. Torque is transferred by shear forces between the attracting magnetic disks, [5] but this attraction can also produce an axial load as the disks pull on each other. There are two main designs for the magnetic pattern on each disk. One design minimizes the axial load by counterbalancing a magnetically attractive section with a magnetically repulsive section near the axis. [6] [5] The other design maximizes torque and resists the consequential axial load with a mechanical thrust bearing.
A magnetic stirrer is another example of magnetic coupling.
Magnetic couplings are often synchronous, meaning the output shaft speed equals input shaft speed (a 1:1 ratio).[ according to whom? ]
The first few gears in the geartrain of an Omega Megasonic wristwatch have no teeth; instead, magnetic north and south poles on neighboring gears act like the teeth and trough of spur gears, allowing each gear to drive the next gear in the chain. [7] Such magnetic gears, like spur gears, always have gear ratios consisting of small integers.
More sophisticated magnetic gearings use pole pieces to modulate the magnetic field. They can be designed to have gear ratios from 1.01:1 to 1000:1. [8]
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Magnetic couplings have some notable properties: [9]
Because there is no contact between the active part and the driven part of a magnetic coupling, and there is no rigid connection problem. Sudden changes and vibrations are not directly transferred across the coupling. Therefore, it can avoid the transmission of vibration, resulting in smoother mechanical operation.
Magnetic couplings offer protection against overload during operation. If the load on the driven component becomes too large, the two parts may slip out of sync and end the transmission of torque. This avoids damage to the system, protecting both the motor from excessive loads and the driven component from deformation.
A magnetic coupling transmission device is relatively simple in structure, and there is a gap between the driving part and the driven part, which is easy to install, disassemble, troubleshoot, and maintain.
Magnetic couplings can transmit power via a linear motion, rotary motion, or helical compound motion (a combination of linear motion and rotary motion). The combination of these transmission methods and different mechanical geometry can realize a wide variety of orderly motion in three-dimensional space.
Because magnetic couplings do not penetrate the surface they operate across, pumps that use this type of coupling can completely avoid leakage. This is particularly important if the pumped fluid or gas is corrosive, toxic, flammable, explosive, acidic, alkaline, or otherwise harmful. This makes magnetic coupling transmission technology especially applicable in the production of petroleum, chemicals, and pharmaceuticals, and in the industries of offshore oil well operations, non-ferrous metal smelting, wet mineral processing, and food processing.
A clutch is a mechanical device that allows the output shaft to be disconnected from the rotating input shaft. The clutch's input shaft is typically attached to a motor, while the clutch's output shaft is connected to the mechanism that does the work.
A coupling is a device used to connect two shafts together at their ends for the purpose of transmitting power. The primary purpose of couplings is to join two pieces of rotating equipment while permitting some degree of misalignment or end movement or both. In a more general context, a coupling can also be a mechanical device that serves to connect the ends of adjacent parts or objects. Couplings do not normally allow disconnection of shafts during operation, however there are torque-limiting couplings which can slip or disconnect when some torque limit is exceeded. Selection, installation and maintenance of couplings can lead to reduced maintenance time and maintenance cost.
An electric motor is an electrical machine that converts electrical energy into mechanical energy. Most electric motors operate through the interaction between the motor's magnetic field and electric current in a wire winding to generate force in the form of torque applied on the motor's shaft. An electric generator is mechanically identical to an electric motor, but operates in reverse, converting mechanical energy into electrical energy.
An automatic transmission is a multi-speed transmission used in motor vehicles that does not require any input from the driver to change forward gears under normal driving conditions. Vehicles with internal combustion engines, unlike electric vehicles, require the engine to operate in a narrow range of rates of rotation, requiring a gearbox, operated manually or automatically, to drive the wheels over a wide range of speeds.
A torque converter is a device, usually implemented as a type of fluid coupling, that transfers rotating power from a prime mover, like an internal combustion engine, to a rotating driven load. In a vehicle with an automatic transmission, the torque converter connects the prime mover to the automatic gear train, which then drives the load. It is thus usually located between the engine's flexplate and the transmission. The equivalent device in a manual transmission is the mechanical clutch.
A continuously variable transmission (CVT) is an automated transmission that can change through a continuous range of gear ratios. This contrasts with other transmissions that provide a limited number of gear ratios in fixed steps. The flexibility of a CVT with suitable control may allow the engine to operate at a constant angular velocity while the vehicle moves at varying speeds.
A brushless DC electric motor (BLDC), also known as an electronically commutated motor, is a synchronous motor using a direct current (DC) electric power supply. It uses an electronic controller to switch DC currents to the motor windings producing magnetic fields that effectively rotate in space and which the permanent magnet rotor follows. The controller adjusts the phase and amplitude of the current pulses that control the speed and torque of the motor. It is an improvement on the mechanical commutator (brushes) used in many conventional electric motors.
A synchro is, in effect, a transformer whose primary-to-secondary coupling may be varied by physically changing the relative orientation of the two windings. Synchros are often used for measuring the angle of a rotating machine such as an antenna platform or transmitting rotation. In its general physical construction, it is much like an electric motor. The primary winding of the transformer, fixed to the rotor, is excited by an alternating current, which by electromagnetic induction causes voltages to appear between the Y-connected secondary windings fixed at 120 degrees to each other on the stator. The voltages are measured and used to determine the angle of the rotor relative to the stator.
A drive shaft, driveshaft, driving shaft, tailshaft, propeller shaft, or Cardan shaft is a component for transmitting mechanical power, torque, and rotation, usually used to connect other components of a drivetrain that cannot be connected directly because of distance or the need to allow for relative movement between them.
Torsional vibration is the angular vibration of an object - commonly a shaft - along its axis of rotation. Torsional vibration is often a concern in power transmission systems using rotating shafts or couplings, where it can cause failures if not controlled. A second effect of torsional vibrations applies to passenger cars. Torsional vibrations can lead to seat vibrations or noise at certain speeds. Both reduce the comfort.
Hydraulic machines use liquid fluid power to perform work. Heavy construction vehicles are a common example. In this type of machine, hydraulic fluid is pumped to various hydraulic motors and hydraulic cylinders throughout the machine and becomes pressurized according to the resistance present. The fluid is controlled directly or automatically by control valves and distributed through hoses, tubes, or pipes.
A linear actuator is an actuator that creates linear motion, in contrast to the circular motion of a conventional electric motor. Linear actuators are used in machine tools and industrial machinery, in computer peripherals such as disk drives and printers, in valves and dampers, and in many other places where linear motion is required. Hydraulic or pneumatic cylinders inherently produce linear motion. Many other mechanisms are used to generate linear motion from a rotating motor.
Motor drive means a system that includes a motor. An adjustable speed motor drive means a system that includes a motor that has multiple operating speeds. A variable speed motor drive is a system that includes a motor and is continuously variable in speed. If the motor is generating electrical energy rather than using it – this could be called a generator drive but is often still referred to as a motor drive.
A fluid coupling or hydraulic coupling is a hydrodynamic or 'hydrokinetic' device used to transmit rotating mechanical power. It has been used in automobile transmissions as an alternative to a mechanical clutch. It also has widespread application in marine and industrial machine drives, where variable speed operation and controlled start-up without shock loading of the power transmission system is essential.
A friction drive or friction engine is a type of transmission that utilises two wheels in the transmission to transfer power from the engine to the driving wheels. The system is inherently a continuously variable transmission; by adjusting the positions of the two disks, the output ratio changes continuously. Although it was once employed in early automobiles, today the system is most commonly used on scooters, particularly go-peds, as a substitute for a chain and gear system. It is mechanically identical to a ball-and-disk integrator, but is designed to handle higher torque levels.
An AC motor is an electric motor driven by an alternating current (AC). The AC motor commonly consists of two basic parts, an outside stator having coils supplied with alternating current to produce a rotating magnetic field, and an inside rotor attached to the output shaft producing a second rotating magnetic field. The rotor magnetic field may be produced by permanent magnets, reluctance saliency, or DC or AC electrical windings.
Electromagnetic brakes or EM brakes are used to slow or stop vehicles using electromagnetic force to apply mechanical resistance (friction). They were originally called electro-mechanical brakes but over the years the name changed to "electromagnetic brakes", referring to their actuation method which is generally unrelated to modern electro-mechanical brakes. Since becoming popular in the mid-20th century, especially in trains and trams, the variety of applications and brake designs has increased dramatically, but the basic operation remains the same.
The Beier variable-ratio gear or Beier variator is a mechanical drive offering a continuously variable gear ratio between input and output.
A magnetic gear resembles the traditional mechanical gear in geometry and function, using magnets instead of teeth. As two opposing magnets approach each other, they repel; when placed on two rings the magnets will act like teeth. As opposed to conventional hard contact backlash in a spur gear, where a gear may rotate freely until in contact with the next gear, the magnetic gear has a springy backlash. As a result magnetic gears are able to apply pressure no matter the relative angle. Although they provide a motion ratio as a traditional gear, such gears work without touching and are immune to wear of mating surfaces, have no noise, and may slip without damage.
An underwater thruster is a configuration of marine propellers and hydraulic or electric motor built into or mounted to an underwater robot as a propulsion device. These give the robot movement and maneuverability against sea water resistance. The main difference between underwater thrusters and marine thrusters is the ability to work under heavy water pressure, sometime up to full ocean depth.