Halbach array electromagnet with substantially contiguous vertical and horizontal cores
Electromagnetic Halbach array device with substantially contiguous vertical and horizontal cores, comprised of a plurality of horizontal and vertical electromagnets arranged in a Halbach array sequence, where each individual core of every horizontal electromagnet in said Halbach array is equipped with a plurality of fork-like prongs at each end, and where the magnetic coils that surround each individual core of every vertical electromagnet in said Halbach array have gaps where said fork-like prongs are positioned to provide direct physical contact between cores.
Not applicable
SEQUENCE LISTING OR PROGRAMNot applicable
BACKGROUND1. Field of Invention
This invention relates to a novel Halbach array electromagnet with substantially contiguous vertical and horizontal cores. In very simplified terms, a Halbach array effect can be visualized as elastic looping streams of magnetic force emanating like fountains from the poles of the magnets in the array, where sets of three adjacent, similar poles magnify the fountains of magnetic force on one side of the array while elastically decreasing or cancelling the fountains on the opposite side of the array, which only have alternating north and south poles.
Permanent magnets are singular, inherently magnetized polar structures, as such they are relatively easy to orient and assemble in the prescribed sequence to enable the Halbach array effect. Electromagnets however, are structurally and functionally different from permanent magnets since they are comprised of two elements, an energized magnetic coil and an artificially magnetized core segment or tooth (hereinafter referred to as vertical or horizontal core or cores for simplicity).
Merely orienting and assembling electromagnets in a Halbach array sequence does not generally enable a useful Halbach array effect, since the magnetic coils surrounding the vertical core acts as a physical and energized barrier that prevents direct contact with the horizontal core.
Without substantial contiguity between cores, the Halbach array effect can be diminished or even negated, resulting in an ordinary, unenhanced electromagnet.
2. Description of Prior Art
In prior art most closely resembling but fundamentally different from the present invention, the electromagnets used are merely oriented and arranged as Halbach arrays, but there is no provision for establishing direct physical connectivity between the vertical and horizontal cores. The magnetic coils act as a barrier that isolates the two cores, which severely decreases or even negates the Halbach array effect to the point that it generally results in an ordinary unenhanced electromagnet. This is similar to U.S. Pat. No. 7,598,646 which presents electromagnets merely arranged in Halbach array sequence but whose vertical and horizontal cores are clearly isolated by the magnetic coils in the drawings and the description. As such it does not offer substantial contiguity between cores to ensure the direct transfer of flux necessary to guarantee the proper generation of the Halbach array effect, in sharp contrast to the present invention. As such it is fundamentally different and likely far less effective, less efficient and less controllable than the present invention. Likewise, U.S. Pat. No. 7,541,813 is an application for oil drilling, where the cylindrical electromagnets used do not provide contiguous cores, as indicated by the drawings provided. This is also the case of U.S. Pat. No. 5,705,902 which uses Halbach arrays within a generator but there is clearly no contiguity between its octagonal cores.
Most prior art that supposedly offer Halbach array electric motors only have permanent magnets arranged as Halbach arrays, however the electromagnets used are ordinary, standard, non-Halbach configurations. This is the case of U.S. Pat. No. 7,352,096 where two permanent magnet Halbach arrays on two backing plates sandwich a three phase non-Halbach array stator that uses Litz wire winding, and is thus fundamentally different from the present invention. This is also the case for U.S. Pat. No. 8,183,731 discloses a generator that uses permanent magnets mounted on discs and spaced so far apart that it is unlikely to have a strong Halbach array effect. The single reversing electromagnet detail drawing provided clearly does not pertain to a Halbach array and is thus different from the present invention. Likewise, U.S. Pat. Nos. 7,540,004, 7,031,116, 6,906,446, 6,841,910 and 6,858,962 discloses permanent magnet Halbach arrays on the rotor, but the electromagnetic stator is also non-Halbach, or not an electromagnet, and requiring a separate non-Halbach commercially available drive motor. As such, they are all fundamentally different from the present invention.
U.S. Pat. No. 8,264,314 discloses how to arrange a set of permanent magnets to increase magnetic flux. The same is true with U.S. Pat. No. 8,009,001 which discloses ‘hyper’ Halbach permanent magnet arrays. Both do not disclose Halbach array electromagnets and is thus a different category from the present invention.
OBJECTS AND ADVANTAGESSeveral objects and advantages of the present invention are:
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- a) to provide a Halbach array electromagnet with substantially contiguous vertical and horizontal cores that closely replicates permanent magnet Halbach arrays to maximize its effectiveness;
- b.) to harness the magnified and directed nature of Halbach array forces to increase the efficiency of electric motors that utilizes Halbach array electromagnets as one of its components, potentially enabling more powerful motors of the same size or smaller motors with the same power;
- c.) to reduce the weight of an electric motor that utilizes Halbach array electromagnets by harnessing the magnified magnetic forces inherent in Halbach arrays, and by removing the need for metal back plates that would normally be required to complete the non-Halbach electromagnet's circuit;
- d.) to enable the opportunity to switch or use both sides of a Halbach array electromagnet for various applications such as pumps, actuators, transmissions, rechargers, etc; and
- e.) to provide more efficient and controllable Halbach array electromagnets equipped with substantially contiguous cores, to replace permanent magnets in various applications or devices.
Further objects and advantages shall become apparent after considering the ensuing descriptions and drawings.
SUMMARYThe present invention solves a long existing and yet long unresolved need for substantial contiguity between the horizontal and vertical cores of a Halbach array electromagnet to maximize the efficiency of electric motors and other electromagnetic applications that aim to harness the magnified and directed magnetic forces generated by the Halbach array effect. Newer electric motors and other devices designed to integrate the present invention can either generate more power for the same amount of energy consumed, or provide the same amount of power while consuming significantly less energy. The present invention also enables a finer degree of control than prior art.
In the drawings, closely related figures have the same number but different alphabetic suffixes.
- 101 Vertical electromagnets of a Halbach array
- 102 Horizontal electromagnets of a Halbach array
- 103 Vertical electromagnet core or tooth
- 104 Horizontal electromagnet core or tooth
- 105 Magnetic coil surrounding vertical electromagnets
- 106 Magnetic coil surrounding horizontal electromagnets
- 107 Fork like prongs at the ends of each core or tooth of every horizontal electromagnet
- 108 Three-phase wires from magnetic coils for connection to the controller
- 109 Flux aperture between similar adjacent magnetic poles in a Halbach array
The preferred embodiment of the present invention is achieved by integrating a set of horizontal electromagnets 102 between a set of vertical electromagnets 101, and arranging both in the prescribed Halbach array sequence, an example of which is shown in
The Halbach array sequence and orientation causes the magnetic coils surrounding the vertical electromagnets 105 to ordinarily become physical and active barriers that separate the individual cores or teeth of the horizontal 104 and vertical electromagnets 103. The present invention overcomes this barrier by introducing fork like prongs at the ends of each core or tooth of every horizontal electromagnet 107 through gaps made during the winding of aforementioned magnetic coil. Examples of contiguous core Halbach array electromagnets are in
Because the process of winding may damage the film of insulation covering the magnetic coil surrounding the vertical electromagnets 105, the use of optional insulating slot paper (not shown) such as that made from Nomex ™ and Mylar ™ is recommended. Since the magnetic coil surrounding the horizontal electromagnet 106 generally does not interfere with assembly, it can be wound prior to, or after insertion.
Alternative EmbodimentsOne alternative embodiment of form rather than function is driven by convenience in manufacturing and assembly. It primarily uses modular stator or rotor core segments to facilitate automated winding, which are pre-configured to embed insulation and gaps in the magnetic coils. This will be mated to a similarly modularized pre-wound horizontal core that is equipped with fork like prongs at each end to provide substantial contiguity between vertical and horizontal cores. This strategy will likely yield the quickest assembly times compared to other options.
With 3D metal deposition printing, it is possible to create a mesh of embedded electromagnets whereby each element of the core and coil can be multiplied, miniaturized and meshed into Halbach arrays with contiguous cores. One exciting aspect would be spherical, helical or octagonal Halbach arrays with contiguous cores for experiments in energy and other applications, which was heretofore impossible before the advent of 3D printing. Possible variations of the present invention have thus broadened considerably.
Operation—Preferred EmbodimentSince there are a multitude of applications that can benefit from Halbach array electromagnets that offer substantially contiguous cores, it would be impossible to cover all of the possible permutations with regard to wiring and control, thus there is a need to provide a specific example for the operation of the preferred embodiment. For the sake of completeness,
In the wiring example in
Once the present invention is connected as shown in the simplified diagram in
The diagram in
Generally the primary goal of any Halbach array implementation is to maximize efficiency by harnessing the magnified and directed electromagnetic forces produced; otherwise an ordinary, unenhanced electromagnet would be used instead. The stack of coated thin sheets of high-silicon electrical steel that comprise the vertical and horizontal cores have a magnetic resistance that is a thousand times less than empty air. This means that core to core contiguity (measured by the flux aperture 109 shown in
Moreover, magnetic coils are made of copper, different in composition and intended function to the laminations of high-silicon electrical steel which comprises the core. Thus when the magnetic coils surrounding the vertical core obstructs the path of the magnetic flux produced by the horizontal core (as shown in
Thus the reader will see that the Halbach array electromagnet with substantially contiguous cores of the present invention provides a fundamental solution a long existing and yet long unresolved need. It is likely the simplest and closest functional equivalent of permanent magnet Halbach arrays as applied to electromagnets.
While the above description contains many specificities, these should not be construed as limitations on the scope of the invention, but rather as an exemplification of one preferred embodiment thereof.
Accordingly, the scope of the invention should be determined not by the embodiments illustrated, but by the appended claims and their legal equivalents.
Claims
1. Electromagnetic Halbach array device with substantially contiguous vertical and horizontal cores, comprising:
- a) a plurality horizontal and vertical electromagnets arranged in a Halbach array sequence,
- b) a plurality of fork-like prongs at the ends of each individual core of every horizontal electromagnet in said Halbach array, and
- c) gaps in the magnetic coils that surround each individual core of every vertical electromagnet in said Halbach array, where said fork-like prongs are positioned to provide direct physical contact between cores.
2. Halbach array electromagnetic device with conduits for directly transmitting flux between vertical and horizontal cores, comprising:
- a) a plurality horizontal and vertical electromagnets arranged in a Halbach array sequence,
- b) a plurality of fork-like prongs at the ends of each individual core of every horizontal electromagnet in said Halbach array, and
- c) gaps in the magnetic coils that surround each individual core of every vertical electromagnet in said Halbach array, where said fork-like prongs are positioned to provide direct physical contact between cores.
3. Method for creating an electromagnetic Halbach array device with substantially contiguous vertical and horizontal cores, comprising:
- a) arranging a plurality horizontal and vertical electromagnets in a Halbach array sequence,
- b) providing the ends of each individual core of every horizontal electromagnet in said Halbach array with a plurality of fork-like prongs, and
- c) creating gaps in the magnetic coils that surround each individual core of every vertical electromagnet in said Halbach array, so that said fork-like prongs can be inserted to provide physical contact between cores.
Type: Application
Filed: Jul 15, 2013
Publication Date: Jan 15, 2015
Inventor: ROBERTO SANCHEZ CATALAN (ROUND ROCK, TX)
Application Number: 13/941,833
International Classification: H01F 7/06 (20060101); H01F 41/02 (20060101);