MAGNETOSTRICTIVE DRIVE MODULE

Abstract: The drive modules (10) of a magnetostrictive transducer are fabricated from interleaved permanent magnet disks (2) (samarium cobalt) and high-strain, low-permeability magnetostrictive lanthanide alloy (Terfenol-D) disks (1) to form a stack (11) of such interleaved materials of substantially uniform magnetic field distribution in the stack. Two such stacks (11) in side-by-side relationship provide a series-aiding magnetic circuit completed through high-permeability flux return pole pieces (4) at their ends thereby providing a substantially uniform magnetic field distribution in the stack (11). Each stack (11) has longitudinally-­ extending and electrically-insulated planar cuts and each flux return pole piece (4) is a laminate of thin sheets of high-­ permeability electrically-insulated steel to reduce eddy current losses resulting from the AC field. The steel sheets are constrained by a nonmagnetic end-block (5) into which the steel sheets are inserted and bonded. AC coils (3) surround the stacks (11) to provide the AC field.

Description: The present invention concerns a magnetostrictive unit of the kind comprising a stack of interleaved members of permanent magnet and magnetostrictive material. US-A-4 104 549 describes a magnetite ferrite for magnetostrictive vibrators, and a magnetostrictive vibrator element using the magnetite ferrite. In one example, this known vibrator element has a magnetostrictive unit in the form of a stack of interleaved members of permanent magnet and magnetostrictive material comprising a single cylinder of magnetite ferrite having in contact with its upper and lower end surfaces ring-shaped biasing magnets. This assembly is clamped between a pair of annular clamping plates by means of a rod that runs through the stack formed by the upper clamping plate, the upper biasing magnet, the ferrite cylinder, and the lower biasing magnet, and screws into the lower clamping plate, a clamping nut being threaded onto the upper end of the rod. An a.c. drive coil is wound around the ferrite cylinder. Magnetostrictive lanthanide alloys, such as Terfenol-D (Registered Trade Mark) (i.e. Tb.₃Dy.₇Fe 1.9 ), are capable of producing over five times the rms strain developed by the most competitive piezoceramics and ten times the rms strain developed by the most competitive non-lanthanide (i.e. nickel) magnetostrictive alloys. Since the acoustic output power generated by an underwater transducer is proportional to the square of the strain, this can result in a large advantage in power producing capability. Additionally, lanthanides such as Terfenol-D have lower sound speeds than non-lanthanide magnetostrictive alloys and piezoceramics and possess seventeen times the thermal conductivity of piezoceramics such as lead-zirconate-titanate-8. The low sound speed tends to improve bandwidth and lowers resonance frequency, while the high thermal conductivity tends to improve power handling ability and increases attainable duty cycle. The degree to which these advantages can be adequately exploited depends upon overcoming several problems which arise in transducer design because of certain intrinsic properties of the lanthanide material. Terfenol-D has a relative permeability of only four or five, at least an order of magnitude lower than magnetostrictive nickel alloys. In addition, for purposes of economy of length and cost effectiveness, relatively short lengths of the material are used. The combination of low permeability and low length-to-diameter ratio of the Terfenol-D rods resulted in non-uniform bias and drive fields in prior-art transducer designs which led to utilization of only a portion of the material and non-uniform strain in the material. Demagnetization effects and fringing flux tend to increase leakage inductance and degrade transducer coupling. The low length-to-diameter ratio also leads to stray flux finding its way into metallic transducer components where eddy currents and hysteresis losses lower conversion efficiency. Unlike piezoceramics, which are prepoled, Terfenol-D and the other lanthanide alloys require a polarizing field because they are magnetically soft and retain insufficient remanent fields for linear operation. In the case of Terfenol-D, the polarizing field may be supplied by either a coil carrying direct current or permanent magnets. If DC current is used to supply the bias field, it may be superimposed on the AC drive coil or may be carried on a separate coil. If separate AC and DC power supplies are employed and the currents are superimposed in one coil, a large choke is required to pass DC and avoid driving the DC supply with the AC power source. Also, a large condenser is required to pass AC and block DC current from entering the AC supply. If separate windings carry AC and DC, the requirement for the condenser is removed, but a large burdensome choke in series with the DC current winding is still required since the two coils will be coupled due to the transformer action of two concentric coils magnetically linked by a common core. The requirement for separate DC and AC power supplies can be avoided by various solid state amplifier approaches, but these approaches similarly suffer from the requirement for bulky magnetics such as heavy autotransformers. Additionally, all DC-current biasing approaches result in a heavy thermal burden being placed on the transducer, eroding much of the potential advantage gained by the drive material's high thermal conductivity. Overall efficiency is also decreased not only by DC power being dissipated in the transducer, but also because of DC transmission losses occurring in the DC power supply cable, especially when the cable runs are long. The alternative to direct current biasing is biasing with permanent magnets. In the prior art, the cost of permanent magnet biasing is usually decreased AC efficiency, decreased transducer coupling, and overall reduced transducer performance. The AC efficiency is normally reduced because the permanent magnets also have very low permeabilities and therefore increase the reluctance of the magnetic circuit. Hence, greater magnetomotive force (greater AC drive current) is required to achieve a given flux density, resulting in increased coil losses. Also eddy currents in the magnets cause additional losses, and the permanent magnet material may have to be shielded with sheet metal to avoid demagnetizing of the permanent magnets by the AC drive field. As a result of eddy currents, large amounts of energy are dissipated in the magnet shielding, which usually results in a catastrophic decrease in efficiency. The low reluctance of the AC magnetic circuit results in greater fringing, which leads to additional losses due to stray flux entering metal transducer parts. Also, large amounts of energy are stored in permanent magnets, thereby increasing leakage inductance, raising the electrical quality factor, and reducing transducer coupling. If the permanent magnets are not placed in an optimum way, the magnetostrictive drive material is likely to be biased non-uniformly, resulting in poor utilization of the drive material with some regions insufficiently biased and others near saturation. Hence, the use of permanent magnet material as in the prior art does not in itself guarantee high efficiency or improvement in overall performance. According to the present invention, a magnetostrictive unit of the kind defined hereinbefore at the beginning is characterised in that interleaved members comprise a plurality of first disks of permanent magnet material providing a permanent DC biasing field, and a plurality of second disks of magnetostrictive material; and in that the disks of permanent magnet and magnetostrictive materials are interleaved to form the stack, and each of the first and second disks is comprised of portions which are electrically insulated from each other. A magnetostrictive drive module comprising a pair of magnetostrictive units in accordance with the present invention is preferably further characterised by the units being arranged in side-by-side relationship in a series aiding magnetic circuit completed by a pair of high magnetic permeability material flux return pole pieces, each pole piece bridging adjacent ends of said stacks and comprising laminated sheets of said magnetic material; and by a respective solenoid around each of said stacks for providing a substantially uniform alternating field within the respective stack. The aforementioned problems of the prior art are overcome and other objects and advantages of permanent magnet biasing of lanthanide magnetostrictive materials are provided by a magnetostrictive transducer and its drive modules fabricated from interleaved permanent magnet disks and high strain magnetostrictive material disks to form a stack of such interleaved materials. Two such stacks in side-by-side relationship have their series-aiding magnetic circuit completed through high permeability flux return pole pieces. Each stack is surrounded by an electrical solenoid which provides a substantially uniform alternating field within its respective stack. Each stack has longitudinally extending planar cuts which are substantially parallel to the AC field in each stack produced by the solenoid. These planar cuts reduce eddy current loss within the stacked materials. The flux return pole pieces are laminates of thin sheets of high permeability steel which are electrically insulated from one another to likewise reduce eddy current loss resulting from the AC field. The steel sheets are constrained by a non-magnetic end-block into which the steel sheets are inserted and bonded. The mating surfaces of the pole pieces and the stacks are ground flat and smooth so that minimum air gaps exist at their juncture. Excitation of the solenoids is phased to cause each stack to expand and contract in unison to produce relative motion of the end pieces. The outermost surfaces of the end blocks are in contact with the piston masses of the transducer of which the module is a driving element. The piston masses and the end blocks are ground flat so that good contact is made between them. The permanent magnet disks are made of a magnetic material which provides high magnetic flux and whose remanent flux is resistant of the magnetomotive force of the applied AC magnetic field. Samarium cobalt has been found suitable for this application. The magnetostrictive disks are typically made of a lanthanide material, Terfenol-D being preferred, which has high strain per unit AC magnetomotive force. The invention thus relates to transducers for the transmission of sonic energy and more particularly to a self-biased transducer having drive stacks comprised of interleaved high remanent flux magnets and high-strain magnetostrictive material for producing sonic energy of high power and with high performance. Brief Description of the Drawings The aforementioned aspects and other features of the present invention will be apparent from the following description taken in conjunction with the accompanying drawings wherein: FIG. 1 is an isometric view in partial section of a transducer incorporating the drive modules of this invention; FIG. 2 is an isometric view of a drive module of this invention; FIGS. 3 and 4 are cross-sectional views of the drive module of FIG. 2; FIG. 5 is an exploded view of the drive module of FIG. 2; FIG. 6 is a cross-sectional view of another embodiment of the drive module of this invention; and FIG. 7 is an isometric view of another embodiment of the drive stack of the drive module of FIGS. 2 and 6. Description of the Preferred Embodiment FIG. 1 shows an isometric view in partial cross-section of a tonpilz transducer 60 constructed using the drive modules 10 of this invention. The transducer 60 comprises a headmass 61 (typically aluminum) and a tailmass 62 (typically stainless steel) each of which have recesses 63, 64, respectively into which the end blocks 5 of the module 10 are recessed. Only two modules 10 are shown in FIG. 1. However, it should be understood that as many modules as can be accomodated in the space within transducer 60 may be used. A tie rod/belleville spring assembly 65 applies a compressive force between the headmass 61 and tailmass 62 to place the module 10 under the desired compressive force. A shroud 66, connected to the headmass 61 by a vulcanized rubber seal 67, is attached to the housing 68. The tailmass 62 is also in contact with housing 68 through a pressure release material 69 which is in compression from threaded ring 70 which is threaded into the housing 68. A back plate 71 containing a connector assembly 72 is connected to the housing 68 to form a waterproof seal therewith. The cavity 73 formed by the back plate 71 and the tailmass 62 provides space for an electrical tuning network (not shown) and the electrical connection of the modules 10 to the wires of cable 74 through the connector 72. The wires in cable 74 comprise the alternating current power wires for energizing the modules 10 from a transmitter (not shown) and which may also be used for carrying signals detected by the modules 10 to a receiver (not shown). The back plate 71 forms a watertight seal with the housing 68 because of the sealing material 75 which is in compression between the periphery of back plate 71 and the housing 68 provided by the tensioning of screws 76. The interior of the transducer 60 is thus a watertight enclosure in which the modules 10 can be electrically actuated to produce movement of the headmass 61 relative to the tailmass 62. In a transducer such as that typified by the transducer 60, FIG. 1, the drive module 10 is acoustically coupled to the mechanical load provided by the headmass 61 and tail mass 62 by means of greased coupling joints provided by the recess 63 into which the end block 5 is closely fitted. The mating surface 20 of the end block 5 and the bottom of the groove 63 are made smooth and flat so that there is good mechanical contact between these mating parts. These coupling joints are kept in compression by the mechanical pre-stress system comprising the tie rod assembly 65 in which rod 650 is threaded into the headmass 61 and which is tensioned by the nut 651 compressing belleville spring 652 against the tailmass 62. The easily machined end block 5/pole piece 4 assembly 7 (Fig. 2) of module 10 facilitates this type of mechanical coupling. The modular design makes the drive assembly comprising modules 10 easily replaceable in the event of failure of any module. Referring now to FIGS. 2-5, there are shown an isometric view, two cross-sectional views, and an exploded view, respectively, of one embodiment of a magnetostrictive drive module 10 constructed in accordance with this invention. FIGS. 3 and 4 are sectional views taken along section lines I-I and II-II of FIGS. 4 and 3, respectively. Two magnetostrictive stacks 11 are provided for the module 10. Each stack 11 comprises interleaved laminated disks of magnetostrictive material 1 and laminated disks of permanent magnet material 2. Each stack 11 is substantially enclosed except for its ends by a coil 3 which is connected to a source of alternating current (not shown) for providing alternating magnetomotive force to each stack 11. The permanent magnets 2 in each stack 11 have the same direction of magnetization and are arranged so that the stacks 11 are poled in opposite N,S directions as shown in FIG. 3. The magnetic path is completed by causing the ends 110 of stacks 11 to be in contact with pole pieces 4 thereby completing the magnetic circuit comprising stacks 11 and pole pieces 4. The pole pieces 4 comprise a stack of 5.08 x 10⁻³cm (2 mil) laminations of SiFe steel sheets. These pole pieces 4 are contained within an end block 5, typically of aluminum or stainless steel, and secured within said end block 5 by structural epoxy 6, such as commercially available type A-2/E. The drive coils 3 are wound with high temperature magnet wire, typically number 18 AWG insulated magnet wire. The space between a stack 11 and the coil 3 is filled with silicone rubber 8. In one embodiment, the stack 11 is wrapped with silicone tape (such as commercially available Moxness tape) prior to the preceding step and assembly into the module 10. The silicone rubber serves to decouple the coil 3 from the stack 11, which vibrates when the coil 3 is driven with alternating current. The silicone rubber 8 also serves to insulate the stack from the coil, to support the coil, and to improve thermal conduction from the coil to the stack. In a preferred embodiment of the invention, the stacks 11 of interleaved magnetostrictive material 1 and permanent magnet material 2 comprises stacks of disks of Terfenol-D (or other lanthanide drive material) interleaved with disks of samarium cobalt permanent magnet material 2. The samarium cobalt magnets have the property of having high energy product with high intrinsic coercivity such that the magnet is not demagnetized, but maintains a stable direct magnetic field in the magnetic circuit comprising stacks 11 and pole pieces 4 in spite of large AC drive fields and high temperatures within the stack 11 produced by the coils 3. The magnetic circuit is completed by the pair of return paths provided by the pole pieces 4 which consist of low loss, high permeability, laminated silicon iron, µ r approximately equal to 10⁴, or similar ferromagnetic material. The laminations 15 are electrically insulated from one another by insulating varnish 16 as in conventional transformer design technology and the laminations are very thin (2.54 x 10⁻³ or 5.08 x 10⁻³cm (1 or 2 mils) thickness). The laminations 15 are oriented such that they are in the same direction as the magnetic flux of the magnetostrictive stacks. This orientation, in addition to providing a low reluctance path with low eddy current losses, results in a pole piece 4 which is mechanically very rigid in the direction of longitudinal vibration produced by the Terfenol-D material 1 and serves to enhance thermal conduction from the magnetostrictive stacks 11 to the end blocks 5. Heat is conducted from the end blocks 5 to head mass 61 and tail 62 mass components of a transducer 60 (shown in FIG. 1). The head mass, when in operation, is in thermal contact with sea water. The aluminum (or nonmagnetic stainless steel) hollow end blocks 5 serve as shells into which the silicon iron laminations 15 are cemented into place with structural epoxy 6. The resulting pole piece/end block assembly 7 has nearly the same structural rigidity as a solid block of metal. The self-biased magnetostrictive stack 11 shown in isometric view in FIG. 5 is fabricated by initially longitudinally cutting with a diamond saw substantially equal diameter cylindrical rods of Terfenol-D and unmagnetized samarium cobalt into slabs 13, 14, respectively of approximately 0.635cm (1/4 inches) thickness . Each slab has plane parallel faces produced by the cut. The Terfenol-D and samarium cobalt slabs 13, 14 are each reassembled to form slightly elliptical rods using an electrical insulative adhesive 9 such as commercially available General Electric Type 7031. The reassembled rods are then cut into disks 1 of Terfenol-D and disks 2 of samarium cobalt. Disks of Terfenol-D are interleaved with disks of samarium cobalt and are cemented together with structural epoxy 6, typically commercially available Type A-2/E, under 444.8-889.6 Newtons (100-200 pounds) which provides a 2.54 x 10⁻³cm (one mil) thick film of epoxy 6 bonding the disks 1, 2 to thereby form stack 11. The maximum thickness of the slabs of Terfenol-D and samarium cobalt is determined by allowable eddy current losses. The characteristic frequency (the frequency at which the skin depth is twice the thickness of the slab) is given by the equation (2ρ)/(πµ (thickness)²) where ρ = resistivity of Terfenol-D ≅ 6.10⁻⁷ ohms-meters µ = permeability of Terfenol-D ≅ 4µ o µ o = permeability of air The resistivity and permeability of samarium cobalt are similar in magnitude to that of Terfenol-D. Since the permeability of lanthanide alloys and samarium cobalt is low and the resistivity high, the allowable thickness is relatively thick (≅ 0.635cm (0.25 inches)) relative to that of steel laminations (≅ 2.54 x 10⁻³-5.08 x 10⁻³cm (1-2 mils)) in the pole pieces 4, which have a much higher permeability. Reduction of eddy currents has the desirable effect of reducing the eddy current I²R losses and also reducing the opposing magnetomotive force of the non-uniform eddy currents which in turn causes a non-uniform flux density. The number of slabs, their dimensions, and their placement are determined by an optimization procedure using a finite difference numerical computer program which solves Maxwell's equations and determines the magnetic field distribution throughout the magnetic circuit. The design of the self-biased drive module 10 is optimized with respect to leakage inductance, the amount of fringing flux, AC and DC magnetic field strengths, and field uniformities throughout the magnetic circuit. Since permeability and optimum DC bias points in lanthanide magnetostrictive materials are a function of applied stress, the values for incremental permeabilities for the entire range of expected stress conditions in the transducer are utilized in the optimization process. The AC and DC fields in a self-biased lanthanide magnetostrictive stack 11 with distributed samarium cobalt magnets 2 can be made very uniform when combined with the high permeability return paths in the magnetic circuit of the pole pieces 4. Prior to being placed in the magnetic circuit, the magnetostrictive stacks 11 are placed in a strong magnetic field (approximately 15T (150 KG)) to fully magnetize the interleaved samarium cobalt disks 2. The self-biased stacks 11 are fitted with the high temperature magnet wire drive coils 3 prior to being joined with the pole pieces 4 by the above-mentioned structural epoxy 6 to form the module 10. FIG. 5 is an exploded view showing the drive module 10 components for a typical drive module. A drive module 10 comprises a two-leg closed-path magnetic circuit. Magnetic flux generated by alternating current excitation of the solenoids 3 passes through the magnetic circuit comprising the solenoid enclosed Terfenol/samarium cobalt drive stacks 11, typically 7.62 to 15.25 cm (3 to 6 inches) long and 2.54 cm (1 inch) or more in a diameter through glass fiber disks 17, typically 15.24 x 10⁻³cm (6 mil) thick type G10 glass fiber reinforced resin, and high permeability pole pieces 4, typically 5.08 x 10⁻³cm (2 mil) laminations of silicon iron. The disks 17, 17' are optional, but if used, serve to insulate the stacks 11 from the head and tail masses 61,62 which may be in contact with water when transducer 60 is in use. Each drive coil 3 consists typically of 700 to 1400 turns of number 18 gauge high temperature magnet wire. The drive coils 3 are wired so that the flux generated by each is in the series aiding direction around the magnetic circuit. The module design ensures near uniform AC and DC field distributions and minimizes demagnetization and leakage effects. The silicon iron pole piece laminations 4 are cemented to nonmagnetic end blocks 5 by a structural epoxy 6 (not shown in FIG. 5). The end blocks 5 have polished external surfaces 20 on their ends which enable them to be acoustically coupled to the head and tail masses 61, 62 of FIG. 1 by a grease joint of high temperature grease 51 between each of the end surfaces 50 and recesses 63, 64 of masses 61, 62, respectively. Typical dimensions in a stack 11 for the Terfenol-D material 1 would be 2.54cm (one-inch) diameter disks, 1.40cm (.55 inches) in length for the four innermost disks and 0.699cm (.275 inches) in length for the two outermost disks of each stack 11 of FIGS. 3-5. The samarium cobalt permanent magnet disks 2 of FIG. 1 are typically 0.381cm (.150 inches) in length. Each slab is 0.635cm (1/4 inch) in thickness measured in the direction transverse to the long dimension of the stack 11. When terminated as in the module 10 in the silicon iron pole pieces 4, the AC and DC flux distribution throughout the stack 11 is sufficiently uniform and free of leakage flux that a high efficiency, high coupling factor module is obtained. With these typical dimensions, the variation in the longitudinal AC and DC fields is within several percent (5-10%) throughout the self-biased magnetostrictive stack 11 assembly. In the construction of the self-biased drive module 10, the polarity of the self-biased magnetostrictive stacks 11 are such that the north pole of one stack and the south pole of the second stack are cemented to the same end block/pole piece assembly 7 in order to avoid bucking fields. The north and south field polarities are shown in FIG. 3. Similarly, the drive coils 3 are wired such that they both circulate the AC flux in the same direction through the magnetic circuit when energized either in parallel or in a series electrical connection. Thus, the polarizing DC flux travels upward in one stack 11 and downward in the remaining stack 11 of the module 10, and the AC flux follows the same path but reverses direction for each reversal of direction of the alternating current excitation of the coils 3. The modules 10, when tested as drive elements in transducers, resulted in overall efficiencies several times greater than those normally obtained in lanthanide-driven devices of the noninterleaved type of the prior art. In addition, the measured AC efficiencies compare very favorably with the best AC efficiencies (i.e. DC losses ignored) obtained in the most advanced prior art direct current-biased magnetostrictive transducers and in piezoelectric transducers. These desirable results provided by the inventive structure are a direct consequence of distributing the samarium cobalt disks throughout the Terfenol-D stack and using the low reluctance return paths of the pole pieces 4. This technique results in highly uniform AC and DC fields and full utilization of the Terfenol-D drive material. Flux is constrained to remain in the intended magnetic circuit and additional losses due to stray flux have been eliminated. The unshielded samarium cobalt magnets 2 have been subjected to high drive AC magnetic fields in modules 10 constructed in accordance with the invention for extended periods of time with no degradation in the DC magnetic field supplied by the magnets or in measured transducer performance. Since the samarium cobalt magnet disks 2 do not require shielding, the losses due to eddy currents generated in the prior art shield are eliminated in the embodiments of FIGS. 3-5. The self-biased drive module 10 completely eliminates the need for a direct current polarizing field and its associated losses common in the embodiments of the prior art. The direct current induced thermal burden that is normally placed on the direct current biased transducer of the prior art and the accompanying transmission cable losses are also eliminated. The distributed permanent magnet assembly of module 10 with its low reluctance return path virtually eliminates AC and DC stray flux external to the magnetic path of the module thereby resulting in a negligible magnetic signature and making the self-biased transducer containing such modules 10 virtually undetectable. FIG. 6 shows in cross-section a drive module 50 which is an alternative embodiment of the module 10 shown in FIGS. 2-5. The slight increase in length of the magnetostrictive drive stack 11 of module 10, because of the insertion of the permanent magnets 2, can be reduced somewhat as in module 50 by placing two of the biasing magnets 2' in the pole piece/end block assembly 7 as shown in FIG. 6. It is seen that the disks of Terfenol-D magnetostrictive material 1 are all of equal length and the number of permanent magnet disks 2 have been reduced by one in each stack 11', the total number of permanent magnet disks 2, 2' being the same as that in module 10. The magnetic polarity of the permanent magnets 2, 2' is series-aiding just as in the module 10. Module 50, although being slightly shorter in length than module 10 because of the placement of permanent magnets 2' between the two sections 4' of the pole piece 4, results in increased leakage flux between the two sections 4'. An alternative form of the drive stack 11 of FIG. 3 is shown as drive stack 170 of FIG. 7. The magnetostrictive drive elements 171 were fabricated from hexagonal rods of zone-melted grain-oriented Terfenol-D. The grain orientation in the material results in higher permeability, higher longitudinal coupling factor, higher compliance, and lower sound speed. The method used to obtain grain orientation is a free-standing zone-melting technique that limits the maximum diameter of the Terfenol-D rods to about 0.762cm (3/10 inch). Hence, a high packing factor and large cross-sectional area of material enclosed by a single coil is obtained by using many component rods 172 as shown in FIG. 7. In order to achieve a high packing factor, the 0.762cm (0.3 inch) diameter grain oriented rods were machined into hexagonal cross-section (0.635cm (0.25 inch) across the flats) and bonded together with electrical insulative adhesive 173. The use of electrical insulative adhesive is important in order to electrically isolate the rods from each other, thereby limiting the orbital diameters of eddy currents to approximately 0.635cm (0.25 inches). The bundle of adhered rods formed by the adhesive are cut into disks 171. The disks 171 are interspersed with the samarium cobalt disks 174, which were prepared as in the drive stack 11. Disks 171, 174 are bonded to each other to form an alternative form of magnetostrictive stack 170. Stacks fabricated from large diameter round rods producing drive stacks 11 as shown in FIGS. 3-5 are preferred over the hexagonal-bar form of stack 170 because they are cheaper, and because it is more difficult to fabricate a coil 3 with an internal diameter which minimizes the air space between the coil 3 and the stack 170 than it is when the stack is substantially round as is stack 11. A close fit is desired in order to reduce leakage inductance of the coil 3. Tonpilz projectors or transducers of the type shown in FIG. 1, which incorporate the drive module 10 of this invention, resulted in improved performance characteristics over those which were previously obtainable. An in-water transducer coupling factor of 0.50, overall efficiencies in excess of 65 percent, and duty cycles approaching 50 percent at high drive levels have been achieved. The magnetostrictive alloys of the lanthanide series, such as those used in the drive module 10, possess advantages over competing drive materials for low-frequency applications. The degree to which these advantages can be exploited is determined by the extent to which engineering problems arising from the intrinsically low permeability associated with the lanthanide materials can be overcome. The term "lanthanide" refers to the lanthanide series of elements (lanthanum, atomic number 57, is the first in the series), several of which (Sm, Tb, Dy, Ho, Er, and Tm) in the form of alloys display extraordinary magnetostriction. The term "rare earth" has been used to characterize these elements, but since they are neither rare nor are they earths (a term meaning "oxide"), the term "lanthanide" is to be preferred. The highly magnetostrictive nature of these lanthanide elements and the development of lanthanide alloys which produce large magnetostrictions at normal operating temperatures has resulted in at least one presently preferred lanthanide alloy, Terbium-Dysprosium-Iron alloy, i.e., Tb 0.3 DY 0.7 Fe 1.9 (Terfenol-D). Terfenol-D is capable of producing over 5 times the rms strain developed by the most competitive piezoceramics, and over 10 times the rms strain developed by the most competitive non-lanthanide (i.e. nickel) magnetostrictive alloys. Since the acoustic output power generated by an underwater projector or transducer is proportional to the square of the strain, lanthanide-driven transducers result in a large advantage in power producing capability. Additionally, Terfenol-D has a sound speed that is roughly 60 percent that of piezoceramic and possesses about 17 times the thermal conductivity. The low sound speed tends to improve bandwidth and lowers resonance frequency, while the high thermal conductivity tends to improve power handling capability and increases attainable duty cycle. The preceding description of the invention has described several embodiments of a novel transducer drive module and its incorporation into a transducer which has the following novel features. The module 10 incorporates samarium cobalt magnets which are stable even under conditions of extreme vibration and strong AC fields. Prior art magnets used in self-biasing configurations required sheet copper to shield the magnets from the AC field. Only samarium cobalt magnets (with the possible exception of other lanthanide-based magnets such as neodymium boron iron) possess the high intrinsic coercivity, residual induction, and stability to adequately bias lanthanide magnetostrictive projectors and do not require AC shielding. The self-biased drive module 10 results in a very uniform bias and drive field because the disks 2 of samarium cobalt are distributed throughout the magnetostrictive stack. If, as in the prior art, the magnets were lumped, the fields would be nonuniform and efficiency and performance would be degraded. The end block/pole piece assembly 7 design is exceedingly stiff and mechanically strong even though the pole pieces 4 are made of very fine laminations of steel. Being nonmagnetic, made of either aluminum or stainless steel, the end block 5 does not interfere with flux passing through the pole pieces 4. The end blocks 5 enable the ends 20 of drive module 10 to be ground flat and parallel to each other and to the same length as all other modules 10 in the same transducer much more easily than if the module were terminated solely with steel laminations 15. The end blocks 5 with end 20 surfaces ground smooth and flat can be inserted into slots 63, 64 of the transducer end masses 61, 62, respectively, which are also preferably ground flat and parallel. Grease 51 in the recesses 63, 64 between the drive module ends 5 and the transducer end masses 61, 62 acts to protect the module 10 from externally produced shock waves and allows the module 10 to be more easily replaced in the event of failure. The modular construction of the drive assembly 10 facilitates easy installation and transducer manufacturability. Since it is anticipated that most lanthanide magnetostrictive transducers will incorporate a multitude of drive elements 10, the modular form of the transducer drive module 10 makes relatively simple the fabrication of the transducer and its servicing should a module need to be replaced. The high temperature class silicon rubber 8, which fills the gap between the drive coil 3 and the magnetostrictive stack 11, miminizes mechanical friction losses, decouples the coil from the stack, and provides an improved heat path from the coil to the stack. Heat transfer between the coil 3 and the transducer end masses 61, 62 is further assisted by the orientation of the laminations 15 of the pole pieces as shown in FIG. 2. Heat flux flows through the pole piece laminations 15 without having to pass through the varnish insulation 16 between the laminations 15. The heat transfer capability is so good that a self-biased transducer similar to that shown in FIG. 6 may be driven at 15.9 x 10³A/m (200 oersteds) indefinitely at a 40 percent duty cycle without overheating (temperature rise is approximately 76.7°C (170°F)). Other advantages of the invention may be summarized as field uniformity for both AC and DC fields which is maintained in the low permeability lanthanide magnetostrictive drive elements even with low length-to-diameter ratios. Typically, the ratio of length-to-diameter of the drive stack 11 is approximately 3.5. The entire amount of Terfenol-D in the drive stack 11 is fully utilized. With the construction of the invention, demagnetization, fringing and stray flux are virtually eliminated. The transducer 60 has high conversion efficiency with peak overall efficiencies varying with specific transducer design and loading from 60 percent to 75 percent efficiency. The DC power requirements and their attendant losses for biasing the magnetostrictive material 1 has been eliminated. Blocking network electronics required to separate AC current from DC current has been eliminated by the self-biasing technique of the invention. The transducer's thermal burden has been greatly reduced by the elimination of the DC power required to bias the magnetostrictive material 1. Cable transmission losses when providing the DC current for biasing have been eliminated. The samarium cobalt permanent magnets need not be shielded from the AC field and are stable even when exposed to large AC fields. The improved thermal capability of the magnetostrictive drive 10 results in increased duty cycle capability for the transducer. There is low leakage inductance compared to prior art permanent magnet-biasing techniques, because substantially all of the flux is contained within the magnetic circuit. Because of the containment of the magnetic flux, the self-biased transducer made in accordance with this invention has a very low magnetic external field. Finally, the modular form of construction of the magnetostrictive drive 10 makes these drivers easy to install and remove for fabrication and repair. There is only a slight sacrifice in AC efficiency which, however, results in a far greater increase in overall efficiency because of the elimination of DC biasing. Typically, self-biased lanthanide transducers have AC efficiencies that are a few percent lower than an optimized transducer with corresponding return path pole pieces. The slight reduction in AC efficiency is caused by some additional copper losses that arise from the increased reluctance of the magnetic circuit caused by the inclusion of permanent magnets 2 and the small additional eddy current losses in the laminated magnets. Typical dimensions of the permanent magnet and magnetostrictive disks 1, 2 in the stacks 11, in the preferred embodiments have been given earlier and resulted in an AC and DC magnetic field distribution in the low-permeability Terfenol-D magneostrictive material which was uniform within 5-10 percent. Uniformity of magnetic field is desired to avoid degradation in performance which results from magnetic saturation in portions of the structure of the drive module. It is intended that this invention include dimensioning of the disks 1, 2 other than that illustrated in the preferred embodiment which likewise produce the desired degree of uniformity of magnetic field. In addition to the tonpilz type transducer shown in FIG. 1, the drive modules of this invention can also be used with a cylindrical type transducer, well known to those skilled in the art, where the drive modules of this invention are between adjacent segments of the cylinder to which a force is applied by tensioned bolts or wires to compress the drive modules. Having described a preferred embodiment of the invention, it will be apparent to one of skill in the art that other embodiments incorporating its concept may be used. It is believed, therefore, that this invention should not be restricted to the disclosed embodiment but rather should be limited only by the appended claims.

Claims: A magnetostrictive unit comprising a stack of interleaved members (1,2) of permanent magnet and magnetostrictive material; characterised in that the interleaved members comprise a plurality of first disks (2) of permanent magnet material providing a permanent DC biasing field, and a plurality of second disks (1) of magnetostrictive material; and in that the disks (1,2) of permanent magnet and magnetostrictive materials are interleaved to form the stack (11), and each of the first and second disks (1,2) is comprised of portions which are electrically insulated from each other. A unit according to claim 1, characterised in that: said permanent magnet disks have high resonant flux density and high coercive-force; and said magnetostrictive material is a high-strain coefficient material of low permeability. A unit according to claim 2, characterised in that: said permanent magnet disks are samarium cobalt magnets; and said magnetostrictive material is a lanthanide alloy. A unit according to claim 3, characterised in that said lanthanide alloy is Tb 0.3 Dy 0.7 Fe 1.9 . A unit according to claim 1, characterised in that each of the second disks comprises: a plurality of rods (171) of magnetostrictive material in side-by-side contact with each other to form a bundle of rods, the rods (171) in the bundle being electrically insulated from each other and adhesively connected to each other; and in that each first disk (174) comprises slabs of partial disks electrically insulated from and adhesively attached to each other to form the disk (174); and in that means are provided for compressing the stack of disks. A magnetostrictive drive module comprising a pair of magnetostrictive units (11) according to claim 1, and further characterised by the units (11) being arranged in side-by-side relationship in a series aiding magnetic circuit completed by a pair of high magnetic permeability material flux return pole pieces (4), each pole piece (4) bridging adjacent ends of said stacks (11) and comprising laminated sheets of said magnetic material; and by a respective solenoid (3) around each of said stacks (11) for providing a substantially uniform alternating field within the respective stack (11). A drive module according to claim 6, characterised by: each stack (11) having longitudinal slots which electrically insulate portions of said disks (1,2) formed by said slots. A drive module according to claim 6, characterised by: at least one end pole piece (4) having said laminated sheets transversely separated into at least two groups; said groups being separated by a permanent magnet (2') having longitudinal slots with electrical insulation therein to electrically isolate the portions of said permanent magnet (2') formed by said slots. A drive module according to claim 6, characterised by: for each pole piece (4) a nonmagnetic end block (5) having a cavity; said laminated sheets being contained within and adhered to the cavity of said end block (5) to form an end pole assembly (7). A drive module according to claim 9, characterised in that the drive module is incorporated in a transducer having: a head mass (61) and a tail mass (62); said drive module having its end pole assemblies in contact with said head and tail masses (61,62); and the transducer includes means (65,651,652) for providing a force on said head and tail masses (61,62) to thereby compress said drive module. A transducer according to claim 10, characterised in that: said head and tail masses (61,62) having slots (63,64) sufficiently large to allow said end blocks (5) to be retained within said slots (63,64) when in contact with said head and tail masses (61,62). A module according to claim 6, characterised in that said stack (11) of disks contains at least one longitudinal slot extending through said stack (11) from one end to the other, said slot being transverse to the surfaces of said disks (1,2). A module according to claim 6, characterised in that: each said stack (11) and its disks (1,2) are cylindrical and have an axis of symmetry; each of said disks (1,2) having flat surfaces transverse to said axis and in direct contact with adjacent ones of said surfaces in said stack (11). A drive module according to claim 6, characterised in that the respective disks (1,2) are dimensioned to produce substantially uniform magnetic flux within said stack (11). A drive module according to claim 6, characterised in that said disks (1) of magnetostrictive material have a permeability less than ten. A drive module according to claim 6, characterised in that the disks in each stack (11) comprise disks of low permeability permanent magnet material (2) and low permeability magnetostrictive material (1); and the magnetic field within said magnetic circuit produced by said permanent magnet disks (2) is substantially uniform. A drive module according to claim 12, characterised in that in each unit (11) there is an elastomer (8) between said solenoid (3) and the stack (11) holding said solenoid (3) in fixed relationship with respect to said stack (11). A drive module according to claim 16, characterised in that: each said stack (11) has a longitudinal axis; each end of said stacks (11) is polished flat and is transverse to the axis; and said pole pieces (4) also are polished flat at the area of contact with said stacks (11). A drive module according to claim 18, characterised by: an end block (5) in which said pole piece (4) is adhered to one side of said block (5); said end block (5) having a flat surface on the opposite side of said end block (5), said surface being transverse to the axes of said stacks (11). A magnetostrictive drive module comprising a magnetostrictive unit according to claim 1 and further characterised by: an electrical coil (3) extending over the length of said stack (11); and a magnetic circuit means (4,11,4) arranged in contact with the ends of said stack (11) so as to provide a magnetic return path for the flux of said stack (11).

Inventors: HARROLD, WILLIAM J., PORZIO, RAYMOND, STURGES, JAMES R.
Applicants: RAYTHEON COMPANY
Application year: 1987
Main classification: H01L41
IPC codes: H04R15, B06B1, H01L41