VARIABLE RELUCTANCE TORQUE COUPLER

Abstract: An improved high speed reluctance type torque coupler (10) having adjustable maximum pullout torque characteristics includes a pair of rotors (12, 18) one (18) including a permanent magnet (22) and the other (12) including a pair of adjustable geometry flux poles (14).

Description: " VARIABLE RELUCTANCE TORQUE COUPLER BACKGROUND OF THE INVENTION This invention relates to a torque coupling device of the reluctance type which uses two rotors, one rotor containing a permanent magnet and being concentrically mounted within the second rotor. The second outer rotor has no magnets or electrical windings, and includes a pair of relatively movable concentric members allowing adjustment of the pull-out torque of the coupling device. This application is related to co-pending U.S. patent application no. 345,342, incorporated herein by reference, and is an improvement thereupon. A unique feature of a synchronous reluctance coupling is that it maintains a precise angular displacement between the two magnetically coupled rotors, the driver leading the driven rotor in phase by a few degrees depending on the torque and the field. The angular displacement, or phase angle, between the two rotors is independent of the speed of the rotors. It is zero when there is no torque on the driven shaft. There is a precisely discernible phase angle at which a maximum or pullout torque occurs and synchronism between the rotors is lost. The phase angle between zero and the pullout angle increases with the applied torque, but is inversely proportional to the magnetic field. For any given steady-state torque, not exceeding the pullout angle, there is no energy expenditure in the rotors, mechanical losses due to windage and bearing friction excepted. If synchronism is lost, a pulsating torque with an average value of zero is developed. However, losing synchronism within a torque coupling device having permanent magnets in both the outer and inner rotors will cause demagnetization of the permanent magnets, resulting in failure of the device. Similarly, a torque coupling device utilizing magnetic fields generated by electrical windings will be subject to excessive back EMF within the windings, leading to winding burnout and failure. A distinction should be noted between synchronous reluctance couplings and couplings based on either the hysteresis principle or the induction principle. These other couplings develop torque as a consequence of energy losses, i.e., heating, in one of the rotors. The torque is proportional to the quotient of the rotor loss divided by the slip speed. The induction, or eddy current coupling cannot develop torque when the rotors are running synchronously. The hysteresis coupling can develop a reduced torque at synchronism, however the precise phase relationship between the rotors is indeterminate, depending on the previous torque history of the device. DISCLOSURE OF THE INVENTION The present invention discloses an improved high speed reluctance type torque coupler. The torque coupler includes an outer rotor assembly and an inner rotor assembly having a diametrically magnetized two pole magnet contained within a high strength non-magnetic retaining sleeve which is attached to a shaft. The outer rotor assembly generally includes two high strength ferromagnetic flux poles. Each of the two flux poles having two sections or parts carried within two relatively movable concentric members. The sections of the flux poles are HIP bonded or brazed with the members, which are high strength, non-magnetic material, and combine to form a support assembly. The outer rotor assembly is a generally cup shaped cantilevered projection attached to a shaft and disposed about the inner rotor. In the maximum pull-out torque configuration, each of the flux poles has a generally crescent shaped cross section. The two relatively movable members define the cup shaped portion of the outer rotor assembly. Thereby, the two flux poles are disposed facing one another about the two pole magnet of the inner rotor. Thus, magnetic flux exits one pole of the magnet, flows out and penetrates the flux poles, travels along the flux poles around the magnet to the opposite magnetic pole, thereupon reentering the magnet. Within the outer rotor assembly, the space between the facing edges of the flux poles defines a magnetic air gap. The torque coupler develops torque between the inner and outer rotors due to the change in reluctance of the magnetic circuit when the magnetic axis is angularly displaced from the centerline of the air gap. The torque increases to a maximum value at approximately 45 degrees from the air gap centerline. The torque then decreases, reaching an unstable zero level at about 90 degrees. The relative torque between the rotors will reverse when 90 degrees is exceeded, and the inner rotor will then tend to rotate the remaining 90 degrees to realign with the air gap centerline, 180 degrees out of phase with its previous alignment. It should be noted however that the torque coupler will not demagnetize when synchronization is lost and relative rotation continues. Additionally, the torque spring rate and maximum pullout torque can be adjusted to a smaller value by changing the relative angular positions of the two relatively movable members of the outer rotor assembly. This changes the geometric configuration of the two flux poles. Thereby, the reluctance of the magnetic circuit of the torque coupler is changed, altering the torque spring rate and pullout torque. Additionally, a hermetic bore seal of non-magnetic material may be interposed between the inner and outer rotors. The bore seal allows segregation of the environments surrounding the two rotors, while allowing rotational torque transmission therebetween. Thus, it is an objective of the invention to provide a torque coupling device having a variable pull- out torque which can be precisely set and which will maintain the set value indefinitely. A further object of the invention is to provide a torque coupling device utilizing permanent magnets which are not subject to demagnetization when rotor synchronization is lost. Another object of the invention is to provide a torque coupling device having an optimized design for the flux pole members within the outer rotor. A further object of the invention is to provide for rotational torque transmission between two isolated environments. These and other objects of the invention will become apparent from a reading of the following specification when considered in combination with the appended figures. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a cross sectional view of the torque coupler of the present invention perpendicular to the axis of the inner and outer rotors in the maximum pullout torque configuration. Figure 2 is a cross sectional view taken along sectional line 2-2 of the torque coupler of Fig. 1. Figure 3 is a cross sectional view similar to Fig. 1 wherein the outer rotor assembly is in the minimum pullout torque configuration. Figure 4 is a cross sectional view similar to Fig. 1 wherein the outer rotor assembly is in an intermediate pullout torque configuration. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Figure 1 shows a cross sectional view through a torque coupler 10 according to the present invention. The torque coupler 10 includes an outer rotor assembly 12 which includes a pair of two piece flux poles 14. the outer rotor assembly 12 is generally cup shaped, having a hollow cylindrical interior. Disposed within the hollow cylinder of outer rotor assembly 12 is non-magnetic bore seal 16, as well as an inner rotor assembly 18. Inner rotor assembly 18 includes a retaining sleeve 20 enclosing a cylindrical, diametrically magnetized, two pole permanent magnet 22. Figure 2 shows a cross sectional view along the line 2-2 of Fig. 1, generally being a cross section along the axis of the torque coupler 10. Within Fig. 2, the cup of outer rotor assembly 12 may readily be appreciated. In addition, outer rotor assembly 12 is shown as being attached at the bottom of the cup shape to the end of a shaft 24. Shaft 24 is supported by a bearing 26, mounted within a housing member 28, and is connectable to other machinery (not shown) . Bore seal 16 is also generally cup shaped, and is sized for non-contacting fit within outer rotor assembly 12. In addition, bore seal 16 includes a flange 32 extending radially outward from the edge of its cup shaped portion, flange 32 allowing attachment to another housing member 34. Bore seal 16 is preferably made from a non-magnetic material. Additionally, a non reactive, impermeable material may be required for the bore seal 16 in order to segregate highly reactive environments. For these types of applications, the material for bore seal 16 may be selected from the group including glass, ceramics, and plastics. Inner rotor assembly 18 is attached to a stub end 36 of a shaft 38. The stub end 36 is cantilevered from the end of shaft 38. Shaft 38 is supported by bearings 40 within housing member 34. Thus, stub end 36 projects into the cup shaped portions of bore seal 16, and outer rotor assembly 12. Inner rotor assembly 18 also includes an end disk 42, which covers the end of magnet 22, and attaches to the end of retaining sleeve 20 at the end of stub end 36. Within the outer rotor assembly 12, in the maximum pullout torque configuration, the two piece flux poles 14 extend a majority of the arcuate distance between opposite magnetic poles of magnet 22. Additionally, the spaces between the facing edges of the flux poles 14 define magnetic air gaps 44. The widths of the air gaps 44 are one of the factors which determine the maximum torque coupling force for the torque coupler 10, and may be designed to be in the range of from slightly greater then 0 degrees up to 30 degrees in arcuate width. Preferably the air gaps 44 have an arcuate width of between 0.1 and 10 degrees. Thus, each of the flux poles 14 may have an arcuate width of from 150 degrees to almost 180 degrees, and preferably, from about 170 degrees to 179.9 degrees. The outer rotor assembly 12 is made up of two relatively movable cylindrical members 50, 52. Member 50 is mounted within member 52, with close dimensional tolerances between the outer diameter of member 50 and the inner diameter of member 52. Member 50 includes two primary flux pole sections 54 and 56, in spaced apart, facing relationship to one another. The primary flux pole sections 54 and 56 are ferromagnetic, and are preferably formed from silicon steel. Additionally, the primary flux pole sections 54 and 56 are preferably partial-crescent in cross sectional shape. Member 50 also includes a non-magnetic support element 58 having spacers 60, 62 filling the gap 42 between the ends of the primary flux poles sections 54, 56, and a flange 64 attached to the spacers 60, 62. Flange 64 allows an easy method of angularly turning the member 50 relative to member 52, which may be accomplished by hand turning for example. Member 52 includes oppositely disposed secondary flux pole sections 66 and 68, contained within a non¬ magnetic high strength support sleeve 70. The support sleeve 70 is designed to contain the secondary flux pole sections 66 and 68, as well as the member 50 during high speed operation of the torque coupler 10. The support sleeve 70 is integrally attached to, or forms a part of, shaft 24. Also, a threaded bore 72 extending through the support sleeve 70 accommodates a positioning screw 74 which may be moved into, or out of contact with the member 50 to fix, or allow relative rotation of the two members 50, 52. The secondary flux pole sections 66, 68 of member 52 are configured to cooperate with the primary flux pole sections 54, 56 of member 50 to provide a magnetically easy flux return path for magnetic flux generated by the magnet 22 of the inner rotor 18. Secondary flux pole sections 66, 68 are preferably crescent shaped in cross section, thereby when aligned in the maximum pull-out torque configuration, the flux poles 14 which are made up of paired primary and secondary flux pole sections from members 50 and 52, are generally crescent shaped. The torque coupler 10 develops torque between the outer and inner rotors 12, 18, due to the change in reluctance of the magnetic circuit when a magnetic axis 46 of magnet 22 is angularly displaced from a centerline 48 of the air gaps 44. The torque increases to a maximum value when the inner rotor 18 is rotated approximately 45 degrees from the air gap centerline 48 of outer rotor assembly 12. The torque then decreases, reaching an unstable zero level at 90 degrees of relative rotation. Fig. 1 shows a maximum pull out torque configuration for the flux poles 14 of the outer rotor assembly 12 wherein the design of the flux poles 14 is optimized. For flux poles 14 formed of a ferromagnetic material with any given properties, maximum torque will be realized from a magnet of any given diameter and length when the maximum radial thickness (Rm) of the flux pole 14 is determined by the equation: Rm = Rmag * (Bmag/Bpole) and the radial thickness (R) of the flux poles 14 varies according to the equation: R = Rm * cos θ where: Rmag is the radius of the magnet 22; Bmag is the flux density in the magnet at the minimum reluctance position; Bpole is the optimum maximum density in flux pole iron at the minimum reluctance position, (about 90 KL/sq. in. for silicon steel) ; and θ is the angular deviation from Rm. Thus it may be appreciated that the optimum cross section for the flux poles 14 is generally a crescent shape. Furthermore, the torque developed in a reluctance coupling is given by the equation: wherein E is the magnetic co-energy of the system; φ is the angular displacement of the members 12, 18; and K is a constant. The maximum change in the magnetic co-energy (E) for an ideal coupling is a function of the change in magnetic flux density for a 90 degree displacement and zero pole leakage. In practice, the ideal is not realizable due to the flux leakage existing between the two flux poles 14. Although leakage can be reduced by reducing flux pole dimension Rm, the higher saturation which occurs at the minimum reluctance position is counter productive. It may be appreciated that at the minimum reluctance position and with negligible iron saturation, flux density in the magnet is uniform regardless of the width of air gap 44 between outer and inner rotor assemblies 12, 18, and that the magnetic flux density in the air gap varies sinusoidally, being maximum in the direction of magnetization of the magnet 22. Thus, the flux poles 14 are preferably designed to the cosine rule 5 in order to obtain minimum leakage and most economical use of materials. Fig. 3 is a cross sectional view perpendicular to the axis of rotors 12 and 18, wherein the outer rotor assembly 12 is configured in the minimum pull out torque 10 configuration. Here, members 50 and 52 have been rotated 90 degrees to one another and fixed in location by positioning screw 74. In this configuration, the secondary flux pole sections 66 and 68 span the magnetic air gap 44 between the primary flux pole sections 54 and 15 56. The secondary flux pole sections 66, 68 provide an easy magnetic flux path bridging the two primary flux pole sections 54, 56. A magnetic return circuit is thereby provided which flows around the magnet 22 within the outer rotor assembly 12 within a magnetically easy, 20 although circuitous magnetic circuit. In this configuration for the outer rotor assembly 12, the magnetic axis 46 of magnet 22 will still preferably align with the magnetic air gap centerline 48 between the two primary flux pole sections 54, 56. 5 However, the resistance to change from this position, and the maximum torque developed between the inner rotor 18 and outer rotor assembly 12 is significantly reduced, and depending upon specific geometries of the flux pole sections 66, 68, the torque may approach zero. This 0 position thus defines the minimum spring rate and pull out torque configuration for the torque coupling device 10. Fig. 4 shows another cross sectional view where members 50 and 52 of the outer rotor assembly 12 are 5 relatively positioned intermediate the maximum and minimum pull out torque configurations of Fig. 1 and Fig. 3. By providing for a method of adjusting the maximum pull out torque for the device 10, the torque coupler can be readily adapted to specific applications. In the arrangement of Fig. 4, the magnetic reluctance between the respective flux poles has been reduced as compared to Fig. 1, and the magnetic circuit within the outer rotor assembly 12 has been altered, thereby reducing the maximum pull out torque and changing the torque spring rate of the torque coupler 10. it should be noted also that varying the relative geometric sizes and thicknesses of the primary flux pole sections 54, 56 and secondary flux poles sections 66, 68 provides another method of specifically tailoring the ability to change the maximum pull out torque and torque spring rate for the torque coupler 10. Thus, by providing secondary flux pole sections 66, 68 which are relatively thin in cross section compared to the primary flux pole sections 54, 56, very fine tuning within a narrow range for the maximum pull out torque is provided. Conversely, where the secondary flux pole sections 66, 68 have a thickness approximately equal to the primary flux pole sections 54, 56 large variations of the maximum pull out torque can be accomplished. In order to reduce flux leakage between flux poles 14 to a minimum or negligible value, the spacers 60, 62 of support element 58 may be formed from either normal conductor material or dia agnetic superconductive material. When normal conductive material is used, the ideal maximum torque can be approached, but only momentarily while the induced damping current exists. This will help stabilize the rotors 12, 18 during load pulsations. Superconductive spacers 60, 62 will reduce flux leakage to zero, thereby the ideal maximum torque for any particular torque coupler 10 can be achieved. i may therefore be appreciated that the present invention details an embodiment of a torque coupling device having an adjustable torque capability. Other configurations for such a device will become apparent to those skilled in the art. Therefore, the invention is not limited by the specific example herein, but only by the proper scope of the appended claims.

Claims: Clai s : 1. An adjustable reluctance torque coupler (10) for coupling rotational torque between two shafts (24,38) comprising: first rotor means (18) for generating a magnetic field, said rotor means (18) secured for rotation with one of said coupled shaft (38) ; second rotor means (12) secured for rotation with the other of said coupled shafts (24) for providing a magnetic circuit flux return path for said magnetic field; and means for varying the reluctance (50,52) within the magnetic circuit of said second rotor means (12) to provide an adjustable maximum pull-out torque. 2. The torque coupler (10) of claim 1 wherein said means for varying the reluctance (50,52) comprises: a first member (50) including a pair of primary flux poles (54,56) of ferromagnetic material; and a second member (52) including a pair of secondary flux poles (66,68) of ferromagnetic material, said second member (52) secured to said shaft (24) and said first member (50) relatively rotatably mounted to said second member (52), said primary flux poles (54,56) and said secondary flux poles (66,68) co-operating to define two variable geometry flux poles (14) within said magnetic circuit. 3. The torque coupler (10) of claims 1 or 2 wherein said first rotor means (18) further comprises: a solid two pole permanent magnet (22) which is diametrically magnetized; and a retaining hoop (20) of high strength, nonmagnetic material mounted about and containing said magnet (22) said retaining hoop (20) secured to said shaft (38) . 4. The torque coupler (10) of claim 2 wherein said primary flux poles (54,56) are generally part-crescent in cross-sectional shape and extend a majority of the arcuate distance between opposite poles of said magnetic field of said first rotor means (18), and said primary flux poles (66,68) are generally crescent in cross-sectional shaped. 5. The torque coupler (10) of claims 1,2 or 4 further comprising: a hermetic seal (32) of non-magnetic material disposed between and separating the environments of the first rotor means (18) from that of the second rotor means (12). 6. The torque coupler (10) of claim 2 wherein said second rotor means (12) further comprises: a pair of spacer bars (60,62) of non-magnetic material separating said primary flux poles (54,56) and a disk shaped flange (64) of non-magnetic material attached to said spacer bars (60,62). 7. The torque coupling device of claim 2 wherein said secondary flux poles (66,68) are shaped to allow the decoupling torque to be varied from between a theoretical maximum decoupling torque to a specific minimum decoupling torque. 8. A method of providing an adjustable torque characteristic for torque coupling between a pair of shafts (24,38) comprising: attaching a first rotor assembly (18) to one of said shafts (38) said first rotor assembly (18) including a magnetic field generator (22) ; attaching a second rotor assembly (12) to the other of said shafts (24) , said second rotor assembly (12) including magnetically permeable flux cores (14) traversing between opposite magnetic poles of said magnetic field generator (22); agnetically coupling said second rotor assembly (12) and said first rotor assembly (18) ; and varying the geometry of said flux cores (14) of said second rotor assembly (12) to adjust the decoupling torque. 9. The method of claim 8 further comprising: providing first and second relatively rotatable members (50,52) forming said second rotor assembly (12), said first member (50) including primary flux poles (54,56) of ferrogmagnetic material and said second member including secondary flux poles (66,68) of ferromagnetic material, said primary flux poles (54,56) and said secondary flux poles (66,68) co-operating to define said magnetically permeeUDle flux cores (14) of said second rotor assembly.

Inventors: MCCARTY FREDERICK B, MCCARTY, FREDERICK, B.
Applicants: ALLIED SIGNAL INC, ALLIED-SIGNAL INC.
Application year: 1990
Main classification: H02K49
IPC codes: H02K5, H02K49