Abstract:
A sphere zone coupling of magnetic devices has a first rotor containing permanent magnet array and a second rotor. The first rotor and the second rotor have the sphere zone surfaces forming from magnetic array or similar of almost the same sphere radius facing with constant air gap at overlapped area. The axle of the first rotor and the axle of the second rotor are concentric and non-coaxial. The second rotor has permanent magnet array, ferromagnetic or conductive material to couple with the first rotor at the sphere zone surfaces. The rotation of the first rotor causes magnetic force to drive the second rotor. The transmission ratio will depend on the average zone radius ratio of two coupling rotors and the pair number ratio of magnets in magnetic arrays.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the invention 
         [0002]    The present invention relates generally to magnetic coupling, and more particularly to sphere zone coupling of magnetic rotors for drive devices, and multiple applications can apply in magnetic drive mechanism and combination to work for efficient torque transmission. 
         [0003]    2. Description of the Related Art 
         [0004]    Mechanical gear will generate much noise, vibration and wear than magnetic gear. Mechanical gears need lubrication and more maintenance for wear and tear. While magnetic gear can provide better benefits from mentioned problem in transmission system. Recent advances in the material research have developed powerful magnets and applied in wide range of use for magnetic transmission. Thus make the magnetic gear to be workable in industrial application. 
         [0005]    Generally magnetic coupling of gear is the magnet arrays arranged at a circumferential radius to work with cylindrical or disk-shaped drive rotating members. In such a magnetic device the magnetic coupling is radial coupling at different rotating radius. The interaction force is strong at the closest position, and weak as the air-gap increased from the central closest position. Axial and disk-shaped magnetic coupling of gears can work better because consistent air-gap between magnetic arrays. While the interaction faces have limits and make the magnetic area to be large for efficiency. And the rotating axles of radial or axial coupling of magnetic devices need to be parallel with structure design. Some magnetic spur gears can work in angled axial position but are the same as cylindrical type to have strong interaction at the closest position only. Thus make the magnetic devices work less efficient. However, there are still needs for increased torque interaction and some better utilization of the permanent magnets to work in magnetic couplings and transmission devices. 
         [0006]    Because a lot of the magnetic couplings are less efficient and cannot assist in transferring torque, and magnetic coupling cannot work as mechanical gears in transmission methods. The magnetic application of transmission is not so wide for industrial application as mechanical systems. The reasons might due to directional restriction of coaxial or parallel type of magnetic transmission system. So comparing with some mechanical mechanism, non-coaxial or angled magnetic transmission system has some more usages and freedom in transmission design. There are needs for better improvement in magnetic coupling systems. 
         [0007]    The present invention provides a solution to the above problems by sphere zone coupling to increase effective coupling interaction and minimize whole air gap of working area. This means like two different sphere zones of a sphere to couple with some overlapped area for magnetic drive. Basically sphere zone couplings have more freedom in axial arrangements and choices of transmission ratio. A large torque can be transmitted from sphere zone coupling system. These non-parallel and angled axial arrangements of magnetic coupling devices have practice value and un-replaceable benefits in rotary transmission designs. Furthermore multiple applications from sphere zone couplings can work as coaxial and parallel coupling systems and have better performance. 
         [0008]    More particularly, combination of sphere zone couplings can work from one input drive to multiple outputs. Alternatively sphere zone couplings can work from multiple inputs to collect driving forces to single output. Thus the sphere zone coupling systems can use for adaptive magnetic devices in wide range. 
       SUMMARY OF THE INVENTION 
       [0009]    The present invention relates to sphere zone coupling of magnetic rotors of devices, and multiple applications for magnetic transmission. The sphere zone coupling of the present invention can possess a variety of embodiments based on different coupling arrangements or combinations for drive and transmission. 
         [0010]    An embodiment of sphere zone coupling of magnetic devices preferably includes at least one magnetic rotor having permanent magnet array at the radial sphere zone face, and a second rotor having permanent magnet array, ferromagnetic or conductive material at the radial sphere zone face. The sphere zone faces of two rotors have almost the same sphere radius. The zone radius of two rotors can be the same or different at constant ratio as gear ratio for drive coupling, and the transmitting ratio depends on zone radius ratio and number ratio of the magnet pairs of magnetic arrays of coupling. Two rotors are non-coaxial and concentric coupling at the sphere zone faces with the maximum overlapped area. When the first rotor rotates will drive the second rotor with magnetic interactive force to rotate. Basically two rotors were coupling with about the same sphere radius, the air-gap between two rotors in overlapped area will be consistent and can retain as close as possible for maximum magnetic coupling for transmission. 
         [0011]    In certain embodiments, the present invention provides mechanism design of drive with multiple gear rotors to transmit torque to single output rotor and axle. The rotors of sphere zone coupling can generate efficient transmitting forces. And the gear ratios have more freedom than traditional magnetic coupling in mechanism design. 
         [0012]    Particular embodiment of the present invention provides mechanism design of single drive with two opposite gear rotors fixing in one axle with same rotating direction. Thus the driving and transmitting force will be double and combined to output. 
         [0013]    In other embodiments, the present invention provides mechanism design of drive with several transmitting gears to transport driving forces to output rotor and axle. Thus greater torque can be transmitted from the combination of multiple sphere zone couplings to the specified output rotor. Additionally different gear rotors can output torque as different transmitting systems in different directions from the drive. So in the coordinating system some gear rotors can be transporting gears and some rotors can be output gears. The mechanism design has more freedom for multiple outputs or torque transmissions. 
         [0014]    In further embodiments of the present invention, instead of rotating the drive rotor when the carrier frame of gear rotors rotates with constant speed, the output rotor can rotate with ratio speed plus carrier driving speed. The features and functions will be the same as the planetary gears for the best transmission and performance from efficient sphere zone couplings. 
         [0015]    The present invention provides several technical advantages. For example, because magnetic flux is penetrated magnetic body and can work in opposite faces of magnet. Generally magnetic design works with one face of magnets or one side of magnetic arrays. Some structures design double sides coupling but have high limit in axial arrangement. For sphere zone couplings of magnetic arrays beside the basic working face the opposite side can adapt other magnetic devices. Two sphere zone faces of main rotor can be designed to work at different sphere center for space arrangements. The sphere zone couplings have more freedom in axial and mechanism design. Thus the advantages are quite apparent. 
         [0016]    Instead of using magnetic rotors, the drive can be electromagnetic drives like electric stator with sphere zone coupling in mechanism design. Stator works like the drive of magnetic arrays. Thus can achieve same advantages of the present invention and work in more wide industrial applications. 
         [0017]    Additional features and advantages of the invention will be set forth in the description as embodied in sphere zone coupling of magnetic transmission, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims. The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0018]      FIG. 1 . is a explanatory view of the sphere zone coupling of magnetic rotors of the present invention. 
           [0019]      FIG. 2 . is a explanatory view showing prior art of the magnetic couplings of cylindrical types. 
           [0020]      FIG. 3 . is a explanatory view showing prior art of the magnetic couplings of disk-like types. 
           [0021]      FIG. 4 . is a explanatory illustration showing principle of sphere zone couplings. 
           [0022]      FIG. 5 . is a explanatory view showing the sphere zone coupling of one drive with two gear rotors fixed in one axle for efficient transmission. 
           [0023]      FIG. 6 . is a explanatory view showing the sphere zone coupling mechanism like planetary gear. 
           [0024]      FIG. 7 . is a explanatory view showing a transmitting and coordinating system of sphere zone couplings. 
           [0025]      FIG. 8 . is a explanatory view showing a different transmitting and coordinating system than  FIG. 7 . 
           [0026]      FIG. 9 . is a explanatory view showing a design to drive the carrier frame of gear rotors of the present invention. 
           [0027]      FIG. 10 . is a explanatory view showing two systems of the present invention working with one magnetic array of rotor at both sides. 
           [0028]      FIG. 11 . is a explanatory view showing a unsymmetrical mechanism of the present invention. 
           [0029]      FIG. 12 . is a explanatory view showing a comparison of mechanism arrangements from the present invention. 
       
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0030]    Detailed descriptions of preferred embodiments are provided herein. It is to be understood, however, that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in virtually any appropriately detailed system, structure or manner. 
         [0031]    In  FIG. 1 , a first rotor  10  with magnetic array  14  in annular and arranged to comprise a sphere zone face. The magnetic array is provided with a plurality of magnetic poles of comprising opposite polarity next to each other in turn. The first rotor  10  is supported for rotation about a first axle  12 . 
         [0032]    A second rotor  20  is provided with magnetic array  24  in annular and arranged to comprise a sphere zone face which has almost the same sphere radius as the sphere zone face of the first rotor, but the zone radius can be the same or different for the different gear ratio arrangements. Transmission ratio is the ratio of two zone radius ratio with magnetic array arrangements and the number ratio of the magnet pairs of magnetic arrays of coupling. The second rotor  20  is supported for rotation about a second axle  22 . Two rotors are coupling at the sphere zone faces with the maximum overlapped area for magnetic coupling forces. In  FIG. 1 , two sphere zones are perpendicular coupling , while not limited to perpendicular and just explanatory for better understanding the principle of sphere zone coupling. Alternatively for the first or second rotor, one of two magnetic arrays can be replaced by ferromagnetic or conductive material to produce magnetic working force, and achieve some or similar effect as magnetic array in transmitting torque. The first axle  12  and the second axle  22  are concentric and non-coaxial arrangement. Two rotors are contactless and have consistent and small air-gap  99  between the overlapped sphere zone faces. And if possible some more gear rotors can be arranged to couple with drive rotor to induce more torque to other outputs, or collect more torque to single output. If collecting for single output the gear rotors need to be the same zone radius to couple with drive rotor and output rotor. If designed for different outputs, the gear rotors can be different in zone radius for different transmissions and axle alignments in the system. Herein if use electromagnetic stator with sphere zone coupling method as the drive the work will be similar. 
         [0033]    In  FIG. 2  of prior art of cylindrical magnetic coupling of gears, two rotors have the strongest working force at the closet position and become weaker as the air-gap increase from the closest position because of the different or opposite radius in coupling. The axles of cylindrical coupling should be paralleled, and are difficult to design if inside coupling for better magnetic working method. 
         [0034]    In  FIG. 3  of prior art of disk-shaped magnetic coupling of gears, two rotors have consistent and small air-gap. The axles of disk-shaped coupling also need to be paralleled. If inside coupling the axle design is more difficult than cylindrical coupling because structure confliction between disks and axles. There are some magnetic spur gears, the axial arrangements can be better but the working methods are similar to cylindrical couplings. The magnetic working forces become weak from increased air-gap outside the central close area. 
         [0035]    While for the sphere zone coupling, the axle design has more freedom than prior art. From  FIG. 4  of explanatory illustration of sphere zone couplings, sphere zone  1  couples with sphere zone  2  at the overlapped area A. Sphere zone  1  can couple with different sphere zone  3  with overlapped area B. In a sphere face, different zone radius and zone axle arrangement for coupling will have different overlapped area. The air-gap is consistent in overlapped area because the same sphere radius. In a sphere system two rotors have much freedom in zone choices for gear ratio choices. The transmission ratio is the zone radius ratio and the number ratio of magnet pairs in annular magnetic array. For coupling design, the maximum overlapped and working area will be two equatorial zones like zone  3  to coupling as gear ratio of  1 , the overlapped area is full sphere zone. This is similar as cylindrical coupling. And compared with the disk-shaped couplings, it will be similar as two pole zones like zone  2  to couple. Such the sphere zone couplings also have the advantages of prior art and better benefits. 
         [0036]    Particularly as show in  FIG. 5 , drive rotor  10  with magnetic array  14  and axle  12  couples with two same or similar gear rotors  20  with magnetic arrays  24  and axle  22 . Two gear rotors  22  are fixed in one axle  22 . The coupling is designed for magnetic array  12  of drive rotor  10  to work in different sides of magnetic array  24  of gear rotors  20  in referring position on driving side. Rotors are concentrically constructed at the supporting frame  19  with drive bearings  17  and gear bearings  27 . In this way two gear rotors will rotate in same rotating direction for efficient transmission. Thus the coupling and driving force will be double than single coupling in a simple transmitting mechanism. 
         [0037]    As show in  FIG. 6 , drive rotor with magnetic array  14  and axle  12  couples with two gear rotors  20  with magnetic arrays  24  and axles  22  and transmits torque to output rotor  30  with magnetic array  34  and axle  32 . In such as planetary gear mechanism of sphere zone coupling there is some space inside of coupling rotors for construct the joint or connecting structure. For example of  FIG. 5  the axles of drive rotor  10  and output rotor  30  need to be coaxial. So output rotor  30  can be design with bearing loaded at the same axle  12  of drive rotor  10 . Or in  FIG. 6  to add some more joints, two axles  12  and  32  connect with coaxial and bearing loaded structure inside rotors. Then the system will be more stable and rigid in working. Some more rotors also can add for more torque transmission or output torque to other sources. 
         [0038]    In  FIG. 7  of transmitting and coordinating system, drive rotor  10  will rotate rotors  20 ,  40 ,  50  and through the transmission to drive the rotor  30 . Rotors have magnetic arrays  14 ,  24 ,  34 ,  44 ,  54  and axles  12 ,  22 ,  32 ,  42 ,  52 . In this or similar arrangement rotor  30  can be as a transporting gear to transmit torque from rotor  40  or  50  to rotor  20 . The rotor  20  will collect more torque in this way for more output torque. So some rotors can be output rotor and some rotors can be transporting rotors. More rotors can be added for transporting torque or output torque to other sources. This will be depended on the zone space between rotor  10  and  30  for gear arrangement. Rotor  30  can be another drive input with same rotating speed as rotor  10  and opposite rotating direction. 
         [0039]      FIG. 8  shows a different design of transmitting and coordinating system from  FIG. 7 . With magnetic array  14  and axle  12 , rotor  10  will drive gear rotor  20  and  40  with magnetic arrays  24 ,  44  and axles  22 ,  42 . Rotors  20  and  40  have another sphere zone coupling system than rotor  10  to transmit torque to rotor  30  with axle  32  and magnetic array  34 . Rotors  20  and  40  have another magnetic array  25 ,  45  for the different sphere zone coupling with rotor  30 . Rotors and axles are constructed at the supporting frame  19  with bearings  17 ,  18 ,  27 ,  28 ,  37 ,  38 ,  47 . And there is a central connecting frame  29  for supporting and axle arrangements. Rotor  30  can be output rotor or transporting rotor. Rotor  20  also can be output rotor. More rotors can be added at the annular position of magnetic array  14  of rotor  10  for the similar coupling way. It&#39;ll be notice that rotor  30  and axle  32  also can be installed at the vertical position to rotor  10  and rotor  20 . Alternatively in this way two of similar like rotor  30  can be vertically installed at opposite coupling position with rotor  20  and  40  for efficient torque transmission. 
         [0040]    For planetary gear when rotate the planetary gear frame instead to rotate the sun gear, the transmitting speed will be the ratio speed plus the driving speed. In  FIG. 9  rotor  10  with axle  12  and magnetic array  14  is fixed at the supporting frame  19  and bearings  17  with bolts  18 . Two gear rotors  20  with magnetic arrays  24 ,  25  and bearings  27  are fixed at axle  22 . Axle  22  is fixed at the carrier flange  29  with the drive axle  12 . The drive axle  12  rotates the carrier flange  29  and axle  22 . Thus the torque is transmitted from outside sphere zone coupling system to rotor  30  with magnetic array  34  and axle  32  through the inside sphere zone coupling system for output. In this way rotor  30  can achieve higher speed and better performance. And axle  32  of rotor  30  can connected to carrier flange  29  and axle  12  with bearing  28  for construction stability. More gear rotors like rotor  20  can be added for better efficiency. 
         [0041]    Magnetic flux will penetrate the magnetic body. Magnetic field exists at the both side of magnetic array. Such the usage of magnetic coupling can work in double sides of magnetic array. In  FIG. 10  rotor  10  with magnetic array  14  is fixed at the supporting frame  19 . 
         [0042]    Magnetic array  14  is arranged to form two sphere zone faces at the inner side as well as the outer side, and magnetic contacting faces are clear for coupling. Drive axle  12  is fixed with carrier flange  29  and supporting on rotor  10  with bearings  17 . Two rotors  20  with magnetic arrays  24  are sphere zone coupling with rotor  10  at the inner side of magnetic array  14  and pivoted on the axles  22  with bearings  27  at the carrier flange  29 . Rotor  30  with magnetic array  34  is coupling with two gear rotors  20  and pivoted at axle  12  with bearings  37 . When input drive from axle  12  will rotate the carrier flange  29  and transmit torque through gear rotors  20  to rotor  30  to output. Besides the inner coupling of magnetic array  14 , there is another sphere zone coupling system to work at the outside field of magnetic array  14 . Axle  12  is fixed with another carrier flange  49 . Two gear rotors  40  with magnetic arrays  44  are sphere zone coupling with rotor  10  and pivoted on the axles  42  with bearings  47  at the carrier flange  49 . Another rotor  50  with magnetic array  54  is coupling with two gear rotors  40  and pivoted at axle  12  with bearings  57 . When input drive from axle  12  will rotate the carrier flange  49  and transmit torque through gear rotors  40  to rotor  50  to output. So there are two sphere zone coupling systems to work at the different sides of magnetic array  14 . It&#39;ll be notice that inner and outer sphere zones of magnetic array can be non-concentric, meaning besides different zone radius the different systems can be having different sphere center in arrangement. Thus two sphere zone coupling systems can work in one main rotor. There in much freedom in transmitting ratio design as the figuration. More gear rotors can be added and will depend on the space as well as structure compatibility. Alternatively in  FIG. 10  if fix the carrier flanges  29 ,  49  and rotate rotor  10  by changing joints and supporting structure, there will be  2  sphere zone coupling systems like  FIG. 6  to work with rotor  10 . So as if use electromagnetic stator to work as drive of magnetic array  14  of rotor  10  to couple with the systems, then can have the same functions and advantages in industrial applications. 
         [0043]    Besides symmetrical structures,  FIG. 11  shows an unsymmetrical system of sphere zone couplings. Rotors  10 ,  20 ,  30 ,  40  with magnetic arrays  14 ,  24 ,  34 ,  44  and axles  12 ,  22 ,  32 ,  42  are pivoted at supporting frame  19  with bearings  17 ,  18 ,  27 ,  28 ,  37 ,  38 ,  47 ,  48 .  FIG. 11  takes an example of zone radius ratio about 8:3:6:4 for rotors  10 ,  20 ,  30 ,  40 . If drive rotor  10  with rotating speed of 60 rpm, speed of rotor  20  will be about 160 rpm, rotor  30  about 80 rpm, rotor  40  about 120 rpm. Four rotors coordinate and transmit torque in a close cycle and connecting system. Each rotor can be input source or output source. In  FIG. 11  rotors of zone radius ratio between 3 and 4 in this formula can be installed between rotor  10  and rotor  30 . Rotors of zone radius ratio between 6 and 8 in this formula can be installed between rotor  20  and rotor  40 . There is quite wide range for transmission design at similar configurations. 
         [0044]      FIG. 12  shows the flexibility in mechanism design from sphere zone couplings. Rotors  10 ,  20 ,  30 ,  40  are coupling together with magnetic arrays  14 ,  24 ,  34 ,  44  and axles  12 ,  22 ,  32 ,  42 . Rotor  10  couples with two rotors  20 ,  40  and works as drive input. Two rotors  20  and  40  can be the same. Rotor  30  couples with rotors  20 ,  40  and works as a transporting gear. If drive rotor  10 , rotor  20  will rotate. For rotor  20  beside the interaction with rotor  10 , there is more torque can be transferred from rotor  40  through rotor  30  to rotor  20 . In  FIG. 12  at the same configuration another similar transferring rotors also can be installed at left side of rotor  20  to collect more torque to rotor  20  for better performance. At this mechanism and function gear rotors  20  and  40  need to be close for cost saving and structure connection.  FIG. 12  shows two arrangements of rotors in different positions. At left side of arrangement, rotor  20  and  40  are close and rotor  30  is higher and far to rotor  10 . At right side of arrangement, rotor  20  and  40  are a little far and rotor  30  is lower and close to rotor  10 . The adjustments need to work with magnetic array arrangements and coupling alignments. Such there are design flexibility and mechanism freedom for sphere zone couplings of magnetic devices. 
         [0045]    As descript above, the sphere zone coupling of the present invention is suitable for magnetic devices. And there are multiple applications of the present invention for magnetic system design in wide range. While the present invention has been described in connection with what is considered the most practical and preferred embodiment, it is understood that this invention is not limited to the disclosed embodiments but is intended to cover various arrangements included within the spirit and scope of the broadest interpretations and equivalent arrangements. The present invention is in no way to limit in described configurations. Moreover, variations and changes may be made by those skilled in the art without departing from the spirit of the invention. Accordingly the scope of the invention should be limited only by the claims and the equivalences thereof.