Research On Coils Arrangement Type Controllable Inductive Magnetic Coupler

Magnetic couplers is a highly efficient and eco-friendly speed control device that has been greatly enhanced with the emergence and application of new technologies,materials,and processes.The coupler operates by inducing eddy currents from the relative motion between the conductor disk and permanent magnet disk,exciting an induced magnetic field,and driving the permanent magnet disk for power transmission.The coupler has the advantages of including contactless connection,low environmental sensitivity,low structural complexity,soft start,energy-saving,and environmental protection.This paper proposes a coils arrangement type controllable inductive magnetic coupler based on the traditional disc-type magnetic coupler.This coupler uses coils as conductors and provides two speed control modes: air gap and coils.A method combining theoretical analysis,finite element simulation,and experimental testing is used to investigate the coils configuration,electromagnetic characteristics,and speed control performance of this coupler.Firstly,the paper analyzes the transmission principle of the traditional copper disk magnetic coupler and proposes a circular coils arrangement type magnetic coupler that can adjust speed by changing the gap distance or controlling the on/off of the coils.The equivalent magnetic circuit method is used to analyze the magnetic flux path,and the flux averaging method calculates the equivalent magnetic resistance of each magnetic circuit.Matrix equations are established to solve the gap magnetic flux,and the law of electromagnetic induction,Ampere’s law,and law of conservation of energy are combined to derive the coupler torque expression.Secondly,the paper compares and analyzes the electromagnetic characteristics of the traditional copper disk and circular coils arrangement type couplers using the magnetic simulation software ANSYS Maxwell.It verifies the superiority of the latter in improving coupler transmission performance from aspects such as spatial magnetic density,conductor eddy current,axial force changes,and torque transmission.The paper also builds a magnetic coupler test platform,makes a prototype of the circular coils arrangement type coupler,and conducts theoretical analysis,finite element simulation,and experimental testing to verify the accuracy of the finite element analysis and explore the influence of the working state on the coupler axial force and torque.Thirdly,the paper proposes a fan-shaped coils arrangement type coupler aimed at improving torque increase.Through finite element simulation analysis of the magnetic density,eddy current,torque,etc.of the two types of coils,it is shown that the fanshaped coils arrangement type can greatly improve torque.Then,the fan-shaped coil is structurally optimized using the response surface methodology,with torque and torque ripple as the optimization targets,and the coil width,thickness,and radial length as the optimization variables.The range of variable values is determined by single-factor experiments,taking into account the sensitivity of parameters and the influence of actual processing and assembly,and the optimal parameters of the fan-shaped coil structure are determined.Fourthly,the paper conducts the single-factor experiments study on the optimized fan-shaped coils arrangement type coupler,combining experimental testing with finite element simulation.This reveals the main factors affecting the peak torque-speed difference of the coupler characteristic curve and further enhances the persuasiveness of the finite element simulation.Based on the coupler characteristic curve,the soft start effect and energy-saving effect of the coupler under different loads are discussed,and the speed control range of the three speed control modes of gap,coil,and combined control are explored.In conclusion,the proposed coils arrangement type controllable inductive magnetic coupler offers three speed control modes and simplifies the mechanical structure,avoiding the slow responses and redundant adjustment structure of traditional couplers.The paper demonstrates the advantages and feasibility of the coils arrangement type coupler,providing a new direction for the technological innovation and practical application of magnetic couplers.