Patent Grant
9202616
The present invention relates generally to an intelligent magnetic system. More particularly, the present invention relates to a magnetic system including a multi-pole magnetic structure, one or more sensors to monitor data relating to the magnetic structure, and a control system for receiving the data and using it to manage the use of the magnetic system.
An intelligent magnetic system includes a first piece of ferromagnetic material, a shunt plate, at least one simple machine, at least one sensor, and a control system. The first piece of ferromagnetic material has a first side and a second side opposite the first side and has magnetically printed field sources that extend from the first side to the second side. The magnetically printed field sources have a first multi-polarity pattern and the first side of the first piece of ferromagnetic material is magnetically attached to a second piece of ferromagnetic material.
The shunt plate is disposed on the second side of the first piece of ferromagnetic material for routing magnetic flux through the first piece of ferromagnetic material from the second side to the first side of said first ferromagnetic material.
The as least one simple machine amplifies an applied force into a detachment force that creates an angled spacing between the first piece of ferromagnetic material and the second piece of ferromagnetic material.
The at least one sensor produces sensor data that the control system monitors in order to manage the use of the first ferromagnetic material.
The at least one sensor may measure at least one of a lift force being applied to the intelligent magnetic system or the magnetic force between the first piece of ferromagnetic material and the second piece of said ferromagnetic material.
The second piece of ferromagnetic material may have magnetically printed field sources having a second multi-polarity pattern that is complementary to the first multi-polarity pattern.
The intelligent magnetic system may include the second piece of ferromagnetic material.
The at least one sensor may measure a magnetic field.
The at least one sensor may measure a tensile force.
The at least one sensor may measure a shear force.
The at least one sensor may measure a torque.
The at least one sensor may measure may include at least one of a temperature sensor, a barometric sensor, an accelerometer, a capacitive sensor, an electrical sensor, an optical sensor, an ultrasonic sensor, or a vibration sensor.
The control system may characterize the sensor data as being within an acceptable range or being outside an acceptable range.
The control system may provide a warning indication when the control system characterizes the sensor data as being outside an acceptable range, where a warning indication may be at least one of a visual indication or an audio indication.
The sensor data may be used to control a magnetic property of the first ferromagnetic material or the second ferromagnetic material.
The sensor data may be conveyed from the at least one sensor to the control system using a wire or wirelessly.
A property of the first ferromagnetic material or the second ferromagnetic material may be modulated to convey information to the sensor.
The sensor data may correspond to temperature information that may be used to automatically adjust a property of the first ferromagnetic material or the second ferromagnetic material in order to compensate for temperature-related force variations.
The at least one sensor may measure a separation distance between the first ferromagnetic material and the second ferromagnetic material.
The at least one sensor may be used to determine whether the intelligent magnetic system is in motion.
The at least one sensor may be used to track movement of the intelligent magnetic system.
The present invention is described with reference to the accompanying drawings. In the drawings, like reference numbers indicate identical or functionally similar elements. Additionally, the left-most digit(s) of a reference number identifies the drawing in which the reference number first appears.
The present invention will now be described more fully in detail with reference to the accompanying drawings, in which the preferred embodiments of the invention are shown. This invention should not, however, be construed as limited to the embodiments set forth herein; rather, they are provided so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those skilled in the art.
Certain described embodiments may relate, by way of example but not limitation, to systems and/or apparatuses comprising magnetic structures, magnetic and non-magnetic materials, methods for using magnetic structures, magnetic structures produced via magnetic printing, magnetic structures comprising arrays of discrete magnetic elements, combinations thereof, and so forth. Example realizations for such embodiments may be facilitated, at least in part, by the use of an emerging, revolutionary technology that may be termed correlated magnetics. This revolutionary technology referred to herein as correlated magnetics was first fully described and enabled in the co-assigned U.S. Pat. No. 7,800,471 issued on Sep. 21, 2010, and entitled “A Field Emission System and Method”. The contents of this document are hereby incorporated herein by reference. A second generation of a correlated magnetic technology is described and enabled in the co-assigned U.S. Pat. No. 7,868,721 issued on Jan. 11, 2011, and entitled “A Field Emission System and Method”. The contents of this document are hereby incorporated herein by reference. A third generation of a correlated magnetic technology is described and enabled in the co-assigned U.S. Pat. No. 8,179,219, issued May 15, 2012, and entitled “A Field Emission System and Method”. The contents of this document are hereby incorporated herein by reference. Another technology known as correlated inductance, which is related to correlated magnetics, has been described and enabled in the co-assigned U.S. Pat. No. 8,115,581 issued on Feb. 14, 2012, and entitled “A System and Method for Producing an Electric Pulse”. The contents of this document are hereby incorporated by reference.
Material presented herein may relate to and/or be implemented in conjunction with multilevel correlated magnetic systems and methods for producing a multilevel correlated magnetic system such as described in U.S. Pat. No. 7,982,568 issued Jul. 19, 2011 which is all incorporated herein by reference in its entirety. Material presented herein may relate to and/or be implemented in conjunction with energy generation systems and methods such as described in U.S. patent application Ser. No. 13/184,543 filed Jul. 17, 2011, which is all incorporated herein by reference in its entirety. Such systems and methods described in U.S. Pat. No. 7,681,256 issued Mar. 23, 2010, U.S. Pat. No. 7,750,781 issued Jul. 6, 2010, U.S. Pat. No. 7,755,462 issued Jul. 13, 2010, U.S. Pat. No. 7,812,698 issued Oct. 12, 2010, U.S. Pat. Nos. 7,817,002, 7,817,003, 7,817,004, 7,817,005, and 7,817,006 issued Oct. 19, 2010, U.S. Pat. No. 7,821,367 issued Oct. 26, 2010, U.S. Pat. Nos. 7,823,300 and 7,824,083 issued Nov. 2, 2011, U.S. Pat. No. 7,834,729 issued Nov. 16, 2011, U.S. Pat. No. 7,839,247 issued Nov. 23, 2010, U.S. Pat. Nos. 7,843,295, 7,843,296, and 7,843,297 issued Nov. 30, 2010, U.S. Pat. No. 7,893,803 issued Feb. 22, 2011, U.S. Pat. Nos. 7,956,711 and 7,956,712 issued Jun. 7, 2011, U.S. Pat. Nos. 7,958,575, 7,961,068 and 7,961,069 issued Jun. 14, 2011, U.S. Pat. No. 7,963,818 issued Jun. 21, 2011, and U.S. Pat. Nos. 8,015,752 and 8,016,330 issued Sep. 13, 2011, and U.S. Pat. No. 8,035,260 issued Oct. 11, 2011 are all incorporated by reference herein in their entirety.
Material presented herein may relate to and/or be implemented in conjunction with systems and methods described in U.S. Provisional Patent Application 61/640,979, filed May 1, 2012 titled “System for Detaching a Magnetic Structure from a Ferromagnetic Material”, which is incorporated herein by reference. Material may also relate to systems and methods described in U.S. Provisional Patent Application 61/796,253, filed Nov. 5, 2012 titled “System for Controlling Magnetic Flux of a Multi-pole Magnetic Structure”, which is incorporated herein by reference. Material may also relate to systems and methods described in U.S. Provisional Patent Application 61/735,403, filed Dec. 10, 2012 titled “System for Concentrating Magnetic Flux of a Multi-pole Magnetic Structure”, which is incorporated herein by reference.
The basic use of sensors with a correlated field emission system has been previously described in U.S. Pat. Nos. 7,868,721 and 8,179,219, which are referenced above. The present invention relates to intelligent magnetic systems where sensor data is used to control the use of a magnetic structure. One or more sensors are used to collect data relating to a multi-pole magnetic structure. The sensor data is monitored by a control system and used to manage the use of the magnetic structure. The one or more sensors may include, for example, a temperature sensor, a barometric sensor, an accelerometer, a Hall Effect sensor, a force sensor, a magnetometer, a capacitive, an electrical sensor such as an inductor coil, an optical sensor, a vibration sensor, etc. Data provided by a given sensor may be characterized by the control system as being within an acceptable range or being outside an acceptable range in which case the control system can provide a user of the magnetic system a warning indication, which might be a visual indication (e.g., a flashing red light) or an audio indication (e.g., an alarm sound). Data provided by a given sensor may also be used to control a magnetic property of a magnetic structure during its use. Data may be conveyed from a sensor and a control system using a wire or conveyed wirelessly using any well-known communications method. A property of the magnetic structure can also be modulated to convey information to a sensor associated with a control system.
Data provided by a temperature sensor can be used to determine whether an environment is adversely affecting a magnetic structure. For a given magnetic structure, parameters relating to the susceptibility of the material used in the magnetic structure to temperature can be used to establish an acceptable temperature range used to compare to sensor data. Moreover, variations in forces produced by the magnetic structure resulting from temperature variations can be taken into account by a control system. For magnetic systems whereby magnetic fields can be varied, temperature information may be used to automatically adjust a magnetic structure or a magnetic circuit relating to a magnetic structure in order to compensate for temperature-related force variations.
An accelerometer can be used to determine whether a magnetic system is in motion and to track its movement along a movement path. Such data can be used to control magnetic structure properties. For example, in a robotic application where the magnetic system is used to pick up sheets of metal that are stacked, it may be desirable to set a magnetic field parameter such that the system will only pick up one sheet of metal but once the metal has been picked up, detected movement of the magnetic system may indicate that the magnetic field parameter can be increased until some other movement indicates that the magnetic structure is again about to be used to pick up a piece of metal off of the stack. As such, the field strength can be controlled to vary from a minimum field desired to only pick up one piece of metal to some higher field strength used to handle the metal once it has been removed from the stack.
A Hall Effect sensor placed at a known location relative to a magnetic structure can be used to determine any change to the field produced by the magnetic structure such as demagnetization of the structure. The Hall Effect sensor may also detect presence of an approaching magnetic structure, movement of the magnetic structure along a known movement path, etc. One or more Hall Effect sensors can be used as part of a quality control system, for example to determine if a printed magnetic structure has been properly printed with the desired maxel pattern. Such sensors can be used to detect problems with printed magnetic structures due to material flaws and the like. Such sensors can also be used to install a magnetic structure within a system so as to make sure it has proper alignment, orientation, etc. Such sensors can also be used to verify that a magnetic structure produces the intended amount of flux across an interface, etc. during operation. For example, a device that uses mechanical advantage to vary a magnetic field produced by a structure can be tested within a jig having one or more Hall Effect sensors and its field characteristics can be validated to be correct or it can be determined to be not operating as desired.
One skilled in the art of force measurements will recognize that various sensor configurations are possible for measuring tensile, shear, and torque using various types of strain gages and the like. Such measurements can be made in at least one dimension with multiple degrees of freedom up to 6 DOF measurements enabling the complete force behavior of a magnetic structure to be characterized.
Generally, data from one or more sensors can be collected over the full range of a predefined movement path of a magnetic system and used to control the magnetic system while moving along the movement path and to recognize anomalies during operation of the system. Given the ability to vary forces as described herein, the control system can optimize performance of the system during operation by varying magnetic parameters based on measured sensor data. Moreover, for applications where a movement path function is not predefined, such as with a tool being used manually, forces being produced can be compared to acceptable parameters in order to provide safety warnings and to compensate for movement of the system. For example, a measured tensile force may be compared to determine if the magnetic structure is about to detach from metal. Similarly, vibration sensor measurements can, for example, measure vibration amplitude so as to determine whether a magnetic structure is likely to disengage from metal to which it is attached. Generally, multiple sensors that are tracking movement, the distance between a magnetic structure and a target, and the like can be used to produce data that can be compared to stored data as required to control and monitor a magnetic system.
Under one arrangement measure data can be in response to a known force. For example, by modulating a force applied to the magnetic system a response can be measured. For example, a force may correspond to an impulse or a force may be correspond to a sine wave sweep (Bode plot), where the force may be varied in amplitude or time. For instance, a cable associated with the system could be monitored to see if it is about to fail, where the natural frequency of the cable would increase as an applied force (or load) increases but the body resonance decreases as the load increases.
Under one arrangement, a capacitive sensor can be used to measure the separation distance between the magnetic structure and a target including metal having some substance on it such as paint or rubber (i.e., the distance to the actual metal inself). This information can be used to predict the force curve at that distance. Other forms of sensors can be used to measure a separation distance between a magnetic structure and a target including an ultrasonic sensor.
Under another arrangement, the thickness of a metal target can be determined based on a priori knowledge of the attraction force of the magnetic structure to a known target when combined with the measured separation distance.
Under one arrangement, a reference magnet can be used with an intelligent magnetic system for calibration purposes.
While particular embodiments of the invention have been described, it will be understood, however, that the invention is not limited thereto, since modifications may be made by those skilled in the art, particularly in light of the foregoing teachings.
This application is a continuation-in-part of non-provisional application Ser. No. 13/779,611, titled “System for Detaching a Magnetic Structure from a Ferromagnetic Material”, filed Feb. 27, 2013 by Fullerton et al., and claims the benefit under 35 USC 119(e) of provisional application 61/735,460, titled “An Intelligent Magnetic System”, filed Dec. 10, 2012 by Fullerton et al.; Ser. No. 13/779,611 claims the benefit under 35 USC 119(e) of provisional application 61/640,979, titled “System for Detaching a Magnetic Structure from a Ferromagnetic Material”, filed May 1, 2012 by Fullerton et al. and provisional application 61/604,376, titled “System for Detaching a Magnetic Structure from a Ferromagnetic Material”, filed Feb. 28, 2012 by Fullerton et al. This application is also a continuation-in-part of non-provisional application Ser. No. 14/066,426, titled “System and Method for Affecting Flux of Magnetic Structures”, filed Oct. 29, 2013 by Fullerton et al., which is a continuation of non-provisional application Ser. No. 13/374,074, titled “System and Method for Affecting Flux of Multi-Pole Magnetic Structures”, filed Dec. 9, 2011 by Fullerton et al., which claims the benefit under 35 USC 119(e) of provisional application 61/459,994, titled “System and Method for Affecting Flux of Magnetic Structures”, filed Dec. 22, 2010 by Fullerton et al. This application is also a continuation-in-part of non-provisional application Ser. No. 14/086,924, titled “System and Method for Positioning a Multi-Pole Magnetic Structure” filed Nov. 21, 2013 by Fullerton et al. which claims the benefit under 35 USC 119(e) of provisional application 61/796,863, titled “System for Determining a Position of a Multi-pole Magnetic Structure”, filed Nov. 21, 2012 by Roberts; Ser. No. 14/086,924 is a continuation-in-part of non-provisional application Ser. No. 14/035,818, titled “Magnetic Structures and Methods for Defining Magnetic Structures Using One-Dimensional Codes” filed Sep. 24, 2013 by Fullerton et al. which claims the benefit under 35 USC 119(e) of provisional application 61/796,863, titled “System for Determining a Position of a Multi-pole Magnetic Structure”, filed Nov. 21, 2012 by Roberts; Ser. No. 14/035,818 is a continuation-in-part of non-provisional application Ser. No. 13/959,649, titled “Magnetic Device Using Non Polarized Magnetic Attraction Elements” filed Aug. 5, 2013 by Richards et al. which claims the benefit under 35 USC 119(e) of provisional application 61/744,342, titled “Magnetic Structures and Methods for Defining Magnetic Structures Using One-Dimensional Codes”, filed Sep. 24, 2012 by Roberts; Ser. No. 13/959,649 is a continuation-in-part of non-provisional Application Ser. No. 13/759,695, titled: “System and Method for Defining Magnetic Structures” filed Feb. 5, 2013 by Fullerton et al., which is a continuation of application Ser. No. 13/481,554, titled: “System and Method for Defining Magnetic Structures”, filed May 25, 2012, by Fullerton et al., now U.S. Pat. No. 8,368,495; which is a continuation-in-part of non-provisional application Ser. No. 13/351,203, titled “A Key System For Enabling Operation Of A Device”, filed Jan. 16, 2012, by Fullerton et al., now U.S. Pat. No. 8,314,671; Ser. No. 13/481,554 also claims the benefit under 35 USC 119(e) of provisional application 61/519,664, titled “System and Method for Defining Magnetic Structures”, filed May 25, 2011 by Roberts et al.; Ser. No. 13/351,203 is a continuation of application Ser. No. 13/157,975, titled “Magnetic Attachment System With Low Cross Correlation”, filed Jun. 10, 2011, by Fullerton et al., U.S. Pat. No. 8,098,122, which is a continuation of application Ser. No. 12/952,391, titled: “Magnetic Attachment System”, filed Nov. 23, 2010 by Fullerton et al., now U.S. Pat. No. 7,961,069; which is a continuation of application Ser. No. 12/478,911, titled “Magnetically Attachable and Detachable Panel System” filed Jun. 5, 2009 by Fullerton et al., now U.S. Pat. No. 7,843,295; Ser. No. 12/952,391 is also a continuation of application Ser. No. 12/478,950, titled “Magnetically Attachable and Detachable Panel Method,” filed Jun. 5, 2009 by Fullerton et al., now U.S. Pat. No. 7,843,296; Ser. No. 12/952,391 is also a continuation of application Ser. No. 12/478,969, titled “Coded Magnet Structures for Selective Association of Articles,” filed Jun. 5, 2009 by Fullerton et al., now U.S. Pat. No. 7,843,297; Ser. No. 12/952,391 is also a continuation of application Ser. No. 12/479,013, titled “Magnetic Force Profile System Using Coded Magnet Structures,” filed Jun. 5, 2009 by Fullerton et al., now U.S. Pat. No. 7,839,247; the preceding four applications above are each a continuation-in-part of Non-provisional application Ser. No. 12/476,952 filed Jun. 2, 2009, titled “A Field Emission System and Method”, by Fullerton et al., now U.S. Pat. No. 8,179,219, which is a continuation-in-part of Non-provisional application Ser. No. 12/322,561, filed Feb. 4, 2009 titled “System and Method for Producing an Electric Pulse”, by Fullerton et al., now U.S. Pat. No. 8,115,581, which is a continuation-in-part of Non-provisional application Ser. No. 12/358,423, filed Jan. 23, 2009 titled “A Field Emission System and Method”, by Fullerton et al., U.S. Pat. No. 7,868,721. This patent application is also a continuation-in-part of U.S. patent application Ser. No. 13/918,921, filed Jun. 15, 2013 titled “Detachable Cover System”, by Fullerton et al., which is a continuation application of U.S. patent application Ser. No. 13/629,879, filed Sep. 28, 2012, now U.S. Pat. No. 8,514,046, which is a continuation of U.S. patent application Ser. No. 13/426,909, filed Mar. 22, 2012, now U.S. Pat. No. 8,279,032, which claims the benefit of U.S. Provisional Application Ser. No. provisional application 61/465,810 (filed Mar. 24, 2011), which is a continuation-in-part of U.S. non-provisional patent application Ser. No. 13/179,759 (filed Jul. 11, 2011), now U.S. Pat. No. 8,174,347. This non-provisional patent application is a continuation-in-part of U.S. non-provisonal patent application Ser. No. 14/045,756, filed Oct. 3, 2013, which is entitled “System and Method for Tailoring Transition Regions of Magnetic Structures”, which claims the benefit of U.S. provisional patent application 61/744,864, filed Oct. 4, 2012, which is entitled “System And Method for Tailoring Polarity Transitions of Magnetic Structures”; and this non-provisional patent application is a continuation-in-part of U.S. non-provisional patent application Ser. No. 13/240,335, filed Sep. 22, 2011, which is entitled “Magnetic Structure Production”, which claims the benefit of U.S. provisional patent application 61/403,814, filed Sep. 22, 2010 and U.S. provisional patent application 61/462,715, filed Feb. 7, 2011, both of which are entitled “System And Method For Producing Magnetic Structures”; Ser. No. 13/240,335 is a continuation-in-part of U.S. non-provisional patent application Ser. No. 12/476,952, filed Jun. 2, 2009, now U.S. Pat. No. 8,179,219, which is entitled “Field Emission System And Method”; Ser. No. 13/240,335 is also a continuation-in-part of U.S. non-provisional patent application Ser. No. 12/895,589 (filed Sep. 30, 2010), which is entitled “A System And Method For Energy Generation”, which claims the benefit of provisional patent application 61/277,214, filed Sep. 22, 2009, 61/277,900, filed Sep. 30, 2009, 61/278,767, filed Oct. 9, 2009, 61/289,094, filed Oct. 16, 2009, 61/281,160, filed Nov. 13, 2009, 61/283,780, filed Dec. 9, 2009, 61/284,385, filed Dec. 17, 2009, and 61/342,988, filed Apr. 22, 2010, which is a continuation-in-part of Ser. No. 12/885,450, filed Sep. 18, 2010, now U.S. Pat. No. 7,982,568 and Ser. No. 12/476,952, filed Jun. 2, 2009, now U.S. Pat. No. 8,179,219; Ser. No. 14/045,756 is also a continuation-in-part of U.S. non-provisional patent application Ser. No. 13/246,584, filed Sep. 27, 2011, which is entitled “System and Method for Producing Stacked Field Emission Structures”. The contents of the provisional patent applications, the contents of the non-provisional patent applications, and the contents of the issued patents that are identified above are hereby incorporated by reference in their entirety herein.
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| 61279094 | Oct 2009 | US | |
| 61281160 | Nov 2009 | US | |
| 61283780 | Dec 2009 | US | |
| 61284385 | Dec 2009 | US | |
| 61342988 | Apr 2010 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 13374074 | Dec 2011 | US |
| Child | 14066426 | US | |
| Parent | 14103760 | US | |
| Child | 14066426 | US | |
| Parent | 13481554 | May 2012 | US |
| Child | 13759695 | US | |
| Parent | 13157975 | Jun 2011 | US |
| Child | 13351203 | US | |
| Parent | 12952391 | Nov 2010 | US |
| Child | 13157975 | US | |
| Parent | 12478911 | Jun 2009 | US |
| Child | 12952391 | US | |
| Parent | 12478950 | Jun 2009 | US |
| Child | 12478911 | US | |
| Parent | 12478969 | Jun 2009 | US |
| Child | 12478950 | US | |
| Parent | 12479013 | Jun 2009 | US |
| Child | 12478969 | US | |
| Parent | 13629879 | Sep 2012 | US |
| Child | 13918921 | US | |
| Parent | 13426909 | Mar 2012 | US |
| Child | 13629879 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 13779611 | Feb 2013 | US |
| Child | 14103760 | US | |
| Parent | 14066426 | Oct 2013 | US |
| Child | 13779611 | US | |
| Parent | 14086924 | Nov 2013 | US |
| Child | 14103760 | US | |
| Parent | 14035818 | Sep 2013 | US |
| Child | 14086924 | US | |
| Parent | 13959649 | Aug 2013 | US |
| Child | 14035818 | US | |
| Parent | 13759695 | Feb 2013 | US |
| Child | 13959649 | US | |
| Parent | 13351203 | Jan 2012 | US |
| Child | 13481554 | US | |
| Parent | 12476952 | Jun 2009 | US |
| Child | 12478911 | US | |
| Parent | 12476952 | US | |
| Child | 12478950 | US | |
| Parent | 12476952 | US | |
| Child | 12478969 | US | |
| Parent | 12476952 | US | |
| Child | 12479013 | US | |
| Parent | 12322561 | Feb 2009 | US |
| Child | 12476952 | US | |
| Parent | 12358423 | Jan 2009 | US |
| Child | 12322561 | US | |
| Parent | 14103760 | US | |
| Child | 12322561 | US | |
| Parent | 13918921 | Jun 2013 | US |
| Child | 14103760 | US | |
| Parent | 13179759 | Jul 2011 | US |
| Child | 13426909 | US | |
| Parent | 14103760 | US | |
| Child | 13426909 | US | |
| Parent | 14045756 | Oct 2013 | US |
| Child | 14103760 | US | |
| Parent | 13240335 | Sep 2011 | US |
| Child | 14045756 | US | |
| Parent | 12476952 | US | |
| Child | 13240335 | US | |
| Parent | 12895589 | Sep 2010 | US |
| Child | 12476952 | US | |
| Parent | 12885450 | Sep 2010 | US |
| Child | 12895589 | US | |
| Parent | 12476952 | Jun 2009 | US |
| Child | 12885450 | US | |
| Parent | 13246584 | Sep 2011 | US |
| Child | 14045756 | US |
