US 20090078484A1

(19) United States

(12) Patent Application Publication (10) Pub. No.: US 2009/0078484 A1
Kocijan (43) Pub. Date: Mar. 26, 2009
(54) MAGNETICWHEEL Publication Classification
(75) Inventor: Fey Kocijan, New South Wales (51) Eoivo (2006.01)
HOIF 7/02 (2006.01)
Correspondence Address: A63C I/20 (2006.01)
SHERIDAN ROSS PC
RY,SUTE 12OO
9
(52) U.S. Cl. .......................... 180/167; 335/302; 280/612
(73) Assignee: MATSWITCH TECHNOLOGY
WORLDWIDE PTY LTD, (57) ABSTRACT
Rawdon Island (AU) Magnetic circuit that has (a) a Source of magnetic flux which
includes an electromagnet or one or more permanent mag
(21) Appl. No.: 12/282,830 nets, (b) at least two oppositely polarisable pole extension
1-1. bodies associated with the magnetic flux source, the bodies
(22) PCT Filed: Mar. 6, 2007 being disc, wheel, roller or similarly shaped with an outer
(86). PCT No.: PCT/AU2007/000277 circumferential surface and held rotatable about respective
axes of rotation, and (c) a ferromagnetic counter body which
S371 (c)(1) is arranged to cooperate with the pole extension bodies Such
(2), (4) Date: Oct. 22, 2008 as to provide an external flux path for the magnetic flux when
s in magnetic proximity or contact with the circumferential
(30) Foreign Application Priority Data surface of the pole extension bodies, which is characterised in
that the magnetic flux source is held stationary relative to the
Mar. 13, 2006 (AU) ................................ 2OO6901 247 rotatable pole extension bodies.

13a 13 13b

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Patent Application Publication Mar. 26, 2009 Sheet 1 of 6 US 2009/0078484 A1
Patent Application Publication Mar. 26, 2009 Sheet 2 of 6 US 2009/0078484 A1

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Patent Application Publication Mar. 26, 2009 Sheet 3 of 6 US 2009/0078484 A1
Patent Application Publication Mar. 26, 2009 Sheet 4 of 6 US 2009/0078484 A1
Patent Application Publication Mar. 26, 2009 Sheet 5 of 6 US 2009/0078484 A1

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Patent Application Publication Mar. 26, 2009 Sheet 6 of 6 US 2009/0078484 A1
US 2009/00784.84 A1 Mar. 26, 2009

MAGNETC WHEEL ment of a movable object onto a dedicated ferromagnetic

material Substrate or Support Surface, or (d) indeed the pres
FIELD OF THE INVENTION ence of gravitational forces would necessitate the erection of
or provision of specialised Support, guide or other retention
0001. The present invention relates to the field of magnet structures or measures to enable a vehicle, either self-pro
ics, in particular to the use of magnetic force to attach one pelled or otherwise, to move along steeply inclined, vertical,
object to another whilst allowing movement of the objects and even inclined or horizontal overhanging (eg ceiling) Sur
relative to one another in a magnetically attached State. faces having ferromagnetic properties. However, the below
BACKGROUND OF THE INVENTION
disclosed invention and its underlying principles may find
broader applications, also replacing existing solutions cur
0002 There are numerous situations and applications rently not employing magnetic force to achieve object cou
where it is desirable and/or necessary to secure or Support one pling.
object to or on another object whilst allowing for freedom of 0008. In using particular permanent magnets to secure
translational or rotational movement of these objects relative objects to one another, it is known that the magnetic attraction
to one another. force is a function of the type and amount of active magnetic
0003. In the field of material handling, for example, roller material employed, the geometry of the magnet’s working
conveyors are used to transport sheet metal and other ferro face, air or other magnetic leakage paths in the magnetic flux
magnetic work pieces from one location to another. Gravity circuit encompassing the active magnetic material and the
forces are relied upon to ensure the workpieces remain on the body being Subjected to the magnetic attraction force, the
conveyor rollers (some of which may be driven and others ferromagnetic material properties of the attracted body (ie its
being idle rollers) as these are transported, and thus Such relative permeability and magnetic Saturation limits), and the
conveyor systems will mostly have roller transport paths orientation of the Normal force vector between attracted
extending Substantially in a common horizontal plane, unless objects relative to the gravity force vector. The displacement
additional, dedicated hold-down structures are employed in force required will then be a function of the effective attrac
restraining the work pieces from lifting-off from where roll tion force and the coefficient of friction defined between the
ers are deployed along inclined travel path sections. Surfaces of objects.
0004. In overhead conveying applications in enclosed sur 0009. In other terms, the physical and geometrical factors,
roundings, eg large ware houses, it is known to install over as well as the functional energetic elements of the closed (or
head rails to which are secured wheeled carriages from which loaded) magnetic circuit created between a first object (eg an
in turn may be suspended crane head structures, grippers and object carrying a permanent magnet) and a second object (eg
similar attachment devices. Gravity force is relied upon to ferromagnetic sheet) will determine ultimately how strongly
hold the grooved carriage wheels in engagement with and on the objects are attracted to one another, and whether these
top of the overhead guide rails, and side brackets provide objects can be displaced relative to one another whilst
additional security against lateral dislodgement from the remaining attached to one another.
rails. 0010. The stronger planar surfaces of objects are forced
0005. In the field of high-rise building construction, it is together by a magnetic attraction force, the more difficult it is
known to provide vertically extending rails which provide to displace them relative to one another whilst remaining
guidance for working platforms which are suspended for attached to one another, by exerting a force perpendicular to
vertical movement from the top of the building in order to the attracting force vector, for any given coefficient of friction
carry out maintenance work, Such as window cleaning, etc. which applies for the pairing of materials of the two objects.
The platforms incorporate gripper mechanisms which form It is also recognised that magnetically attractive Surfaces can
fittingly engage over the rails to restrain horizontal movement have very large friction coefficients, and this knowledge has
(eg Swaying) whilst held vertically movable along the rail. found expression in a wide range oftechnical Solutions, such
0006. In the field of robotics, in particular such using as magnetic clamps, magnetic lifters, magnetic chucks, etc.
remote controlled vehicles, it is known to incorporate into where ferromagnetic objects are to be firmly secured against
autonomous, wheeled platform or self-tracked vehicles, a displacement (assuming normal operational condition) at a
multitude of different type of tools and implements by way of Supporting structure that incorporates magnetic active mate
which specific tasks may be carried out remotely by an opera rials.
tor. For example, gripper-arms can be deployed from Such 0011. In seeking to enable magnetically coupled objects to
vehicles to recover samples in difficult to access or hostile move more easily relative to one another, so called magnetic
environments. Whilst friction enhancing wheel and track wheels have been devised for selected industrial applications,
coatings may be used to increase adherence of the vehicle to eg self-propelled welding and inspection robots.
the surface in order to allow the vehicle to climb or descend 0012. In its simplestincarnation, a magnetic wheel may be
along steep inclines, there are limits to the steepness of the comprised of a solid disc of permanent magnetic material, eg
travel path which such vehicle may safely master without a disc-shaped Neodymium-Iron-Boron magnet, magnetised
tipping over or sliding in uncontrolled manner. Such that opposite axial end faces of the magnet have different
0007. The present invention was conceived having regard polarity (here termed axially magnetised). One Such disc each
to applications such as those listed above, and in particular to can be secured on opposite terminal ends of a non-magneti
one or more application environments where (a) ferromag sable axle member, which in turn can be mounted to a vehicle
netic materials require conveying or transporting, (b) the chassis or frame, whereby the discs may engage with their
incorporation of or presence of ferromagnetic structures peripheral Surface on a magnetically attractive Substrate Sur
would allow the use of magnets as a Source of force to secure face and roll on Such surface in a magnetically attached State,
objects to one another in displaceable manner, (c) gravita compare for example U.S. Pat. No. 6,886,651 (Slocum et al.),
tional forces are absent to provide for force-locking engage column 12, lines 44 following. Each disc (or wheel) will
US 2009/00784.84 A1 Mar. 26, 2009

generate an at least partially closed loop magnetic field consist of a plurality of axially polarised annular magnet discs
extending into the Substrate on which it rests, creating a secured to one another to form a cylindrical roller wheel
strong attractive force between the disc and substrate. whose outer (peripheral) surface is coated with a thin layer of
0013 Slocum also discloses a somewhat more elaborate a non-polarizable, anti-friction material, such as PTFE (poly
yet simple magnetic wheel consisting of a disc-shaped, axi tetrafluoroethylene) which minimises drag on the wheel
ally magnetised magnetic core element Sandwiched between assembly as the vehicle frame is propelled.
two magnetically attractive disc members (made of soft steel, 0019 Guy also describes an electromagnetic wheel
permalloy or laminated Structures comprising such magneti assembly, in which a non-magnetic cylindrical shell encloses
sable but otherwise magnetically passive materials) having a an electromagnetic coil about an inner core element mounted
diameter that is somewhat larger than the magnet core so that on the wheel's axle for rotation therewith. Magnetisable pole
only the disc members can come with their peripheral Sur discs are arranged at the axial ends of the shell member, and
faces into contact with the magnetically attractive Surface on electrical energy can be Supplied to the magnet coil through
which the wheel is to magnetically engage. The disc members wiper contacts secured to one of the pole discs. Upon ener
thus represent pole extension pieces which concentrate the gization of the electromagnetic coil, the pole discs will be
magnetic flux originating in the magnetic core element and polarised with opposite polarities. The annular rims of the
provide a low reluctance path for Such flux, thus improving pole discs are again coated with a non-magnetisable, low
the attractive force between each wheel unit and magnetically friction material for rolling contact with the magnetisable
attractive Support Surface as compared to the wheel embodi substrate surface oh which the vehicle is intended to travel.
ment without pole extension discs.
0014 Slocum's magnetic wheels are incorporated into (0020. In contrast, U.S. Pat. No. 2,694,164 (Geppelt) dis
self-propelled carriages that form part of a material transpor closes magnetic wheels of a type used in conjunction with
tation system wherein Such carriages can travel along mag welding and cutting torch carriages which are self-propelled
netically attractive Surfaces that may include a ceiling, verti over ferromagnetic Surfaces. The magnetic wheel units con
cal and inclined walls. sist of an axle sleeve of non magnetisable material received
0015 U.S. Pat. No. 5,809,099 discloses a laser-guided within an annular-cylindrical permanent magnet which is
underwater wall climbing robot for use in inspecting reactor magnetized in its axial direction, two cylindrically cup
pressure vessels, which robot includes a self-propelled shaped wheel members of soft steel material which have their
vehicle Supperstructure that incorporates four magnetic annular flanges extending towards each other and into
wheels used to provide the necessary attraction force to allow clamped close engagement with opposite sides of a non
the vehicle to travel along the ferromagnetic inner Surface of magnetic spacer disc that surrounds the magnet about the
the reactor vessel. Each wheel consists of a ring-shaped per middle of its axial length. The axial end faces of the magnet
manent magnet Supported on a non-magnetic axle shaft for abut against the respectively facing inner faces of the cup
rotation therewith, two steel discs of slightly larger diameter wheel members such as to allow magnetic flux transfer from
than the magnet being magnetically attached and secured to the magnet into the wheels towards their peripheral Surface,
the opposite axial faces of the ring-magnet, ie the discs pro the spacer disc serving to ensure magnetic decoupling of the
vide magnetised pole extension pieces as well as the periph two wheels whereby these will assume opposite polaritries in
eral engagement Surface of the wheel unit, similar to the accordance with the magnetic field generated by the perma
Slocum wheel described above. nent magnet of the wheel. Geppelt outlines that the decrease
in wall thickness of the annular cup flanges towards the spacer
0016 U.S. Pat. No. 5,853,655 describes a magnetic wheel disc (as compared to a prior art embodiment with uniform cup
guided carriage for automated welding and cutting of ferro flange thickness) increases the attractive force that may be
magnetic Substrates such as pipes, steel plates, wherein the exerted between the magnetic wheel and the substrate to
magnetic wheels consist of a plurality (eg three) of axially which it attaches.
magnetised ring-shaped magnets sandwiched between inter
leaving ring-shaped mild steel discs (eg five) of a diameter 0021. In practical terms, and in light of the above descrip
that is larger than that of the magnets. The stacked discs are tion of prior art magnetic wheel constructs, a technical chal
mounted and secured against rotation on a stainless Steel lenge still exists in devising methods and arrangements of
sleeve which in turn will be received on an axle of the car magnetic flux transfer from a magnet, as a source of magnetic
riage. Again, each wheel unit has a plurality of N- and force to attach one object to another, through a wheel struc
S-poles whose magnetic field extends into the ferromagnetic ture into a magnetically attractive body, to meet specified
Substrate thereby creating at each wheel a closed magnetic operational load carrying capacity or retention requirements.
flux path securing the wheels to the substrate surface. 0022. In a more confined aspect, it would be desirable to
0017. Other prior art patent documents are also known to provide a vehicle which uses magnetic energy to secure Such
deal with aspects and methodologies that seek to address vehicle onto a ferromagnetic Substrate Surface and in which
specific shortcomings that basic magnetic wheels may the magnetic flux transfer mechanism will allow for greater
exhibit in certain application fields. flexibility with regards to magnetically coupling and decou
0018. So for example, U.S. Pat. No. 3,690,393 (Guy) pling of the vehicle from the substrate surface.
would seem to aim to address the above mentioned problem 0023. In another more confined aspect, it would be desir
that magnetically attractive Surfaces can have very large fric able to provide a magnetic Support structure by means of
tion coefficients which in certain applications can be detri which a ferromagnetic object may be transported between
mental. Guy describes a vehicle having a frame on which is locations in a secured manner and wherein at the end of Such
mounted a prime mover (eg electric motor) which is coupled transporting operation the object may be safely and easily
by Suitable gearing to a live (or traction) axle to which a pair disengaged from the Support structure.
of wheel assemblies are secured in order to propel the vehicle. 0024. In another aspect, it would be desirable to provide a
In one embodiment, one of the non-driven wheel assemblies magnetic gripper appliance which may be actuated in order to
US 2009/00784.84 A1 Mar. 26, 2009

secure an object thereto whilst allowing for freedom of move fluid confined into the volume present between flux source
ment of the object in order to conduct machining or other unit and pole wheels, the fluid then preferentially providing a
operations on the object. low magnetic reluctance path, ie a magnetisable fluid that has
0025. The term ferromagnetic as used herein is intended a relative magnetic reluctance that is less than air.
to cover not only metals and alloys but also composite mate 0033. It will also be noted that in contrast with prior art
rials which when subjected to an external magnetic field will magnetic wheels, each of which comprises at least one N-S
become magnetised and Subject to magnetisation forces. pole pair, the invention can provide embodiments and
0026. Other aspects of the invention will become apparent arrangements wherein each rotatable pole extension member
below from the following description of preferred embodi assumes only one polarity, ie either S- or N-polarity, so that
ments thereof. the closed magnetic flux path will encompass flux transfer
from one pole extension member through the ferromagnetic
SUMMARY OF THE INVENTION counter body, which provides a low reluctance magnetic flux
0027. In broad terms, the present invention can be defined path, and into the other pole extension member. In other
as residing in a magnetic circuit that has (a) a Source of words, two such rotatable pole extension members are nec
magnetic flux which includes an electromagnet or one or essary and sufficient for a closed flux transfer circuit.
more permanent magnets, (b) at least two oppositely polaris 0034. In the following, for ease of understanding, and
able pole extension bodies associated with the magnetic flux unless it appears differently in the specific context, the term
source, the bodies being disc, wheel, roller or similarly wheel will be used to encompass all types of rotatable pole
shaped with an outer circumferential surface and held rotat extension bodies Such as unitary soft-steel discs, cylindrical
able about respective axes of rotation, and (c) a ferromagnetic rollers, pulleys and other structures that generally comprise a
counter body which is arranged to cooperate with the pole rim and hub united by a radial connection structure, eg
extension bodies such as to provide an external flux path for spokes, face web, etc., and which are capable of rotation about
the magnetic flux when in magnetic proximity or contact with a stationary (axial) axis and which serve to support a vehicle
the circumferential surface of the pole extension bodies, or work piece for translational or rotational movement upon
which is characterised in that the magnetic flux source is held rotation of the rim.
stationary relative to the rotatable pole extension bodies. 0035. In a more specific aspect, the present invention pro
0028 Compared with what may be termed traditional vides a vehicle capable of magnetically attaching to a mag
magnetic wheel circuits utilised in attaching one object to netically attractive Substrate, including a vehicle body at
another, such as those described above, the present invention which are supported at least two wheel members and at least
physically decouples the active magnetic source or compo one dipole magnet, wherein the wheel members include mag
nent (eg electromagnet, Switchable permanent magnet, or netically passive but polarisable material, wherein the wheel
conventional permanent magnet) from the disc-, roller- or members and the dipole magnet(s) are spatially located on the
wheel-like pole extension pieces, wherein the pole extension vehicle body in a manner wherein the wheel members provide
pieces remain free to rotate about their respective axes of rotatable, oppositely polarisable pole extension elements of
rotation but the associated magnetic flux Source remains sta the otherwise stationary dipole magnet(s), whereby resting of
tionary, ie it does not rotate with the pole extension pieces. the wheel members on the surface of the substrate creates a
0029 Preferably, physically decoupling will be accompa closed magnetic circuit encompassing the dipole magnet,
nied by spatially separating the flux source from the rotatable pole piece wheel members and substrate.
pole extension pieces, eg by maintaining a small air gap 0036. In an alternate specific aspect of the invention, there
between these components, see also below. The term small is provided a Support structure capable of magnetically
will depend on the specific application and may for example retaining attached to it in an otherwise translationally or rota
be 0.1 mm (or smaller) up to a few millimetres. tionally displaceable manner a magnetically attractive Sub
0030 Vis a vis the above described prior art magnetic strate, including a Support body at which are mounted at least
wheels, the mass associated with the magnetic flux Source is two wheel or roller members arranged for rotation about
no longer subject to rotation with the wheel, thereby reducing respective axes, and at least one dipole magnet mounted at the
inertia moments at the wheel structure proper, with all the support body separate from the wheel or roller members,
concomitant advantages which Such reduced wheel mass wherein the wheel or roller members include magnetically
brings with it. Physical decoupling of the wheels from the passive but polarisable material, and are spatially located on
magnetic flux Source also enables greater flexibility in devis the support structure in a manner wherein the wheel or roller
ing or designing the flux source itself. members provide rotatable, oppositely polarisable pole
0031 Equally, where the source of magnetic flux of a extension elements of the otherwise stationary dipole magnet
magnetic wheel unit is an electro-magnet, such as described (S), whereby bringing a ferromagnetic Substrate into Surface
in U.S. Pat. Nos. 3,690,393 or 6,886,651, physical decoupling contact with the peripheral surface of both the wheel or roller
of the magnetic flux source from the rotatable wheels in members creates a closed magnetic circuit encompassing the
accordance with the invention simplifies the mechanism/ar dipolemagnet(s), pole extension wheel or roller members and
rangement required for transferring electrical power into the substrate.
magnet coil, given that the later remains stationary and there 0037. In essence, whilst the first aspect is directed at pro
is no need for brushes or pole shoes otherwise required for viding a vehicular implementation of the broader concept
transferring electricity through the pole pieces (or otherwise) underlying the invention, eg providing externally or self
into the rotating electromagnet coil armature. propelled vehicle embodiments capable of movement along
0032. Independently of the type of magnetic flux source inclined or vertical walls, for example, the second aspect is
utilised, magnetic flux transfer from the source into the rotat intended to cover applications where the wheels or roller
able pole extension members will be effected across a work members together with the Support body remain stationary
ing gap that can be air or could conceivably be a different Such as in a conveyor apparatus for conveying of ferromag
US 2009/00784.84 A1 Mar. 26, 2009

netic objects, such as Steel plates, along a plurality of mag gap (not illustrated in FIG. 1). Such that each disc provides an
netically polarisable roller members disposed along a con oppositely polarised pole extension for the respective N--
veying pathway, or applications where the Support body is and S-pole 20, 22 of the magnet 16. Furthermore, the discs 12,
itself carried or mounted at another appliance, eg robotic arm, 14 are supported at not illustrated axle members about a
thereby to allow the pole wheel members to magnetically common axis of rotation 18 to allow rotation thereof, ie the
engage against and secure thereto a ferromagnetic object or discs can be termed as freely spinning pole extension wheel
work piece. pieces which otherwise maintain a fixed spatial relationship
0038. It will also be appreciated that whilst it is feasible to to the dipole magnet 16, the axis of rotation being parallel or
employ conventional permanent magnets (ie such which coinciding with the N-S magnetisation axis of the dipole.
always exhibit an external magnetic field) as the Source of 0045 Magnetic flux transfer from the magnet 16 to the
magnetisation of the pole extension wheels, the basic concept
underlying the present invention is particularly conducive discs 12, 14 will take place across the Small air gaps between
towards implementation of vehicular and other embodiments the facing sides 13.b of the discs and the poles 20, 22 of the
that utilise Switchable permanent magnet structures. Such as magnet 16. The gaps are intended to minimise friction loses at
disclosed in U.S. Pat. Nos. 6,707,360 and 7,012,495. Such the interface between magnet 16 and pole pieces 12, 14, but
Switchable permanent magnet units combine the advantages could be replaced with magnetisable roller bearings that pro
of electromagnets and conventional permanent magnets with vide for direct physical contact between discs 12, 14 and the
out their respective main drawbacks, namely the need for an magnet’s axial end faces and thus improved flux transfer
electric power source to drive an electromagnet and the non between magnet and pole discs 12, 14.
variability of magnetic flux output of permanent magnets, ie 0046 When the surface of a ferromagnetic substrate, eg
a Switchable permanent magnet does not require an electric steel sheet 24, is brought into contact with the peripheral
power source and can be switched to exhibit an external surface 13a of both pole discs 12, 14 of the Magnetic Wheel
magnetic field between strong and weak (practically Zero) Unit 10, a closed magnetic circuit will be created, wherein a
and values between these extremes. For more details, refer to closed magnetic flux loop will comprise a path internal to the
said US patents, the contents of which are incorporated herein magnet 16 and pole extension discs 14, 16, and a path external
by way of cross-reference. to the unit 10 between the pole extension discs 14, 16 and the
0039. The use of magnet units which are capable of pro ferromagnetic Substrate 24. That is, the external magnetic
viding a variable magnetic flux, such as said Switchable per field extends within the substrate 24, and this is schematically
manent magnet units and electro-magnets, provides an illustrated at 26 in FIG.1a, and the entire closed loop flux path
important additional aspect of the invention in that the vari at 27 in FIG 1b.
ability of the magnetic attraction force enables application 0047. The Magnetic Wheel Unit 10 will be attracted and
and machine embodiments where a ferromagnetic workpiece remain strongly secured to the Substrate 24, despite the actual
can be selectively engaged by the rotatable pole extension physical contact area between the discs 12, 14 and the steel
elements, magnetically secured thereto for spatial manipula sheet 24 being essentially confined to a line measuring the
tion upon activation of the magnetic flux source, and ulti sum of the thicknesses (ie widths) of the disc 12, 14. The
mately released there from upon deactivation of the magnet. free-spinning nature of the disc wheels 12, 14 allows transla
0040. Before turning to additional aspects and application tional displacement of the unit 10 over the surface of the
fields of the present invention, as well as additional features substrate 24 by applying but a very small force traverse to the
that may find inclusion in preferred embodiments of the magnetic attraction force which attaches the Wheel Unit 10 to
above broad inventive concepts, reference shall be made to the substrate 24. The small force requirement stems from the
the accompanying FIGS. 1a, 1b and 1c, which represent relatively low rolling resistance coefficient applicable to steel
highly schematic illustrations that will help in understanding discs rolling on a steel Substrate, which is magnitudes Smaller
basic principles underlying the present invention. It shall be than the static and the kinetic friction coefficients applicable
understood that the below explanations rely on approxima to the same material-pair combination but where the pole
tions, idealisations and simplifications of the in part relatively wheels 12, 14 are kept in an immobilised state with respect to
complex phenomena observed and present in magnetic cir the magnet 16 and the surface on which such static wheels
cuits. would otherwise glide.
0041 Turning first to FIG. 1a, it illustrates what shall here 0048. It would seem counterintuitive that despite the pres
be termed as a Magnetic Wheel unit 10, consisting of two ence of air gaps between magnetic flux Source 16 and rotat
disc-shaped wheels 12, 14 and a bar-(or cylindrically) shaped able pole discs 12, 14, and a very Small contact area between
dipole permanent magnet 16. These components represent a pole piece discs 12, 14 and substrate 24, the Magnetic Wheel
basic unit that can be built upon, modified and incorporated in unit 10 will remain securely attached to the substrate. A
numerous applications of the invention as explained below. prototype Magnetic wheel unit 10 embodying the principle
0042. The magnet 16 will be a high coercive, ie rare-earth illustrated in FIG. 1 with the permanent magnetic flux source
magnet capable of inducing high magnetic flux densities being a rare earth NdFeB magnet having a 50mmx40 mm
across air gaps (mainly) through its axial end faces 16a, 16b. flux source area (ie cross-section area of the magnetic flux
and generate a pulling force (magnetic attraction force) in a Source normal to the polarisation axis of the magnet) capable
ferromagnetic body towards the axial end faces as outlined of delivery of 1.2 Tesla magnetic flux density, with two soft
above. steel discs (having a magnetic flux density Saturation level of
0043. The discs 12, 14 have a circumferential contact sur around 2 Tesla) with a dimension of 25 mm width:x90 mm
face 13a and two axial faces 13b and 13c, and are made diameter and keeping an air gap towards the permanent mag
entirely of ferromagnetic soft steel. net of approx 1 to 2 mm is able to attach to a ferromagnetic
0044) The discs 12, 14 are respectively located opposite an steel sheet of 35 mm thickness and carry a load equivalent to
axial end face 16a, 16b of magnet 16, keeping a fixed Small air a breakaway force of over 1200 Newton.
US 2009/00784.84 A1 Mar. 26, 2009

0049. As noted, the actual physical contact Zone or area and application conditions. Generally speaking, the larger the
between substrate 24 and (rotatable) pole discs 12, 14 is very virtual pole Zones can be made, the more magnetic flux trans
Small (in theory a line, given that deformation, ie flattening fer may take place in the vicinity of the disc-substrate inter
of the Soft-steel discs under load is negligible). face. An important consideration is therefore the need to
0050. It has been noted that in the vicinity of the physical avoid or minimise magnetising force losses.
contact area there exist so called virtual pole areas, where 0055 Consequently, in accordance with another aspect
noticeable flux transfer takes place across air, ie (a) from the underlying the present invention, the pole wheels will be of
peripheral surface of the pole discs either side of the contact Such shape and dimensions to cater for (a) optimised flux
Zone towards the substrate surface and (b) from both faces of transfer from the magnetic flux source into the rotatable pole
the disc near the contact Zone and the Substrate Surface. In the wheels and (b) provide relatively larger area virtual poles
present context, such air gaps do not represent and are not to thereby to enable optimised flux transfer also outside of the
be mistaken as unwanted leakage paths, rather the effective direct physical contact Zone between pole discs and Substrate
magnetic contact area between discs and Substrate is Surface, whilst (c) maintaining Sufficient magnetic attraction
enlarged, and the so called virtual poles provide an additional force towards the Substrate; an important point is to avoid, as
means of flux transfer (albeit at lower density values) from far as practically possible, losses in magnetising force at each
discs 12, 14 to substrate 24, thereby adding to the total pulling interface.
power available to secure the unit 10 onto the substrate 24 (or 0056 Having noted the difficulties regarding precise defi
Vice versa). These virtual pole area extensions are schemati nition of the virtual pole Zones, assuming an idealised air-gap
cally illustrated at 30a,30b and 31a and 31b in FIG.1b and in leakage free magnetic flux path between magnet flux source
FIG. 1c, and do contribute in maintaining a closed magnetic (eg permanent magnet) and rotatable pole wheels, it is pos
circuit of sufficient quality at the interface between substrate sible to match the size of the diameter-cross-sectional area of
and Magnetic Wheel unit 10 for the exerted attraction force to the wheel or roller poles as best as constructional possible to
remain high, as exemplified above. the size of the magnetic flux source area, ie the cross section
0051 FIG. 1c illustrates a magnetic field line model with of a pole in the dipole magnet perpendicular to its magneti
measured flux density values at two soft-steel 90 mm diam sation axis. Such measure will produce an optimised, ie a
eterx25 mm thickness pole discs 12, 14 having a magnetic higher magnetising force at the discs working interface (ie air
density saturation level of 2 Tesla, which are polarised with gap) with the Substrate as compared to cases where the geo
opposite polarities and which are held in air in spaced apart metric dimensions of the wheel or roller pole extensions are
relationship on a magnetic substrate 24. It can be seen that on chosen arbitrarily or without regard to magnetic flux transfer
either side of the essentially linear contact Zone 28 between considerations.
pole wheels 12, 14 and substrate 24, a flux density of 2 Tesla 0057 For example, and all other parameters being equal,
will reduce drastically (ie the virtual pole extensions exhibit cup shaped wheels or rollers which are disposed to surround
reduced flux densities), wherein at a linear distance of 10 mm with their annular rim portion a determinable part of the
the flux density is reduced to about 15% of the value at the respectively associated pole of the dipole magnet and main
physical contact area, and about 5% at a distance of 20 mm. tain a small air gap between the wheel's internal disc face
0052 Flux transfer from the magnet 16 into the substrate towards the axial end face of the dipole magnet, exhibit a
24 will thus be influenced and limited by (a) the shape larger total area for flux transfer into and out of such wheel
and dimensions of the interface of the magnetic flux Source than a simple planar disc-shaped wheel where the flux trans
(eg the flux delivery component in a Switchable permanent fer area is confined to the Surface area facing the axial end face
magnet device or electromagnet) at the gap towards the pole of the dipole magnet. One could say cup shaped wheels can
discs, (b) magnetic leakage at the air gap interfaces between capture a larger portion of the flux emanating from the
the passive pole extension discs 12, 14 and magnetic flux magnet which, absent the annular rim portion of the cup
Source 16, (c) geometric and shape constraints of the discs which Surrounds part of the magnetic flux source, would be
which may not be able to support (ie carry and deliver) the lost as stray flux, and use such additionally captured flux to
same flux density at the given field strength which the magnet generate a higher magnetic attraction force towards a ferro
16 generates, (d) the nature of the virtual poles in So far as magnetic Substrate than plain disc-shaped pole extension.
these cannot support the same flux density at the given field 0058. The actual depth of the rim portion of the cup
strength which the ferromagnetic material of the discs 12, 14 shaped wheel or roller will depend on the nature of the mag
can, and (e) the total magnetic path length between flux netic flux Source being employed, and in particular the mag
Source and ferromagnetic Substrate, recalling that the mag netic flux output member of the magnetic flux delivery
netic pulling force by means of which any ferromagnetic device. In essence, the cup depth will represent a compromise
body is attracted to a source of magnetic flux will vary math between maximum flux transfer considerations (optimised
ematically with the square of magnetic flux density provided where the annular rim portion depth is such as to extend and
by the source and linearly with the contact area between the cover the whole length of the respective North/South pole of
Source and the attached body. the magnet) and desired magnetising force (ie magnetic
0053 For example, a magnetic wheel unit 10 using rela attraction force) which will be lower in the flux transfer
tively larger diameter pole discs 12, 14 as those described optimised rim configuration. An empirically determined rela
above, eg 3-times, will have a longer total magnetic path (due tive size of the annular rim with regards to its covering of the
to increased diameter of discs) and the magnetising force at flux source is provided below in connection with a specific
the contact area will be lower then and the virtual pole areas embodiment of the invention.
will be smaller (and in extreme situations virtually non-exis 0059. To conserve the magnetising force of the high coer
tent). citivity flux source it is also desirable to minimise the volume
0054 The actual size, shape and geometric extent of the of the passive ferromagnetic material pole extension wheels.
virtual poles are not fixed but vary with the actual working Viewed only from a point of view of seeking to optimise flux
US 2009/00784.84 A1 Mar. 26, 2009

transfer, a theoretical necessary Volume maximum is given made by reference to information available from Magswitch
where the effective cross section of the flux source equals the Technology Worldwide, depending on load carrying require
diametrical cross-section of the wheel divided by any appli mentS.
cable flux compression/concentration factor (the latter is 0064. As noted above, it is conceivable to have the facing
determined by material specific flux density carrying capacity Surfaces of the pole wheels and magnetic flux source unit
and the flux source density output. For example, if a flux coated with a low friction material and provide for the pres
Source can provide a magnetic flux density of 1.2 Tesla and is ence of soft steel roller bearings at the interfaces unit pole
able to generate a magnetising force Sufficient to induce in wheels. In practical implementations it is however techni
mild steel a flux density of 2 Tesla, the compression factor is cally feasible to maintain very small air gap tolerances
about 1.6). The practical maximum will be lower because of between the movable and stationary components whilst not
total magnetic path length and flux/wheel air gap losses. significantly negatively affecting magnetic flux transfer
across the air gap. In the end, the specific application envi
0060 Turning then to advantageous additional features ronment will dictate air gap distance requirements.
that may be incorporated in different embodiments of the 0065 Equally, applications are conceivable where the
above described broad concepts. pole wheels are mounted to allow free rotation about an axle
0061. In utilising a conventional, non-switchable magnet whilst allowing displacement towards and away from the
or preferably a Switchable permanent magnet arrangement as axial end faces of the magnet, so that they can be selectively
the magnetic flux Source, it will be appreciated that the mag brought into and out of frictional engagement therewith,
netically active material may be encased or otherwise dis whereby an integral clutch and/or brake can be implemented
posed to cooperate with other stationary pole pieces addi at the magnetic wheel unit itself.
tional to the rotatable pole extension elements (ie wheels), in 0066. As already noted, vehicular and stationary imple
which case the flux will originate in the active material and mentations of the invention may incorporate driven or idle
be made available through the other stationary pole pieces pole wheels or rollers. The circumferential surface of the
that will be disposed in facing close proximity to the rotatable wheels and rollers may have a friction coefficient enhancing
pole wheels. The specific shape of the stationary pole pieces or reducing coating, as required, for improving traction or
will also influence flux transfer capabilities and have an effect reducing friction at the wheel—Substrate interface, depend
on the maximum available magnetising force, as the poles do ing on whether the wheels are traction or idle wheels.
represent a load for the magnetic field generated by the 0067 Coating materials may include thin-film rubbers,
active magnetic material (ie the flux source) preferably incorporating ferromagnetic particles, flecks,
powders etc to increase the value of relative magnetic perme
0062. In preferred embodiments of the above described ability of such coating to reduce flux transfer losses whilst
Magnetic wheel units 10, use is made of a switchable perma maintaining the improved friction coefficient which such rub
nent magnet device disclosed in said U.S. Pat. No. 7,012,495, berised coating provides. The wheel contact Surface can have
different types of which can be sourced from Magswitch different textures, eg smooth for low traction or profiled to
Technology Worldwide Pty Ltd (Australia) or its subsidiaries. increase “bite' for higher traction. Coating may also include
In these flux source units, the active magnetic material is processes and use of substances aimed at increasing the over
constituted by two, diametrically oppositely polarised, dipole all hardness of the wheel or roller surface, eg Titanium Nitride
permanent magnet cylinders, stacked within a cylindrical to achieve more slipperiness (Smooth surface) or higher fric
chamber of a two-pole-piece housing Such as to allow rotation tion (textured Surface). Noise reducing coatings are equally
of the magnet discs relative to one another, thereby enabling conceivable, whereas coating films aimed at preventing extra
the respective half-circular N— and S-pole sections of the neous matter adhering onto the wheel/roller peripheral Sur
magnet discs to be brought in and out of axial alignment with face are particularly advantageous in 'dirty application fields
one another. The ferromagnetic (passive) two pole pieces of Such as steel sheet handling operations, use of magnetic
the housing are magnetically separated or isolated along two wheel units in vehicles employed as remote controlled paint
axially extending contact edges, wherein when the respective ing, brazing, welding and other applications.
N— and S-poles of the stacked magnet discs are rotated into 0068 A device incorporating one or more magnetic wheel
full alignment, the diameter separating the N- and S-poles units of the type generically discussed above, can advanta
of the magnet discs will extend between the contact edges of geously incorporate drive means, such as a motor, arranged
the housing, thereby causing one of the pole pieces to be for transferring torque into at least one of the wheel or roller
polarised and provide a N-pole pole extension and the other a (pole piece) members. The torque available at the wheel or
S-pole pole extension. roller members can then be used to impart propulsion to an
0063. Such switchable dipole magnet unit may then con object in contact with the wheels (eg metal sheet conveying),
stitute the magnetic flux source 16 in FIG. 1a, wherein flux self-propel a vehicle incorporating the magnetic wheel unit
transfer into the rotatable pole discs 12, 14 will take place (S), or where the torque transferred is a negative torque
from the magnet discs through the housing pole pieces and aimed at reducing the rotational speed of the wheels where
across the air gap between housing pole pieces and the pole Such are caused to rotate by an external force, slow down or
wheels located in facing proximity to the two pole pieces of brake an object that is in frictional contact with the wheels.
the housing, respectively. The wall thickness and exterior 0069. The pole extension wheel members can be made
shape of the pole piece housing can be chosen to provide a advantageously from Soft steel or other ferromagnetic passive
flux Source unit having a constant magnetic field or approx. materials. An advantageous wheel design may consist of a
constant magnetic flux about the periphery of the housing: composite material consisting of a plastic material or rubber
and spatial orientation of the unit's housing with respect to the matrix in which is dispersed a considerable amount of ferro
rotatable pole wheels can be determined as required. The magnetic material powder for flux carrying purposes.
specific choice of Switchable permanent magnet unit can be Deformability of the pole extension wheel at its interface with
US 2009/00784.84 A1 Mar. 26, 2009

the substrate on which its rests under magnetic load will 0076 Another roll-back prevention mechanism may be
enlarge the contact Zone where flux transfer takes place constituted by a see-saw like arresting frame, wherein a Sub
directly between wheel member and substrate, also providing stantially u- or bracket shaped frame member is mounted for
increased frictional engagement therewith. rotation about but otherwise secured to a common axle to both
0070. It will be appreciated, that the external peripheral pole wheels such that the frame's two parallel lever arms can
surface of the pole piece wheels or rollers may be smooth, be rotated to come with their respective terminal ends into
textured, corrugated or provided with other type of protru forced engagement with the Substrate surface on which the
sions, eg cogwheel teeth. The choice of wheel Surface prop wheels are magnetically attached. The lever arms may them
erties may be such so as cooperate with a complementarily selves be constituted by bent bar sections, eg L-bent arms
prepared surface of the substrate with which the magnetic pivoted at the intersection of the angled arm portions at the
wheel unit will interact. For example, in a friction wheel axle, thereby to provide a pull lever arrangement wherein the
gearbox and variable ratio drive arrangement incorporating braking force is a leveraged factor of the magnetic attraction
one or more basic magnetic wheel units having Smooth, non force provided by the wheel assembly itself.
corrugated pole wheels or rollers, the inherent slippage func 0077. In a vehicular embodiment incorporating four or
tionality which Such provide when rolling on another Smooth more pole wheels, wherein a Switchable permanent magnet
Surface object can be used to minimise overload conditions as device is associated with one wheel pair, provision of a Suit
torque transfer is reduced due to slippage. Of course, where able mechanism that enables the selective Switching on and
slippage in the torque transfer between pole wheels or rollers off (or variation of the magnetic field intensity output) of the
and Substrate is not desirable, form-interlocking complemen individual Switchable magnets provides a number of advan
tary pole wheel or roller and substrate surfaces may be tages. Not only will Such selective magnetic activation and
employed, eg Surfaces having gear teeth.
0071. A particularly useful embodiment of the invention deactivation of individual wheel pairs facilitate operational
will be in a vehicular application that includes means for disengagement of the vehicle from the substrate, it will also
self-propelling the vehicle on the Substrate Surface, regardless facilitate the vehicle being able to climb over step-like
of whether the means for self-propelling include an arrange obstacles or transitions between a horizontal and a steeply
ment for transferring torque which cooperates with the pole inclined or vertical surface, in that forward pair of wheels
wheels or rollers for the latter to effect torque transfer onto a reaching Such path change location may be demagnetised
ground or wall Surface, or whether the propulsion unit is thereby to render them magnetically inoperative, whereby
independent from the magnetic wheel unit(s) present in such they can then lift-off from the initial surface and engage the
vehicle, eg a separate traction wheel drive. inclined surface, whereupon they may be remagnetised and
0072 The torque transferring arrangement can be devised allow the vehicle to transition onto the inclined surface. The
to Suit a given application field, and may include one or more rearward located wheel pair will be switched accordingly as it
ofa belt drive, a sprocket wheel drive, a chain drive or a worm too reaches the path discontinuity.
gear drive or combinations thereof. 0078 Vehicular application fields of the invention include
0073. A preferred option for a torque transferring arrange motional robots which can be magnetically attached to ferro
ment includes one or more friction rollers disposed to trans magnetic Substrates (ie structures and objects) like ship hulls,
mit torque by engagement with an outer circumference of at Submarine hulls, pipelines (inside and outside). Such robots
least one of the pole wheel or roller members. The friction may carry a variety of appliances Such as cameras, all types of
rollers may be selectively brought in and out of engagement sensors employed in detecting of faults in a structure or per
with and biased against the wheel members using a separate form other tasks, eg transporting a cable through a pipeline,
mechanism, but advantageously the friction rollers could cleaning a pipeline, etc. For example, underwater optical and
incorporate ferromagnetic materials operatively arranged for structural inspection of the hull of a moving and Submerged
biasing the rollers into and holding contact with the wheel Submarine hull can be accomplished using a remote-con
member(s) through magnetic force. trolled robot having a streamlined body in which are received
0074. In yet a further vehicular, self-propelled device a suitable number of Magwheel units of general type dis
implementation of the present invention, means can be pro cussed above, which allow the robot to remain securely
vided for restricting rotational movement of the pole wheel or attached to the hull whilst being propelled along a desired
roller members in one direction only, eg. So that the wheels can inspection path.
rotate either clockwise or counter-clockwise, but not both. 007.9 The skilled person will further appreciate that sen
This measure increases traction efficiency in slippage situa sor Systems, motion control equipment, either for remote
tions by removing the otherwise present bi-directional free controlled operation or on-board controlled operation using
wheeling characteristics present in normal wheel axles. signal processing equipment, motor management electronics
0075 Also, it is advantageous to provide mechanisms or and power source, and other type of vehicle management
implements aimed at preventing roll-back of a vehicle equipment can be accommodated in the vehicle Support struc
employing one or more Magwheel units having propelling (ie ture of a self-propelled vehicle as required by the specific
torque transmitting) wheel members climbing along steeply application environment of the vehicle.
inclined or vertical Surfaces whilst remaining magnetically 0080. The skilled person would also be aware of different
attached thereto, One implementation sees the provision of types of axle systems and vehicle chassis types that could be
brake pads or blocks that are selectively movable into a loca employed in creating a vehicle embodying the invention.
tion between wheel member(s) and substrate surface imme I0081 Further features and other aspects of the invention
diately behind the contact area wheel(s)—substrate surface, will be noted also from the following description of a number
thereby to provide a wedging action preventing backward of preferred implementations and embodiments of the inven
rolling of the wheel(s). tion, with reference to the accompanying drawing. It should
US 2009/00784.84 A1 Mar. 26, 2009

be noted, however, that the invention is not restricted to the the surrounding environment, be it air or another fluid like
application fields outlined above, and may be implemented in water, and assuming the Substrate properties are such that no
different forms. flux saturation takes place during flux transfer into the Sub
strate, one would not observe any magnetic field outside the
BRIEF DESCRIPTION OF THE DRAWINGS immediate vicinity of the contact area between pole wheels
0082 FIG. 1a, 1b, and 1c are highly simplified schematic and substrate (refer above to virtual pole extension areas)and
illustrations of basic concepts underlying the present inven the closed magnetic circuit comprised of the pole wheels,
tion;
Substrate and magnetic flux source device.
0.083 FIG.2a to 2c are schematic illustrations of different (0093 Magnetic wheel units 10 (or 10' or 10") can be
configurations of rotatable pole wheel arrangements used embedded and embodied in a multitude of apparatus and
with different magnet configurations, wherein FIG. 2a also devices for a variety of applications.
illustrates a ferromagnetic friction roller used to impart (or 0094 Turning first again to FIG.2a, it schematically illus
receive) torque from the rotatable pole wheels; trates one methodology of effecting torque transfer either into
0084 FIG.3a to 3c are schematic illustrations of imple or from the pole wheels 12, 14 of unit 10, by means of a
ments and devices in which the present invention can be ferromagnetic roller bar 35 whose axis of rotation 36 along
embodied. the axial length of the roller is positioned to extend parallel to
0085 FIGS. 4a, 4b and 4c are schematics by way of which the axis of rotation 18 of the pole wheel pair. The roller bar 35
is illustrated how to optimise rotatable pole piece geometries has a Smooth outer peripheral Surface and is held by any
with regards to the chosen magnetic flux source in a magnetic Suitable mechanism (not illustrated) Such that it is in, or can
wheel unit as per FIG. 2a; and be brought with its outer surface into and out of frictional
I0086 FIG. 5 is a schematic illustration of a magnetic abutment on the smooth peripheral surface 13a of both
wheel unit braking arrangement which translates some of the wheels 12, 14. This basic architecture can then be employed
available magnetic attraction force into a braking force. to effect torque transfer, either positive for propulsion pur
poses or negative for object braking purposes. For example,
DESCRIPTION OF PREFERRED rotation of roller bar 35 as per arrow 37, eg by coupling the
EMBODIMENTS roller with the output shaft of an electro motor, will impart
counter-orientated rotation to wheels 12, 14 as per arrow 38
0087. A basic magnetic wheel unit as illustrated in FIGS. which in turn will then either allow the entire unit 10 to move
1a and 1b has already been described above. Such units can be in translatory manner over a stationarily held substrate 24 as
incorporated in numerous and different machines and appli per arrows 39, or where the unit 10 is otherwise secured
ances. It should be noted that the active magnetic material (ie against movement, impart movement onto anotherwise unse
permanent magnets) or other magnetic flux source (eg elec cured substrate 24 as per arrows 40 in a direction opposite to
tromagnet) can be received within a dedicated housing; thus, 39.
the actual shape of the magnetic flux unit 16 in FIGS. 1 and 2 0095. In using an appropriately dimensioned ferromag
is illustrative only and not representative of the actual shape netic roller bar 35, it is possible to utilise part of the mag
of Such units. netic energy provided by the magnetic flux source 16 of unit
0088 As can be best understood by having reference to 10 to maintain roller 35 in frictional and magnetic contact
FIGS.2a to 2c, depending on the number of and specific types with wheel members 12.14 whilst the majority of the avail
of dipole magnets employed as magnetic flux source, mag able magnetic flux is utilised to secure the unit 10 onto sub
netic wheel units having different pole wheel numbers and strate 24. It will then also be appreciated that where the
arrangements are possible. magnetic flux Source 16 is a Switchable permanent magnet
0089 FIG. 2a illustrates a twin wheel configuration unit device or an electromagnet, variable torque transfer may be
10 utilising a single magnet 16 and two rotatable pole wheels effected, dependent on the amount of flux transferred into
14, 16 as previously described with reference to FIG.1a. roller 35 (and substrate) through wheel pole members 12, 14,
0090 FIG.2b illustrates an arrangement with two pairs of and the friction coefficient that then will be present between
pole wheels 12, 14", one pair at the N– Pole and one at the the abutting surfaces of wheels 12, 14 and roller 35. The
S-pole of the bipolar magnet 16', ie a four-wheel magnetic architecture illustrated in FIG. 2a provides for an inherent
wheel unit 10" with single magnetic flux source 16'. torque slippage functionality which can reduce torque trans
0091 FIG.2c in contrast illustrates a four-wheel magnetic fer between unit 10 and substrate 24 in conditions that may
wheel unit 10" with two spaced apart magnetic flux sources otherwise lead to an overload.
16" (which can but need not be identical with regards to 0096. A more specific application field for magnetic wheel
magnetic flux density delivery qualities), wherein each mag units include roller conveyor systems in various forms like
net 16" is associated with one pole wheel pair 12", 14". It may overhead sheet metal conveyors, one of which is schemati
be noted that the magnetisation axis extending between N cally illustrated in FIG.3a. A plurality of 2-wheeled magnetic
and S-poles of the two magnets 16" are orientated in opposite wheel units 100a to 100g embodying the concept described
directions to one another, but this need not be the case in with reference to FIG. 2a (but with a different torque trans
practical embodiments of such unit 10". missionarchitecture) are suspended from a ceiling rail 150 in
0092. The lines 17, 17 and 17" in FIGS. 2a to 2c, respec predetermined distance from one another along the extension
tively illustrate in crude but figuratively correct manner exter or travel path defined by rail 150. Each unit 100a to 100g
nal flux transfer paths that will be present in the substrate 24 includes one pair of pole wheels accommodated within a
(being represented by a steel plate) that respectively exist Suitable gondola-like housing in which is received a Switch
between the polarised pole wheels of the different units 10, able magnet that provides magnetic flux to the respective
10' and 10". Given that the magnetic permeability of the wheel-pairs. A suitable motor is used to impart selective
ferromagnetic Substrate is by magnitudes higher than that of rotation to the pole wheels of the units. A steel plate 140 can
US 2009/00784.84 A1 Mar. 26, 2009

be conveyed along travel path A held magnetically attached magnetic field is emitted and present, and a deactivated State,
successively at units 100a to 100g. Alternatively, units 100a in which the magnets 316 are turned-off and no external
to g could be 4-wheeled units as illustrated in FIG.2b or 2c, magnet field is present.
in which case one wheel pair would be driven and one pair 0101. As may be best appreciated with reference to FIGS.
could be magnetic idle pole wheels. In yet a further alterna 4a to 4c, which show a simplified isometric representation of
tive, guide rail 150 could be replaced with a chain belt or an individual magnetic source unit 316 with its associated
similar conveyor line on which the units 100a to 100g can be pole wheel pair 312,314, and top and front plan views along
secured; the units 100a to 100g could then all comprise idle arrows IVb and IVc in FIG. 4a, the magnetic flux source units
pole wheels, given that locomotion is provided by the chain 316, which are respectively secured within the vehicle body
drive itself. 324 in a fixed location between each associated pole wheel
0097 FIG.3billustrates an application wherein a 4-wheel pair 312,314, are located such that the N S magnetic axis of
each magnetunit 316 (in the activated State) extends coaxially
magnetic wheel unit 200 embodying the concept illustrated in with the wheel axles 318. Each unit 316 extends with its two
FIG. 2C serves as a magnetic Vice for releasably securing a respective axial ends into the cylindrical void 328 defined
tubular ferromagnetic workpiece 224 whose outer surface is within the annular rim flange 330 of the wheels 312,314 and
to be powder coated by atomiser apparatus 260. The pole to be in facing relationship with the terminal disc web 332 of
wheels 212, 214, 212 (and the counterpart not illustrated the wheels 312,314. A very small air gap 334 is maintained
fourth wheel member) are respectively secured for rotation between the two stationary pole extension pieces 336, 338
about axle bolts 213 and 213' mounted at and within a box that form the housing of the unit 316 in which is received the
like Support body 232. The two magnets (not shown) respec two diametrically polarised permanent magnet cylinders 340,
tively associated with the pole wheel pairs 212, 214 (212) are 342 that provide the active, but switchable, permanent mag
mounted within the support body 232 in such manner that the netic flux source of the unit 316 (compare above and U.S. Pat.
magnetic N-S pole axis of each Switchable magnet coin No. 7,012,495).
cides axially with the axis of rotation band b' of the respec 0102) A prototype vehicle according to FIG.3c (using the
tively associated pole wheel pairs. Refnumeral 250 serves to unit of FIG. 4a) was constructed, using four cup-shaped pole
denote a Support member by means of which the magnetic wheels having an outer diameter of 90 mm, a rim wall thick
vice unit 200 can be secured to a support structure, which ness of 25 mm, a disc web thickness of 25 mm (thereby
itself could be an articulated arm that would enable the vice defining a flux transfer cross-sectional area of 1375 mm2, see
unit 200 to be orientated in space as desired. FIG. 4a, at 344) and made of soft-steel having a magnetic flux
0098. Whilst it is feasible to incorporate a motor unit in saturation limit of about 2 Tesla. The peripheral surface of the
cups was uncoated and machined to a smooth finish as viewed
order to drive one or more of the pole wheels of unit 200, the by the naked eye.
illustrated embodiment simply serves to magnetically hold 0103) The magnetic flux source units comprise each a
work piece 240 securely in space whilst allowing rotation switchable permanent magnet unit of type M5040 sourced
thereofas indicated by arrow 252 about its longitudinal axis. from Magswitch Technology Worldwide and capable of
0099. This same device 200 could be used to magnetically delivering (in unloaded circuit conditions) 1.2 Tesla at the
clamp two tubular pipe sections in end to end abutting rela relevant passive stationary pole Surface employed in flux
tionship, thereby enabling other operations to be carried out, transfer, wherein the magnetic flux area of the active mag
Such as butt welding of the pipe sections. netic material (ie the two cylindrical, stacked magnets) totals
0100 FIG. 3c illustrates in schematic perspective view a 2000 mm (see FIG. 4a at 346).
self propelled prototype of a Magnetic Trolley (vehicle) 300, 0104. The choice of (available) magnetic flux source, ie
which essentially consists of two identical, independently M5040 magnets, which given the shape of the magnetic field
manually Switchable permanent magnet units 316 generally generated in the turned-on state are similar to wide pole
of the basic type described in U.S. Pat. No. 7,012,495, two magnets with non-uniform magnetic field distribution, influ
cup-shaped pole wheel pairs 312,314 respectively associated ences also their spatial arrangement with respect to the cup
with the magnetic flux sources 316, a prime mover inform of shaped wheels as well as the dimension (in axial direction of
an electric motor 320, a not-illustrated power supply for the the wheel members) which the rim wall of the wheel should
motor, eg battery pack, a drive train arrangement 318 for have in order to achieve an optimised flux transfer and mag
transferring torque from the motor 320 into all four of the pole netic field force generated attraction force. Because the wheel
wheels 312,314, an on-board vehicle control system 322 as pole members constitute a load with respect to available mag
would be employed in either remote wirelessly controlled netic force, the depth of the rim portion is chosen such that it
vehicles or on-board computer controlled vehicles, and a covers (surrounds) the M5040 magnet up to a location where
shoe-box-like vehicle body 324 on which all of the aforemen the magnetic field intensity measured along a line running
tioned components are mounted. The individual pole wheels perpendicular to the N S-pole diameter separation line is
312. 314, which are cylindrically cup shaped as detailed in about 0.7 of the maximum field value, see FIG. 4c, which is
FIGS. 4a and 4b, are journaled at respective axle elements about 12.5 mm in the chosen configuration.
326 fixed to the side walls of the vehicle body 324. The drive 0105. The total weight of the vehicle including all drive
train arrangement 318 includes a belt and pulley System kine train and control components, vehicle body and a welding
matically coupling all four wheels 312,314 with a driven gear appliance mounted thereon was recorded at around 12 kg (a
axle supported at body 324 whose cogwheel meshes with a single magnetic wheel unit consisting of magnetic flux Source
helical screw shaft coupled to an output shaft of the electric 316 and cup wheel poles 312,314 weighs about 3 Kg).
motor 320. Reference numerals 328 and 329 serve to denote 0106 Load carrying experiments conducted with vehicle
lever arms utilised for switching of the magnets 316 between 300 demonstrated that the breakaway force required to verti
their respective activated States, in which a strong external cally lift-off the vehicle whilst in magnetic attachment on a
US 2009/00784.84 A1 Mar. 26, 2009

horizontal clean steel sheetamounts to around 2400N, and the magnetic flux source, the bodies being disc, wheel, roller or
vehicle was able to generate a traction force of around 400N similarly shaped with an outer circumferential Surface and
on a clean steel sheet Substrate. held rotatable about respective axes of rotation, and (c) a
0107 Flux transfer efficiency between the active magnetic counter body having ferromagnetic properties which is
material of the Switchable flux units 316 and the substrate was arranged to cooperate with the rotatable pole extension bod
determined to be about 50%. ies in providing an external flux path for the magnetic flux
0108 Experiments have been conducted which suggest when in magnetic contact with the circumferential Surface of
that the four-wheeled self-propelled trolley as described is the pole extension bodies, the magnetic flux source being held
capable of safely transporting an additional payloadequal its stationary relative to the rotatable pole extension bodies.
own weight along a vertically inclined steel sheet. 2. Vehicle capable of magnetically attaching to a magneti
0109. It will then be appreciated that such trolleys may be cally attractive substrate, including a vehicle body at which
used to mount all kind of instruments and appliances that can are Supported at least two wheel members and at least one
be safely conveyed along inclined, Vertical and even over magnet exhibiting a N- and a S-pole, wherein the wheel
hanging ferromagnetic Surfaces, or may be incorporated into members include magnetically passive but polarisable mate
other structures that require safe attachment to a ferromag rial, wherein the wheel members and the magnet(s) are spa
netic structure in displaceable manner. tially located on the vehicle body in a manner wherein the
0110. For example, switchable magnetic wheel units as wheel members provide rotatable, oppositely polarisable
illustrated can be incorporated in all types of working plat pole extension elements of the N—and S-poles of the other
forms that are Suspended from above to carry out mainte wise stationary magnet(s), whereby resting of the wheel
nance and other work on vertically inclined ferromagnetic members on the Surface of a magnetically attractive substrate
Surfaces, ega ship's hull, thereby providing a means of safely creates a closed magnetic circuit encompassing the magnet,
magnetically attaching the platform to the ship hull without pole extension wheel members and the substrate.
inhibiting up and downward movement of the platform. 3. Support appliance capable of magnetically retaining
0111 Turning lastly to FIG. 5, it illustrates schematically attached to it in an otherwise displaceable manner a magneti
a magnetic wheel climb-crawler 500 incorporating a mag cally attractive body, including a Support structure at which
netic wheel unit 510 of similar type to the one illustrated and are mounted at least two wheel or roller members arranged for
described with reference to FIGS. 4a to 4c, with similar rotation about respective axes, and at least one magnet exhib
dimensions as referred to above, which additionally incorpo iting a N- and S-pole mounted at the Support body separate
rates a motion arresting frame 520 which can be selectively from the wheel or roller members, wherein the wheel mem
Swivelled in and out of engagement with the Substrate on bers include magnetically passive but polarisable material,
which the unit 510 is attached for travel. The frame 520 is a and wherein the wheel or roller members are spatially located
substantially u—or bracket having two parallel arms 522 and on the Support structure in a manner wherein the wheel mem
524 incorporating a bent 525 along their length and a traverse bers provide rotatable, oppositely polarisable pole extension
handle arm 526 at an opposite end to the free terminal ends elements of the N— and S-poles of the otherwise stationary
521 and 523 of the arms 522,524. dipole magnet, whereby bringing a magnetically attractive
0112. The frame 520 is mounted for rotation about but substrate into surface contact with the peripheral surface of
otherwise secured to the common axle 528 of both pole the wheel members creates a closed magnetic circuit encom
wheels 512, 514 such that the frame's two parallel lever arms passing the magnet, pole wheel or roller members and the
can be rotated to come with their respective terminal ends 512 substrate.
and 523 into forced engagement with the substrate surface 4. Vehicle according to claim 2, respectively, wherein the at
530 on which the pole extension wheels 512, 514 are mag least one magnetis Supported Such as to maintain an air gap to
netically attached. the wheel or roller pole extension members.
0113. The lever arm geometries, in particular the ratio of 5. Appliance according to claim 3, respectively, further
length L2 between the free ends of arms 522 and 524 and the including drive means arranged for transferring torque into at
pivot point at 528 and the length L1 between pivot point at 528 least one of the wheel or roller members.
and the traverse bar section 529, where force 532 may be
exerted in order to rotate the frame 520, will determine the 6. Vehicle according to claim 2, further including means for
leverage between the force 533 that can be applied at the self-propelling the vehicle on the substrate surface.
contact point of the free ends of arms 522. 524 with the 7. Vehicle according to claim 6, wherein the self-propelling
substrate and the reaction force 534 which is provided by the means include an arrangement for transferring torque to at
magnetic attraction force exerted between wheels 512, 514 least one of the wheel members from an on-board motor.
and Substrate. 8. Appliance according to claim 5, wherein the drive means
0114. The principle of the device 500 can be employed in include one of a belt drive, a sprocket wheel drive, a chain
devices intended for climbing a vertical ferromagnetic wall, drive or a worm gear drive or combinations thereof.
where backward slippage due to low friction coefficients 9. Appliance according to claim8, wherein the drive means
between wheels and substrate is insufficient to secure positive include one or more friction rollers disposed to transmit or
traction forces. It will be appreciated that the arresting device receive torque by engagement with an outer circumference of
may also be used to counter forward slipping, as the relevant at least one of the wheel members.
motion pattern of the unit and the location of ground engage 10. Appliance according to claim 9, wherein the friction
ment of the arresting device ahead or behind the pole wheels rollers incorporate ferromagnetic materials operatively
will dictate the functionality of the arresting device. arranged for biasing the rollers into and holding contact with
1. Magnetic circuit having (a) one or more permanent the wheel member(s) through magnetic force.
magnets as a source of magnetic flux, (b) at least two oppo 11. Vehicle or appliance according to claim 8, wherein the
sitely polarisable pole extension bodies associated with the drive means include a gear box or arrangement.
US 2009/00784.84 A1 Mar. 26, 2009

12. Appliance according to claim 3, respectively, wherein 17. Magnetic circuit according to claim 1, wherein the
one dipole magnet is provided per wheel or roller member rotatable pole extension bodies are wheel shaped and have a
pair. cross-sectional shape and dimensions to (a) minimise flux
13. Appliance according to claim 12, wherein the dipole transfer losses from the magnetic flux Source into the rotat
magnetis a Switchable permanent magnet device arranged for able pole wheels, (b) provide relatively larger area virtual
generating an external magnetic field that can be varied poles thereby to maximise flux transfer outside of the direct
between a maximum flux density output in a fully on or active physical contact Zone between pole extension wheels and
state and a minimum, practically negligible flux density out Substrate Surface, and (c) maintain a predetermined value of
put in a fully off or deactivated state. magnetic attraction force towards the Substrate.
14. Appliance according to claim 13, wherein the Switch 18. Magnetic circuit according to claim 17, wherein the
able permanent magnet device includes one of a toggle Switch pole extension wheels are cylindrically cup-shaped bodies
for changing and selecting between fully on and fully off having an annular flange portion having an axial length which
states and an incremental Switch for setting and fixing a is a function of the magnetic field strength of the magnetic
flux source.
magnetic flux output between fully on and fully off. 19. Magnetic circuit according to claim 18, wherein the
15. Appliance according to claim 12, wherein the wheel or cup-shaped pole extension wheels have an axial length suffi
roller members are cup shaped in cross-section, and wherein cient to cover the magnetic flux source to an extent where the
the dipole magnet extends with one of its poles into the cup flux source exhibits approx. 70% of its maximum field
shaped wheel or roller. strength.
16. Appliance according to claim 13, having at least four of 20. Magnetic circuit according to claim 1, wherein the
said wheels or rollers arranged in pairs, wherein one said magnetic flux source comprises Switchable permanent mag
Switchable permanent magnet device is present per each said net devices switchable to exhibit an external magnet field
wheel or roller member pair, and further including a device between strong and weak (practically Zero) values.
for discretely switching the two Switchable permanent mag
net devices independently or jointly. c c c c c