Flux Drive manufactures Adjustable Speed Drives (ASDs) and ‘Soft-Start’ Couplings that transfer torque by means of magnetic induction across a patented ‘soft-torque’ air gap. These patented devices can be thought of as a frictionless transmission or clutch between a motor and pump, fan, blower, or other rotating machinery. The Coupling eliminates high-peak power demand during start-up and the ASD provides significant energy savings during reduced speed operation.
A Flux Drive is made of two main components: (1) an outer ‘magnet can’ assembly containing an array of permanent magnets with (2) an induction rotor placed inside the magnet can, which provides a continuous (always on) magnetic flux source. These two components are separated by a small air gap and have no physical connection or surfaces in contact. As the magnet can turns on the motor shaft, the induction rotor located inside the can (and connected to the load shaft) starts to rotate due to magnetic induction which in turn creates a coupling force across the air gap. Slight relative motion (called slip) always occurs during the induction process which is designed to be less than 2 percent at full torque / power.
Flux Drive flexible ‘Soft-Start’ Couplings provides an almost one-to-one transfer of power from the motor to the load. Couplings are sized to transfer 100% of the motor’s torque at 1.5% slip (therefore 98.5% efficient).
The ‘soft-start’ capability is inherent in the coupling design and ultimately limits the full torque/power at start-up to 140 percent of the coupling’s full rated power. No longer is a motor subject to high locked-rotor currents nor does the electrical system have to provide high peak power during a motor starting event. In addition, the coupling provides over torque protection during a load shaft seizure event by also limiting the torque and power.
The couplings are simple mechanical devices that are easy to install and require no electrical training (unlike other soft-start solutions using sensitive electronics). Ongoing operation and maintenance is affordable with no touching parts or sensitive electrical components to replace.
The Flux Drive Adjustable Speed Drive (ASD) is a ‘Soft-Start’ Coupling with the ability to configure the linear engagement between the rotating magnet can and the induction rotor assemblies. Adjustable speed is achieved by controlling the overlap of the rotor inside the magnetic can. As the can and rotor are disengaged, the slip increases allowing the output rotor speed to decrease proportionally.
Substantial energy savings. In centrifugal applications, system power requirements vary with the cube of the pump speed or flow. Small decreases in speed or flow can significantly reduce energy use. For example, reducing the pump speed flow by only 20% will reduce input power requirements by as much as 30% with a Flux Drive ASD.
Beside lower power requirements, Flux Drive devices offer:
A major component of the Flux Drive ASD and Coupling are rare-earth (RE), Neodymium, Iron, Boron (NdFeB) permanent magnets. These magnet materials are not actually rare, but are actually found in the rare-earth section of the Periodic table; specifically the fifteen lanthanoids plus scandium and yttrium. These magnet materials are actually very common and mined at various locations around the world as follows ( including estimates % of deposits): 1) China (36%), 2) Russia (20%), 3) USA (15%), 4) Australia (5%), 5) India (3%), others (21%).
As noted by their name, permanent magnets are magnetized for life, and will operate the Flux Drive ASD and Coupling for hundreds of years if operated within the Flux Drive standard specifications. These RE magnets became commercially available in the early 1980’s and have become the standard for permanent magnet motors and generators world-wide. They will retain their performance with temperatures up to 350 degrees F, and last for hundreds of years without loss in performance.
The Flux Drive, Magnet Can contains an array of permanent magnets arranged to provide high strength magnet flux for torque transmission to the Induction Rotor. This patented magnetic circuit creates the extremely high efficiency coupling and the base design for the adjustable speed drive. The magnetic circuit is completely contained inside the magnet can, with no magnetic flux leaking outside the can assembly.
All standard field maintenance can be performed without having to remove the induction rotor from the magnetic can. The magnet can pilot bearing can even be changed without disassembling the Flux Drive device. Removal of the Induction Rotor from the Magnet Can assembly will void the warrantee of the Flux Drive device and is not recommended.