ELECTROMAGNETICALLY CONTROLLED SEGMENTED MIRROR, ELECTROMAGNETIC ACTUATOR FOR USE THEREIN AND METHOD FOR MANUFACTURING THE SAME

Abstract

An electromagnetic actuator including a soft-ferromagnetic yoke is described. The electromagnetic actuator includes, an at least substantially cylindrical circumferential wall covered at a first end with a base and at a second end with a top, the circumferential wall defining an axis in a direction from the base end to the top. An intermediate yoke section holds a permanent magnet fixed that leaves an inner space housing an axially movable core element being flexibly restrained with at least one resilient element. One of a base yoke section and/or a top yoke section houses an electromagnetic coil.

Claims

1. An electromagnetic actuator comprising a soft-ferromagnetic yoke, with an at least substantially cylindrical circumferential wall covered at a first end with a base and at a second end with a top, wherein the circumferential wall defines an axis in a in an axial direction from the base end to the top, wherein the soft-ferromagnetic yoke comprises, in the axial direction a base yoke section, an intermediate yoke section and a top yoke section, wherein the base yoke section forms the base and a first axial section of the circumferential wall, as well as a base protrusion surrounded with space by the first axial section of the circumferential wall, wherein the intermediate yoke section forms a second axial section of the circumferential wall, and wherein the top yoke section forms the top and a third axial section of the circumferential wall, as well as a top protrusion surrounded with space by the third axial section of the circumferential wall, wherein the base yoke section and/or the top yoke section house an electromagnetic coil in the space between their protrusion and their axial section of the circumferential wall, wherein the intermediate yoke section holds at least one permanent magnet fixed with a first magnetic pole facing an inner surface of the cylindrical wall, and with a second magnetic pole facing an inner space in the intermediate yoke section, wherein the permanent magnet exerts an attractive force having negative stiffness on an axially movable core element housed in the inner space, wherein at least one of the base and the top define an axially extending opening through which protrudes an actuation rod fixed to the axially movable core element, wherein the actuator further comprises: a first membrane and a second membrane of an at least substantially non-magnetic material, wherein the first membrane is arranged between the base yoke section and the intermediate yoke section and wherein the second membrane is arranged between the intermediate yoke section and the top yoke section, wherein the axially movable core element is flexibly restrained between the first and the second membrane, and wherein the first membrane and the second membrane, together, form a resilient element having a stiffness with a value that is equal to or greater than a magnitude of the negative stiffness.

2-6. (canceled)

7. The actuator according to claim 1, wherein the first membrane comprises: a central portion fixed to the axially movable core element: a first suspension arm; a second suspension arm; and a third suspension arm wherein each suspension arm radially extend outwards to respective end where it is mechanically coupled between a pair of yoke sections.

8. The actuator according to claim 7, wherein the respective end bifurcates into a first end portion and a second end portions that at least partly extend radially inward.

9. The actuator according to claim 8, wherein the first end portion and the second end portion of each suspension arm further extend in mutually opposite tangential directions to a respective connection element to which they are fixed.

10. An actuator array comprising a plurality of spatially distributed actuators according to claim 1.

11. The actuator array according to claim 10, wherein the spatially distributed actuators comprise at least one part that is integrally formed.

12. The actuator array according to claim 11, wherein the at least one integrally formed part is a section of the yoke, wherein for each of the electromagnetic actuators the section of the yoke is formed in a single patterned block of ferromagnetic material, and/or wherein the at least one integrally formed part is a membrane, wherein the membranes of the actuators are formed as a single patterned plate of a resilient, non-magnetic material.

13. The actuator array according to claim 10, wherein each intermediate yoke section bounds to at least one other intermediate yoke section that has a permanent magnet with a polarity opposite to that of the each intermediate yoke section.

14. A mirror comprising: an actuator array with a plurality of spatially distributed electromagnetic actuators, a plurality of mirror segments which are movable relative to each other, respective mirror segments being mechanically coupled to an actuation rod of a respective electromagnetic actuator of the actuator array, wherein the electromagnetic actuators each comprise a soft-ferromagnetic yoke, with an at least substantially cylindrical circumferential wall covered at a first end with a base and at a second end with a top, wherein the circumferential wall defines an axis in an axial direction from the base end to the top, wherein the soft-ferromagnetic yoke comprises, in the axial direction, a base yoke section, an intermediate yoke section and a top yoke section, wherein the base yoke section forms the base and a first axial section of the circumferential wall, as well as a base protrusion surrounded with space by the first axial section of the circumferential wall, wherein the intermediate yoke section forms a second axial section of the circumferential wall, and wherein the top yoke section forms the top and a third axial section of the circumferential wall, as well as a top protrusion surrounded with space by the third axial section of the circumferential wall, wherein the base yoke section and/or the top yoke section house an electromagnetic coil in the space between their protrusion and their axial section of the circumferential wall, wherein the intermediate yoke section holds at least one permanent magnet fixed with a first magnetic pole facing an inner surface of the cylindrical wall, and with a second magnetic pole facing an inner space in the intermediate yoke section, wherein the permanent magnet exerts an attractive force having negative stiffness on an axially movable core element housed in the inner space, wherein at least one of the base and the top define an axially extending opening through which protrudes an actuation rod fixed to the axially movable core element, wherein the actuator further comprises: a first membrane and a second membrane of an at least substantially non-magnetic material, wherein the first membrane is arranged between the base yoke section and the intermediate yoke section and wherein the second membrane is arranged between the intermediate yoke section and the top yoke section, wherein the axially movable core element is flexibly restrained between the first and the second membrane, and wherein the first membrane and the second membrane, together, form a resilient element having a stiffness with a value that is equal to or greater than a magnitude of the negative stiffness.

15. A method of assembling an actuator comprising: providing: a base yoke section, an intermediate yoke section and a top yoke section, each of a soft-ferromagnetic material; a first and a second membrane of an at least substantially non-magnetic material; a core element; a permanent magnet; and an electromagnetic coil; mounting the electromagnetic coil in one of the base yoke section and the top yoke section; mounting the base yoke section with the first membrane against the intermediate yoke section; mounting the permanent magnet against an inner wall of the intermediate yoke section, a first magnetic pole thereof facing the inner wall and a second magnetic pole facing inwards; inserting the core element in a remaining inner space of the intermediate yoke section; and mounting the upper yoke section with the second membrane against the intermediate yoke section.

16. The mirror according to claim 14, wherein the spatially distributed actuators comprise at least one part that is integrally formed.

17. The mirror according to claim 16, wherein the at least one integrally formed part is a section of the yoke, wherein for each of the electromagnetic actuators the section of the yoke is formed in a single patterned block of ferromagnetic material, and/or wherein the at least one integrally formed part is a membrane, the membranes of the actuators being formed as a single patterned plate of a resilient, non-magnetic material.

18. The mirror according to claim 14, wherein each intermediate yoke section bounds to at least one other intermediate yoke section that has a permanent magnet with a polarity opposite to that of the each intermediate yoke section.

19. The mirror according to claim 16, wherein each intermediate yoke section bounds to at least one other intermediate yoke section that has a permanent magnet with a polarity opposite to that of the each intermediate yoke section.

20. The mirror according to claim 17, wherein each intermediate yoke section bounds to at least one other intermediate yoke section that has a permanent magnet with a polarity opposite to that of the each intermediate yoke section.

21. The mirror according to claim 14, wherein, the first membrane of each actuator comprises: a central portion fixed to the axially movable core element; a first suspension arm; a second suspension arm; and a third suspension arm wherein each suspension arm radially extend outwards to a respective end where it is mechanically coupled between a pair of yoke sections.

22. The mirror according to claim 21, wherein the respective end bifurcates into a first end portion and a second end portion that at least partly extend radially inward.

23. The mirror according to claim 22, wherein the first end portion and the second end portion of each suspension arm further extend in mutually opposite tangential directions to a respective connection element to which they are fixed.

24. The mirror according to claim 16, wherein, the first membrane of each actuator comprises: a central portion fixed to the axially movable core element; a first suspension arm; a second suspension arm; and a third suspension arm wherein each suspension arm radially extend outwards to a respective end where it is mechanically coupled between a pair of yoke sections.

25. The mirror according to claim 17, wherein, the first membrane of each actuator comprises: a central portion fixed to the axially movable core element; a first suspension arm; a second suspension arm; and a third suspension arm wherein each suspension arm radially extend outwards to a respective end where it is mechanically coupled between a pair of yoke sections.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] These and other aspects of the present disclosure are described in more detail with reference to the drawings. Therein:

[0021] FIG. 1A, FIG. 1B schematically show a top-view of an embodiment of the improved electromagnetically controlled segmented mirror;

[0022] FIG. 2 shows an axial section of an embodiment of an improved electromagnetic actuator suitable for use therein;

[0023] FIG. 3 shows an exploded view of said embodiment according to the same axial section;

[0024] FIG. 4 schematically shows an axial section of an embodiment of an improved electromagnetic actuator in its operational state;

[0025] FIG. 5, 5A show in more detail aspects of an embodiment of the improved electromagnetically controlled segmented mirror; Therein FIG. 5 is a cross-section and FIG. 5A is a section according to VA-VA in FIG. 5;

[0026] FIG. 6 shows a first part of an embodiment of an improved actuator assembly;

[0027] FIG. 7 shows a second part of an embodiment of an improved actuator assembly;

[0028] FIG. 8 shows an assembly of these parts;

[0029] FIG. 9A, 9B and 9C shows various configurations of permanent magnets in an intermediate yoke section;

[0030] FIG. 9D shows an example of magnetic polarity variations in an improved actuator assembly.

DETAILED DESCRIPTION OF EMBODIMENTS

[0031] FIG. 1A, FIG. 1B schematically show a top-view of a electromagnetically controlled segmented mirror 30. Therein FIG. 1B shows a cross-section according to BB in FIG. 1A. The mirror 30 comprises a plurality of mirror segments 31a, 31b, . . . ,31n. Each mirror segment is controlled by a proper electromagnetic actuator 1a, 1b, . . . 1n, to which it is mechanically coupled to by an associated actuation rod. For example mirror segment 31a is mechanically coupled by an actuation rod 22a to an electromagnetic actuator 1a. For illustration purposes, the mirror of FIG. 1A has 16 mirror segments. In practice, the number of segments may be significantly higher e.g. in the order of a few hundred or a few thousands. As further shown in FIG. 1B, the actuators 1a, 1b, . . . receive a respective control signal from an actuator controller 40.

[0032] FIG. 2 and FIG. 3 schematically show an embodiment of an electromagnetic actuator 1 as used in the mirror 30 of FIG. 1. Therein FIG. 2 shows a cross-section of the electromagnetic actuator 1 in its assembled state and

[0033] FIG. 3 shows an exploded view of the actuator 1 according to the same cross-section. The actuator 1 comprises a yoke 10 of a soft-ferromagnetic material with an at least substantially cylindrical circumferential wall 11 that is covered at a first end with a base 12 and at a second end with a top 13. Examples of soft-ferromagnetic materials are iron, nickel, and alloys of iron and nickel and/or cobalt. The circumferential wall 11 defines an axis 14 in a direction 14 from the base 12 to the top 13. In that direction 14′, the yoke 10 subsequently has a base yoke section 10a, an intermediate yoke section 10b and a top yoke section 10c. The yoke sections 10a, 10b and 10c have a respective section 11a, 11b, 11c of the cylindrical wall 11. In the embodiment shown, the base yoke section 10a, the intermediate yoke section 10b and the top yoke section 10c are mutually distinct components that are assembled to form the yoke 10. In turn, the base yoke section 10a is assembled from a first subcomponent 10a1 forming the base 12 with the protrusion and a second, cylindrical subcomponent 10a2. In other examples the two or more components or subcomponents are replaced with an integral component. For example, the base yoke section may be provided as an integral component. As a further example, the intermediate yoke section 10b and the top yoke section 10c may be provided as an integral component.

[0034] As shown in FIG. 2 and in the exploded view in FIG. 3, the base yoke section 10a houses an electromagnetic coil 16 having power supply lines 161 in the space between its protrusion 10a1 and its axial section 10a2 of the circumferential wall. Alternatively, or additionally, an electromagnetic coil may be housed in the space between the protrusion 10c1 and the cylindrical section 10c2 (11c) of the circumferential wall of the top yoke section. The electromagnetic coil 16 has power supply lines 161 with which the electromagnetic actuator 1 can be driven by a controller 40.

[0035] The intermediate yoke section 10b holds a cylindrical permanent magnet 20 that is fixed within an inner surface of the cylindrical wall 11b in the intermediate yoke section. The cylindrical permanent magnet 20 has a first magnetic pole directed radially outward, therewith facing the inner wall and a second magnetic pole faces an axially movable core element 17 housed in an inner space enclosed by the permanent magnet 20. Instead of a single, cylindrical permanent magnet 20, a plurality of separate permanent magnets may be used that are distributed over the inner wall of the inner surface of the cylindrical wall 11b. In some embodiments the permanent magnet comprises a material selected from a group comprising NdFeB, SmCo or AlNiCo.

[0036] As shown in FIG. 2, the core element 17 is clamped between a pair of membranes 18, 19. The membranes act as resilient elements that compensate a an attractive force having negative stiffness characteristics exerted by the permanent magnet 20 on the core element 17. The membranes are of a resilient, non-magnetic material such as stainless steel, aluminum, titanium or alloys thereof, for example with vanadium, for example the alloy Ti-6Al-V (TiAlV) and/or molybdenum, but also plastics may be contemplated for this purpose.

[0037] The actuation rod 22, which is fixed to the core element 17, extends with space in an axial direction through an opening 21 in the top 13 of the actuator 1. In some other embodiments an opening for the actuation rod is provided in the base of the actuator.

[0038] FIG. 4 shows in the same cross-section the actuator in an operational state, for example to control a segment 31a, with reflective surface portion 31as of the mirror 30 of FIG. 1A, 1B. Therein a control voltage Vc is supplied to the electromagnetic coil 16, for example by a controller 40 as shown in FIG. 1B. Therewith a magnetic flux is induced along a path Fc that extends from the base 12, through the cylindrical wall 11, through the top 13 and through the axially movable core element 17. As further shown in FIG. 4, the permanent magnet 20 provides for a magnetic flux along a first path FPt extending through the top 13 and along a second path FPb extending through the base 12. The polarity of the magnetic flux density (Dp) originating from the permanent magnet 20 in the upper portion of the core element 17 (facing the top 13) is opposite to the polarity of the magnetic flux density (−Dp) originating from the permanent magnet 20 in the lower portion of the core element 17 (facing the base 12). The magnetic flux (Dc) of the electromagnetic coil 16 has a flux density Dc with the same polarity in both core element portions. The magnetic force Fm exerted on the core element is proportional to the integral of the squared total flux density. As a result, in a first axial portion of the core element 17, for example the upper half a magnetic force is induced of the order (Dc+Dp).sup.2 and in the second axial portion of the core element, in that case the lower half, a magnetic force of the order (Dc−Dp).sup.2 is induced. The sum of these terms is linear in Dc. Therewith the operation of the electromagnetic actuator 1, for example to actuate a mirror segment 31a is well controllable.

[0039] FIG. 5 schematically shows an exemplary membrane 18. The exemplary membrane 18 is provided with a central portion 180 that is to be fixed to the axially movable core element 17 (schematically indicated by the dashed contour) and with a first, a second and a third suspension arm 181, 182, 183 that radially extend outwards to an end 184, 185, 186 where it is mechanically coupled between a pair of yoke sections. As further shown in FIG. 5, the ends 184, 185, 186 bifurcate each into a first and a second end portions 1841, 1842; 1851, 1852; 1861, 1862 that at least partly extend radially inward. The end portions 1841, 1842; 1851, 1852; 1861, 1862 further extend in mutually opposite tangential directions where they are fixed to a proper mounting element 1843, 1844; 1853, 1854; 1863, 1864 that is fixed to the wall 11 of the yoke, for example being clamped and/or adhered by an adhesive. FIG. 5A shows a cross-section according to VA-VA in FIG. 5. As shown in more detail therein, the cylindrical wall 11 defines a space 11S for the radially extending suspension arms, e.g. 181 and their corresponding ends, e.g. 184 with end portions 1841, 1842, so that their movements are only restricted due to their attachment to the mounting elements, e.g. 1843, 1844.

[0040] In the example of FIG. 1A, 1B, the actuators 1a, 1b, . . . , 1n, form an actuator array 100 of spatially distributed actuators. In the example shown the actuators of said plurality of actuators are arranged with their axis 14a, 14b, 14c in a mutually parallel direction for example corresponding to the surface normal of a virtual plane 101. The virtual plane 101 in this case indicates a neutral state of the mirror 30. In some embodiments, the mirror 30 has a curved shape in its neutral state and the axis of each actuator is parallel to the surface normal of the mirror segment that it controls.

[0041] In the embodiments of the electromagnetically controlled segmented mirror 30 shown in FIG. 1A, 1B, the actuators 1a, 1b, . . . , 1n are mutually separate units. The actuators 1a, 1b, . . . , 1n in that case are for example locally assembled with the mirror 30, for example using an additional carrier frame.

[0042] In alternative embodiments, the actuators comprise at least one part that is integrally formed. In the example of FIG. 6, the intermediate yoke sections indicated as 10b in FIGS. 2 and 3 are formed as a single block 50 of a soft ferromagnetic material. The block 50 is patterned by forming an inner space therein for each of the actuators 1a, 1b, . . . , 1n. The individual actuators, e.g. 1m are provided with a proper permanent magnet fixed 20m that is fixed to the inner wall of its inner space and a respective movable core element 17m. In the embodiment shown in FIG. 6, the dark grey portions 51 indicate locations for attaching mounting elements, e.g. 1843, 1844; 1853, 1854; 1863, 1864 (see FIG. 5, 5A). The light gray portions 52 indicates areas where a space 11S (see FIG. 5, 5A) is formed to allow movements of the ends 184, 185, 186 of the suspension arms 181, 182, 183 and their end portions 1841, 1842, etc. coupling them to these connection elements. Also the other sections of the yoke, i.e. the base section and the top section can be provided as a single patterned block of a soft ferromagnetic material.

[0043] As shown in FIG. 7, also the membranes 18a, 18b, . . . of actuators 1a, 1b are integrally formed, in this cases as a single patterned plate 60 of a resilient, non-magnetic material. Therewith amounting element of a membrane 18a of an actuator is shared with membranes of other actuators.

[0044] FIG. 8 shows how these components 50, 60 are stacked when constructing an actuator assembly. For illustration purposes only a portion of the patterned plate 60 is shown, to reveal the clock 50 of soft-ferromagnetic material below.

[0045] As noted above, also the other sections of the yoke, i.e. the base section and the top section can be provided as a single patterned component. Therewith the assembly process of an actuator assembly can be strongly simplified.

[0046] In an embodiment, a single actuator as shown for example in FIGS. 2 and 3 is manufactured as follows. In first steps a base yoke section 10a, an intermediate yoke section 10b and a top yoke section 10c are provided, each of a soft-ferromagnetic material. Also a first and a second membrane 18, 19 of an at least substantially non-magnetic material is provided. Furthermore, a core element 17, a permanent magnet 20 an electromagnetic coil 16 are provided. The electromagnetic coil 16 is mounted in the base yoke section 10a or in the top yoke section 10c. The base yoke section 10a with the first membrane 18 is mounted against the intermediate yoke section 10b. Hence the first membrane 18 is accommodated between the base yoke section and the intermediate yoke section 10b. In a preceding step, the first membrane 18 may first be adhered to one of the base yoke section and the intermediate yoke section.

[0047] The permanent magnet 20 is mounted against an inner wall of the intermediate yoke section 10b, so that a first magnetic pole thereof faces the inner wall and a second magnetic pole facing inwards. The core element 17 is inserted in a remaining inner space of the intermediate yoke section 10b. The upper yoke section 10c with the second membrane 19 against the intermediate yoke section 10b. Hence the second membrane 19 is accommodated between the top yoke section and the intermediate yoke section. In a preceding step, the second membrane 19 may first be adhered to one of the top yoke section and the intermediate yoke section. In this example the actuator is assembled in a direction from the base to the top. Alternatively the actuator may be assembled in a direction from the top to the base.

[0048] As noted, parts of actuators in an actuator array may be provided integrally, for example as shown in FIGS. 6, 7 and 8. In that case manufacturing of an actuator array may take place as follows. A respective electromagnetic coil 16 for each actuator in the actuator array is mounted in the block of soft-ferromagnetic material forming the base yoke sections (base block) or in the block of soft-ferromagnetic material forming the top yoke sections (top block). The patterned plate of a resilient material forming the first membranes (first patterned plate) is attached to the base block or to the block of soft-ferromagnetic material forming the intermediate yoke sections (intermediate block). Then the base block, the first patterned plate and the intermediate block are assembled. A respective permanent magnet is mounted in a proper opening for each actuator in the intermediate block. Furthermore a proper core element for each actuator is inserted in the remaining inner space. Then the subassembly so obtained is further assembled with a second patterned plate forming the second membranes and the top block. Alternatively, the assembly may take place in a top down order.

[0049] In some embodiments, as shown schematically in FIG. 9A, the at least one permanent magnet fixed 20 that is accommodated in the intermediate yoke section 10b is a single cylindrical magnet with its first magnetic pole (e.g. a northpole N) facing radially outward towards the inner surface of the cylindrical wall 11b of the intermediate yoke section 10b.

[0050] In other embodiments, shown schematically in FIG. 9B, a cylindrical magnet with its first magnetic pole N facing radially outward is formed by a set of magnet components 20a, b, c, d that each are arranged with their first magnetic pole N facing outward. By way of example it is shown in FIG. 9C that magnet component(s) do not need to form an uninterrupted ring inside the intermediate yoke section. It will be appreciated that the first magnetic pole of a magnet 20 or magnet component 20a, . . . ,20d is not necessarily the northpole N. However, a plurality of magnet components in an intermediate yoke section 10b should mutually have the same pole facing outwards, e.g. their northpole N as shown in FIG. 9B or the southpole S as shown in FIG. 9C.

[0051] In some embodiments of the actuator array, each intermediate yoke section bounds to at least one other intermediate yoke section having a permanent magnet with opposite polarity. In some examples for each intermediate yoke section at least two out of three neighboring intermediate yoke section have a permanent magnet with opposite polarity. This is illustrated in FIG. 9D, wherein the character “N” indicates that the northpole of the at least one magnetic element faces outward in the intermediate yoke section, and the character “S” indicates that the southpole of the at least one magnetic element faces outward in the intermediate yoke section. In the example of FIG. 9D, the intermediate yoke section 10b1 bounds to four intermediate yoke sections 10b2, 10b3, 10b4, 10b5 having a permanent magnet with opposite polarity.

[0052] In this embodiment wherein intermediate yoke section bound to one or more other intermediate yoke section having a permanent magnet with opposite polarity it is achieved that the net magnetic flux in the yokes is substantially cancelled. Therewith a saturation of the yoke can be more easily avoided and in some cases the wall of the yokes can be thinner than otherwise would be the case.