Multilayered microcoils are of great importance for the development of advanced electromagnetic microactuators and especially important to develop high sensitivity microsensors and magnetic field neural stimulators for medical applications. A clean room-free procedure for manufacturing multilayered micrometric coils is presented in this work. The production of miniaturized multilayered coils from tens to hundreds of micrometres long is demonstrated. The microcoils have outer diameters ranging between 150 and 300 µm, arrangements of up to 5 consecutive layers, and an average fill factor of 85%. This means 3 times smaller diameters than the smallest diameter ever achieved by winding techniques while keeping a high fill factor and a large number of layers. Such small and highly performant microcoils have never been demonstrated neither by winding processes nor epitaxial growth techniques. These microcoils were tested inside different human body-like environments. Maximum current density vs. temperature was measured in air, fat tissue, muscle tissue and simulated body fluid at 36 °C. A maximum current density of 3600 A/m 2 has been measured before coil failure. Experiments demonstrated that current densities up to 610 A/m 2 can safely be supplied to coils without risk of harm to internal tissues. These counterintuitive values are orders of magnitude larger than typical current densities used in macroscale actuators windings. 1
Satellites with cryogenic instrumentation have great potential for military, commercial, and scientific space missions due to the increased sensitivity of their sensors, even for Low Earth Orbit (LEO) missions. For these missions, magnetorquers are a common electromagnetic actuation solution for controlling the attitude and orientation of the satellite. As for any other component of a satellite, the optimization of power consumption and weight is always beneficial for the design. In this work, we propose a novel idea to reduce power consumption during magnetorquer operation: installing the magnetorquer in the cryogenic area of the satellite, instead of installing an actuator in the hot area. As the electric resistivity of the wire is greatly reduced, power consumption is also reduced. However, the heat generated in the magnetorquer, even if lower, must still be dissipated by the cryocooling system, which has an additional energetic cost. The cryogenic temperature range where this effect is beneficial, and the amount of power saved, was determined as a function of different cryocooler technologies’ efficiency and the purity of the copper wire material. It is analytically demonstrated that the operation of the magnetorquer in a temperature range from 10 to 40 K could save energy with respect to operation at 300 K if the copper wires have a residual resistance ratio larger than 200 RRR. A prototype magnetorquer suitable for cryogenic temperatures was manufactured and tested at liquid nitrogen temperature, 77 K, to experimentally demonstrate the variation in the energy consumption. The magnetorquer comprised an iron core with copper wire winding that achieved 1.42 Am2 by applying 0.565 W at 0.5 A. When operating submerged in liquid nitrogen at a temperature of 77 K, the power used by the magnetorquer was reduced by eight times due to the change in electrical resistivity.
A novel concept of a rotary electromagnetic actuator for positioning with ultra-low power consumption is presented. The device is based on harnessing potential magnetic energy stored between permanent magnets facing each other with opposing magnetization polarities. When combined with an active electromagnetic control and passive stabilization system, the rotor of the device can switch between stable equilibrium positions in a fast way with a minimal fraction of the power and energy consumption of a traditional electromagnetic actuator. In this paper, a theoretical model, supported by finite element analysis results, is presented. The actuator has been designed in detail to operate as an optical filter wheel actuator. Calculations demonstrate that the device has the potential to provide a power-consumption saving of up to 86.6% and an energy consumption reduction of up to 58.6% with respect to a traditional filter wheel actuator.
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