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fully edited. Content may change prior to final publication. Citation information: DOI
10.1109/TMAG.2015.2435817, IEEE Transactions on Magnetics
AU-14
Index Terms Magnetic gears, contactless coupling, ferromagnetic pole pieces, 3D printing.
I. INTRODUCTION
It is known that magnetic gears have been widely
developed due to their contactless property and potential
benefits, such as low acoustic noise, low vibration, and
overload protection [1]-[5]. The vast majority of literature
about magnetic gears was presented in the last decade and
primarily focused on the radial-field topology of magnetic
gears (RFMGs). In 2005, Mezani proposed an axial-field
topology for magnetic gears (AFMGs) that is suitable for
hermetically isolated systems [6]. In order to improve AFMG
performance, Acharya investigated an AFMG design with
magnets arranged in a flux focusing configuration [7]. For the
application of contactless coupling, AFMGs are more
applicable than RFMGs because of the assembly difficulty
[8]-[9]. However, AFMG design faces the challenges of high
cost resulting from the magnetic material and the
complications in the assembly process of the 3D pole-piece
shapes. This paper investigates a novel AFMG design that
uses L-type ferromagnetic pole pieces and ferrite magnets
with spoke-type magnet arrangement to reduce the flux
leakage as well as increase the flux in the air gap. The AFMG
structure is composed of numerous parts with configurations
that will be difficult to fabricate using traditional methods.
Therefore, a newly developed 3D printing process is employed
to overcome the fabrication difficulty of the proposed model,
reduce the waste material from machining, and assemble parts
precisely without screws.
II. MODEL DESIGN
The proposed AFMG is illustrated in Fig.1, and the
structure includes a high-speed rotor, a low-speed rotor, and a
stationary ring. The high-speed rotor and the stationary ring
are comprised of permanent magnets, while the low-speed
rotor is composed of ferromagnetic pole-pieces. The pole
directions of the magnets and the L-type ferromagnetic polepieces used to reduce the flux leakage are indicated in Fig.2.
The design criterion of the magnetic gear, which can also
function as a mechanical gear, is based on the total number of
P1 pole-pair permanent magnets (PMs) on Rotor 1 rotating at
1, P3 pole-pairs PMs on Rotor 3 rotating at 3, and N2
P3
N2
2
3 .
N2 P3
P3 N2
(2)
Gr
where
N2
,
N2 P3
(3)
stationary ring
(Rotor 3)
low-speed rotor
(Rotor 2)
high-speed rotor
(Rotor 1)
steel poles
L-type
ferromagnetic
pole-pieces
stationary
ring
magnets
high-speed
rotor
magnets
steel poles
low-speed
rotor
0018-9464 (c) 2015 IEEE. Personal use is permitted, but republication/redistribution requires IEEE permission. See
http://www.ieee.org/publications_standards/publications/rights/index.html for more information.
This article has been accepted for publication in a future issue of this journal, but has not been fully edited. Content may change prior to final publication. Citation information: DOI
10.1109/TMAG.2015.2435817, IEEE Transactions on Magnetics
AU-14
Cf
2 PN2
,
Ns
(4)
8l1s P1
,
C1
( Rout Rin )
flux leakage
(5)
where Rout, Rin, l1s, and P1 are the outer radius, inner radius,
thickness of Rotor 1, and pole pairs on Rotor 1, respectively.
Similarly, the flux focusing ratio of Rotor 3 is given by
C3
8l3s P3
,
( Rout Rin )
Rotor 3
(6)
where l3s and P3 are the thickness of Rotor 3 and pole pairs on
Rotor 3, respectively.
Thus, the flux density of pole-steels on both Rotors 1 and 3 are
expressed respectively as
Bg1 C1 Bm1
(7)
Bg3 C3 Bm3 ,
(8)
and
where Bm1 and Bm3 are the flux density of magnets on both
Rotors 1 and 3, respectively. From (7) and (8), the parameters
of the magnet rings can be designed based on the material
characteristics of pole-steels to prevent saturation.
Position 1
Fig.5 Operation point along radius position
axial
flux
axial
flux
Rout
Rin
rotor 3 3
Rotor
Rotor 2
Rotor 1
Rotor 3
radial
flux
Fig.6 L-type ferromagnetic pole-pieces
0018-9464 (c) 2015 IEEE. Personal use is permitted, but republication/redistribution requires IEEE permission. See
http://www.ieee.org/publications_standards/publications/rights/index.html for more information.
This article has been accepted for publication in a future issue of this journal, but has not been fully edited. Content may change prior to final publication. Citation information: DOI
10.1109/TMAG.2015.2435817, IEEE Transactions on Magnetics
AU-14
3
TABLE I
AFMG SPECIFICATIONS
Index
PM material
Pole-steel material
Pole-piece material
Pole pairs on Rotor 1 (P1)
Pole pairs on Rotor3 (P3)
Number of pole-pieces on Rotor 2 (Ns)
Outer radius (Rout)
Inner radius (Rin)
Thickness of Rotor 1 (l1s)
Thickness of Rotor 3 (l3s)
Thickness of Rotor 2 (l2s)
Air gap between Rotor 1 and 2
Air gap between Rotor 2 and 3
Quantity
Ferrite (Y30)
low carbon steel
low carbon steel
6
19
25
100
40
22
15
8
4
3
Unit
mm
mm
mm
mm
mm
mm
mm
Note that the solid low carbon steel used in this prototype will
cause eddy current losses according to the 3D FEM analysis
result as shown in Fig.10. The lamination steels or soft
magnetic composite can be adopted to improve the
performance of the proposed AFMG, but the manufacturing
process would become complex. Currently, a high
permeability soft magnetic composite powder dedicated to 3D
printing has been developed in our study to achieve the needed
3D structure.
pole-steel
Ag1
Ag 2
IV. RESULTS
Rotor 3
rotor
0.5
Pc Bmin(without L-type)
Pc Bmax(without L-type)
Pc Bmin(with L-type)
Pc Bmax(with L-type)
demagnetize curve
0.45
0.4
0.35
Rotor 1
0.2
0.15
0.1
0.05
0
-0.45
-0.4
-0.35
-0.3
-0.25
-0.2
u0H (T)
-0.15
-0.1
-0.05
high speed
rotor
high speed
rotor
low speed
rotor
low speed
rotor
4
Torque (Nm)
B (T)
0.3
0.25
pole-steel
ferrite
magnet
3D printed prop
-4
-6
0
0.05
0.1
0.15
0.2
0.25
0018-9464 (c) 2015 IEEE. Personal use is permitted, but republication/redistribution requires IEEE permission. See
http://www.ieee.org/publications_standards/publications/rights/index.html for more information.
This article has been accepted for publication in a future issue of this journal, but has not been fully edited. Content may change prior to final publication. Citation information: DOI
10.1109/TMAG.2015.2435817, IEEE Transactions on Magnetics
AU-14
4
structure, making the fabrication a huge challenge. To remedy
this, this study employed a 3D printing technology. The
prototype is fabricated to demonstrate the feasibility of the 3D
printing approach. Due to the simplicity of experiment, we
only adopted the ferrite magnets to verify the feasibility and
compare the experimental result with that of its simulation.
magnet on Rotor 3
magnet on Rotor 1
shaft
[1]
[2]
[3]
3D printed prop
L-type ferromagnetic pole-pieces
[4]
[5]
[6]
[7]
bar
(linked Rotor 2)
fixed bar
(linked Rotor 1)
[8]
Rotor 3
(stationary permanent magnet ring)
Rotor 1
(high speed rotor)
Rotor 2
(low speed rotor)
[9]
V. CONCLUSIONS
This paper has proposed a novel AFMG design with L-type
ferromagnetic pole-pieces, which cannot only decrease the
flux leakage, but also improve the torque density. However,
the proposed AFMG is inherently a three-dimensional
[10]
0018-9464 (c) 2015 IEEE. Personal use is permitted, but republication/redistribution requires IEEE permission. See
http://www.ieee.org/publications_standards/publications/rights/index.html for more information.