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Coaxial Magnetic Gear Analysis

Conference Paper October 2014

DOI: 10.13140/RG.2.1.3786.3848

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3rd The International Conference on Renewable Energy Research and Applications 19-22 Oct 2014 Milwakuee-USA

axial Magnetic Gear Analysis and Optimization

Coaxial

C.G.C Neves ly Ferreira Flores

GMSC/EERA - Fundao Universidade Federal do Pampa LME - UFRGS
Bag - Brazil Porto Alegre - Brazil
carlosneves@unipampa.edu.br aly.flores@ufrgs.br

Abstract In this paper the CMG working principle is [7]. In view of the coaxial structure, the CMG can be
explained with help of Finite Elements Method (FEM) and artfully integrated with a high high-speed outer-rotor PM
Fast Fourier Transform (FFT). A parametric study is
performed to determine how the modulators dimensions brushless machine to constitute a composite electrical
affect the pull-out
out torque. An optimization procedure is machine named as the magnetic
magnetic-geared permanent-magnet
applied to maximize the pull-out torque. (MGPM) machine, which can achieve low low-speed high-
torque driving while providing high torque density. The
KeywordsMagnetic
Magnetic gear; FEM; permanent magnet. MGPM machine has attracted wide attention for
I. INTRODUCTION application to wind power generation and direct-drive
electric vehicles [12, 13].
Gears and gearboxes are extensively used for speed In this paper the CMG working principle is explained
change and torque transmission in various industrial with help of Finite Elements Method (FEM) and Fast
applications. It is well known that the mechanical gear hasha Fourier Transform (FFT). This means, the flux densities
a high torque density, but suffers ers from some inherent waves in both gaps are obtained by FEM and its harmonics
problems such as contact friction, noise, and heat, while spectrum it is obtained by FFT to explain the modulation
vibration and reliability
lity are of great concern. In contrast, phenomena which plays the fundamental hole in its
the magnetic gear (MG) offers significant cant advantages of behavior. A Parametric sweep study is performed to define
reduced vibration and noise,, free maintenance, better how the modulators dimensions affect the pull pull-out torque
reliability, inherent overload protection, and non contact and after that a Quasi Newton optimization procedure
between shafts. Moreover, for many years,years MGs have got which automatically changes the modulators dimensions to
relatively little attention, probably due to the low torque meet the maximum pull-out out torque is applied. The main
density and relative magnetic complexity [1, 2]. contribution of this paper is to show the CMG modulators
The idea of MGs can be tracked down to the beginning behavior in a clear and detailed way in order to realize the
of the 20th century. In 1913, a US Patent Application design optimization.
described an electromagnetic gearing which should be the
original topology [3], but almost no one was interested in it
at that time. Until a MG topology quite similar to a
mechanical spur gear was proposed by Faus in 1941 [4],
people gradually paid attention to MGs. However,Ho low
utilization and poor performance of ferrite permanent
magnet (PM) material made it impossible to be widely used
performance neodymium iron
in industry. Until the high-performance
nvented in the 1980s, the
born (NdFeB) PM material was invented
research on MGs arousedd great interests again. Naturally,
the earlier MG topologies were converted from mechanical
gear topologies. These converted MGs simply replaced the
slots and teeth of iron core by N-poles
poles and S-poles
S of PMs,
respectively. The low utilization of PMs was the t key
problem which caused poor torqueorque density.
In 2001, Atallah and Howe proposed a high-performance
high Figure 1. Coaxial
axial magnetic gear
gear.
MG named as the coaxial magnetic gear (CMG), whose
principle of operation was based on the magnetic II. OPERATION PRINCIPLE
modulation produced by two PM rotors via the The CMG shown in Fig. 1 comprises three components:
ferromagnetic pieces [5, 6]. Unlike the converted
onverted MGs, the
1. A high speed inner rotor composed of eight
CMG has a higher torque density, because all the PMs
simultaneously contribute to torque transmission. Based on pole-pairs, pin 4 ).
permanent magnets (four pole
the field
eld modulation principle, many improved CMG 2. A low speed outer rotor composed of twenty
topologies are invented to further obtain a better efficiency pole-pairs, pout 10 ).
permanent magnets (four pole

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3. A magnetic steel modulator putted between the
two rotors, which creates a square-wave
modulation function (number of pole pieces,
n p 14 ).
The relation between the above variables above can be
summarized by:
p in in + p out out = n p p
Generally, the electromagnetic field of an electric
machine is governed by Maxwells equation:
A J (5)
Where is the reluctivity, J is the current density and
A is the magnetic vector potential. Ignoring the end effect
in the machine, (5) can be solved in two dimension (2-D)
(1) electromagnetic field:

Where, in is speed of inner rotor, out is speed of the

A A
outer rotor, p is the speed of modulator. : J PM (6)
x x y y
When one of the three parts of the gear is stationary,
there will be a constant gear ration between the other two S1 : A 0 (7)
parts. For example when the modulators are stationary (
p 0 ), the gear ration between the inner and outer rotors Where is the field solution region, A is the z-axis
is: components of vector potential A and J PM is the
equivalent surface current density of PMs, and S1 is the
p out
Gr = (2) machine periphery.
p in Neglecting the eddy current in both iron core and PM,
the field equations of different regions in the CMG
And the rotors are rotating in opposite directions. The
machine become:
electromagnetic torque developed on the inner rotor and
outer rotor can be obtained by Maxwell stress tensor in the
inner air gap and outer rotor, respectively: Air-gap and iron core:

A A
Lef Rin2 0 (8)
x x y y
2
Tm _ in
0 0
Br _ in B _ in d (3)
Permanent magnets:

2
Lef Rout 2 A A B ry B rx
(9)
Tm _ out = Br _ out B _ out d (4) x x y y x y
0 0

Where B rx and B ry are the x-axis and y-axis

where Lef is the effective axial length, Br _ in is radial
flux density in inner air gap, Br _ out is radial flux density in
outer air gap, B _ in is tangential flux density in inner air
gap, B _ out is tangential flux density in outer air gap, Rin
components of the PM remanent flux density, respectively.
Secondly, with the value of magnetic vector potential A ,
the x-axis component B x and y-axis component B y of the
flux density can be easily deduced as:

radius of inner air gap, Rout radius of outer air gap and 0 A
Bx (10)
air permeability. y
It can be proved that the product Br _ in B _ in and the
A
product Br _ out B _ out contribute to the average By (11)
x
electromagnetic torque in inner and outer rotor,
respectively, if it satisfies these rules:
Further, for the nodes in the air-gaps, Br and B can be
Rule 1 - Br _ in and B _ in have equal number of calculated with respect to angle between x-axis and the
poles and different phase angles; tangent on this node as:
Br B x cos B y sin (12)
Rule 2 - Br _ out and B _ out have equal number of
poles and different phase angles;
B B x sin B y cos (13)
III. STATIC ANALYSIS BY FINITE ELEMENTS
In order to understand the CMGs working principle is Figure 2 shows that the radial flux density in outer air
interesting to get the field density in air gap near to outer gap is almost a four-pairs sine wave with some harmonic
magnets (outer air-gap) with only the inner PMs presents, content due magnetization of the curved magnets. The
the outer PMs and the modulating rotor are putted of. spatial harmonic spectrum of this magnetic field, which is

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shown in Fig. 3 clearly shows that the field has 4 pole-pairs
( pin = 4 ), besides some minor harmonic content.
Figure 2. Radial field density at outer air-gap due to the inner magnets
only, without modulating rotor.
shows the respective harmonic content. Figure 12 shows
the flux density tangential component at outer air-gap,
while Fig. 13 shows the respective harmonic content. It is
visibly at inner air-gap for both flux density components,
that the 4-pole-pair is the fundamental harmonic and the
10- pole-pair is the supporting one, while at outer air-gap
for both flux density components, the 10-pole-pair is the
fundamental harmonic and the 4-pole pair is the supporting
one. The stationary pieces actuate as a modulator to change
pole pairs between inner and outer gaps. The 4-pole-pair
magnetic flux created by the high speed rotor becomes 10-
pole-pair in the low speed rotor due to the modulation
effect of the steel modulators. Conversely, the 10-pole-pair
flux created by low speed rotor becomes 4-pole-pair in the
low speed rotor due to the modulation effect of the steel
modulators.

Figure 4. Radial field density at outer air-gap due to the inner magnets
only, with modulating rotor.

Figure 3. Radial field density harmonic content at outer air-gap due to

the inner magnets only, without modulating rotor.

If the modulators are putted, the magnetic flux density

from inner rotor is modulated such that a spatial harmonic
with the same number of poles as the outer rotor is created,
this means, n p pin 10 , as shown in Fig. 4. This
harmonic is not synchronous since it rotates at a different
speed from the original rotor.
This is shown in Fig. 5, it can be clearly seen that in
addition to the harmonic with p in pole-pairs ( pin = 4 ),
another harmonic is created with p out pole-pairs ( Figure 5. Radial field density harmonic content at outer air-gap due to
p out = 10 ), which will interact with the outer rotor to the inner magnets only, with modulating rotor.

transmit torque. Because the harmonic with p in pole-pairs

moves at a different speed than the harmonic with p out
pole-pairs, there exists a torque transmission between both
rotors similar to a mechanical transmission but without
contact.
If the calculation is performed with the CMG complete,
this means, with the outer magnets, it is possible to observe
the influence of both permanent magnets arrays in both air-
gaps. Figure 6 shows the flux density radial component at
inner air-gap, while Fig. 7 shows the respective harmonic
content. Figure 8 shows the flux density tangential
component at inner air-gap, while Fig. 9 shows the
respective harmonic content. Figure 10 shows the flux
density radial component at outer air-gap, while Fig. 11 Figure 6. Radial field density at inner air-gap with CMG complete.

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Figure 7. Radial field density harmonic content at inner air-gap with

CMG complete. Figure 11. Radial field density harmonic content at outer air-gap with
CMG complete.

Figure 12. Tangential field density at outer air-gap with CMG complete.
Figure 8. Tangential field density at inner air-gap with CMG complete.

Figure 13. Tangential field density harmonic content at outer air-gap with
CMG complete.
Figure 9. Tangential field density harmonic content at inner air-gap with
CMG complete. This modulation phenomenon is clearly observable in the
flux line distribution of the CMG, shown in Fig. 14.

Figure 10. Radial field density at outer air-gap with CMG complete. Figure 14. Flux line distribution in the CMG.

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It can observed 8 poles in inner air-gap

gap and 20 poles in
outer air-gap.
gap. It can be observed that a large part of flux-
lines can pass through the two air gaps. This part of flux-
flux
lines contributes to the torque transmission. There are also
some flux leakages between adjacent poles.
poles These leakage
flux-lines do not contribute for transmitting torque or
power, and generate losses.
Besides the modulation phenomena responsible for the
torque transmission, it is also important to consider the
torque ripple, since this decreases the performance. Torque
ripple or cogging torque is caused by the interaction of the
rotor PMs with the steel pole-pieces.
By calculating the Maxwells stress tensors in the outer
and inner air-gap,
gap, the cogging torque and the gear ratio of
Figure 17. Harmonic content of magnetic torque at inner gap
gap.
the CMG can be determined: The static torque on inner gap
is obtained, as shown in Fig. 15, holding the outer rotor
rot The magnetic torque on outer gap is obtained, as shown
static and rotating the inner rotor step by step through the in Fig. 18,, holding the outer rotor still and incrementally
movement band shown in Fig. 16. Figure 17 shows that the rotating the inner rotor step by step through the movement
fundamental harmonic has 4- pole-pairpair number, this agrees band shown in Fig. 19. Figure 20 shows that the
with Rule 1, since Br _ in and B _ in have the same fundamental harmonic has 10 10- pole-pair number, this
fundamental 4-pole-pair
pair number and a phase shift of 180 agrees with Rule 2, since Br _ out and B _ out have the same
degrees, according figures 7 and 9. The cogging torque fundamental 10-pole-pair
pair number and a phase shift of 180
harmonic is equal to 56,, this means, the smallest common degrees according
ng figures 11 and 13.
multiple between the poles of inner rotor, 2 pin 8 , and the
number of ferromagnetic pole-pieces, n p 14 .

Figure 15. Magnetic torque on inner gap througout a complete revolution. Figure 18. Magnetic torque on outer gap througout a complete revolution.

Figure 16. Moviment band used to calculate the torque on inner gap Figure 19. Moviment band used to calculate the torque on outer gap.

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3rd The International Conference on Renewable Energy Research and Applications 19-22 Oct 2014 Milwakuee-USA

Figure 22. Pull-out torque at outer gap versus superior arc-length.

Figure 20. Harmonic content of Magnetic torque at outer gap.

The torque ripple harmonic is equal to 140, this means,

the smallest common multiple between the poles of outer
rotor, 2 pout 20 , and the number of ferromagnetic pole-
pieces, n p 14 . The higher the fundamental order, the
lower the harmonic magnitude is resulted. Thus, the
cogging torque on the high speed rotor is more obvious
than that on the low speed rotor. It can be visualized that
the torque versus angle curves have a sinusoidally shape, in
which the maximum torque values represent the pull-out
torques. On the inner-rotor and the outer-rotor, the pull-out Figure 23. Pull-out torque at outer gap versus inferior arc-length.
torques is 2.3 Nm and 5.7 Nm, respectively. Their gear
ratio is 1:2.47, which has a good agreement with the ratio
of pole-pair numbers of two rotors that equals 1:2.50.
However, there is a 180 degrees phase shift between the
phase angles of two waveforms. This means that the rotors
will rotate in opposite directions, which is in accordance
with mentioned in Section II.
IV. PARAMETRIC SWEEP STUDY
As shown in Fig. 19, the dimensions of the modulator are
the nominated are superior arc-length ( s ), inferior arc-
Figure 24. Pull-out torque at outer gap versus height.
length ( i ) and the height in radial direction ( h ). Figures
V. OPTIMIZATION STUDY
20, 21 and 22 shows the pull-out torque variation in
relation to s , i and h , respectively. One can notice that In this section a optimization procedure based on Quasi-
the pull-out torque is more sensitive to h than the other Newton which automatically changes s , i , h to achieve
two parameters. the maximum pull-out torque is applied. Figure 23 shows
the cust function variation per iteration.

Figure 25. Cust function versus iteration.

The highest value of cust function obtained was -6.06,

Figure 21. Modulator dimensions. corresponding to h =10.0 mm, i = 5.12 mm and s = 7.57

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mm for iteration 84. The pull-out torque in outer gap algorithm," Progress In Electromagnetics Research, Vol. 116, 297-
312, 2011.
obtained for theses parameters was 5.6 Nm, the respective
torque curve was shown in Fig 18.

VI. CONCLUSION
In this paper, the operating principle of coaxial magnetic
gear has been elaborated. By analyzing the field
distribution in the two air gaps, it can be found that the
stationary ring could modulate the magnetic fields
produced by the PMs on the two rotors, such that specific
space harmonics with different space pole-pair numbers
and different rotational speeds could contribute to the
stable torque transmission when the rotors rotations are
governed by the gear ratio given by (2). In addition, those
harmonics which will create torque ripples have also been
identified. A parametric study was performed to detect the
influence of modulators dimensions. An optimization
procedure calculated the parameters dimensions which give
the maximum pull-out torque.

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