Recent Developments in Permanent Magnet Gear Systems & Machines

Recent Developments In
Permanent Magnet
Gear Systems & Machines
Gareth P Hatch, PhD CEng FIMMM

Director of Technology
Dexter Magnetic Technologies, Inc.
Presented at the Magnetics 2010 Conference

held in Lake Buena Vista, Florida, USA, in January 2010
Copyright 2010 Gareth P Hatch. All Rights Reserved.
This paper was downloaded from Terra Magnetica, an independent online

resource for information and commentary on magnetics & permanent
magnets - covering materials, applications, technologies, sourcing issues,
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Gareth Hatch
About the Author

Gareth Hatch is Director of Technology at Dexter Magnetic Technologies, a world leader in the
design, engineering & manufacture of magnetic devices for clients in the aerospace, defense,
medical, data storage, oil & gas, renewables and industrial sectors. He holds five US patents on a
variety of magnetic devices. Gareth is based at Dexters headquarters in the suburbs of Chicago,
USA.
Gareth is particularly interested in the strategic challenges faced by the permanent magnet industry
and its supply chain. This includes the growing demand for rare earth elements and other
technology metals, particularly in the areas of renewables and electric vehicles.
Gareth has a B.Eng. with Honours in Materials Science & Technology and a Ph.D. in Metallurgy &
Materials, both from the University of Birmingham in the UK. He is a Fellow of the Institute of
Materials, Minerals & Mining, a Chartered Engineer, a Senior Member of the IEEE and a Member
of ASTM Committee A06 on Magnetic Properties. Gareth is also a Chartered Scientist and a
Chartered Physicist through the Institute of Physics, of which he is a Member.
Gareth is Founding Editor of Terra Magnetica (www.terramagnetica.com), Editor-in-Chief of
RareMetalBlog (www.raremetalblog.com) and is Newsletter Editor & Chicago Chapter Chair of the
IEEE Magnetics Society. He is a Member of the UK Magnetics Society and is Founder of the
Magnetism & Electromagnetics Interest Group and Strategic Materials Network (both at Linkedin).
Magnetics Conference 2010
Recent Developments
In Permanent Magnet
Gear Systems & Machines
Dexter Magnetic Technologies Inc.
Elk Grove Village, Illinois - USA
http://www.dextermag.com
January 28, 2010
1
Outline
Overview of mechanical gearing

Benefits of magnetic gear systems
Historical overview of magnetic gears
Recent developments in magnetic gears
Low gearing ratio systems
High gearing ratio systems
Integrated gear electric machine systems

Potential applications of magnetic gearing
Final thoughts
2
Dexter Magnetic Technologies
Design & manufacture of magnetic devices

Permanent magnets and electromagnets
Components, assemblies & control systems
0.1 grams o 10 tonnes
0 T o 3.5 T
Outline

Historical overview
Recent developments in magnetics gears

Final thoughts
4
Primary purpose: speed torque conversion

Rotating input power source (typically)
Increase or decrease input speed
Increase or decrease input torque
Examples
Automobile: reduce speed / increase torque
Wind turbine: increase speed / decrease torque
A form of power conversion

Torque (Nm) x RPM (s-1) = power (Nms-1 = Js-1 = W)
5
Specific conversion depends on gear ratio

Circumference and number of teeth of gears
Number of gears and stages
Variety of gear topologies

Spur gears
Planetary gears
Bevel gears
Worm gears
Helical gears
Etc.
6
Variety of gear topologies
Key drawbacks
Friction, wear and tear gears are in contact
Only a few teeth mesh at any one time
Rated torque less than peak avoid fatigue issues
Require lubrication and maintenance
Shafts require seals
Failures tend to be catastrophic
Noise
Outline


Other considerations
9
Several reasons for consideration

Non-contact elements no friction between gears
Highly efficient multiple magnetic poles engaged
Utilization of peak torque
Input and output shafts can be isolated
Increased temperature range no elastomeric seals
Inherent overload protection
Increased tolerance of misalignment
More detail on best in class devices later
10
Outline


Other considerations
11
Armstrong: US Pat. 687,292 (1901)

Magnetic spur gear
Used magnetized coils
12
Neuland: US Pat. 1,171,351 (1916)

Magnetic planetary gear
Used magnetizing coils
Variable gear ratios
From Joergensen et al (2003)
13
Faus: US Pat. 2,243,555 (1941)

Magnetic spur gears
14
Reese: US Pat. 3,301,091 (1967)

Input rotor with mounted permanent magnet
Outer rotor - iron or steel
50:1 gear ratio
15
Martin: US Pat. 3,378,710 (1968)

Magnetic planetary gear & parallel shaft variations
16
Laing: US Pat. 3,645,650 (1972)

Magnetic planetary gear variations
17
Hetzel: US Pat. 3,792,578 (1974)

Magnet spur gear
18
Mabe: US Pat. 5,013,946 (1991)

19
Kikuchi & Tsurumoto (1993)

Magnetic worm gear variations
20
10
Yao et al (1996)
Magnetic bevel gear variations
21
Furlani (1997)
Calculated torque & efficiencies for radial 1:1 gears
22
11
Ackerman & Honds: US Pat. 5,633,555 (1997)

Magnetic planetary gears problem with short circuiting
23
Ackerman: US Pat. 5,994,809 (1999)

Improved magnetic planetary gear variation
Steel on the outside
24
12
Outline


Final thoughts
25
Key publication: Atallah & Howe (2001)

Innovation: slotting the intermediary pole pieces
Very significant torque per volume
26
From Infolytica Corporation
13
Key publication: Atallah & Howe (2001)

4 pole pairs on high speed inner rotor
22 pole pairs on low speed outer rotor
26 intermediary pole pieces
Produces 5.5:1 gear ratio
Predicted 100 Nm / l torque density
> single-stage mechanical gearbox
27
Direction of rotation can be chosen

Standard approach: fix the intermediary
Inner & outer rotate in opposite directions
28
from Frank & Toliyat (2009)
14
Direction of rotation can be chosen

Alternative approach: fix the outer or inner
Other magnets & intermediary rotate in same direction
29
from Frank & Toliyat (2009)
Experimental work by Rasmussen et al (2003)

First practical example of built device
Used 5.5:1 ratio but simplified inner magnets
30
15
Experimental work by Rasmussen et al (2003)

Encountered various mechanical issues
Noted significant end effects & reduced efficiency
Still comparable to mechanical gearboxes
31
Experimental work by Atallah et al (2004)

Prototyped a 5.75:1 ratio magnetic gear device
Used laminated pole pieces to reduce eddy currents
Measured 97% efficiency in speed-torque conversion
Produced over 70 Nm / l torque density
Superior to transverse field PM electrical machine
32
16
Linear variations also possible

Simulations completed by Atallah et al (2005)
Used 3.25:1 ratio
Calculated 1.7 kN / m force density
Superior to linear motors
33
Variation: face-to-face gear by Mezani et al (2006)

Analogous to pancake synchronous magnetic coupling
Calculated up to 70 Nm / l torque density
34
From Asia-Pacific Engineer Magazine (2009)
17
Outline


Final thoughts
35
Cycloidal gears promising for high ratios

Elimination of intermediary pole pieces
Increase diameter / number of pole pairs
Can be hard to visualize
From Davey et al (2008)

36
18
Joergensen et al (2006)
Cycloidal / eccentric motion + more pole interactions
Depending on element fixed: 22:1 or 21:1 ratio
Initial prototype produced 142 Nm / l torque density
Optimized simulation produced 183 Nm / l model
37
Rens et al (2007): magnetic harmonic gear

Analogous to mechanical harmonic gear
Calculated ratios of 210 to 860:1 in two stage gear
Calculated 110 Nm / l torque density ripple-free
Utilizes flexible rotor assembly limited practicality
38
From Wikimedia Commons
19
Atallah: WO 2007/144556 (2007)

Cycloidal gear [referred to as rigid harmonic gear]
Detailed by Rens et al (2009)
Calculated 150 Nm / l for 20:1 magnetic gear
Calculated 75 Nm / l for 360:1 two-stage magnetic gear
39
From Rens et al (2009)
Outline


Final thoughts
40
20
Combine magnetic gear with electrical machine

Significant area of current focus
Leads to best-in-class electromagnetic machines
Suitable for generators and motors
41
Razzell & Cullen: US Pat. 6,794,781 (2004)

Combination magnetic gear and electrical generator
Assigned to Rolls-Royce
42
21
Jian et al (2007)
Combination gear / generator with multiple windings
More robust design
43
Atallah & Rens: WO 2007/125284 (2007)

Coined term pseudo-direct drive to describe device
Variety of topologies windings inside, outside & within
Calculated 70 Nm / l torque density
44
From Atallah et al 2008
22
Atallah & Rens: WO 2007/125284 (2007)
45
From Asia-Pacific Engineer Magazine (2009)
Wang et al (2008)
Magnetically-geared outer rotor PM BL motor
Only one set of magnets
46
23
Wang (2008)
Magnetic continuously variable transmission (CVT)
Achieved through regulation of high speed outer rotor
47
Rasmussen et al (2009)
Motor integrated permanent magnet gear
Calculated up to 179 Nm / l for certain configurations
Achieved 130 Nm / l in prototype no cooling required
35 kW device potential for direct drive wheel motors
48
24
Outline


Final thoughts
49
Torque conversion device
Torque density (Nm/l)
Magnetic worm gear
Magnetic bevel gear
Magnet radial gear
Magnetic spur gear
10-20
Forced air cooled PM BL machine

Liquid cooled PM BL machine
20
30
Liquid cooled transverse PM BL machine
40-80
2 stage high ratio magnetic cycloid gear
75
Toyota Camry HEV Synergy Drive
80
45-90
1 stage low ratio concentric magnetic gear
70-100
1 stage low ratio magnetic harmonic gear
110
Integrated magnetic gear / electrical machine
60-130
1 stage low ratio magnetic cycloid gear
140-180
50
25
Several leading areas of potential interest

Wind & marine turbine generators
Automotive motors and generators for EVs
Energy storage flywheels
Numerous other speedtorque conversion applications
Seems to be early days few real world examples
Cost and perhaps novelty are drivers
51
Wind turbine generators

Key drivers: reduce weight + increase reliability
Non-contact gearbox or integrated gearbox / generator
Reduce direct drive diameter
From Jian et al (2007)

From Waszak et al (2007)
From Razzell & Cullen (2004)
52
26
Wind turbine generators
From Clark et al (2009)
53
Marine turbine generators

Key drivers: reduce form factor + increase reliability
Integrated gearbox / generator of particular interest
Some unique design constraints
Significant interest little actual progress!
54
27
Automotive motors & generators for EVs

Major area of interest [cars + motorcycles]
Much focus on in-wheel integrated gearbox + motor
Key drivers: reduce weight + increase power & torque
From Chau et al (2007)

55
Energy storage flywheels

Commercial power utility back up
Off-grid renewably-generated energy storage
Automotive regenerative braking systems
56
From Ricardo UK (2009)
28
Gearing for well bore drilling motors

Convert high speed to high torque for drilling
Isolation of drill bit axial / thrust loads from motor
Hollow bore to allow drilling fluid flow
57
McDonald et al - US Pats. 7,481,283 & 7,549,467 (2009)
Oil well sub-surface safety valve

For emergency shutoff of oil well, deep underground
Linear gear provides force multiplication
Reduces size / output required by hydraulics
58
McDonald & Price - US Pat. 7,487,829 (2009)
29
Final thoughts
Magnetic gears have significant potential

Reduced maintenance and increased reliability
Reduced form factors and increased torque densities
Wide range of gearing ratio options
Best-in-class electromechanical machines
Enabling new approaches to machine design
E.g. may reduce need for HREE-containing Nd-Fe-B magnets
59
Thank you!
For further information:

Dexter Magnetic Technologies, Inc.
1050 Morse Avenue
http://www.terramagnetica.com
Elk Grove Village, IL 60007

USA
Tel: +1-847-956-1140
Fax: +1-847-956-8205
Email: info@dextermag.com
http://www.memig.org
(at Linkedin.com)
Web: http://www.dextermag.com
60
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Recent Developments In

Gareth P Hatch, PhD CEng FIMMM

Presented at the Magnetics 2010 Conference

This paper was downloaded from Terra Magnetica, an independent online

About the Author

Magnetics Conference 2010

Overview of mechanical gearing

Integrated gear electric machine systems

Dexter Magnetic Technologies

Design & manufacture of magnetic devices

Overview of mechanical gearing

Integrated gear electric machine systems

Overview of mechanical gearing

Primary purpose: speed torque conversion

A form of power conversion

Overview of mechanical gearing

Specific conversion depends on gear ratio

Variety of gear topologies

Overview of mechanical gearing

Variety of gear topologies

Overview of mechanical gearing

Overview of mechanical gearing

Integrated gear electric machine systems

Benefits of magnetic gear systems

Several reasons for consideration

Overview of mechanical gearing

Integrated gear electric machine systems

Historical overview of magnetic gears

Armstrong: US Pat. 687,292 (1901)

Historical overview of magnetic gears

Neuland: US Pat. 1,171,351 (1916)

From Joergensen et al (2003)

Historical overview of magnetic gears

Faus: US Pat. 2,243,555 (1941)

Historical overview of magnetic gears

Reese: US Pat. 3,301,091 (1967)

From Joergensen et al (2003)

Historical overview of magnetic gears

Martin: US Pat. 3,378,710 (1968)

Historical overview of magnetic gears

Laing: US Pat. 3,645,650 (1972)

Historical overview of magnetic gears

Hetzel: US Pat. 3,792,578 (1974)

Historical overview of magnetic gears

Mabe: US Pat. 5,013,946 (1991)

Historical overview of magnetic gears

Kikuchi & Tsurumoto (1993)

From Joergensen et al (2003)

Historical overview of magnetic gears

From Joergensen et al (2003)

Historical overview of magnetic gears

From Joergensen et al (2003)

Historical overview of magnetic gears

Ackerman & Honds: US Pat. 5,633,555 (1997)

Historical overview of magnetic gears

Ackerman: US Pat. 5,994,809 (1999)

Overview of mechanical gearing

Integrated gear electric machine systems

Recent developments in magnetic gears

Key publication: Atallah & Howe (2001)

From Infolytica Corporation

Recent developments in magnetic gears

Key publication: Atallah & Howe (2001)

Recent developments in magnetic gears

Recent Developments in Permanent Magnet Gear Systems & Machines

Recent Developments in Permanent Magnet Gear Systems & Machines