Magnetic-geared Machine Research Articles

A Magnetic-Geared Machine With Improved Magnetic Circuit Symmetry for Hybrid Electric Vehicle Applications

Magnetic-geared machine (MGM) has been widely investigated as the power split device for hybrid electric vehicles with the inherently high-integration of multi-mechanical ports. It is revealed that the magnetic circuits of armature winding in MGM are essentially asymmetrical for different phases under the magnetic field modulation effect. This inevitably results in unbalanced phase back electromotive force (EMF) waveforms, severe torque ripples, acoustic noise, and difficulty for precise control. To alleviate the asymmetry problem, a generic winding design model is presented for MGMs in this paper, which allows for consideration of all potential winding configurations. Firstly, a novel back EMF harmonic factor is proposed to account for both the harmonic content and asymmetric level in MGM. The genetic algorithm (GA) is further employed to optimize the winding in terms of minimizing the back EMF harmonic factor, armature magnetomotive force harmonic contents, and phase winding resistance. The proposed winding layout exhibits superior filtering capability for three-phase asymmetric magnetic field harmonics. As compared with the conventional integral-slot distributed winding, the MGM with the proposed winding exhibits improved back EMF waveform symmetry, suppressed torque ripple, and reduced core losses. Finally, an experimental prototype is manufactured to validate the effectiveness of asymmetric magnetic field suppression for MGMs. The results show the investigated winding design method is an effective solution to the asymmetric issue of MGMs, paving the way to research opportunities for further improvements.

An Enhanced Axial-Flux Magnetic-Geared Machine with Dual-Winding Design for Electric Vehicle Applications

An Enhanced Axial-Flux Magnetic-Geared Machine with Dual-Winding Design for Electric Vehicle Applications

A Torque-Enhanced Magnetic-Geared Machine with Dual-Series-Winding and Its Design Approach for Electric Vehicle Powertrain

Magnetic gear and magnetic-geared machine (MGM) are the potential solutions in electric vehicles (EVs) powertrains for inherent high efficiency and mechanical simplification. However, the torque density issue of the MGM greatly limits its industrial application. To enhance the torque performance of the MGM, a torque-enhanced magnetic-geared machine with dual-series-winding and its design approach are proposed. The key merits of the proposed design are to achieve a high space utilization with a dual-winding design, with no additional control topologies and power converters required. The auxiliary winding is supplemented and integrated with modulation rings. The relative position of the stator and armature winding are designed and rotated compared to the modulation rings with auxiliary winding, to ensure the auxiliary winding shares the excitation with the armature winding. Accordingly, simplifying the external control topologies. With the proposed design, the torque of the MGM can be significantly enhanced with a single three-phase driving. Theoretical analysis, parameters optimization and electromagnetic verification are given, demonstrating that the proposed machine can achieve an efficiency of 93.2%, generate a torque of 107.2 N·m, and reach a torque density of 10.81 N·m/kg.

Investigation of the electromagnetic characteristics and operating performance of a bidirectional PM excited machine

This paper presents a study of bidirectional permanent magnet excited machine (BPMEM) based on the study of field-modulation permanent magnetic gear machine (FPGM). The BPMEM structure includes the installation of consequent-pole permanent magnets (PMs) on both the stator and rotor sides of the FPGM so that the stator and rotor can be bidirectionally excited to increase the working airgap flux density amplitude, reduce the flux leakage between poles, and increase the torque density. Therefore, the paper first analysis the influence of different airgap structures and PM arrangements on the airgap flux density and studies the winding slot–pole combination and the resulting working flux density harmonics to analyse the electromagnetic torque generation mechanism. By using the finite element analysis (FEA), the quantitative analysis and comparison of the FPGM, slot-wedge-less FPGM (SWL-FPGM), consequent-pole FPGM (CP-FPGM) and BPMEM verify the superiority of BPMEM in improving electromagnetic torque. In addition, the paper also studies the key performance of BPMEM’s overload capacity, power factor and flux-weakening capability. Finally, no-load and independent load experiments are carried out on the FPGM prototype to verify the correctness of the FEA model and analysis method of the machine in this paper.

A Consequent-Pole Magnetic-Geared Machine With Axially Embedded Permanent Magnets for Hybrid Electric Vehicle

This paper reveals the fundamental reason for the asymmetrical issue in magnetic-geared machines (MGMs) based on flux modulation theory. The analysis indicates that the magnetic circuits of three-phase windings in MGMs are inherently asymmetrical. This asymmetrical issue is even more severe in conventional consequent-pole MGMs (CP-MGMs) because of the more distorted magnetic field. Hence, to address the asymmetrical issue, a novel structure featuring enhanced harmonic elimination capability is proposed in this paper. Consequently, torque density can also be improved. In particular, the proposed CP-MGM employs modular structure and axially embedded permanent magnets (PMs) to achieve symmetrical back electromotive force (EMF) waveforms and improved torque capability, respectively. To further improve the electromagnetic performance of the proposed CP-MGM, the PM arc ratio and flux modulator width ratio are analytically designed, which provides a general design guideline for CP-MGMs. To illustrate the merits of the proposed CP-MGM, a few other MGMs are included for a fair comparison based on finite element analysis (FEA). Results show the proposed CP-MGM can achieve more symmetrical back EMF waveforms and lower torque ripple, as well as lower PM consumption and higher torque density, as compared with its MGM counterparts.

Optimization of Rotor Salient Pole Reluctance for Typical Field Modulated Electric Machines

The objective of this article is to investigate the possibility to improve the torque characters of electric machines featuring rotor salient pole reluctance from the perspective of the general airgap field modulation theory. The torque production mechanisms of two typical field modulated machines, namely, the magnetically geared machine (MGM) and the flux-reversal permanent magnet (FRPM) machine, are discussed based on the Maxwell stress tensor (MST) method, where the mono-harmonic mechanism of rotor PM machine like the MGM is revealed. Several common theoretical salient rotor pole configurations, like the upright/inverted trapezoidal configuration, are introduced in detail, based on which general and modified rotor configuration advices for the two electric machines are proposed to provide initial design and future optimization guidance. It is proven that there is a possible opportunity to make the torque characters better via reasonable selection of rotor configuration and topological parameters. Electromagnetic performances validation based on 2-D finite-element analysis, such as improved airgap magnetic field harmonic distributions, load flux linkage/electromotive force (EMF), and general torque performances of two field modulated machines is provided to demonstrate the effectiveness of theoretical analysis. It is also verified by experimental measurements on the FRPM machines with different pole pair combination.

A Dual-Modulator Magnetic-Geared Machine for Tidal-Power Generation

In this article, a new dual-modulator magnetic-geared machine (DM-MGM) is proposed for tidal-power generation with the virtue of high-torque output at low speed. First, the requirement of the DM-MGM for tidal-power generation is derived. Then, the flux-modulation principle and flux-enhancing effect of the extra modulator of the proposed DM-MGM are elaborated. After that, a finite-element analysis and multi-objective genetic algorithm (FEA-GA) combined method is used to solve a multi-objective optimization problem for the DM-MGM design. The electromagnetic performances of the optimized DM-MGM with different pole-pair combinations are quantitatively compared by FEA. The results show the effectiveness of the proposed machine, which is suitable to be applied in the tidal-power-generation scenario.

Multi-Objective Robust Optimization of a Dual-Flux-Modulator Magnetic Geared Machine With Hybrid Uncertainties

In order to improve the robustness and torque performance of a dual-flux-modulator magnetic-geared machine (DFM-MGM) considering simultaneously both random and interval uncertainties of design parameters, a multi-objective robust optimization (MORO) method with multiple Monte Carlo simulations (MCSs) is proposed. In this method, the multiple MCSs are adopted to evaluate the effects of parametric hybrid uncertainties on the robustness of optimization results. To build a MORO model of the DFM-MGM, the three-dimensional finite element model is established firstly and then validated by the experiment. Through a parametric study, it is found that five dimensional parameters of the permanent magnets (PMs) and stator have more significant effects on the stall torque (ST) and ST per PM volume (STPPV). Finally, a multi-objective particle swarm optimization algorithm with surrogate models, sigma criteria design and multiple MCSs method is implemented to solve the MORO problem. Both the average standard deviations and standard deviation differences of the ST and STPPV are used to deal with hybrid uncertainties during MORO. The optimized DFM-MGM by MORO has a STPPV 6.3% higher than that of the initial design under the same ST constraint. Moreover, the average standard deviations and standard deviation differences obtained by MORO are much smaller than those achieved by the deterministic optimization, indicating that the robustness of optimal results can also be significantly improved by the MORO.

Analytical Modeling and Comparison of Two Consequent-Pole Magnetic-Geared Machines for Hybrid Electric Vehicles

The exact mathematical modeling of electric machines has always been an effective tool for scholars to understand the working principles and structure requirements of novel machine topologies. This paper provides an analytical modeling method—the harmonic modeling method (HMM)—for two types of consequent-pole magnetic-geared machines, namely the single consequent-pole magnetic-geared machine (SCP-MGM) and the dual consequent-pole magnetic-geared machine (DCP-MGM). By dividing the whole machine domain into different ring-like subdomains and solving the Maxwell equations, the magnetic field distribution and electromagnetic parameters of the two machines can be obtained, respectively. The two machines were applied in the propulsion systems of hybrid electric vehicles (HEVs). The electromagnetic performances of two machines under different operating conditions were also compared. It turns out that the DCP-MGM can reach a larger electromagnetic torque compared to that of the SCP-MGM under the same conditions. Finally, the predicted results were verified by the finite element analysis (FEA). A good agreement can be observed between HMM and FEA. Furthermore, HMM can also be applied to the mathematical modeling of other consequent-pole electric machines in further study.

Analytical Investigation of the On-Load Electromagnetic Performance of Magnetic-Geared Permanent-Magnet Machines

In this paper, the electromagnetic performance and operating characteristics of magnetic-geared permanent-magnet machines (MGPMMs) are evaluated using the subdomain analytical method. We derive the governing equations for each region based on the electromagnetic theory and some assumptions. The undetermined coefficients of the governing equations are calculated using boundary conditions. Based on the analytical solutions, the electromagnetic performance is analyzed. The proposed analytical method is validated through the nonlinear finite-element method and an experiment. In particular, an analysis of the performance analysis of the slot combination, which is one of the design variables, suggests the increased power factor and operating range. The analytical method can be useful for the initial and optimal designs of MGPMMs.

Design, Construction, and Analysis of a Large-Scale Inner Stator Radial Flux Magnetically Geared Generator for Wave Energy Conversion

A magnetically geared machine (MGM) integrates a magnetic gear with a low-torque, high-speed electric machine to create a single compact high-torque, low-speed device with the size advantages of a mechanically geared system and the reliability of a direct drive machine. This work investigates the use of MGMs for wave energy conversion through the development of a large-scale magnetically decoupled inner stator radial flux magnetically geared generator rated for 10 kW at an input speed of 30 r/min. Critical design trends are illustrated using parametric two-dimensional and three-dimensional finite element simulation results. Information is also provided about the prototype's mechanical structure and key magneto-mechanical design considerations, including the impact of modulator bridges and the extent of axially escaping leakage flux. The prototype's experimental stall torque of 3870 Nm represents a 99.1% match with the simulated stall torque and corresponds to volumetric and gravimetric torque densities of 82.8 kNm/m3 and 14.5 Nm/kg, respectively. Additionally, the prototype achieves an experimental efficiency of approximately 90% for operation near rated torque.

Comparison of Radial Force at Modulating Pieces in Coaxial Magnetic Gear and Magnetic Geared Machine

Unlike the coaxial magnetic gear (CMG), the magnetic geared machine (MGM) has the ac armature winding on the inner part or the outer part. Besides, the PM excitation field of the CMG and the ac armature field of the MGM have different space harmonic components of magnetic field from one other. Hence, the flux modulation characteristics in the CMG and the MGM are different, and the resultant magnetic radial forces at the modulating pieces are also occurred differently from one another. Thus, in this paper, first, the flux modulation characteristics of the PM excitation field in the CMG and the ac armature field in the MGM are presented. Second, the characteristics of the magnetic radial forces at the modulating pieces are analyzed, and the causes of the radial force according to the space harmonic components of the magnetic field are compared in the CMG and the MGM.

Torsional Shear Stress Minimization Techniques and Implications on Electromagnetic Performance of Flux-Modulated Double Rotors

Magnetic-geared machines are based on the flux-modulation principle and typically constructed with a flux-modulated double rotor (FMDR). The modulator experiences high torsional stresses when designed for high torque transmission. As a result, the FMDR has high probability of failure if not designed appropriately. In this paper, the FMDR design options are investigated with mechanical and electromagnetic finite element (FE) modeling. The addition of filler material in between the poles of the modulator pole-pieces is found to reduce the shear stresses by $61.7\%$ to $87.2\%$ at the cost of $2.6\%$ to $3.2\%$ lower pull-out torque. Possible shear stress reduction with the design of bridged modulators is investigated. Increase in pole number is shown to increase localized stress levels in bridged modulators. Electromagnetic simulations show that for a given FMDR specification, the highest pull-out torque is at an optimal pole number. The tradeoff between FMDR weight, losses, and shear stress are discussed. A scaled-size prototype FMDR with a bridged modulator is constructed. The FMDR is tested and is shown to achieve comparable results with the FE simulations. At field intensity levels above 600 kA/m in the periphery, the FMDR achieves reduced pull-out torque $28.7\%$ lower in comparison with three-dimensional simulations. The losses at different load levels of the FMDR are also compared with experimental and FE simulation result and are shown to confirm the FE simulation results.

A New Electric Magnetic-Geared Machine for Electric Unmanned Aerial Vehicles

This paper proposes a new electric magnetic-geared (EMG) machine, which artfully incorporates the magnetic gear into an outer-rotor inserted permanent-magnet (PM) machine, purposely for electric unmanned aerial vehicle (e-UAV) application. The proposed EMG machine artfully shares the sandwiched-rotor for both the PM machine and the magnetic gear. As a result, the proposed machine can run in the high speed and high power for propelling the e-UAV. The design details, operation principles, static characteristics, and machine performances, as well as the propulsion performances of the proposed machine, are elaborated and discussed. The finite-element method is utilized to verify the validity of the machine design and performances, with emphasis on the e-UAV application.

Modulating Ring Structural Configuration Influence on the Dual Air-Gap Magnetic Gear Electric Machine

In this paper, a study was conducted using a unit equivalent magnetic circuit (EMC) in correlating the relationship between the magnet thickness, the modulating ring pole-piece thickness, and their circumferential pitch. A numerical optimization method is employed in selecting the optimum ratio of the magnet to pole-piece thickness. The study reveals the need to simultaneously consider these parameters during the design of a magnetic gear electric machine because of their strong mutual dependency. A finite element analysis (FEA) was conducted using the optimum ratios. The results correspond to those of the EMC. Also, the performance of the machine is analyzed and found to have a power factor of 0.78. To further verify the results of FEA, a prototype was built using the same configurations of the FEA model. Measurements taken from the prototype are on par with the simulated results.

Comparative Analysis of Partitioned Stator Flux Reversal PM Machine and Magnetically Geared Machine Operating in Stator-PM and Rotor-PM Modes

In this paper, the partitioned stator flux reversal permanent magnet (PM) (PS-FRPM) machine and the conventional magnetically geared (MG) machine operating in both stator-PM (SPM) and rotor-PM (RPM) modes are comparatively analyzed in terms of electromagnetic performance to provide design guides for an MG machine regarding an SPM- or RPM-type machine and a higher or lower gear ratio machine. It is found that an SPM-type machine is recommended since both PS-FRPM and MG machines operating in SPM modes have a higher phase back-EMF and hence torque than their RPM counterparts, respectively, as a result of a similar phase flux linkage but a higher electric frequency since the iron piece number is larger than the PM pole-pair number. Moreover, a smaller gear ratio machine is preferred from the perspective of a higher power factor and hence a lower inverter power rating, as the conventional MG machines with higher gear ratios suffer from larger flux-leakage, higher synchronous reactance and hence lower power factors, as well as higher iron losses, than the PS-FRPM machines. However, higher gear ratio machines feature lower cogging torques and torque ripples due to the smaller difference between the PM pole-pair number and iron piece number. Both prototypes of PS-FRPM machine operating in SPM mode and MG machine operating in RPM mode are built and tested to verify the finite element predicted results.

A Novel Hybrid Dual-PM Machine Excited by AC With DC Bias for Electric Vehicle Propulsion

This paper proposes a novel hybrid-excited dual-PM machine for electric vehicle propulsion. The key is to use an integrated stator winding to replace the armature winding and the field winding in the conventional hybrid-excited machine. The stator winding is excited by ac current with dc bias, in which the ac component is used to produce the rotating armature field, while the dc bias current is used for the flux regulation. Therefore, the function of the ac and dc windings can be incorporated and realized by using just one set of winding. The torque density and flux regulating capability can be improved, and the winding configuration is also simplified. In addition, dual-PM excitation structure combines the advantage of stator-PM doubly salient machine and rotor-PM magnetic-geared machine, which can further enhance the torque capability. The operating principle and control strategy of the proposed machine are discussed. The electromagnetic performances are studied using the time-stepping finite-element method. A machine prototype is manufactured and experimental tests are conducted to verify the effectiveness of the machine design.

Analysis of Magnetic Gearing Effect in Partitioned Stator Switched Flux PM Machines

The partitioned stator switched-flux permanent magnet (PM) (SFPM) (PS-SFPM) machine is a novel stator-PM machine in which PMs and armature windings are separately placed in two different stators. Compared with the conventional SFPM machine with a single stator in which both PMs and armature windings are located, the PS-SFPM machine can generate higher torque density due to the utilization of the machine's inner space. In this paper, the magnetic gearing effect in the PS-SFPM machine is investigated in terms of air-gap field harmonics based on a simple magnetomotive force (MMF)-permeance model. It is found that the PS-SFPM machine is one type of magnetically-geared machine, in which the modulations of rotor iron pieces to the open-circuit PM and armature reaction fields are similar to those found in the magnetic gear and the conventional magnetically geared machine. The pole-pair numbers and rotating speeds of the air-gap field harmonics obtained by the MMF-permeance model are verified by finite element (FE) analysis. More than 93% of the average electromagnetic torque is contributed by the main air-gap field harmonics having pole-pair numbers $(2i - 1){\boldsymbol p}$ PM and $\rm{| N}_{\rm{r}} \,\pm \, $ (2 i -1) p PM| ( i = 1,2,3) in a PS-SFPM machine with p PM-pole-pair PMs and Nr -rotor-pole. A prototype machine is fabricated and tested to verify the FE analysis.

A Novel Flux Focusing Magnetically Geared Machine with Reduced Eddy Current Loss

This paper proposes a novel flux focusing magnetically geared (MG) machine for wind power generation, considering the permanent magnets (PMs) eddy current loss and the balance between the pull-out torque of MG machine and the back-electromotive force (EMF)of the PM brushless machine. The PM eddy current loss in the two rotors of the conventional surface-mounted MG machine is calculated and analyzed by using finite-element method. By adopting serial-spoke structure in the inner rotor, a novel rotor structure for a MG machine is proposed to reduce the PM eddy current loss. Moreover, in order to balance the pull-out torque and the back-EMF, several serial-spoke structures and the main design parameters are investigated. Then, a quantitative comparison between the proposed topology and the conventional surface-mounted MG machine is performed. The analysis results indicate that the PM eddy current loss of the proposed MG machine can be significantly reduced and its pull-out torque and back-EMF can be balanced well.

Optimal Design of Ferromagnetic Pole Pieces for Transmission Torque Ripple Reduction in a Magnetic-Geared Machine

This paper derives an effective shape of the ferromagnetic pole pieces (low-speed rotor) for the reduction of transmission torque ripple in a magnetic-geared machine based on a Box-Behnken design (BBD). In particular, using a non-linear finite element method (FEM) based on 2-D numerical analysis, we conduct a numerical investigation and analysis between independent variables (selected by the BBD) and reaction variables. In addition, we derive a regression equation for reaction variables according to the independent variables by using multiple regression analysis and analysis of variance (ANOVA). We assess the validity of the optimized design by comparing characteristics of the optimized model derived from a response surface analysis and an initial model.