Magnetic Gear Mechanism Reducing Eddy Current Losses

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Solution Overview

Problem

Magnetic gear mechanisms face issues with eddy current generation and heat loss due to the division of permanent magnets, which affect torque transmission efficiency, especially when using surface magnet structures.

Innovation Solution

The magnetic gear mechanism employs rotors made of laminated soft magnetic material with permanent magnets arranged internally and exposed to surface-facing pole shoe members, and these magnets are divided in the axial direction to minimize eddy current losses by modulating magnetic fluxes and using an embedded magnet structure to reduce harmonic magnetic flux interactions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If permanent magnets are divided into a plurality of pieces in the axial direction, then eddy current losses are reduced, but torque transmission efficiency deteriorates due to increased magnetic flux leakage at division interfaces

Engineering Contradiction:
Improveeddy current lossVSAvoidtorque transmission efficiency
Core Design Contradiction:
Loss of energyVSReliability

Solution Approach 1:

A magnetic flux shielding member made of soft magnetic material is introduced as an intermediary component between divided permanent magnets. This shielding member bridges the magnetic flux paths at division interfaces, preventing flux leakage that would otherwise occur due to the gaps between divided magnet pieces. The shielding member thus mediates between the need for magnet division (to reduce eddy currents) and the need for continuous magnetic flux (for torque transmission), resolving the contradiction by eliminating flux leakage without requiring the magnets to be undivided.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Ease of manufacture

If surface magnet structure is used, then manufacturing is simplified, but eddy current losses increase due to exposed magnet surfaces facing pole shoes

Engineering Contradiction:
Improvemagnet arrangement simplicityVSAvoideddy current loss
Core Design Contradiction:
Ease of manufactureVSLoss of energy

Solution Approach 1:

The magnetic flux shielding member acts as an intermediary layer between the surface-mounted permanent magnets and the pole shoes. This shielding member intercepts and redirects the magnetic flux, preventing it from forming eddy current loops in the pole shoe surfaces. The shielding member thus enables the use of simple surface magnet structures while eliminating the harmful eddy current effects that would otherwise result from direct exposure of magnet surfaces to pole shoes.

Inventive Principle:
Principle #24Intermediary (Mediator)

3Loss of energy

If embedded magnet structure is used, then eddy current losses are reduced, but device complexity increases due to internal magnet arrangement

Engineering Contradiction:
Improveeddy current lossVSAvoidrotor structure complexity
Core Design Contradiction:
Loss of energyVSDevice complexity

Solution Approach 1:

The solution segments the permanent magnets into multiple pieces arranged in the axial direction, with magnetic flux shielding members positioned between them. This segmentation approach reduces eddy current losses by breaking up large magnet surfaces while maintaining manageable individual components. The segmented structure achieves the benefits of embedded magnet configurations without requiring complex internal embedding, as the magnets can be surface-mounted in a modular, segmented arrangement that simplifies manufacturing while reducing eddy currents.

Inventive Principle:
Principle #1Segmentation

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This configuration significantly reduces eddy current losses, enhancing torque transmission efficiency to nearly 100% by minimizing heat generation and maintaining mechanical reliability without mechanical contact.

Implementation Method 1

rotation is transmitted by modulating magnetic fluxes each having a ratio of magnet pole numbers by pole shoes thereof

Methodology Applied
Scientific EffectMagnetic flux: Magnetic Field

Implementation Method 2

pole shoe members formed of a soft magnetic material, having a plurality of poles, and arranged between the rotors

Methodology Applied
Scientific EffectSoft magnetic material property: Ferromagnetism

Data Source

PatentUS9385581B2Magnetic gear mechanism
Publication Date: 2016.07.05 HITACHI LTD
  • US9385581B2 patent drawing
  • US9385581B2 patent drawing
  • US9385581B2 patent drawing

AI summary

The present invention is intended to provide a magnetic gear structure that realizes a magnetic gear that transmits a torque efficiently by reducing eddy currents generated in the interior of magnets. In order to solve the subject described above, in the magnetic gear structure, a structure in which magnets are arranged in the interior of an iron core in an inner rotor portion. Bonded magnets formed by molding, for example, NdFeB powder may be used as the magnets. Since the influence of the eddy current on the side of an outer rotor having a larger pole number is large, a structure in which the magnets are arranged in the interior only of an outer rotor portion having a larger pole number is also applicable. In addition, the magnets to be embedded may be divided into a plurality of pieces. The finer the division of the magnets, the less eddy currents are generated, so that a method of further fining down and assembling the same is also effective. Further reduction of the eddy currents is possible by laminating the plate-shaped magnets having a thickness equivalent to an electromagnetic steel plate in the axial direction.