Symmetric Transverse-Flux Magnetic Gear for Higher Torque Density
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Solution Overview
Problem
Existing transverse-flux magnetic gears suffer from lower torque density due to magnetic flux saturation in ferromagnetic rotors, leading to inefficiencies and mechanical complexity, particularly in low-speed pseudo direct drive applications.
Innovation Solution
The development of symmetric transverse-flux coaxial magnetic gears (STCMGs) with a symmetrical configuration and a stator coupled to high-speed rotors, distributing magnetic flux efficiently between identical high-speed rotors and reducing mechanical connections, thereby increasing torque density and design compactness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If ferromagnetic rotor is used in traditional transverse-flux magnetic gears, then torque transfer is enabled, but ferromagnetic rotor saturation occurs leading to lower torque density
Solution Approach 1:
The patent replaces the ferromagnetic rotor with a permanent magnet rotor, substituting a mechanical/ferromagnetic system with a magnetic field-based system. This eliminates rotor saturation issues and increases torque density while reducing mechanical complexity in the rotor structure.
Solution Approach 2:
The patent changes the magnetic field distribution parameters by using permanent magnets with specific pole pairs arranged in a transverse flux configuration. This parameter change optimizes the magnetic coupling between rotors and eliminates saturation, directly improving torque density.
2Power
If high flux density is used in ferromagnetic materials, then torque is increased, but heat management becomes complicated
Solution Approach 1:
By replacing the ferromagnetic rotor with a permanent magnet rotor, the patent eliminates the source of excessive heat generation from high flux density saturation. The permanent magnet system operates below saturation levels, significantly reducing heat management complexity.
3Power
If symmetric transverse-flux coaxial magnetic gear configuration is used, then torque density increases, but mechanical complexity increases
Solution Approach 1:
The patent replaces complex mechanical connections and ferromagnetic coupling mechanisms with a magnetic field-based permanent magnet system. The direct magnetic coupling between the permanent magnet rotor and ferromagnetic rotor eliminates the need for complex mechanical interfaces, reducing overall mechanical complexity despite the symmetric transverse-flux configuration.
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
STCMGs enhance torque density and operational efficiency by minimizing flux saturation and mechanical wear, enabling more robust and compact direct drive systems suitable for low-speed applications.
Implementation Method 1
Magnetic flux generated by the third magnet ring is distributed between the first magnet ring and the second magnet ring during operation of the magnetic gear assembly
Implementation Method 2
They are attractive over conventional mechanical gears because the rotating shafts have no mechanical connection and all torque is transferred magnetically
Data Source
AI summary
A magnetic gear assembly includes a first magnet ring comprising first magnetic pole-pairs disposed evenly along the first magnet ring, a second magnet ring comprising second magnetic pole-pairs disposed evenly along the second magnet ring, a third magnet ring comprising third magnetic pole-pairs disposed evenly along the third magnet ring, wherein each of the first magnetic pole-pairs, the second magnetic pole-pairs, and the third magnetic pole-pairs comprises two opposing magnets, and a fourth ring comprising ferromagnetic pieces disposed evenly along the fourth ring. The first, second, third, and fourth magnet rings are arranged along an axis, wherein the first and the second magnet rings are positioned on either side of the third magnet ring along the axis, and wherein magnetic flux generated by the third magnet ring is distributed between the first and the second magnet rings during operation of the magnetic gear assembly.