The Cycloid Permanent Magnetic Gear

7
IEEE TRANSACTIONS ON INDUSTRY APPLICA TIONS, VOL. 44, NO. 6, NOVEMBER/DECEMBER 2008 1659 The Cycloid Permanent Magnetic Gear Frank T. Jørgensen, Torben Ole Andersen, and Peter Omand Rasmussen  Abstract—This paper presents a new permanent-magnet gear based on the cycloid gearing principle, which normally is char- acterized by an extreme torque density and a very high gearing ratio. An initial design of the proposed magnetic gear was de- signed, analyzed, and optimized with an analytical model regard- ing torque density. The results were promising as compared to other high-performance magnetic-gear designs. A test model was constructed to verify the analytical model.  Index Terms —Anal yti cal modeli ng, ni te elemen t analys is (FEA), magnetic gear, permanent magnets. I. I NTRODUCTION R ECENTLY, magnetic gears have gained some attention due to the following reasons: no mechanical fatigue, no lubrication, overload protection, reasonably high torque den- sity, and potential for very high efciency. Focus [1], [4], [5] ha ve bee n add res sed to a kind of pla netary ma gne tic gea r , probably already invented before the strong NdFeB magnets came into the market in the early 1980s [6]. An active torque density is in the range of 100 N · m/L, which is a very high torque density for a magnetic device [4]. However, there is still a need for increased torque density and a better utilization of the permanent magnets. The torque density of a magnetic coupling is in the range of 400 N · m/L, and this is, in principle, a magne tic gear wit h a 1 : 1 gearin g ratio. In this paper, a magnetic gearing topology with better uti- lization of the permanent magnet is presented. This gearing topology makes it possible to increase the torque density to almost twice the state-of-the-art magnetic gears and, therefore, might be a useful alternative in applications using traditional mechanical gears or, at least, in gearing applications where some of the other advantages, e.g., overload protection, oil-free construction, and separation, are vital. This paper will rst give a description of the cycloid per- manent magnetic gear and how the idea is derived from the classical magnetic spur gear. Due to the fact that the cycloid permanent magnetic gear is a 2-DOF topology, description of gearing ratios with different xed axes (1 DOF) is stated. In Pape r IPCSD-07-129 , prese nted at the 2006 Industry Applic ations Society Annu al Mee tin g, T ampa , FL, Oct obe r 8–12 , and app rov ed for publ ica - ti on in the IEEE T RANSACTIONS ON INDUSTRY APPLICATIONS by the Electr ic Machi nes Commi ttee of the IEEE Industry Applic ations Society . Manuscript submitted for review October 10, 2007 and released for publication Februa ry 19, 2008. Current versio n publis hed November 19, 2008. This work was supported in part by ELFOR, in part by Danfoss Drives A/S, and in part by Sauer Danfoss A/S. The authors are with the Institute of Energy Technology, Aalborg University, DK 9220 Aalborg, Denmark (e-mail: [email protected]; [email protected]; por@iet. aau.dk). Color versions of one or more of the gures in this paper are available online at http://ieeexplore.ieee.org. Digital Object Identier 10.1109/TIA.2008.2006295 Fig. 1. Perman ent-ma gnet and mechan ical s pur gear . Fig . 2. (a) Inne r type spur gear . (b) Inner spur gear wit h high magne tic interaction and low gearing ratio. order to optimize the layout of the new cycloid magnetic gear, a parametric analytical model to calculate the torque density is developed. The construction of an initial test model is given, and mea- surement is performed in order to validate the analytical model. Next, an optimization is utilized with the analytical model to quant ify the cyc loid permanent -mag net gear capab ility , and nally, a conclusion is given. II. DESCRIPTION AND DEVIATION OF THE CYCLOID PERMANENT MAGNETIC GEA R A permanent-magnet version to the classical spur gear can be made, where the teeth are substituted by permanent magnets; see Fig. 1. From Fig. 1, it is quite clear that a lot of the magnets are inactive and cannot assist in transferring torque between the two rings. In addition, volume taken up from the gear is quite high because the two rings are separated. In order to reduce the volume and also increase the interaction, it is therefore more suitable to use an inner type spur gear; see Fig. 2(a). From Fig. 2, it is shown that more magnets gets active if the number of poles on the inner ring is getting closer to the number of poles on the outer ring. If the number of poles on 0093-9994/$25.00 © 2008 IEEE Authorized licensed use limited to: IEEE Xplore. Downloaded on December 18, 2008 at 02:07 from IEEE Xplore. Restrictions apply.

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IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 44, NO. 6, NOVEMBER/DECEMBER 2008 1659

The Cycloid Permanent Magnetic GearFrank T. Jørgensen, Torben Ole Andersen, and Peter Omand Rasmussen

 Abstract—This paper presents a new permanent-magnet gearbased on the cycloid gearing principle, which normally is char-acterized by an extreme torque density and a very high gearingratio. An initial design of the proposed magnetic gear was de-signed, analyzed, and optimized with an analytical model regard-ing torque density. The results were promising as compared toother high-performance magnetic-gear designs. A test model wasconstructed to verify the analytical model.

  Index Terms—Analytical modeling, finite element analysis(FEA), magnetic gear, permanent magnets.

I. INTRODUCTION

RECENTLY, magnetic gears have gained some attention

due to the following reasons: no mechanical fatigue, nolubrication, overload protection, reasonably high torque den-sity, and potential for very high efficiency. Focus [1], [4], [5]have been addressed to a kind of planetary magnetic gear,probably already invented before the strong NdFeB magnetscame into the market in the early 1980s [6]. An active torquedensity is in the range of 100 N ·m/L, which is a very hightorque density for a magnetic device [4]. However, there isstill a need for increased torque density and a better utilizationof the permanent magnets. The torque density of a magneticcoupling is in the range of 400 N ·m/L, and this is, in principle,a magnetic gear with a 1 : 1 gearing ratio.

In this paper, a magnetic gearing topology with better uti-lization of the permanent magnet is presented. This gearingtopology makes it possible to increase the torque density toalmost twice the state-of-the-art magnetic gears and, therefore,might be a useful alternative in applications using traditionalmechanical gears or, at least, in gearing applications wheresome of the other advantages, e.g., overload protection, oil-freeconstruction, and separation, are vital.

This paper will first give a description of the cycloid per-manent magnetic gear and how the idea is derived from theclassical magnetic spur gear. Due to the fact that the cycloidpermanent magnetic gear is a 2-DOF topology, description of gearing ratios with different fixed axes (1 DOF) is stated. In

Paper IPCSD-07-129, presented at the 2006 Industry Applications SocietyAnnual Meeting, Tampa, FL, October 8–12, and approved for publica-tion in the IEEE T RANSACTIONS ON INDUSTRY APPLICATIONS by theElectric Machines Committee of the IEEE Industry Applications Society.Manuscript submitted for review October 10, 2007 and released for publicationFebruary 19, 2008. Current version published November 19, 2008. This work was supported in part by ELFOR, in part by Danfoss Drives A/S, and in part bySauer Danfoss A/S.

The authors are with the Institute of Energy Technology, Aalborg University,DK 9220 Aalborg, Denmark (e-mail: [email protected]; [email protected]; [email protected]).

Color versions of one or more of the figures in this paper are available onlineat http://ieeexplore.ieee.org.

Digital Object Identifier 10.1109/TIA.2008.2006295

Fig. 1. Permanent-magnet and mechanical spur gear.

Fig. 2. (a) Inner type spur gear. (b) Inner spur gear with high magneticinteraction and low gearing ratio.

order to optimize the layout of the new cycloid magnetic gear,a parametric analytical model to calculate the torque density isdeveloped.

The construction of an initial test model is given, and mea-surement is performed in order to validate the analytical model.Next, an optimization is utilized with the analytical model toquantify the cycloid permanent-magnet gear capability, andfinally, a conclusion is given.

II. DESCRIPTION AND DEVIATION OF THE CYCLOID

PERMANENT MAGNETIC GEA R

A permanent-magnet version to the classical spur gear can bemade, where the teeth are substituted by permanent magnets;see Fig. 1.

From Fig. 1, it is quite clear that a lot of the magnets areinactive and cannot assist in transferring torque between thetwo rings. In addition, volume taken up from the gear is quitehigh because the two rings are separated. In order to reduce thevolume and also increase the interaction, it is therefore moresuitable to use an inner type spur gear; see Fig. 2(a).

From Fig. 2, it is shown that more magnets gets active if the number of poles on the inner ring is getting closer to thenumber of poles on the outer ring. If the number of poles on

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1660 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 44, NO. 6, NOVEMBER/DECEMBER 2008

Fig. 3. Cycloidal movement principle shown with nine illustrations.

Fig. 4. Different configurations for the cycloid-gear parts.

the inner ring is equal to the number of poles on the outer ring,the gearing ratio will be unity, and the gear can be consideredas a magnetic coupling. With almost equal number of poles onthe two rings, the gearing ratio is very low. Fig. 2(b) shows anexample where the number of poles on the outer rotor is 44 andon the inner rotor 42. This example gear has very high magneticinteraction but the gearing ratio is only 44/42 ≈ 1.05.

In order to improve the low gearing ratio for the gear shownin Fig. 2(b), a cycloidal principle is considered. Cycloidal gear-ing principle has significant gear-reduction capability. Move-ment principle for this gear is explained with nine illustrationsshown in Fig. 3. The illustrations show an outer rotor with

44 poles and an inner rotor with 42 poles. The outer rotoris stationary while the inner rotor is magnetically connectedto outer rotor and placed eccentrically relative to outer rotor.Clockwise angular-position change for the air gap will resultin a small change of the inner rotor rotation in anticlockwisedirection. The angular position for the air gap has rotated oneanticlockwise revolution from illustrations one to nine while theinner rotor has only rotated 1/21 revolution anticlockwise.

This gearing principle has significant gear-reduction ability.Same example is shown in Fig. 4(c), where the outer rotorpart C is fixed. An eccentric B is driving the inner magneticplate, and this plate will make a combined orbit and rotationalmotion. The rotational part of this motion is transferred to the

output shaft A. The gear ratio is (−21/1) = −21, which ismuch higher than a simple inner spur-gear configuration.

Fig. 5. (a) Spur-gear coordinate system and magnets. (b) Cycloid-gear coor-dinate system and magnets.

III. GEARING RELATIONSHIP FOR THE CYCLOIDAL GEA R

The movement principle of the permanent-magnet cycloidgear is described in the previous section, where the outer rotoris fixed from rotation. However, it is also possible to fix otherparts of the gear. In Fig. 4, the other possible combinations of fixed parts are shown together with equations for the gearing

ratio.Gear configuration in Fig. 4(c) is the configuration alreadydescribed in Section II, and the gear configuration in Fig. 4(b)is equivalent to the internal spur gear with the relatively lowgearing ratio. The configuration shown on Fig. 4(a) has thelargest gearing ratio, and the input and output axes are sepa-rated by an air gap. The configuration in Fig. 4(c) has similarcharacteristics as the one in Fig. 4(a) and may be preferred insome applications due to its layout for integration. The torquedensity is almost similar for all configurations.

IV. ANALYTICAL MODEL

In order to be able to design and optimize the cycloid mag-netic gear, a model is required. An analytical model is preferredwhen optimization has to be applied because of significantreduced computational time as compared to a finite elementanalysis (FEA).

Due to the fact that the permanent-magnet cycloid gear is avariation of the permanent-magnet spur gear, it is obvious to usethe same theory used for this gear type. In [2], the authors havederived an analytical model for permanent magnetic spur gearswith parallel magnetized magnets. This model is only brieflyintroduced as function expressions in this paper and, for furtherdetailed explanation, is the reader referred to [2] and [3].

  A. Magnetic-Field Expression

The magnetic-field solutions for a parallel magnetized mag-netic ring are written by (1) and (2). This magnetic ring is theso-called source shown in Fig. 5(a).

Equations (1) and (2) have origin in the source co-ordinate system and, therefore, named Bext

r (r, φ,v) andBextφ (r, φ,v), respectively,

B(2)r (r, φ,v) =μ0

∞i=1,3,5,...

1

2iN  pr

−( 1

2iNp+1)

× U (2)i (v)cos

12N  piφ

(1)

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JØRGENSEN et al.: CYCLOID PERMANENT MAGNETIC GEAR 1661

B(2)φ (r, φ,v) =μ0

∞i=1,3,5,...

1

2iN  pr

−( 1

2iNp+1)

×U (2)i (v)sin

1

2N  piφ

. (2)

These field-solution equations are transformed into the drive-magnet coordinate system Bext

r (r,φ,v) and Bextφ (r,φ,v). Fur-

ther explanation of the field transformation is explained in [3].The two field expressions depend on coefficient terms, andthese terms can be expressed as (3)–(8). The field expressions(1) and (2) are indirectly used in parts of the torque calculationexpression (9)

U (2)i (v) =−2μ0

H ri(v)

Li(v)M ri−2μ0

H φi(v)

Li(v)M φi (3)

H ri(v) =R2sμ0

R(N pi)2s

32

N  pi+2R(N pi)1s

 RN pi2s R2sμ

−R(N pi)1s  R

(N pi)2s R2sμ0N  pi

−2

 R(N pi)1s μR1sR

(N pi)2s N  pi

−2R2sμR(N pi)2s

32

+4

 R(N pi)1s R

(N pi)2s μ0R1s

+ R(N pi)1s

 R(N pi)2s R2sμN  pi

−2R(N pi)1s

 R(N pi)2s R2sμ0

−2R2sμ0

R(N pi)2s

32

+ R2sμR(N pi)2s

32

N  pi

(4)

H φi(v) =−R2sμ0

R(N pi)2s

32

N  pi−4

 R(N pi)1s μR1sR

(N pi)2s

−R2sμR(N pi)2s

3

2 N  pi + 2R(N pi)1s

 R(N pi)2s R2sμ

− 2R(N pi)1s

 R(N pi)2s R2sμ0

+ R(N pi)1s

 R(N pi)2s R2sμN  pi

+ 2

 R(N pi)1s R

(N pi)2s μ0N  piR1s+2R2sμ

R(N pi)2s

32

+ 2R2sμ0

RN pi2s

32

−R(N pi)1s

 R(N pi)2s R2sμ0N  pi

(5)

Li(v) =(−2 + N  pi)

(2 + N  pi)

× −2μμ0R(N pi)

2s −2μμ0R

(N pi)

1s

−μ2R(N pi)2s +μ2R

(N pi)1s

−μ20R(N pi)2s +μ20R

(N pi)1s

(6)

M ri =Br

μ0π

2N  p

1−12 iN  p

sin

π

N  p

cos

π2i−

1

2iN  p cos

π

N  p

sin

π2i

(7)

M φi=Br

μ0π

2N  p

1−12iN  p

2

×

cos π

N  p

sinπ

2 i−

1

2 iN  p sin π

N  p

cosπ

2 i.

(8)

 B. Torque-Calculation Expression

The instantaneous torque on a parallel magnetized spur gearis described by

T (R2s, R1s, R2d, R1d, d) = T r(v) + T t1(v) + T t2(v). (9)

The three terms are scalars and represent one radial torqueintegration and two tangential torque integrations in the drive-magnet coordinate system, which is tilted an angle ϕ forcalculating the torque at a operational point of maximal torquebetween source-and-drive-magnet parts. The torque-integrationexpressions are written in (10)–(12) and subexpressions for theintegration are written in (13)–(15)

T r(v) =2M s cos

π

N pole

L(R2d −R1d)

N r

×

N pole−1

 p=0

N p

q=0(−1)

 p

S r(q)r(q,v

)

×

cos(φedge(φ, p))Bextx (r(q), φedge(φ, p),v)

+sin(φedge(φ, p))Bexty (r(q), φedge(φ, p),v)

(10)

T t1(v) =−M sLR

21d

N pole

N t

×

N pole−1 p=0

N tq=0

(−1) pS r(q)sin(θ(q))

×

cos

θ(q) + p

N pole+ φ

Bextx

×

R1d, θ(q) + p

N pole+ φ,v

+ sin

θ(q) + p

N pole+ φ

Bexty

×

R1d, θ(q) + p

N pole+ φ,v

(11)

T t2(v) =M sLR

22d

N pole

N t

×

N pole−1 p=0

N tq=0

(−1) pS r(q)sin(θ(q))

×

cos

θ(q) + p 2π

N pole+ φ

Bextx

×

R2d, θ(q) + p

N pole+ φ,v

+ sin

θ(q) + p

N pole+ φ

Bexty

×

R2d, θ(q) + p

N pole+ φ,v

(12)

θ(q) =−π

N pole+

q

N t

N pole(13)

r(q, v) =R1d +q

N r(R2d −R1d) (14)

θedge( p) =φ + πN pole

(1 + 2 p). (15)

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1662 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 44, NO. 6, NOVEMBER/DECEMBER 2008

TABLE IDIMENSIONS

C. Modified Torque Calculation From Spur Gear to

Cycloid Type

The torque-calculation model for the spur gear is general, andthereby, it is possible to change the separation distance betweenthe two rings to the eccentricity of the inner ring, see Fig. 5.This dimensional change will only change the equations for fluxtransformations [3]. Source and drive magnet is inside of eachother, and the torque is calculated on the outer drive magnet (9).The system configuration is equivalent to the inner magneticspur gear shown in Fig. 2(b).

Torque equations, for the gear type shown in Fig. 4(b), can

be used to calculate the nominal corresponding output torque of a gear type shown in Fig. 4(c). This torque transformation canbe written by

T Cyc = T in ·P AP C 

. (16)

Pole-number configuration for the cycloid permanent-magnetinitial design comes partly from a previous developed magneticgear [1]. The gear in [1] has 44 permanent magnets on theouter ring, and this pole number is reused for the cycloidpermanent-magnet gear design. The inner ring is designed with42 magnets. The minimum air gap is fixed at 0.5 mm, and the

eccentricity is optimized to be 2.5 mm. The parameters for theinitial design are listed in Table I.

Fig. 6. Analytic and FEA-calculated torque–angle curve.

In Table I, it is seen that the initial cycloid permanent-magnet gear has a calculated torque density of 141.9 N ·m/L,i.e., around 40% more than the “planetary” magnetic gearsdeveloped in [4]. In order to validate the analytical model forthe initial design, a static FEA was made, and the results fromthe two models are shown in Fig. 6.

In Fig. 6, good agreement is seen between the two calculationmethods. The reason for the small deviation is mainly causedby the assumption of a unity relative permeability of the per-manent magnets in the derivation of the analytical model. TheFEA model uses 1.05 in relative permeability for the NdFeBmagnets.

V. CONSTRUCTION OF A TES T MODEL

Starting point for making a test model is the cycloidal mov-ing principle shown in Fig. 3. It was chosen to use sheet steelyokes for both rings, meaning that the height of the permanentmagnets can be reduced by a factor of two because the steel willbridge neighboring magnets (magnetic mirrors). The steel yokehas also the advantages of limiting magnetic field around theconstruction.

In order to make the test model simple, rectangular magnetswere used instead of arc-shaped magnets, and to reduce largeunbalanced magnetic forces, two gear sets were used. Fig. 7shows a rendered view of the constructed model. Outer dimen-sions of the experimental test model are 130 × 130 mm, and

the gearbox total length is 86 mm.The input shaft is placed at the center of the gearbox. Abearing is placed on the eccentric and connected to the innersteel yoke. Circular motion of the input shaft will force theinner yoke to move in orbital motion. Inner yoke magnets willperform a cycloidal motion. Strong magnetic-flux paths be-tween the inner and outer ring will ensure torque on the outputshaft. The output shaft is connected to the inner yoke withtree columns and eccentrics. These eccentrics can compensatefor misalignment between inner yoke and output shaft. Thecolumns will act like mechanical coupling and transfer torquefrom the inner yoke to the output shaft.

The rotor yokes are placed on the eccentric input shaft. The

eccentricity is made by a central eccentric bushing. Togetherwith six support eccentrics, 12 extra needle bearings are added.

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JØRGENSEN et al.: CYCLOID PERMANENT MAGNETIC GEAR 1663

Fig. 7. Rendered view of the cycloidal gear design.

Their functionality is to ensure a parallel motion of the innerrotors relative to the output shaft reference. The proposedconstruction will therefore have 18 bearings in total.

The total volume of the magnetic gear could have beenreduced by choosing a circular design and also by choosingsmaller bearings.

The cycloid gear has been tested in two situations. The firsttest was a static test where the output torque was measuredto be 33 N ·m. This measurement is shown in Fig. 6 with a

single measurement at peek output torque for comparison withthe 2-D models. The measured torque of the experimental testmodel is lower than the results from the 2-D models. For thisdeviation, 3-D end effects are assumed to be the most dominantfactor.

It has to be noted that the length of the magnets are verysmall, so large 3-D effects should be expected. The length of the magnet is based on the availability of standard magnetsand, thus, not optimized. However, for future optimization, itmight be worth to consider the third dimension in the analytical-calculation methods, since it apparently has a large effect forthis relatively short layout. Basically, this means that the stack 

length cannot be considered as a simple scaling parameter as itis for typical electrical machines.The constructed cycloid gear is reasonably comparable with

the gear developed in [1]. Both gears use 44 times two of thesame type of rectangular magnets in the outer ring, and theair-gap radius is, thus, similar. In [1], 216 standard rectangularmagnets were used, while the cycloid gear in this paper onlyuses 172 of the same type of magnet. In [1], the stall torque wasmeasured to 16 N ·m, which means that the cycloid gear hasdoubled the torque density.

The other test was a dynamic test where input and outputtorques were measured. The test was performed with two servodrives. One of the drives was set up as load drive, and the other

was set up as input drive. Three input velocities were tested,and different loads were applied by the load control drive. The

Fig. 8. Sketch of dynamic test bench.

Fig. 9. Measured efficiency for the cycloid magnetic gear.

torque on both sides of the gear was measured with torquetransducers (Fig. 8).

Efficiencies were calculated from the measured torque val-ues, and the results are shown in Fig. 9.

The efficiency were measured at 1500, 500, and 50 r/min.The highest efficiencies were generally obtained at low speed

and high torque. The best gear efficiency measured at 50 r/minwas 94%. Efficiencies of 500 and 1500 r/min were 93% and92%, respectively.

VI. OPTIMIZATION

The initial design may not give the full picture of the capabil-ity of the cycloid permanent-magnet gear. Optimizations weretherefore performed by formulating the analytical equationsto a general optimization problem [7] with a cost function(17), equality constrains (18), inequality constrains (19), and anumber of constants from Table I. The cost function (17) is the

torque density of the magnetic spur gear with the torque cal-culated from the parallel magnetization expressions developedin [2]. The volume is set by the area given by drive-magnetwheel radius and a constant length. It is necessary to havean equality constrain h1 for limitation of the used permanent-magnet material, i.e., the area, since the length is fixed. Thispermanent-magnet area constrain were set up to be the samearea as used for the analytical model of the initial magnetic-gear test model (Aconst = 35.4 · 10−4 m2). Another equalityconstrain h2 is set to keep a separation distance of 0.5 mmbetween the magnetic wheels. Inequality constrains is set forthe minimization routine. The outer radius has to be somewhatgreater than the inner radius in g1 and g2. Largest radius of the

drive wheel radius has to be less than a certain value in g3. Thesmallest radius for the inner gear wheel had to be greater than

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1664 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 44, NO. 6, NOVEMBER/DECEMBER 2008

TABLE IIOPTIMIZATION RESULTS

a certain value in g4. The distance of the eccentric also has alimitation in g5 and g6

f (x) = f (x1, x2, . . . , xn) ⇒

f (R2s, R1s, R2d, R1d, d) =T (R2s, R1s, R2d, R1d,−d)

Lπ (R22d)

·N  pN pole

(17)

hj(x) = (x1, x2, . . . , xn) = 0 ⇒

h1(R2s, R1s, R2d, R1d) =Aconst

− πR22s−R

21s+R2

2d−R21d

= 0

h2(R2s, R1d, d) =R1d−d−g−R2s = 0 (18)

gi(x) = gi(x1, x2, . . . , xn) ≤ 0 ⇒

g1(R2s, R1s) =R1s −R2s+4 · 10−3 ≤ 0

g2(R2d, R1d) =R1d −R2d+4 · 10−3 ≤ 0

g3(R2d) = − 61.5 · 10−3+R2d ≤ 0

g4(R1s)=48.5 · 10−3−R1s ≤ 0

g5(d) = − 20 · 10−3 + d ≤ 0

g6(d) = 1 · 10−3 − d ≤ 0. (19)

A constrained nonlinear-minimization routine was per-formed to find the optimal dimensions for the magnetic spurgear. The initial design is very close to the computer-optimizedsolution. The initial design was 141.9 kN ·m/m3, and thecomputer optimized solution was 142.5 kN ·m/m3. The reasonwhy the results are so close to each other is mainly caused bytight constrains limitations. The computerized model is lockedby an area constrain h1, and radius and inner radii must also bewithin limited values.

The influence of using different amount of magnetic materialwas also investigated. The investigation has only been madewith the 42- and 44-pole configuration and wider boundary onthe radius constrains. The result of this analysis is shown inTable II. The optimal torque density is increased to a certainamount if more magnetic material is put into the magneticcycloid gear.

The last result of the torque-density optimization gave

183 kN ·m/m3 or 183 N ·m/L, which is nearly twice thecapability of state-of-the-art permanent magnetic gears.

VII. MANUFACTURABILITY

The proposed test-model design seems quite complicated atfirst sight, and other designs might be worth considering forsimplifying the manufacturing process. Argumentation for thechosen design is shortly described, and possible simplificationsfor future designs are mentioned.

The proposed test-model configuration is equivalent to theconfiguration shown in Fig. 4(c). The advantage of choosingthis configuration is that the output shaft can be designed withrelatively large distance between bearings for better supportof loads on the output shaft. Two rotors are used for the test-model design, primarily to compensate for reaction forces in thegearbox housing. The design with two rotors makes the systemmore complex regarding the number of parts, and this designmight not be the best design regarding manufacturability. Thereare also used double-needle bearings in the eccentrics thatsupport the inner magnetic parts. Such configuration could bereplaced by simple hardened columns.

It is the general opinion that internal tolerances for keepinggear part fixed must have the same level of precision as othermechanical cycloid gear types. However, tolerances for place-ment of magnets might have minor demands for precision.

VIII. CONCLUSION

A new cycloid magnetic-gear configuration has beenpresented. This magnetic gear is characterized by having hightorque density and a high gearing ratio. The maximum achiev-able torque of the proposed gear was calculated by analyticalexpressions derived in [2] and the transformation equation

(16). An initial design of the cycloid gear was able to reach141.9 N ·m/L, which is around 40% more than the “planetary”magnetic gears developed in [4]. An experimental test model of the initial design was constructed and tested. The experimentaltest model reached 33 N ·m. Optimizations for cycloid gearsshowed that it was possible to reach torque densities up to183 N ·m/L, which is almost twice the density as comparedto the “planetary” magnetic-gear types [4]. A cycloid magneticgear could therefore be a possible choice for future applicationswhere, for example, a motor or generator is integrated togetherwith the cycloid-gear design. The proposed configurationsmight also be used as power-split devices for hybrid cars orwind turbines with a fixed-speed synchronous generator.

ACKNOWLEDGMENT

The authors would like to thank B. Kristensen for construct-ing the prototype.

REFERENCES

[1] P. O. Rasmussen, T. O. Andersen, F. T. Jørgensen, and O. Nielsen, “De-velopment of a high-performance magnetic gear,” IEEE Trans. Ind. Appl.,vol. 41, no. 3, pp. 764–770, May/Jun. 2005.

[2] F. T. Jørgensen, T. O. Andersen, and P. O. Rasmussen, “Two dimensionalmodel of a permanent magnet spur gear,” in Conf. Rec. 40th IEEE IAS

 Annu. Meeting, 2005, vol. 1, pp. 261–265.[3] E. P. Furlani, “Analytical analysis of magnetically coupled multipole cylin-ders,” J. Phys. D, Appl. Phys., vol. 33, no. 1, pp. 28–33, Jan. 2000.

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[4] K. Atallah and D. Howe, “A novel high-performance magnetic gear,” IEEE 

Trans. Magn., vol. 37, no. 4, pp. 2844–2846, Jul. 2001.[5] K. Atallah, S. D. Calverley, and D. Howe, “Design, analysis and realisation

of a high-performance magnetic gear,” Proc. Inst. Electr. Eng.—Electr.

Power Appl., vol. 151, no. 2, pp. 135–143, Mar. 9, 2004.[6] T. B. Martin, Jr., “Magnetic transmission,” U.S. Patent 3 378710,

Apr. 16, 1968.[7] J. S. Arora, Introduction to Optimum Design. New York: McGraw-Hill,

1989.

Frank T. Jørgensen was born in 1973. He receivedthe B.Sc. degree in mechanical engineering jointlyfrom the University College of Aarhus, Aarhus,Denmark, and from the Fachschule Kempten,Kempten, Germany, where he spent a year and ahalf as an exchange student, and the M.Sc. degreein electromechanical system design from AalborgUniversity, Aalborg, Denmark, where he is currentlyworking toward the Ph.D. degree with a main focuson magnetic gears.

He is currently working in industry. He got work-

ing experience from the company Grundfos A/S, where he was educated as amechanic.

Torben Ole Andersen was born in 1966. He re-ceived the B.Sc.M.E. degree from the Universityof Southern Denmark, Odense, Denmark, in 1989,and the M.Sc. and Ph.D. degrees in mechanical/ control engineering from the Technical Universityof Denmark, Lyngby, Denmark, in 1993 and 1996,respectively.

From 1996 to 2000, he was with the R&D Depart-

ment, Sauer-Danfoss A/S, where he worked in thearea of fluid power and control engineering. In 2000,he joined Aalborg University, Aalborg, Denmark, as

an Associate Professor. Since 2005, he has been a Full Professor in fluid powerand mechatronics. His main research interests include design and control of mechatronic systems.

Peter Omand Rasmussen was born in Aarhus,Denmark, in 1971. He received the M.Sc. degreein electrical engineering and the Ph.D. degree fromAalborg University, Aalborg, Denmark, in 1995 and2001, respectively.

In 1998, he joined Aalborg University as an As-sistant Professor. Since 2002, he has been an Asso-ciate Professor. His research areas are in the designand control of switched reluctance and permanent-magnet machines.