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FEATURE GEARS & GEARBOXES Magnetic gears – An


innovAtive wide-reAching solution for the future


OEMs, design engineers and machine builders across all sectors face the ongoing challenge of making their products more efficient, reliable and


M


cost-effective. Gary Rodgers, chief executive officer (CEO) of Magnomatics, examines magnetically geared motors, a technology with potential applications across multiple industries, and discusses their advantages While the motor may be smaller, its


agnetically geared motors are a significant development over traditional drive systems. They can provide benefits


across a range of different applications, including increased efficiency, better performance and a lower environmental impact. Integral to this is a design which eliminates mechanical contact within the gears. This minimises the amount of energy lost to friction, enabling the motors to work more efficiently and at a reduced operational cost. Without friction, the motors don’t get as


hot as conventional systems, minimising the amount of cooling required and resulting in a number of benefits. Firstly, with smaller or in some cases no


cooling systems needed, the products into which they are built can be smaller and lighter, making them easier to manoeuvre and less expensive to transport. When used in vehicles, the reduced weight


also means less energy is required to drive the vehicles forward, making them more efficient to operate. In addition, being smaller, product designs are simplified which often equates to a reduction in manufacturing costs.


compactness does not affect performance. Indeed, magnetic gears are able to produce higher power outputs than larger, conventional motors. What’s more, the combination of small size and large power output makes magnetically geared motors ideal for use in situations where


AdvAnced mAgnetic drive systems


As magnetic gear technology has evolved, innovations – like the Pseudo Direct Drive (PDD) – bring new advantages. The PDD’s revolutionary design produces a high-speed, low-load electric motor that benefits from low electrical currents


“Magnetically geared motors can provide


benefits across a range of different applications, including increased efficiency, better


performance and a lower environmental impact”


space-saving solutions are essential or preferred. As there is no direct mechanical link in the


system, the drive is transmitted through the magnetic gear, making it extremely effective at reducing, and in most cases eliminating, shock loads being transmitted. It can also be configured to act as a torque fuse and prevent the motor from overloading and damaging driveline components.


and low temperatures. These features give the motor exceptional efficiency and extended durability while ensuring the unit’s outer magnetic array cannot be demagnetised. At the same time, the inner rotor’s torque can be geared up by around 5:1 to 10:1 in the PDD’s polepiece rotor, enabling the electric motor to be both highly efficient and very compact. This efficiency and size make it a viable solution for applications large and small – from lightweight micromobility vehicles to commercial ships. Built to mirror the attributes of a direct


As magnetic


gear technology has evolved,


innovations – like the Pseudo Direct


Drive (PDD) – bring new advantages


drive, but without the need for a standard gearbox, the PDD’s motor system is engineered in a way that outperforms the torque generation of conventional direct drive electric motors. It also reduces the time and cost factors associated with repair. Featuring a high-precision gear system,


it produces high torque at low speeds with superior efficiency and minimal backlash. It even maintains efficiency under partial loads, making it suitable for variable load applications. This makes it ideal for situations including heavy-duty operations, where high torque and high precision are essential but where size, weight and power consumption make a conventional drive unsuitable.


A breAdth of ApplicAtions


The PDD has the potential to deliver benefits across a wide range of sectors. In aerospace, for example, its fault tolerance can provide the


1 Design sOLUtiOns FEBRUARY 2024 4


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