GEARS & GEARBOXES
RING EFFICIENCY TRY
FEATURE
For aerospace manufacturers looking to develop the next generation of innovative aircraft, including UAMs, magnetic motor systems can play a key role in delivering safety, reliability, energy efficiency and sustainability
systems are specifically engineered to overcome the torque limitations imposed when using traditional direct drive electrical machines. To achieve this, their design features a magnetic gear housed inside a stator, with the gear’s outer magnetics attached to the stator’s inner bore. This sophisticated approach enables the gear’s inner rotor to be driven by the stator’s copper windings, resulting in a high-speed, low-load electric motor that operates with low currents and at low temperatures and therefore does not require external liquid cooling, and removes the risk of demagnetisation of its outer magnet array. Aside from being compact and durable, when the inner rotor torque is geared up between 5:1 and 10:1 in the novel polepiece rotor, the electric motor delivers exceptional efficiency. In terms of its suitability for aerospace applications, its ability to deliver a torque density of >30Nm/kg makes it the highest- density motor for electric actuation systems. In comparison to conventional motor
systems, magnetic motor systems offer manufacturers benefits in terms of safety, reliability, cost-efficiency and sustainability. Being less than 60% the size and mass of a permanent magnet machine, they take up less space and are easier to install, reducing manufacturing costs, while the reduced
mass improves operational efficiency and cuts carbon footprints. The benefits are enhanced by the fact these
systems operate at low temperatures and have no minimum cooling requirements, so there is a reduced need for cooling equipment, which in turn reduces the weight of the aircraft, further improving energy efficiency. The use of standard power electronics, meanwhile, provides cost efficiencies in both manufacturing and maintenance through the wide availability of reliable components, compatibility with other systems and ease of integration. With regard to reliability and safety, the lack of mechanical gears eradicates the potential for wear and mechanical failure, while the fault- tolerant motor acts as a passively resettable torque fuse and does not require a clutch or shear pins in the event of jamming. Moreover, the motor system is able to deliver a full load torque even in the event of a phase-bank failure, while the thermal, magnetic and mechanical isolation of each phase bank delivers maximum reliability and full duplex redundancy. Aside from safety, the lack of gear wear also reduces the maintenance burden for operators. As these motor systems are highly efficient,
compact and lightweight they play a key role in cutting energy consumption. This reduces energy costs for operators while
making the aircraft a more environmentally friendly vehicle. The system’s design also has environmental and passenger comfort benefits, as it operates quietly, reducing both external and internal noise.
THE POTENTIAL The wide range of applications for magnetic motor systems means they offer enormous potential across a range of sectors, including automotive, renewable energy, rail, aerospace and marine. Within the aerospace and UAM industry, not only are they suitable for eVTOL, UAM and traditional winged aircraft, but they can also be put to various uses, such as for e-propulsion, electric braking, pitch control, landing gear deployment and magnetically geared actuation for flight control surfaces. For aerospace manufacturers looking to
develop the next generation of innovative aircraft, including UAMs, magnetic motor systems can play a key role in delivering safety, reliability, energy efficiency and sustainability. Moreover, by being lightweight, compact, easy to install and durable, they help streamline the manufacturing process and cut manufacturing and maintenance costs.
Magnomatics
www.magnomatics.com
FEBRUARY 2025 DESIGN SOLUTIONS 21
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