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GEARS & GEARBOXES FEATURE GEARS FOR DEMANDING TASKS


With their high power density, reliability and compact design, Nabtesco’s gears and drives are suitable for demanding automation tasks. The gear systems combine high dynamics,


GNETIC GEAR ONS FOR OCEAN WIND ENERGY


that are ideal for both wind and ocean turbines, providing manufacturers with enhanced durability, reduced maintenance, contactless power transfer and inherent overload protection. For turbines located in hard-to-reach locations and with challenging operating conditions, these features can help to reduce maintenance costs and minimise the need to replace expensive components.


What challenges are there to overcome and how do the benefits of magnetically geared motors help ease these? In traditional energy conversion systems, including turbines, mechanical gears are used to connect a high-speed electric machine to a low-speed physical energy source. One of the main challenges for operators of wind and ocean power generators is that gearbox failure can result in downtime. This prevents power from being generated and often requires expensive maintenance or replacement. If turbines are located in challenging conditions, such as at sea, then downtime, intervention costs and the potential loss of revenue can all be increased. In these types of applications, magnetic gears are a practical alternative to mechanical gears. Their superior reliability and low maintenance requirements are highly advantageous assets for the environments in which these machines need to operate. Magnetic gears also have an environmental


advantage over conventional mechanical systems. As there is no mechanical contact in the transmission of torque between input and output shafts, they produce far less acoustic noise. This can make them more suitable for windfarms located near to residential areas or farms with livestock, or for ocean power generators where noise can have a negative impact on sea life. Additionally, with a significant reduction in


generator size, magnetically geared generators enable manufacturers to simplify the design of their equipment, potentially reducing the cost of production, transport and installation. Furthermore, with reduced cooling


requirements, wind turbines with magnetic gears are more suitable for locations with extreme temperatures, while even less maintenance is required for ocean turbines.


What are the specific benefits of magnetic gears for ocean and wind energy? Compared to both conventional generator and mechanically geared systems, magnetic gears offer a high torque system that delivers increased power output while maintaining reduced costs. Much smaller, lighter and quieter than other systems, their superior reliability and low maintenance requirements reduce both the cost of repairs and losses from operational downtime. For ocean power generation in particular


the compact high torque magnetic motor system provides reduced flow restriction while maximising hydrodynamic efficiency, resulting in increased power output at lower cost points. The magnetic gear, meanwhile, can be readily pressure compensated, making it ideal for underwater use. Magnomatics’ magnetic gears provide


significant benefits for ocean and wind energy, and the wider renewable energy sector. The company also offers efficient systems to multiple sectors, bringing sustainable operations to aerospace, automotive, rail amongst other industries. The company complements the technology by providing a comprehensive consultancy service for the design and development of products and services.


Magnomatics www.magnomatics.com


JUNE 2024 DESIGN SOLUTIONS 49


precision (hysteresis loss 0.5 to maximum 1 arcmin) and light weight with power. Their design allows the cycloidal gears to provide high reduction ratios with two or three gear stages – and without the need for the additional pre-stages. They are also rigid and compact, and weigh less than multi-stage planetary gears, the company explains. Of additional benefit, the gears are said to offer outstanding resistance to shock loads – up to 500% of the rated torque. The gears are suitable for installation in robots, machines and systems of smaller size. The solid shaft servo gears of the series


Necoâ and NecoâHT (high-torque gears for heavy-duty applications) offer precision, repeatability and smooth operation, corrosion protection, motor connection, and modularity. Instead of using a separate interface to connect each motor type, a system boasting modular sleeves and flanges guarantees easy adaptation of all standard servo motors. This guarantees maximum flexibility, a simpler configuration, and faster assembly with shorter delivery times. Available as coaxial (RDS-C), parallel shaft (RDP-C), or bevel gears (RDR-C), the hollow shaft gears of the RD-C series can be used for a wide variety of applications. The large hollow shaft offers sufficient room for convenient and space-saving routing of cables and hoses – such as data and supply lines – through the centre of the cycloidal gear unit. It does not remain rigid, but is designed to rotate at the output rpm. The advantage of this is that a sensor on the hollow shaft can determine the position of the drive shaft. Nabtesco developed the fully integrated,


decentralised drive unit with a Mecanum wheel specifically to accommodate the needs of mobile automation solutions. The RV-W Mecanum wheel drives used also allow for high torque capacity in a compact design and are equipped with an integrated main bearing for optimal absorption of the radial and axial forces generated. Maintenance-free operation of the compact and extremely robust drive concept is ensured thanks to cycloidal gears.


Nabtesco https://nabtesco.eu/


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