High-Torque-Density Low-Cost Magnetic Gear Utilizing Hybrid Magnets and Advanced Materials

Two major challenges of existing high-performance magnetic gears are: (i) High content of rare-earth permanent magnets which results in high cost as well as price fluctuation; (ii) Conflict between mechanical and electromagnetic performances, especially in the design of highspeed rotor. A magnetic gear using a blend of magnet types, i.e NdFeB, or Dy-free NdFeB and ferrites, is proposed in this paper. The goal is to bring down the cost while retaining comparable torque-transducing performance to a baseline magnetic gear only using rare-earth NdFeB magnets. A variety of topologies based on different combinations of magnet types and geometric shapes have been studied and compared. In addition, the potential impact of using an advanced dual-phase material is evaluated. The goal is to eliminate the well-known tradeoff between rotor mechanical integrity and PM flux leakage