Design and Optimization of a Double V-Shaped Coaxial Magnetic Gear with Hybrid PM Array
摘要
The non-contact structure of coaxial magnetic gears (CMG) offers significant advantages over mechanical gears, including reduced maintenance and inherent overload protection. However, the development of CMG faces challenges due to the unstable supply and high cost of rare-earth permanent magnet materials. To address this issue, this paper proposes a novel double V-shaped CMG with a hybrid permanent magnet (PM) array. The innovative topology strategically integrates NdFeB and ferrite PMs within the inner rotor, substituting the lower NdFeB sections with ferrite to substantially reduce rare-earth material usage while enhancing torque output through an optimized flux-focusing double V-shaped structure. Furthermore, a systematic optimization methodology combining Response Surface Methodology (RSM) and a Multi-Objective Genetic Algorithm (MOGA) was employed to maximize torque and minimize torque ripple, leading to an optimal CMG topology with 4 inner and 17 outer pole pairs. Finite element analysis (FEA) results demonstrate that, compared to a conventional all-NdFeB spoke-type CMG, the proposed design achieves a 34.1% increase in outer rotor torque and a 12.1% reduction in torque ripple, while simultaneously reducing the amount of NdFeB required by 21.77%. This work validates the proposed hybrid PM configuration as a highly effective solution for enhancing the torque density and cost-effectiveness of CMG in applications such as wind energy systems, marine propulsion, and electric vehicles.