Cycloidal Magnetic Gear Combining Axial and Radial Topologies

Axial flux and radial flux cycloidal permanent magnetic gears are characterized by high gear ratios and high torque densities; however, their rotors experience large unbalanced forces, which stress the bearings used in the gear. This paper presents a new cycloidal magnetic gear topology that combines the radial and axial flux topologies. The paper analyzes the forces and torques contributed by the axial and radial magnets in this topology using 3D finite element analysis. It was found that the perpendicular force is necessary to transfer torque to the high-speed shaft and, thus, cannot be cancelled out, but the eccentric component of the magnetic forces can be largely cancelled out, potentially reducing bearing losses and increasing the lifespan of the bearings used in the gear. A proof-of-concept prototype was constructed. Experimental slip torque results matched 3D finite element analysis (FEA) simulations to within 15%, and testing showed that no-load losses were reduced and the slip torque was increased by combining both axial and radial topologies, compared to using an axial configuration alone.