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I. INTRODUCTION
OR LOW-SPEED electrical machine applications, it
is usually weight/size and cost effective to employ a
high-speed machine together with a mechanical gearbox.
However, in many instances, the disadvantages associated
with mechanical gearboxes, such as acoustic noise and
mechanical vibration, the need for lubrication, concerns
regarding reliability and maintenance requirements, make
direct-drive solutions more functionally and/or economically
attractive. Liquid-cooled permanent magnet (PM) brushless
machines exhibit relatively high torque densities, typically
30 kNm/m for radial-field and
50 kNm/m for
being
transverse-field topologies, respectively [1][3]. However,
although transverse-field machines exhibit the highest torque
density, since their power factor is very low [4], typically
ranging from 0.3 to 0.5, the required inverter/converter VA
rating is a factor of 2 3 times higher than that for an equivalent
conventional brushless machine. This results in a significant
cost penalty, which is limiting the take-up of transverse-field
machine technology.
Recent advances in magnetic gears have led to their torque
transmission capability becoming competitive to that of mechanical gears, whilst they offer significant operational advantages [5]. Further, there are various ways in which a magnetic
gear may be combined with an electrical machine to realize a
high torque density pseudo direct-drive. Irrespective of the
machine technology, the simplest method is simply to mechanically couple the output shaft of the machine to the input shaft of
the magnetic gear, as illustrated in Fig. 1, or to incorporate the
electrical machine within the bore of a magnetic gear [6].
This paper describes a radically different approach to creating
a pseudo direct-drive machine by combining a magnetic gear
and electrical machine both mechanically and magnetically [7].
It will be shown that a torque density in excess of 60 kNm/m
can then be achieved from an air-cooled machine, while the
power factor can be larger than 0.9.
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Fig. 6. Harmonic spectra of radial flux density waveforms due to stationary permanent magnets in airgap adjacent to permanent magnets of high-speed rotor.
the ferromagnetic pole-pieces now results in a 2 pole-pair asynchronous field harmonic which interacts with the 2 pole-pairs
high-speed rotor.
and the stator winding is similar to that of a conventional surface-mounted permanent magnet machine, and is given by
(1)
B. Electromagnetic Torque
In the brushless ac mode of operation, the electromagnetic
torque which results from the interaction of the high-speed rotor
where
is the stator bore diameter,
is the peak fundamental
airgap flux density, is the active length of the machine,
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where is the electromagnetic torque, resulting from the interaction of the stator winding and the rotor, is the load torque,
is the angular position of the load, and
is the combined
inertia of the rotor and the load.
For the pseudo direct-drive machine shown in Fig. 2, since
the torque is transmitted magnetically from the high-speed rotor
to the output rotor (low-speed), the equations which govern the
motion of the high-speed and low-speed rotors are
(5)
and
(6)
C. Cogging Torque
The cogging torque which manifests itself as torque ripple
on the output rotor results from interactions between the ferromagnetic pole-pieces and both the high-speed rotor permanent
magnets and the stationary permanent magnets. Qualitatively,
the cogging torque is determined by the cogging torque factor
, which has been shown to be applicable to mag[8],
is the smallest common multiple benetic gears [5], where
tween the number of poles
(
or
) and the number of
ferromagnetic pole-pieces .
,
For the pseudo direct-drive shown in Fig. 2,
,
, and the cogging torque factor is 1. Hence, the
cogging torque is inherently small. Fig. 7 shows the variation
of the output torque with the angular rotor position when the
machine is on full-load. It can be seen that the torque ripple is
less than 0.7% of the rated full load torque.
D. Electromechanical Modeling
For a conventional permanent magnet brushless machine, the
motion of the rotor is governed by
(4)
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A novel method of coupling a magnetic gear and a permanent magnet brushless machine, both mechanically and magnetically, to realize a pseudo direct-drive machine has been
presented. It has been shown that a torque density in excess of
60 kNm/m can be achieved from a naturally air-cooled machine, at a power factor of 0.9 or higher.
ACKNOWLEDGMENT
This work was supported by the U.K. Engineering and
Physical Science Research Council, EPSRC, under Grant
GR/S70685.
REFERENCES
Fig. 10. Variation of low-speed torque with average rms stator current density.
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2/12/7.
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