Performance evaluation and optimization of flux-regulated axial-radial eddy current coupling

Abstract This paper proposes a novel axial-radial permanent magnet eddy-current coupling equipped with a mechanical magnetic adjuster. The innovative design integrates mechanical flux weakening technology with an enhanced magnetic method rooted in axial-radial hybrid flux topology. Concise analytical models for air-gap field and torque are developed, leveraging the magnetic equivalent circuit method and Faraday’s law. These models are subsequently validated using the 3D finite-element method. The results indicate that this device boasts an exceptionally broad torque adjustment range, reaching approximately 93% at a given slip. Furthermore, it exhibits a substantial optimal working area, spanning from 20% to 80% of the mechanical magnetic adjuster’s movable distance. To comprehensively analyze the impact of structural parameters on overall performance, three novel metrics are defined. The analysis reveals that the pole pairs of the radial magnetic circuit (RMC) have the most significant influence on the device’s comprehensive performance. In the end, a multi-objective optimization method to maximize the global torque regulation capabilities, local torque regulation abilities, and maximum torque potential is developed to enhance the overall performance of this innovative magnetic coupling design.