Controllable electromagnetic hybrid magnetic coupler: An electro-magnetic-thermal-stress coupling model and numerical simulation study

Addressing prevalent issues such as substantial size and inadequate precision in the air gap adjustment mechanisms of adjustable-speed magnetic couplers, this study introduces an innovative controllable electromagnetic hybrid magnetic coupler. This coupler utilizes electromagnetic gap adjustment for precise, non-contact speed regulation. A comprehensive electro-magnetic-thermal-stress coupling model is established, grounded on the principles of electromagnetic induction and heat transfer under variable air gaps. Numerical simulations are conducted, assessing temperature and stress variations under different scenarios involving permanent magnet width, air gap length, winding slot depth, and coil turn count. The optimal parameters of the core device-electromagnetic gap adjuster are obtained by orthogonal experimental method, and the results show that when the width of the permanent magnet is 5 mm, the length of the air gap is 1.5 mm, the depth of the winding slot is 10 mm, and the number of turns of the coil is 14, the mechanism has the lowest steady-state field temperature rise of 23.689 °C. This research lays a foundational basis for advanced mastery of controllable electromagnetic hybrid variable air-gap transmission technology.