Manufacturing of flux modulators for mass-optimized concentric magnetic gearing

Magnetic gears and magnetically-geared motors are attractive for several applications due to their lack of lubrication and contact between gears. However, higher specific torque is desired to improve their competitiveness with mechanical gears, particularly in mass-sensitive applications such as aerospace. In concentric magnetic gearing, thinner flux modulators and smaller air gaps can provide the desired performance improvement but structural and manufacturing limitations have so far prevented this. This paper presents lessons learned from six methods used to manufacture modulators for 3 magnetic gears and 1 magnetically-geared motor with high specific torque.