In the field of electric machine design, a trend in many applications has been to design machines with increasing torque density. When machines fail to meet torque density requirements or are simply incapable of matching load torque, gears are commonly used. Magnetic gears have been proposed as a means of increasing torque density within electromechanical systems, while avoiding problems associated with traditional mechanical gears. While the idea behind magnetic gears goes back to early patents, their study and use in industry has been very limited to date. This study looks into variations of the gear which could lead to more industrial use. The effect of pole count upon torque ripple is investigated with finite element analysis (FEA). The analysis is extended to new magnetic layouts which borrow from permanent magnet machine design. One of the most critical components of the gear, the stator pole pieces, are also investigated for variations which aid in construction while maintaining the performance of the gear. As a means of supplementing analysis of the gear, winding function theory (WFT) is used to analyze the gear. Winding function theory has enjoyed success with induction, synchronous, and even switched reluctance machines in the past. This study is the first of its kind to apply winding function theory to a device devoid of windings altogether. It is shown that this method is capable of generating the stall torque and steady-state torque ripple waveforms which have been commonly attempted with FEA. While magnetic gears enjoy distinct advantages over mechanical gears such as inherent overload protection, they are not as torsionally stiff as their mechanical counterparts. As such, the use of damper windings for the purpose of stiffening the gear against transient oscillations is also investigated. Several competing designs are investigated for their performance, and a final design is studied which is capable of arresting transient oscillations in less than a second. In addition, a prototype has been fabricated and will be used to verify the analysis undertaken. The prototype is used to verify variations of the stator pole pieces as well as the inner rotor magnetic layout. A dynamometer has been assembled to test the performance of the prototype. A new design is also proposed for future work.

Thesis (MScEng)--Stellenbosch University, 2012. / ENGLISH ABSTRACT: This thesis is a description of how the first magnetically geared axial flux permanent magnet generator (MGAFG) is designed, constructed and experimentally evaluated. Magnetic gears (MGs) allow for contact-less power transfer and lubricant free operation, which may solve the reliability concerns with current mechanically geared wind energy converters. However, the complex structure of MGs may present serious challenges to its design. Thus, special care should be given to the mechanical layout and the electromagnetic influence of every component. The MGAFG can be configured to be magnetically coupled or decoupled. In the coupled configuration the permanent magnets (PMs) of the MG contribute to the total flux linkage in the PM generator (PMG). The coupled configuration is therefore more efficient. The processing time required to optimise the decoupled configuration is however much faster, since the MG and the PMG can be optimised separately. The optimised results show that a torque density in excess of 100kNm/m3 could be achieved, which is significantly higher than any of known electrical machines. However, owing to excessive losses in the mechanical support structures, the prototype exhibited lower torque density and poor efficiency. The design related aspects and issues are analysed and discussed in detail in an attempt to outline problem areas in the design process. Relevant recommendations are also given for future design improvements. The costs of magnetic material accounts for over fifty percent of the total cost of the prototype. Therefore to make the manufacturing of the MGAFG more economically viable magnetic material should be minimised in the design process. / AFRIKAANSE OPSOMMING: In hierdie tesis word die eerste magnetiese geratte aksiale vloed permanente magneet generator (MGAVG) ontwerp, vervaardig en eksperimenteel geëvalueer. In magnetiese ratte (MR) is daar geen kontak tussen werkende dele nie, daarom word geen smeermiddels benodig nie. Dit dra by tot die betroubaarheid van die ratkaste in wind energie generators en kan onderhoud grotendeels uitskakel. Die komplekse struktuur van magnetiese ratte kan egter die betroubaarheid van die ontwerp juis verswak. Daarom moet die meganiese uitleg noukeurig beplan word sodat dit nie die elektromagnetiese werking ondermyn nie. Die magnetiese rat (MR) en die permanente magneet generator (PMG) van die masjien kan magneties of sonder magnetiese koppeling verbind word. In die gekoppelde konfigurasie dra all die permanente magnete van die MR gesamentlik by tot die totale vloed-koppeling in die PMG. Wat die magnetiese gekoppelde konfigurasie meer doeltrefend maak. Minder tyd word benodig om die nie magnetiese gekoppelde konfigurasie te optimaliseer omdat die MR en die PMG apart geoptimaliseer kan word. Die optimale resultate toon dat ’n wringkrag van meer as 100kNm/3 bereik kan word, wat aansienlik beter is as die van bekende elektriese masjiene. Maar as gevolg van oormatige verliese in die meganiese strukture, toon die prototipe lae wringkrag digtheid en swak doeltreffendheid. Die ontwerp probleme word ontleed en bespreek in ’n poging om probleem areas in die ontwerp te identifiseer. Relevante aanbevelings word gegee vir toekomstige ontwerp verbeterings. Die koste van die magnetiese material verteenwoordig meer as vyftig persent van die vervaardigings koste van die prototipe. Koste kan bespaar word op die vervaardiging van die MGAVG deur die hoeveelheid magnete wat gebruik word te beperk.

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