Design Optimisation of MAGSPLIT

- a Magnetic Power Split e-CVT

P. Chmelicek , S.D. Calverley, R.E. Clark

Magnomatics Limited
 Presentation Outline

Intro
Magnetic Gears principles
Magnetically Geared Motors
Variable Magnetic Gear
Magnetic Power Split
Design optimisation of MagSplit using Opera

Testing and system performance

Evolution to two-rotor Magsplit

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Background

Company
Spin out from University of Sheffield - formed in 2006
30 full time staff 23 engineers (7 PhDs)
2 Sites in Sheffield
Main office & production + satellite test facility
3 Dynamometer systems (50kW, 150kW & 300kW)
21 patent families, 5 granted
ISO9001 accreditation - 2012

Opera
First seats purchased in 2007
Currently 8 seats (six 2D & two 3D)
8 users
Main design tool for electromagnetics

OPERA EUGM 2014

 Presentation Outline

Intro
Magnetic Gears principles
Magnetically Geared Motors
Variable Magnetic Gear
Magnetic Power Split
Design optimisation of MagSplit using Opera

Testing and system performance

Evolution to two-rotor Magsplit

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Magnetic Gears
Analogous to Mechanical Planetary Gears

Permanent Magnets
High speed magnet rotor (HSR)
(Sun Gear) Ferromagnetic Pole-Pieces

Benefits of magnetic
transmissions

Increased efficiency (>99%)

No transmission oil
Low noise & vibration
Improved reliability
Reduced maintenance
Overload protection
Range 1:1 to 1:15
Steel pole piece rotor (PPR)
(Planet carrier)

Low speed magnet rotor (LSR)

(Ring gear)

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Magnetic Gear - principle of operation

23 pole pair permanent magnets

rotating flux field
Insert 27 steel pole piece ring
Steel provides flux path
4 pole pair dominant harmonic now seen
at inner gap
Gear ratio 1 : 23/4 = 5.75

Back Iron N S
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Magnetic Gear - principle of operation

Back Iron N S
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Magnetic Gear - Field Line Animation

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Magnetic gear application example
Thru-wall gearing
Transmit geared torque through a barrier
Pole-piece structure provides seal wall
Isolates shafts
Use in pumps, flywheel energy storage, etc

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Derived Products

PDD - Pseudo
Direct Drive
High Torque motors and
generators with integrated
magnetic transmission

Magnetic CVT/MAGSPLIT
Continuously variable transmission.
Magnetic Gear Power split device
Passive, fixed ratio

OPERA EUGM 2014

 Presentation Outline

Intro
Magnetic Gears principles
Magnetically Geared Motors
Variable Magnetic Gear
Magnetic Power Split
Design optimisation of MagSplit using Opera

Testing and system performance

Evolution to two-rotor Magsplit

OPERA EUGM 2014 11

 PDD - Aerospace Actuation

Electro-mechanical actuation (control surfaces etc)

Inherent torque fuse (overload protection)
Very high torque density

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 PDD Traction Motors Commercial vehicle wheel hub

2- 4 kNm direct drive wheel motor

Urban delivery vehicle / city bus
Fits with 22 wheel rim
High efficiency over wide range

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300kW 16,000 Nm Magnetically Geared Permanent Magnet
Propulsion Motor
De-risking program for multi-MegaWatt machines
16kNm, 180rpm demonstrator built & tested

OPERA EUGM 2014

 Presentation Outline

Intro
Magnetic Gears principles
Magnetically Geared Motors
Variable Magnetic Gear
Magnetic Power Split
Design optimisation of MagSplit using Opera

Testing and system performance

Evolution to two-rotor Magsplit

OPERA EUGM 2014 15

Inverted Gear
Magnetic Gears not limited to big wheel small wheel principle

Inner Sun gear (high speed rotor) Outer Sun Gear

Analogous to Mechanical Planetary Impossible with mechanical gear

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Three rotor system

HSR NPPHS = 3

PPR NPP = 13

LSR NPPLS = 10

Input (PPR) : Output (LSR)

N PPHS N PPPP N PPLS LS

HS

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1. Control Rotor = 0 rpm
Intrinsic gear ratio = 1:1.3 (13/10)

Ratio 1:1.3 (1300/1000)

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2. Control rotor -500rpm

Ratio 1:1.6 (800/500)

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3. Control rotor = +500rpm

Ratio 1:1.2 (1800/1500)

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4. Declutch

Ratio 1 : 0

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5. Reverse

Ratio 1:-0.2 (-200/1000)

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Variable Ratio Magnetic Gear
- Integrated Control Machine

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 Presentation Outline

Intro
Magnetic Gears principles
Magnetically Geared Motors
Variable Magnetic Gear
Magnetic Power Split
Design optimisation of MagSplit using Opera

Testing and system performance

Evolution to two-rotor Magsplit

OPERA EUGM 2014 24

Variable Magnetic Gear as a POWER SPLIT

Outer machine controls speed of

external sun rotor
As machine is reacting torque, it
Pelec
acts as motor/generator
Power exported/imported from/to
mechanical powertrain
Pmech_in Pmech_out 4 quadrant electrical system
(sinks and sources power)

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 Blended Hybrid Vehicle - e-CVT architecture
Mechanical Power Split Device

Planetary gear acts as power a

power split device
Motor/Generator 1 connected to
sun gear (complex shaft
arrangement)

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Mechanical power split Hybrid power train

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 Concentric packaging of Mag Gear and MG1

Inverted gear simplifies shaft arrangement

Short concentric package

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MAGSPLIT TSB Funded Projects

TSB LCV mCVT for Heavy Duty

TSB HVM MagSplit

OPERA EUGM 2014

 Presentation Outline

Intro
Magnetic Gears principles
Magnetically Geared Motors
Variable Magnetic Gear
Magnetic Power Split
Design optimisation of MagSplit using Opera

Testing and system performance

Evolution to two-rotor Magsplit

OPERA EUGM 2014 30

Multi-Rotor / Multi-Airgap models

Multiple airgap models

Stator + 2 rotors with 2 airgaps
Stator + 3 rotors with 3 airgaps

Stator
Airgap 3
High speed control rotor
Airgap 2

Pole-piece rotor (input)

Airgap 1
PM rotor (output)

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Magsplit operation - animation

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In-house Model Builder
Generic tool for PDD/Magnetic Gears/Magsplit

Control Pole-piece Inner

Stators
rotors rotors rotors

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Parametric models

Models built from library of standard

Magnomatics components
2 and 3 rotor models built from same library of
components
All models fully parameterised
Automated scanning using COMI files

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Analysis driven design now possible

Fast 2D FEA models

Very large design sweeps possible with Pareto optimum type post-processing

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 Validation of 2D design

Due to the aspect ratio of air gap length to axial length, the 2D design has to be
validated by 3D model

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 Magnetic Forces

Pole pieces subject to complex forces

radial magnetic forces / circumferential torque loads, and torsion about own axis
Maxwell stress contour taken around pole-piece
Forces currently extracted and used in external mechanical FEA models
Calculate deflections / material selection etc

Animation of pole-piece force vectors

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 Eddy current losses in solid bodies

Dynamic CARMEN model is used for eddy current loss prediction

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 Magnet loss analysis

The same approach is used to determine magnet loss and required segmentation of
conductive magnets

3D slice model

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 AC copper loss analysis

Time-stepping RM solver is used for AC copper loss analysis (proximity effects)

Each strand in a coil is modelled as a separate conductor and coupled to an external
electrical circuit

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Iron Loss Analysis
Data links with external analysis code

Flux loci for each element exported for further post-processing

In-house tool built on matlab platform

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Efficiency mapping
Complex 3-dimensional functions ( dependent on 2 speeds and torque)

Copper loss Engine speed (rpm)

0 3000 6000
6000 40Nm
60Nm
80Nm
100Nm
120Nm

Output speed (rpm)

140Nm
160Nm
Iron loss 180Nm
3000

0
Magnet loss

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 System controller optimisation

Vehicle efficiency dependent on ICE, MAGSPLIT, battery and traction motor

Vehicle controller optimises power flow through all components
Optimisation employs large number of driving cycles

140km/h

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Optimisation of Magsplit gear ratio
Effect on battery charge and engine speed
Vehicle speed
[km/h]

Time [s]
Battery SOC
[%]

Time [s] Battery charge

swing reduced
by ratio selection
Engine speed
[rpm]

Time [s]
Engine down-speeding
Planetary Magsplit at higher vehicle speeds

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 Presentation Outline

Intro
Magnetic Gears principles
Magnetically Geared Motors
Variable Magnetic Gear
Magnetic Power Split
Design optimisation of MagSplit using Opera

Testing and system performance

Evolution to two-rotor Magsplit

OPERA EUGM 2014 45

 Magsplit components (200Nm)

Stator Pole piece rotor and flywheel

Stator and Inner Magnet Rotor Assembly

Magsplit
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Testing

Fully automated testing

Maps full operating range
Representative drive cycles
Transient and heat soak tests

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Magsplit test video

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Transmission efficiency
MAGSPLIT Benefits

Direct

In-Direct

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Why Magsplit hybrid is more efficient than a planetary hybrid?

Define intrinsic gear ratio as sun/ring

Typical planetary ratio ~ 0.40 Typical Magsplit ratio >0.7

(Feasible 0.25 - 0.67 )

1. Magsplit hybrid transfers more energy along the direct paths from the fuel tank
to the wheels than the planetary hybrid (most efficient path no inverter/battery
losses) due to optimum gear ratio

2. The efficiency of both direct and indirect energy flow paths is higher for the
Magsplit hybrid

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 Presentation Outline

Intro
Magnetic Gears principles
Magnetically Geared Motors
Variable Magnetic Gear
Magnetic Power Split
Design optimisation of MagSplit using Opera

Testing and system performance

Evolution to two-rotor Magsplit

OPERA EUGM 2014 51

MagSplit 2 - two rotor system

Magsplit 1 Magsplit 2

3 rotors 2 rotors
System reduced to a dual rotor system by deleting the control/HSR rotor

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Virtual Rotor Animation

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Rapid development Concept to fully tested hardware

Smart award
funding

<7 months

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Which MAGSPLIT?

MAGSPLIT 1 MAGSPLIT 2
3 - rotors 2 - rotors

Dominant speed dependent losses Dominant torque dependent losses

Choice of device is made by assessing driving cycle behaviour

Low speed, extended periods of high torque (commercial vehicles) > MAGSPLIT1
High speed, intermittent high torque (passenger cars) > MAGSPLIT2

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MAGSPLIT 2 differences

Up to 70% reduction in magnet mass

Reduction in part count

Removal of a bearing and associated drag loss

Increased load dependent losses, but reduced speed dependent losses

200Nm for C-class passenger car

Magsplit type Key features Magnet mass
Magsplit1 3 rotors, surface mount magnets N40SH 3.3kg
Magsplit2a 2 rotors, surface mount magnets N40SH 2.0kg
Magsplit2b 2 rotors, interior magnets N48H 1.5kg

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 Magsplit benefits

Benefits over typical drive cycles (fuel economy)

C Class eCVT (hybrid) 3 5%
Conventional Bus (non-hybrid) >36%
Urban HGV (non-hybrid) - 30%

Reduces system complexity

Removes system components (delete dual mass flywheel)

High potential for reduced system cost

No lubrication
Lower battery charge swing
Battery downsized or life extended

Short concentric package

Eases crash protection

Scalable (Car, HGV, Off-Highway)

High reliability

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Magnomatics Limited
Park House
Bernard Road
Sheffield
S2 5BQ
UK

Tel: (+44) 114 241 2570

Email: [email protected]

www.magnomatics.com