The document discusses the design optimization of Magnomatics' Magnetic Power Split e-CVT called MAGSPLIT® using Opera software. It describes how Opera is used to build multi-rotor models of MAGSPLIT® and analyze magnetic forces, losses, and efficiency mapping to optimize the design. Testing results showed MAGSPLIT® can achieve higher transmission efficiency than a conventional planetary hybrid system.
The document discusses the design optimization of Magnomatics' Magnetic Power Split e-CVT called MAGSPLIT® using Opera software. It describes how Opera is used to build multi-rotor models of MAGSPLIT® and analyze magnetic forces, losses, and efficiency mapping to optimize the design. Testing results showed MAGSPLIT® can achieve higher transmission efficiency than a conventional planetary hybrid system.
The document discusses the design optimization of Magnomatics' Magnetic Power Split e-CVT called MAGSPLIT® using Opera software. It describes how Opera is used to build multi-rotor models of MAGSPLIT® and analyze magnetic forces, losses, and efficiency mapping to optimize the design. Testing results showed MAGSPLIT® can achieve higher transmission efficiency than a conventional planetary hybrid system.
The document discusses the design optimization of Magnomatics' Magnetic Power Split e-CVT called MAGSPLIT® using Opera software. It describes how Opera is used to build multi-rotor models of MAGSPLIT® and analyze magnetic forces, losses, and efficiency mapping to optimize the design. Testing results showed MAGSPLIT® can achieve higher transmission efficiency than a conventional planetary hybrid system.
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
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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
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Magnetic Gears
Analogous to Mechanical Planetary Gears
High speed magnet rotor (HSR)
(Sun Gear)
Permanent Magnets 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
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. Power split device
Magnetic Gear Passive, fixed ratio
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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
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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
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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Inverted Gear
Magnetic Gears not limited to big wheel small wheel principle
Inner Sun gear (high speed rotor)
Analogous to Mechanical Planetary
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Outer Sun Gear
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
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Variable Magnetic Gear as a POWER SPLIT
Pelec
Pmech_in
Pmech_out
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Outer machine controls speed of
external sun rotor
As machine is reacting torque, it
acts as motor/generator
Power exported/imported from/to
mechanical powertrain
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
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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
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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
Stators
Control rotors
Pole-piece rotors
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Inner 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
Iron loss
Output speed (rpm)
6000
3000
6000 40Nm 60Nm 80Nm 100Nm 120Nm 140Nm 160Nm 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
Vehicle speed [km/h]
Effect on battery charge and engine speed
Battery SOC [%]
Time [s]
Engine speed [rpm]
Time [s]
Planetary
Battery charge swing reduced by ratio selection
Engine down-speeding at higher vehicle speeds
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Time [s]
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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
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Magsplit components (200Nm)
Stator
Pole piece rotor and flywheel
Stator and Inner Magnet Rotor Assembly
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Magsplit 46
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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MAGSPLIT Benefits Transmission efficiency
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 (Feasible 0.25 - 0.67 )
Typical Magsplit ratio >0.7
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
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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 OPERA EUGM 2014
Which MAGSPLIT?
MAGSPLIT 1 3 - rotors
Dominant speed dependent losses
MAGSPLIT 2 2 - rotors
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 OPERA EUGM 2014
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Magnomatics Limited Park House Bernard Road Sheffield S2 5BQ UK Tel: (+44) 114 241 2570 Email: magnomatics@magnomatics.com www.magnomatics.com
