Design Optimisation of MAGSPLIT - a Magnetic Power Split e-cvt. P. Chmelicek, S.D. Calverley, R.E. Clark Magnomatics Limited

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1 Design Optimisation of MAGSPLIT - a Magnetic Power Split e-cvt P. Chmelicek, S.D. Calverley, R.E. Clark Magnomatics Limited

2 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 2

3 Background Company Spin out from University of Sheffield - formed in 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 Opera First seats purchased in 2007 Currently 8 seats (six 2D & two 3D) 8 users Main design tool for electromagnetics

4 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 4

5 Magnetic Gears Analogous to Mechanical Planetary Gears High speed magnet rotor (HSR) (Sun Gear) Permanent Magnets Ferromagnetic Pole-Pieces Benefits of magnetic transmissions Steel pole piece rotor (PPR) (Planet carrier) Increased efficiency (>99%) No transmission oil Low noise & vibration Improved reliability Reduced maintenance Overload protection Range 1:1 to 1:15 Low speed magnet rotor (LSR) (Ring gear) 5

6 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 6

7 Magnetic Gear - principle of operation Back Iron N S 7

8 Magnetic Gear - Field Line Animation 8

9 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

10 Derived Products PDD - Pseudo Direct Drive High Torque motors and generators with integrated magnetic transmission Magnetic Gear Passive, fixed ratio Magnetic CVT/MAGSPLIT Continuously variable transmission. Power split device

11 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 11

12 PDD - Aerospace Actuation Electro-mechanical actuation (control surfaces etc) Inherent torque fuse (overload protection) Very high torque density

13 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

14 300kW 16,000 Nm Magnetically Geared Permanent Magnet Propulsion Motor De-risking program for multi-megawatt machines 16kNm, 180rpm demonstrator built & tested

15 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 15

16 Inverted Gear Magnetic Gears not limited to big wheel small wheel principle Inner Sun gear (high speed rotor) Analogous to Mechanical Planetary Outer Sun Gear Impossible with mechanical gear 16

17 Three rotor system HSR N PPHS = 3 PPR N PP = 13 LSR N PPLS = 10 Input (PPR) : Output (LSR) HSN PPHS N PP PP N PPLS LS 17

18 1. Control Rotor = 0 rpm Intrinsic gear ratio = 1:1.3 (13/10) Ratio 1:1.3 (1300/1000) 18

19 2. Control rotor -500rpm Ratio 1:1.6 (800/500) 19

20 3. Control rotor = +500rpm Ratio 1:1.2 (1800/1500) 20

21 4. Declutch Ratio 1 : 0 21

22 5. Reverse Ratio 1:-0.2 (-200/1000) 22

23 Variable Ratio Magnetic Gear - Integrated Control Machine 23

24 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 24

25 Variable Magnetic Gear as a POWER SPLIT Outer machine controls speed of external sun rotor P mech_in P elec P mech_out 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) 25

26 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) 26

27 Mechanical power split Hybrid power train

28 Concentric packaging of Mag Gear and MG1 Inverted gear simplifies shaft arrangement Short concentric package 28

29 MAGSPLIT TSB Funded Projects TSB LCV mcvt for Heavy Duty TSB HVM MagSplit

30 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 30

31 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) 31

32 Magsplit operation - animation 32

33 In-house Model Builder Generic tool for PDD/Magnetic Gears/Magsplit Stators Control rotors Pole-piece rotors Inner rotors 33

34 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 34

35 Analysis driven design now possible Fast 2D FEA models Very large design sweeps possible with Pareto optimum type post-processing 35

36 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 36

37 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 37

38 Eddy current losses in solid bodies Dynamic CARMEN model is used for eddy current loss prediction 38

39 Magnet loss analysis The same approach is used to determine magnet loss and required segmentation of conductive magnets 3D slice model 39

40 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 40

41 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 41

42 Output speed (rpm) Efficiency mapping Complex 3-dimensional functions ( dependent on 2 speeds and torque) Copper loss Iron loss Engine speed (rpm) Nm 60Nm 80Nm 100Nm 120Nm 140Nm 160Nm 180Nm Magnet loss 0 42

43 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 43

44 Engine speed [rpm] Battery SOC [%] Vehicle speed [km/h] Optimisation of Magsplit gear ratio Effect on battery charge and engine speed Time [s] Time [s] Battery charge swing reduced by ratio selection Planetary Magsplit Engine down-speeding at higher vehicle speeds Time [s] 44

45 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 45

46 Magsplit components (200Nm) Stator Pole piece rotor and flywheel Stator and Inner Magnet Rotor Assembly Magsplit 46

47 Testing Fully automated testing Maps full operating range Representative drive cycles Transient and heat soak tests 47

48 Magsplit test video 48

49 Transmission MAGSPLIT Benefits efficiency Direct In-Direct

50 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 ) 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 50

51 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 51

52 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 52

53 Virtual Rotor Animation 53

54 Rapid development Concept to fully tested hardware Smart award funding <7 months

55 Which MAGSPLIT? MAGSPLIT rotors MAGSPLIT 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 55

56 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 56

57 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 57

58 Magnomatics Limited Park House Bernard Road Sheffield S2 5BQ UK Tel: (+44)

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