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Design and fabrication of MAGNETIC TRANSMISSION system

ABSTRACT

Neodymium magnets are powerful magnets which are about 12 times stronger than normal magnets used in speakers. With the
advent of magnetic gears, researchers have developed a new breed of permanent-magnet machines. These magnetic geared
permanent-magnet machines artfully incorporate the concept of magnetic gearing into the permanent-magnet machines, leading
to achieve low-speed high-torque direct-drive operation. Gears and gearboxes are extensively used for speed change and torque
transmission in various industrial applications. It is well known that the mechanical gear has a high torque density, but suffers
from some inherent problems such as contact friction, noise, heat, vibration and reliability are of great concern. In order to
avoid these types of problems we are using magnetic meshing gears. That is the gears are meshed together with the help of
magnetic force of attraction without making into contact. By using such kind of gearing systems we can reduce the wear and
tear that are commonly seen in mechanical spur gear systems and the magnetic gears works smoothly without any sound and
the main advantage of magnetic gearing is it will not get heated as long as it works. Magnetic gearing systems can be used in
vehicle transmissions that reduce the friction and improve the efficiency without usingany type of additional lubricants. We are
using high power rare earth neodymium magnets for the purpose of making gears.

ISBM COLLEGE OF ENGINEERING PUNE [BE Mechanical]


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Design and fabrication of MAGNETIC TRANSMISSION system

TABLE OFCONTENT

CHAPTER NO. TITLE NAME


ABSRACT
CONTENT
LIST OF FIGURES
LIST OF TABLES
CHAPTER 1 INTRODUCTION
1.1 PROBLEM STATEMENT
1.2 OBJECTIVES
1.3 SCOPE
1.4 METHODOLOGY
CHAPTER 2 LITERATURE REVIEW

CHAPTER 3 NEODYMIUM MAGNET

CHAPTER 4 DESIGN OF PART


4.1 BIG MAGNETIC WHEEL
4.2 FRAME STRUCTURE
4.3 MS SHAFT
4.4 HOUSING BEARING
4.5 SMALL MAGNETIC WHEEL
4.6 NEODYMIUM MAGNET
4.7 MOTOR
CHAPTER 5 MATERIAL SELECTION
CHAPTER 6 PART OF MAGNETIC
TRANSMISSION
CHAPTER 7 CONSTRUCTION & WORKING

7.1 CONSTRUCTION
7.2 WORKING

CHAPTER 9 COST ESTIMATION

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Design and fabrication of MAGNETIC TRANSMISSION system
CHAPTER 10 ADVANTAGES & APPLICATIONS
10.1 ADVANTAGES
10.2 APPLICATIONS
CHAPTER 11 CONCLUSION
CHAPTER 12 FUTURE SCOPE

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Design and fabrication of MAGNETIC TRANSMISSION system

LIST OFFIGURES

FIGURE NO FIGURE NAME

Systematic components assembly of Model


1.1

1.2 Methodology

2.1 Big magnetic wheel

2.2 Drawing Frame


Structure
2.3 Frame Structure
2.4 MS Shaft
2.5 Housing Bearing
2.6 Small Magnetic Wheel

2.7 Neodymium magnets

2.8 Motor

LIST OF TABLES

TABLE NO TABLE NAME

1 Observation Table
2 Cost Estimation

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Design and fabrication of MAGNETIC TRANSMISSION system

1. INTRODUCTION

The power transmission is mechanical in most machines, and it is commonly achieved


in the use of gear transmissions. Mechanical gear transmissions have a high torque
density, but the friction occurs in them, which is often the cause of thegear failure.
Also, the noise, heat and vibration are present, so the reliability of these gears is reduced.
Nowadays, it is more and more taken care of the energy conservation, and therefore
the environment as well, when designing new products. The goal is to reduce the noise,
vibration, to simplify maintenance more, reduce heat and reduce dimensions. The
magnetic gears are the new type of gears, which attract the attention of the constructors
because of the possibility to overcome some of these problems. These are non-contact
gears, where the power and torque transmission is achieved with the help of magnetic
forces. Friction, wear and fatigue are not present in magnetic gears, they do not require
lubrication, and they can be applied as a protective mechanism against overloading. They
can operate in a wide temperature range, from -270°C to 350°C. Also, the operation is
reversible, so the same device, in which they are installed, can be used as a reducer and
as a multiplier

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Design and fabrication of MAGNETIC TRANSMISSION system

Fig 1.1: Systematic components assembly of Model

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Design and fabrication of MAGNETIC TRANSMISSION system

1.1 PROBLEM STATEMENT

Power Transmission is major part in industry and automobile and other sector. When Power transmission
comes mechanical gears also comes but life of mechanical gear reduce due to friction and wear. Failure due
to Overload and improper periodic lubrication and maintenance.

1.2 OBJECTIVES

● Reduce Friction and wear and increase life cycle of gear by implementing magnetic gear.

● Avoid Failure during overload and overheated condition.

● Reduce Noise, Vibration by contact-less power transmission.

● Avoid Periodic lubrication and maintenance.

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Design and fabrication of MAGNETIC TRANSMISSION system

1.3 SCOPE

As the automobile is one of the most rising sector this project can have very good
advantages for power transmission in automobile. Also use for power transmission in
Conveyor belt over chain.
Magnetic gears are becoming competitive alternatives to conventional gears. They
present no contact and no wear. They do not produce debris and they do not require
lubricant, being able to be operated at abroad range of temperature ranging from - 270ºC
up to 350ºC. They present intrinsic anti-jamming properties and there is a clutching effect
if the applied torque exceeds a limit therefore protecting the output from overloads.
This effect is completely reversible without any damage or wear. This technology is
currently increasing making it available for consideration for aerospace uses. The
radically different behavior against torque overloads, the isolation of vibrations, the
absence of maintenance, the compatibility with sand or dust, broad temperature range
and the through wall capability are some properties that make these devices attractive
for aerospace and other future applications.

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Design and fabrication of MAGNETIC TRANSMISSION system

1.4 METHODOLOGY

IDENTIFICATION OF NEED

LITERATURE REVIEW

PROBLEM STATEMENT

CONCEPTUAL DESIGN

DETAILED DESIGN

DETAILED CALCULATIONS

FEASIBILITY OF DESIGN

EVALUATION

FABRICATIONS AND ASSEMBLY

TEST EXECUTION AND ERROR CORRECTIONS

REPORT PREPARATION

FINAL SUBMISSION

Fig 1.2 Methodology

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Design and fabrication of MAGNETIC TRANSMISSION system

2. LITERATURE REVIEW

[1] Magnetic Gear Technologies:


Theoretical and experimental approach
(September 2014)
Gear and geared machines are widely used in a broad spectrum of industry, where the rotational speed of an
input source must be matched to the required rotational speed of an output load. Mechanical gears are often
employed for this purpose but they are subject to wear, can overheat, are often damaged in an over-torque
situation and require periodic lubrication and maintenance. So contactless transmission reduce this
problems.

[2} The development of magnetic gears for transportation application


(Number 1, 2017) International Journal of Engineering Research and General Science Volume 4,
Issue 1, January-February, 2016 ISSN 2091-2730
These are non-contact gears, where the power and torque transmission is achieved with the help of
magnetic forces. Friction, wear and fatigue are not present in magnetic gears, they do not require
lubrication, and they can be applied as a protective mechanism against overloading. They can operate in a
wide temperature range, from -270°C to 350°C. Also, the operation is reversible, so the same device, in
which they are installed, can be used as a reducer and as a multiplier.

[3] Review on Parking Lateral play in Four Wheeler


(1 June 2009) Journal of Asian Electric Vehicles
This paper proposes an integrated Halbach-magnetic-geared permanent-magnet (PM) motor to meet the
new demands arising from electric vehicles. It can offer the advantages of lightweight, compact size and low-
speed high-torque operation. The key is to newly incorporate the Halbach arrays into the coaxial magnetic
gear (MG) in such a way that the PM motor field and the MG field are decoupled.

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Design and fabrication of MAGNETIC TRANSMISSION system

[4] Advancements in Automatic Hand Brake System


(July 2001) Atallah, K IEEE Transactions on Magnetics 37(4):2844 - 2846
Automatic hand brake release mechanism is beneficial for operator’s safety by reducing accident chances
as well as disengaging chances of braking. This system can also be used in commercial cars for ease of
operating as well for reducing cost purpose. The working is quite simple and doesn’t require any extra
effort to operator or driver.

[5] Electrical Machines and Systems (ICEMS), 2012 15th International Conference (January 2012)
Electrical Machines and Systems (ICEMS), 2012 15th International Conference on: 10.4271/2013-01-
0199 ISSN 0148-7191
This paper presents some calculated and measured results of a surface permanent magnet (SPM) magnetic
gear. First, the torque characteristics, iron loss in the core, and eddy current loss in permanent magnets of
the magnetic gear are calculated by three-dimensional finite element analysis (3D-FEA). Next, no-load and
load test results of the trial magnetic gear are indicated. The experimental results are comparison with the
ones obtained from the FEA.

[6] A novel high-performance magnetic gear IEEE


IEEE transactions on magnetics, Institute of Electrical and Electronics Engineers transactions on
magnetics April 2013
In this paper, a novel magnetic planetary gear (MPG) is proposed and illustrated, which is composed of one
magnetic sun gear, one magnetic ring gear, and three magnetic planet gears. Because the contact-free gear
structure results in lower stiffness, proper design methods are needed to improve gear properties.

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Design and fabrication of MAGNETIC TRANSMISSION system

3. Neodymium magnets

Neodymium is a metal which is ferromagnetic, meaning that like iron it can be magnetized to become
a magnet, but its Curie temperature (the temperature above which its ferromagnetism disappears) is
19 K (−254.2 °C; −425.5 °F), so in pure form its magnetism only appears at extremely low
temperatures. However, compounds of neodymium with transition metals such as iron can have Curie
temperatures well above room temperature, and these are used to make neodymium magnets.

The strength of neodymium magnets is the result of several factors. The most important is that
the tetragonal Nd2Fe14B crystal structure has exceptionally high uniaxial magneto crystalline
anisotropy (HA ≈ 7 T – magnetic field strength H in units of A/m versus magnetic moment in
A·m2). This means a crystal of the material preferentially magnetizes along a specific crystal axis but
is very difficult to magnetize in other directions. Like other magnets, the neodymium magnet alloy is
composed of microcrystalline grains which are aligned in a powerful magnetic field during
manufacture so their magnetic axes all point in the same direction. The resistance of the crystal lattice
to turning its direction of magnetization gives the compound a very high coercivity, or resistance to
being demagnetized

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Design and fabrication of MAGNETIC TRANSMISSION system

4. Design of part

4.1 Big magnetic wheel:

150 mm Nylon wheel machined and 20 mm circular Slot made for neodymium magnets. Neodymium
magnets pressed in slots.

Fig 2.1: Big magnetic wheel

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Design and fabrication of MAGNETIC TRANSMISSION system

4.2 Frame Structure:

Frame structure is made from 40*40 mm MS Square pipe on this frame Motor, Small and Big magnetic
wheel assembled with housing bearing.

Fig 2.2: Drawing Frame Structure

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Design and fabrication of MAGNETIC TRANSMISSION system

Fig 2.3: Frame Structure

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Design and fabrication of MAGNETIC TRANSMISSION system

4.3 MS Shaft:

20 MM Diameter MS rod with 285 mm length used for power Transmission From small gear to big gear
and small gear mounted on this shaft.

Fig 2.4: MS Shaft

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Design and fabrication of MAGNETIC TRANSMISSION system

4.4 Housing Bearing:

Standard housing bearing used for mount shaft from both end.
ID – 20 mm

Fig 2.5: Housing Bearing

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Design and fabrication of MAGNETIC TRANSMISSION system

4.5 Small Magnetic Wheel:


Dia. 60 mm Nylon wheel machined and 20 mm rectangular slot made for neodymium
magnets. Neodymium magnets pressed in slots.

Fig 2.6: Small Magnetic Wheel

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Design and fabrication of MAGNETIC TRANSMISSION system

4.6 Neodymium magnets:

Circular Neodymium magnets-


OD- 20mm
Thickness- 5mm

Rectangular Neodymium magnets-


Length – 30 mm
Width – 10 mm
Thickness – 5mm

Fig 2.7: Neodymium magnets

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Design and fabrication of MAGNETIC TRANSMISSION system

4.7 MOTOR:

Power Requirement – 230V

Power Cunsumption-50 watt

Fig 2.8: Motor

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Design and fabrication of MAGNETIC TRANSMISSION system

5. MATERIAL SELECTION

The proper selection of material for the different part of a machine is the main objective in the fabrication
of machine. For a design engineer it is must that he be familiar with the effect, which the manufacturing
process and heat treatment have on the properties of materials. The Choice of material for engineering
purposes depends upon the following factors:
1. Availability of the materials.
2. Suitability of materials for the working condition in service.
3. The cost of materials.
4. Physical and chemical properties of material.
5. Mechanical properties of material.

The mechanical properties of the metals are those, which are associated with the ability of the material to
resist mechanical forces and load. We shall now discuss these properties as follows:

1. Strength: It is the ability of a material to resist the externally applied Forces.


2. Stress: Without breaking or yielding. The internal resistance offered by a part to an externally applied
force is called stress.
3. Stiffness: It is the ability of material to resist deformation under stresses.
4. Elasticity: It is the property of a material to regain its original shape after deformation when the
external forces are removed. This property is desirable for material used in tools and machines. It may
be noted that steel is more elastic than rubber.
5. Plasticity: It is the property of a material, which retain the deformation produced under load
permanently. This property of material is necessary for forging, in stamping images on coins and in
ornamental work.
6. Ductility: It is the property of a material enabling it to be drawn into wire with the application of a
tensile force. A ductile material must be both strong and plastic. The ductility is usually measured by
the terms, percentage elongation and percent reduction in area. The ductile materials commonly used in
engineering practice are mild steel, copper, aluminum, nickel, zinc, tin and lead.

7. Brittleness: It is the property of material opposite to ductile. It is property of breaking of a material


with little permanent distortion. Brittle materials when subjected to tensile loads snap off without giving
any sensible elongation. Cast iron is a brittle material.

8. Malleability: It is a special case of ductility, which permits material to be rolled or hammered into thin
sheets, a malleable material should be plastic but it is not essential to be so strong. The malleable
materials commonly used in engineering practice are lead, soft steel, wrought iron, copper and
aluminum.

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Design and fabrication of MAGNETIC TRANSMISSION system

9. Toughness: It is the property of a material to resist the fracture due to high impact loads like hammer
blows. The toughness of the material decreases when it is heated. It is measured by the amount of
absorbed after being stressed up to the point of fracture. This property is desirable in parts subjected to
shock an impact loads.

10. Resilience: It is the property of a material to absorb energy and to resist rock and impact loads. It is
measured by amount of energy absorbed per unit volume within elastic limit. This property is essential
for spring material.

11. Creep: When a part is subjected to a constant stress at high temperature for long period of time, it will
undergo a slow and permanent deformation called creep. This property is considered in designing
internal combustion engines, boilers and turbines.

12. Hardness: It is a very important property of the metals and has wide variety of meanings. It embraces
many different properties such as resistance to wear scratching, deformation and machinability etc. It
also means the ability of the metal to cut another metal. The hardness is usually expressed in numbers,
which are dependent on the method of making the test.

The selection of the materials depends upon the various types of stresses that are set up during
operation. The material selected should with stand it. Another criteria for selection of metal depend
upon the type of load because a machine part resist load more easily than a live load and live load more
easily than a shock load. Selection of the material depends upon factor of safety, which in turn depends
upon the following factors.

1. Reliabilities of properties
2. Reliability of applied load
3. The certainty as to exact mode of failure
4. The extent of simplifying assumptions
5. The extent of localized
6. The extent of initial stresses set up during manufacturing

Material Used L Shape Mounting Bracket: Mild Steel

1. M.S. has carbon content from 0.15% to 0.30%. They are easily weld able thus can be hardened only.
2. They are similar to wrought iron in properties. Both ultimate tensile and compressive strength of
these steel increases with increasing carbon content. They can be easily gas welded or electric or arc
welded.

3. Mild steel is readily available in market. It is economical to use and it is available in standard sizes.

4. It has moderate factor of safety, because factor of safety results in unnecessary wastage of material
and heavy selection. Low factor of safety results in unnecessary risk of failure.

5. It has good mechanical properties. I.e. it is easily machinable.

6. It has high tensile strength and Low co-efficient of thermal expansion.

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Design and fabrication of MAGNETIC TRANSMISSION system

6. Part of MAGNETIC TRANSMISSION SYSTEM

• Motor:
A DC relies on the fact that like magnet poles attract each other. A coil of wire with a current
running through it generates an electromagnetic field aligned with the center of the coil. The
motor is used to drive the worm wheel which drives the worm so that circular motion occurs.
The source of current is obtained from the 12 v dc battery from the car.

• Neodymium magnets:
A neodymium magnet is the most widely used type of rare-earth magnet. It is a permanent magnet
made from an alloy of neodymium, iron, and boron to form the Nd2Fe14B tetragonal crystalline
structure. Developed independently in 1984 by General Motors and SumitomoSpecial Metals
neodymium magnets are the strongest type of permanent magnet available commercially.
Because of different manufacturing processes, they are divided into two subcategories, namely
sintered NdFeB magnets and bonded NdFeB magnets. They have replaced other types of magnets
in many applications in modern products that require strong permanent magnets, such as electric
motors in cordless tools, hard disk drives and magnetic fasteners.

• Small Magnetic Wheel:

Small magnetic wheel mainly play role of driving gear. It carry rectangular shape
Neodymium magnets which is explain early. This wheel create ripple force on big magnetic
disk.

• Big Magnetic Wheel:

Big magnetic wheel is disk shape driven gear. This magnetic disk reacted cause of small
magnetic wheel rotations. It drive output shaft.

• Housing bearing:
The function of housing bearing is hold shaft on positon w.r.t. reduce friction in rotation. It’s
made from cast iron.

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Design and fabrication of MAGNETIC TRANSMISSION system

7. CONSTRUCTION& WORKING

7.1 CONSTRUCTION

• Total component mounted on frame. Frame is Skelton of model. Frame provide support to whole
model.

• Electric Motor is act as torque machine which give rotation to input shaft by mean of rope drive.

• Rope is hub between motor and drive shaft.

• Input shaft one end carry Small magnetic wheel. Input shaft fitted in housing bearing.

• Output shaft fitted on frame as like simply supported.

• Big magnetic disk fitted middle portion of output shaft.

• Neodymium magnet pressed in slot of Big and Small wheel.

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Design and fabrication of MAGNETIC TRANSMISSION system

7.2 WORKING

In this model we focused on physical contactless transmission. So, magnetic ripple force help us to transmit
torque without physical contact.

• Motor is power input device which provide torque. Motor rotate input shaft using belt.

• Input shaft rotate small magnet wheel.

• Small magnet wheel carry neodymium magnet which create ripple force on big magnetic disk. Here
without physical contact torque transmitted.

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Design and fabrication of MAGNETIC TRANSMISSION system

9. COST ESTIMATION
Cost estimation may be defined as the process of forecasting the expenses that must be estimated to
manufacture a product. These expenses take into a consideration all expenditure involved in a design
and manufacturing with all related services facilities such as grinding, turning, welding, assembly as
well as a portion of the general administrative and selling costs.

• PURPOSE:

1. To determine the selling price of a product for a quotation or contract so as to ensure a reasonable profit to
the company.
2. Check the quotation supplied by vendors.
3. Determine the most economical process or material to manufacture the product
4. To determine standards of production performance that may be used to control the cost.

TABLE 2: Operational cost

Sr. No Part Name Qty. Amount


1 Neodymium Magnets disc 16 1600
2 Neodymium magnets 10 1400
3 Frame with Welding 1 2000
4 Housing Bearing 4 1000
5 Nut And Bolts 10 200
6 Small and Big Gear with machining 2 3000
7 Motor 1 2000
8 Rod with machining 2 1500
Total 12700

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Design and fabrication of MAGNETIC TRANSMISSION system

10. ADVANTAGES & APPLICATIONS

10.1 ADVANTAGES

• Make System without physical contact hence no friction, wear or vibration.

• Achieve higher transmission efficiency.

• Make system easy to maintenance.

• Reduce maintenance effort.

• Reduce overall cost of system

10.2 APPLICATIONS

Industrial Application:
-For Industrial Conveyor System

Automobile Transmission System


-Power Transmission for Car, Buses, Trucks.

Turbine Generators:
- Key drivers: reduce weight + increase reliability
- Non-contact gearbox or integrated gearbox / generator
- Reduce direct drive diameter

Energy Storage Flywheels:


- Commercial power utility back up
- Off-grid renewably-generated energy storage
- Automotive regenerative braking systems

Gearing For Drilling Motors:


- Convert high speed to high torque for drilling
- Isolation of drill bit axial / thrust loads from motor
- Magnetic Gearing System
- Hollow bore to allow drilling fluid flow

Robotics:
- Easy movement’s arms for other parts
- Less constraints in motion
- Reliability

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Design and fabrication of MAGNETIC TRANSMISSION system

Aerospace:
- The isolation of vibrations
- The absence of maintenance
- Broad temperature range

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11. CONCLUSION

• MGs potentially have high efficiency and reliability due to their contact-less operation,
overload protection and little to no maintenance. Magnetically geared machines have
emerged as a new class of electrical machine with high torque density. Several topologies
have been proposed and further research is needed to ascertain their merits.

• Contact less Transmission done with no Noise, no wear and tear of gear, no periodic
lubrication and maintenance required.

12. FUTURE SCOPE

• Magnetic gears are becoming competitive alternatives to conventional gears. They present no
contact and no wear. They do not produce debris and they do not require lubricant, being able
to be operated at abroad range of temperature ranging from -270ºC up to 350ºC

• They present intrinsic anti-jamming properties and there is a clutching effect if the applied
torque exceeds a limit therefore protecting the output from overloads. This effect is
completely reversible without any damage or wear. This technology is currently increasing
making it available for consideration for aerospace uses. The radically different behavior
against torque overloads, the isolation of vibrations, the absence of maintenance, the
compatibility with sand or dust, broad temperature range and the through wall capability are
some properties that make these devices attractive

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13. REFERENCES

1) Pushman M. Tlali (M 014) was born in Leribe, Lesotho in 1987. He received his BEng in Electrical
and Electronic Engineering at Stellenbosch University, South Africa in 2012. He is currently pursuing his
MScEng degree in the field of electrical machines. His research interests are in the optimal design of
magnetically geared electrical machines.

2) Stiaan Gerber (M 013) was born in Bellville in South Africa on February 20, 1986. He received his
BEng (cum laude) in the field of Electrical and Electronic Engineering with Computer Science at
Stellenbosch University in 2008 and his MSc Eng (cum laude) in 2011. He is currently studying towards his
PhD in the field of electrical machines, with specific focus on magnetically geared electrical machines. His
main interests in the engineering field are electrical machine design, numerical optimization, renewable
energy power generation and finite element methods.

3) Rong-Jie Wang (M 000-SM 008) received the PhD(Eng) degree from Stellenbosch University in
2003. He is currently an Associate Professor in the Department of Electrical and Electronic Engineering of
Stellenbosch University. His research interests are computer-aided design and optimization of electric
machines, computational electromagnetics and thermal modeling of electric machines. He has published
more than 50 journal and conference papers and was a co-author of the monograph Axial Flux Permanent
Magnet Brushless Machines (2nd ed., Springer 2008)

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