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New Report Project
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.
TABLE OFCONTENT
7.1 CONSTRUCTION
7.2 WORKING
LIST OFFIGURES
1.2 Methodology
2.8 Motor
LIST OF TABLES
1 Observation Table
2 Cost Estimation
1. INTRODUCTION
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.
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.
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
2. LITERATURE REVIEW
[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.
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
4. Design of part
150 mm Nylon wheel machined and 20 mm circular Slot made for neodymium magnets. Neodymium
magnets pressed in slots.
Frame structure is made from 40*40 mm MS Square pipe on this frame Motor, Small and Big magnetic
wheel assembled with housing bearing.
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.
Standard housing bearing used for mount shaft from both end.
ID – 20 mm
4.7 MOTOR:
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:
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.
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
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.
• 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 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 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.
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.
• Input shaft one end carry Small magnetic wheel. Input shaft fitted in housing bearing.
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.
• Small magnet wheel carry neodymium magnet which create ripple force on big magnetic disk. Here
without physical contact torque transmitted.
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.
10.1 ADVANTAGES
10.2 APPLICATIONS
Industrial Application:
-For Industrial Conveyor System
Turbine Generators:
- Key drivers: reduce weight + increase reliability
- Non-contact gearbox or integrated gearbox / generator
- Reduce direct drive diameter
Robotics:
- Easy movement’s arms for other parts
- Less constraints in motion
- Reliability
Aerospace:
- The isolation of vibrations
- The absence of maintenance
- Broad temperature range
• 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.
• 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
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)