Background. Magnomatics was founded in 2006 by a group of engineers from the University of Sheffield (UK) to commercialize magnetic gearing and motor technology developed there.

Magnomatics has received funding from the UK’s Technology Strategy Board (TSB) for a number of projects investigating the application of its technology in hybrid systems. These include:

• HiTED In wheel motor for bus/truck (Volvo, Kollmorgen, Magnet Applications);

• HiUCV In wheel motor for refuse vehicle (Dennis Eagle, MIRA, Arnold Magnetics, MTL);

• MCVT Magnetic eCVT for heavy duty vehicles (Volvo, Arnold Magnetics); and

• MAGSPLIT Magnetic eCVT for passenger car (Ford, Romax Technology, Arnold Magnetics).

In 2012 Magnomatics secured £2.5 million (US$4.1 million) funding to develop magnetically geared motors and generators for the hybrid and electric vehicle market. £1.06 million (US$1.7 million) was provided by IP Group which was matched by Finance Yorkshire. Fusion IP also invested £366,000 (US$602,000) in the technology.

In August 2013, Magnomatics joined The Proving Factory to meet the medium-volume requirements of automotive customers for its MAGSPLIT power split device. (The Proving Factory is a UK collaborative project designed to bridge the market gap between technology developers making innovative, low-carbon “proof of concept” prototypes, and the need to develop vehicle manufacturer’s confidence in the new technology by providing volume supply.)

MAGSPLIT principle. MAGSPLIT essentially integrates the magnetic equivalent of a planetary gearset with a high-performance permanent magnet brushless motor. Variable speed mechanical output with a fixed input mechanical speed is achieved by exporting/importing electrical power through a set of control windings—splitting the power along a “variator” path.

The original MAGSPLIT. The magnetic gear is central to MAGSPLIT. The gear itself is “turned inside out”—the high-speed “sun gear” is on the outside. With the outer PM control rotor held static, the magnetic gear has an intrinsic fixed ratio gear. By controlling the current flow through the stator control windings the rotational speed of the PM control rotor is varied and hence the gear ratio can be controlled over a broad range about the intrinsic ratio. Through this speed control the MAGSPLIT is also capable of fully disconnecting the output drive (declutching), and of delivering reverse. The gear ratio is controlled by varying the speed of the outer array of magnets which become the high speed element of the gear. The gear ratio can range from 1:1 to 1:15, Kirby said. With no friction or pumping losses, MAGSPLIT can offer high efficiency operation over a broad range of speeds. The basic technology offers a large degree of freedom in design through the breadth of design factors (gear ratios, magnet shape and grade). In-built torsional compliance reduces drivetrain pulsations, and could obviate the need for flywheels and torsional dampers, Kirby suggested. Click to enlarge.

Magnomatics says that a typical installation would have MAGSPLIT mounted directly onto the crankcase of the internal combustion engine. The gear ratio is controlled by varying the electrical power flow through the motor/generator. This electrical energy is either transiently stored or directed back to the drive train via a second traction motor.

Typical installation. The configuration offers a direct mechanical power flow path, a direct electrical path, and an indirect electrical path. Click to enlarge.

This would allow the engine to operate over a narrow speed band offering peak efficiency while delivering a variable speed drive to the wheels.

The magnetic gear within the MAGSPLIT has a typical efficiency of 99.5% at rated load. Losses are associated with importing/exporting power through the electrical path (i.e. winding copper losses). However, the total efficiency over a typical drive cycle is >95%.

MAGSPLIT 2. With the MAGSPLIT 2 system, Magnomatics reduced the package to a dual rotor system by removing the two outer arrays of magnets (for the control rotor and the sun gear) and essentially creating an electromagnetic sun gear, Kirby said.

MAGSPLIT 2 provides a lot more control and flexibility of design, Kirby said, while reducing magnet material as well.

Magnomatics has created three prototypes based on the specification of a 200 N·m C-Class passenger car: the original MAGSPLIT 1 with three rotors; MAGSPLIT 2a with surface mount magnets, running about the same magnet grade as the original MAGSPLIT; and MAGSPLIT 2b with interior magnets (magnets embedded within the rotor. MAGSPLIT 2b has about 1.5 kilos of magnet material, compared to the original 3.3 kg of MAGSPLIT 1.