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Ganesh V. Bhosale,
Aditya R. Raut,
Anand M. Jadhao,
Rupesh A. Shiralkar,
- Assistant Professor, Department of Mechanical Engineering, Rajgad Technical Campus, Dhangawadi, Pune, Maharashtra, India
- Student, Department of Mechanical Engineering, Rajgad Technical Campus, Dhangawadi, Pune, Maharashtra, India
- Student, Department of Mechanical Engineering, Rajgad Technical Campus, Dhangawadi, Pune, Maharashtra, India
- Student, Department of Mechanical Engineering, Rajgad Technical Campus, Dhangawadi, Pune, Maharashtra, India
Abstract
Modern engineering prioritizes speed, efficiency, and reliability, spurring innovations like contactless magnetic gear systems that transmit torque through interacting magnetic fields from permanent magnets, eliminating physical contact to drastically cut friction, backlash, wear, lubrication needs, and heat—operating silently with minimal vibration and peak efficiencies up to 99% under ideal conditions, outperforming traditional gears in low-speed, high-torque direct-drive applications such as motors. The design centers on two rotors: an outer high-speed magnet array and an inner low-speed modulator with ferromagnetic poles that enable non-contact power transfer via flux modulation, providing backlash-free performance, overload protection through safe slipping, and durability exceeding 20,000 maintenance-free hours. This project covers the full design and fabrication workflow, starting with finite element analysis (FEA) in ANSYS Maxwell to optimize magnet setups like Halbach arrays for intensified fields, pole ratios, precise airgaps (0.5-2 mm), and materials including neodymium-iron-boron (NdFeB) magnets paired with soft magnetic composites. Fabrication used 3D-printed non-magnetic housings, epoxy-bonded precision magnet assembly, and dynamic balancing to counter imbalances. Rig testing delivered torque up to 50 Nm at 300 RPM, with 95-98% efficiency across loads, noise below 40 dB, and temperatures under 60°C—validating potential in electric vehicles for gearbox-free drives, wind turbines, robotics, and pumps where longevity offsets initial costs. Ultimately, magnetic gears transform industries by enabling sustainable, high-performance machinery with unmatched reliability.
Keywords: Magnetic gears, contactless transmission, frictionless torque, high-efficiency gearing, Halbach arrays, NdFeB magnets.
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Trends in Mechanical Engineering & Technology
| Volume | 16 | |
| 02 | ||
| Received | 08/05/2026 | |
| Accepted | 29/06/2026 | |
| Published | 25/07/2026 | |
| Publication Time | 78 Days |