Magnetic Gearboxes for Aerospace Applications

Magnetic gearboxes are contactless mechanisms for torque-speed conversion. They present no wear, no friction and no fatigue. They need no lubricant and can be customized for other mechanical properties as stiffness or damping. Additionally, they can protect structures and mechanisms against overloads, limitting the transmitted torque. In this work, spur, planetary and "magdrive" or "harmonic drive" configurations are compared considering their use in aerospace applications. The most recent test data are summarized to provide some useful help for the design engineer

Performance of Magnetic-Superconductor Non-Contact Harmonic Drive for Cryogenic Space Applications

Harmonic drives are profusely used in aerospace mainly because of their compactness and large reduction ratio. However, their use in cryogenic environments is still a challenge. Lubrication and fatigue are non-trivial issues under these conditions. The objective of the Magnetic-Superconductor Cryogenic Non-contact Harmonic Drive (MAGDRIVE) project, funded by the EU Space FP7, is to design, build, and test a new concept of MAGDRIVE. Non-contact interactions among magnets, soft magnetic materials, and superconductors are efficiently used to provide a high reduction ratio gear that smoothly and naturally operates at cryogenic environments. The limiting elements of conventional harmonic drives (teeth, flexspline, and ball bearings) are substituted by contactless mechanical components (magnetic gear and superconducting magnetic bearings). The absence of contact between moving parts prevents wear, lubricants are no longer required, and the operational lifetime is greatly increased. This is the first mechanical reducer in mechanical engineering history without any contact between moving parts. In this paper, the test results of a −1:20 inverse reduction ratio MAGDRIVE prototype are reported. In these tests, successful operation at 40 K and 10−3 Pa was demonstrated for more than 1.5 million input cycles. A maximum torque of 3 N·m and an efficiency of 80% were demonstrated. The maximum tested input speed was 3000 rpm, six times the previous existing record for harmonic drives at cryogenic temperature

Mechanical Impedance Matching Using a Magnetic Linear Gear

As part of the Fp7 Clean Sky Project, a linear magnetic gear prototype, called Z-transmitter, for aerospace application was designed, built, and tested. It demonstrates a maximum force capacity of 4700 N at 25°C and 4500 N at 90°C. Force ratio between slow and fast stages remains constant and equal to the design value: 7.0. The behavior of the real Z-transmitter as a mechanical impedance matching device when any stiffness is attached to the fast stage including the limit cases of a blocked fast stage or a free to move fast stage is experimentally explored. Although the real Z-transmitter deviates from the ideal, frictionless and massless, device, it still provides an impedance matching effect large enough to potentially become an extremely useful technology for vibration control when combined with other elements such as dampers, springs, or active elements

Aeronautical Magnetic Torque Limiter for Passive Protection against Overloads

Actual aerospace and defense technologies present multiple limitations that need to be overcome in order to evolve to less contaminating and more efficient aircraft solutions. Contactless technologies come with essential advantages such as the absence of wear and friction. This work describes the design, prototype, and performance test according to RTCA-DO-160 of an aeronautical magnetic torque limiter. The results show correct continuous transmission operation (2250 rpm and 24 Nm) from −50 °C to +90 °C. Moreover, overload protection has been demonstrated for more than 200 jamming events without damage or required maintenance to the device

Mechanical Impedance Matching Using a Magnetic Linear Gear

As part of the Fp7 Clean Sky Project, a linear magnetic gear prototype, called Z-transmitter, for aerospace application was designed, built, and tested. It demonstrates a maximum force capacity of 4700 N at 25°C and 4500 N at 90°C. Force ratio between slow and fast stages remains constant and equal to the design value: 7.0. The behavior of the real Z-transmitter as a mechanical impedance matching device when any stiffness is attached to the fast stage including the limit cases of a blocked fast stage or a free to move fast stage is experimentally explored. Although the real Z-transmitter deviates from the ideal, frictionless and massless, device, it still provides an impedance matching effect large enough to potentially become an extremely useful technology for vibration control when combined with other elements such as dampers, springs, or active elements

Contactless Mechanical Components: Gears, Torque Limiters and Bearings

Contactless mechanical components are mechanical sets for conversion of torque/speed, whose gears and moving parts do not touch each other, but rather they provide movement with magnets and magnetic materials that exert force from a certain distance. Magneto-mechanical transmission devices have several advantages over conventional mechanisms: no friction between rotatory elements (no power losses or heat generation by friction so increase of efficiency), no lubrication is needed (oil-free mechanisms and no lubrication auxiliary systems), reduced maintenance (no lubricant so no need of oil replacements), wider operational temperature ranges (no lubricant evaporation or freezing), overload protection (if overload occurs magnet simply slides but no teeth brake), through-wall connection (decoupling of thermal and electrical paths and environmental isolation), larger operative speeds (more efficient operative conditions), ultralow noise and vibrations (no contact no noise generation). All these advantages permit us to foresee in the long term several common industrial applications in which including contactless technology would mean a significant breakthrough for their performance. In this work, we present three configurations of contactless mechanical passive components: magnetic gears, magnetic torque limiters and superconducting magnetic bearings. We summarize the main characteristic and range of applications for each type; we show experimental results of the most recent developments showing their performance