Search Results (366)

Magnetic gears (MGs) are attracting increasing attention in power transmission systems due to their contactless operation principles, low frictional losses, and high efficiency. However, the broad application potential of these technologies requires a comprehensive evaluation of engineering parameters, such as material selection, energy efficiency, and structural design. This review focuses solely on solid-core magnetic gear systems designed using laminated electrical steels, soft magnetic composites (SMCs), and high-saturation alloys. This review systematically examines the topological diversity, torque transmission principles, and the impact of various core materials, such as electrical steels, soft magnetic composites (SMCs), and cobalt-based alloys, on the performance of magnetic gear systems. Literature-based comparative analyses are structured around topological classifications, evaluation of material properties, and performance analyses based on losses. Additionally, the study highlights that aligning material properties with appropriate manufacturing methods, such as powder metallurgy, wire electrical discharge machining (EDM), and precision casting, is essential for the practical scalability of magnetic gear systems. The findings reveal that coaxial magnetic gears (CMGs) offer a favorable balance between high torque density and compactness, while soft magnetic composites provide significant advantages in loss reduction, particularly at high frequencies. Additionally, application trends in fields such as renewable energy, electric vehicles (EVs), aerospace, and robotics are highlighted. Full article

Bearingless interior permanent magnet synchronous motors (BIPMSMs) have received considerable attention in recent research due to their advantages of high speed, high power density, and absence of mechanical wear. In order to improve the torque and suspension performance of the BIPMSM, an optimization design method of BIPMSM is proposed in this paper based on sensitivity analysis, response surface fitting, and the multi-objective whale optimization algorithm (MOWOA). Firstly, the structure and operation principle of the BIPMSM are introduced. Secondly, significant variables are extracted based on sensitivity analysis. Then, regression equations of the significant variables and optimization objectives are fitted by the response surface method, and global optimization is performed with MOWOA. Finally, the motor performance before and after optimization is compared. The results demonstrate that the proposed multi-objective optimization design scheme can significantly improve the performance of the BIPMSM and effectively shorten the design cycle. Full article

Permanent magnetic couplings provide critical advantages for deep-sea systems through static-sealed, contactless power transmission. However, conventional metallic isolation sleeves incur significant eddy current losses, limiting efficiency and high-speed operation. Limited torque capacities fail to meet the operational demands of harsh marine environments. This study presents a novel permanent magnet coupling featuring a ceramic isolation sleeve engineered for deep-sea cryogenic ammonia submersible pumps. The ceramic sleeve eliminates eddy current losses and provides exceptional corrosion resistance in acidic/alkaline environments. To withstand 3.5 MPa hydrostatic pressure, a 6-mm-thick sleeve necessitates a 10 mm operational air gap, challenging magnetic circuit efficiency. To address this limitation, an improved 3D magnetic equivalent circuit (MEC) model was developed that explicitly accounts for flux leakage and axial end-effects, enabling the accurate characterization of large air gap fields. Leveraging this model, a Taguchi method-based optimization framework was implemented by balancing key parameters to maximize the torque density. This co-design strategy achieved a 21% increase in torque density, enabling higher torque transfer per unit volume. Experimental validation demonstrated a maximum torque of 920 Nm, with stable performance under simulated deep-sea conditions. This design establishes a new paradigm for high-power leak-free transmission in corrosive, high-pressure marine environments, advancing applications from deep-sea propulsion to offshore energy systems. Full article

In this study, we present the design and electromagnetic performance optimization of a micro-electromechanical system (MEMS) miniature outer-rotor permanent magnet motor. With increased attention towards higher torque density and lower torque pulsations in MEMS micromotor designs, an adaptation of an external rotor can be highly attractive. However, with the design complexity involved in such high-performance MEMS outer-rotor motor designs, the ultra-miniature 3D coil structures and the thin-film topology surrounding the air gap have been one of the main challenges. In this study, an ultra-thin outer-rotor motor with 3D MEMS silicon-based coils and a MEMS-compatible manufacturing method for the 3D coils is presented. Additionally, finite element simulations are conducted for the thin-film topology around the air gap to optimize performance characteristics such as torque developed, torque pulsations, and back electromotive force amplitude. Ultimately, the average magnetic flux density increased by 37.1%, from 0.361 T to 0.495 T. The root mean square (RMS) value of the back EMF per phase rises by 14.4%. Notably, the average torque is improved by 11.3%, while the torque ripple is significantly reduced from 1.281 mNm to 0.74 mNm, corresponding to a reduction of 49.9% in torque ripple percentage. Full article

Electric mountain bikes (eMTBs) demand compact, high-torque motors capable of handling steep terrain and variable load conditions. Surface-mounted permanent magnet synchronous motors (SPMSMs) are widely used in this application due to their simple construction, ease of manufacturing, and cost-effectiveness. However, SPMSMs inherently lack reluctance torque, limiting their torque density and performance at high speeds. While interior PMSMs (IPMSMs) can overcome this limitation via reluctance torque, they require complex rotor machining and may compromise mechanical robustness. This paper proposes a surface-inset PMSM topology as a compromise between both approaches—introducing reluctance torque while maintaining a structurally simple rotor. The proposed motor features inset magnets shaped with a tapered outer profile, allowing them to remain flush with the rotor surface. This geometric configuration eliminates the need for a retaining sleeve during high-speed operation while also enabling saliency-based torque contribution. A baseline SPMSM design is first analyzed through finite element analysis (FEA) to establish reference performance. Comparative simulations show that the proposed design achieves a 20% increase in peak torque and a 33% reduction in current density. Experimental validation confirms these findings, with the fabricated prototype achieving a torque density of 30.1 kNm/m³. The results demonstrate that reluctance-assisted torque enhancement can be achieved without compromising mechanical simplicity or manufacturability. This study provides a practical pathway for improving motor performance in eMTB systems while retaining the production advantages of surface-mounted designs. The surface-inset approach offers a scalable and cost-effective solution that bridges the gap between conventional SPMSMs and more complex IPMSMs in high-demand e-mobility applications. Full article

Recently, humanoid robots with personification behavior and high working efficiency have received significant attention. Meanwhile, high-torque-density motors, which serve as the core power source for robot joints, have also been widely researched. In this paper, a high-torque-density double-stator permanent-magnet (DSPM) motor is designed for robot joint applications, and its outer stator (OS) split ratio (the ratio between the inner and outer diameters of the OS) and inner stator (IS) split ratio (the ratio between the inner and outer diameters of the IS) are analyzed and optimized. Since the DSPM motor has different heat dissipation capabilities for the OS and IS, their different loss limitations should be considered to avoid the risk of local overheating, especially for the IS. This paper shows that the loss limitations affect the optimal OS and IS split ratios, as well as the maximum average torque. The IS loss limitation increases the optimal OS split ratio and decreases the optimal IS split ratio; however, the OS loss limitation has the opposite effect. Additionally, an investigation into the electromagnetic characteristics of the optimized DSPM motor was conducted using the finite element method. Finally, a prototype was manufactured, and the results of the temperature rise experiments verified the feasibility of the proposed DSPM motor and the effectiveness of the optimal method. Full article

Axial flux motors have attracted significant attention in recent years due to their advantages such as shorter axial length and high torque density. However, the optimization of axial flux motors is an extremely time-consuming process. To reduce the computational time required for motor optimization, this study employed a magnetic charge model to establish a coreless axial flux motor model and analyzed the advantages of this approach. This method is applicable to coreless axial flux motor optimizations with surface-mounted rotors and concentrated windings. Parameter optimization was subsequently performed based on the theoretical model. In terms of seeking optimal solutions, the torque obtained through the magnetic charge method (MCM) reached 99.67% of the finite element method (FEM) results. Finally, a prototype was fabricated, and a test platform was constructed based on the optimization results. The experimental torque showed a 4% deviation from simulations, validating the accuracy of the optimization. Full article

The recycling of plastics collected from household waste to produce post-consumer recycled (PCR) materials is a critical step of sustainable waste management. However, the processing of PCR materials presents unique challenges, particularly in the context of seasonal input stream fluctuations and resulting PCR material composition variations. Within this paper, the influence of batch-to-batch fluctuations on the processing stability and product properties of high-density polyethylene (HDPE) PCR from the German municipal waste system is analysed. It examines how variations in batch composition affect key parameters such as processing data (injection pressure, torque), mechanical properties (tensile strength, E-modulus, impact strength), and product quality (gel formation, part dimensions, part weight). Therefore, six consecutive household HDPE PCR material batches are analysed regarding their composition, contaminations, and rheological characteristics through ashing, differential scanning calorimetry, high-temperature gel permeation chromatography, and high-pressure capillary rheometry. The batches are then processed using blown- and cast-film extrusion as well as injection moulding, and the resulting process stability and product quality are analysed. The results show a strong correlation between thermal properties, such as crystallisation enthalpy, molecular weight, polypropylene (PP) content, varying batch viscosities, and changes in processing data as well as the resulting product properties. Full article

Implant primary stability is a prerequisite for obtaining osseointegration and clinical success. Insertion torque (IT) is measured during implant placement and is expressed in Ncm. It represents the quantification of the frictional force experienced by the implant as it progresses apically through a rotational motion along its axis. Usually, to achieve osseointegration, a value within the range of 20–40 Ncm is desirable. Below a threshold of 20 Ncm, implants have a decrease in survival rate, while implant stability is guaranteed above 20 Ncm. The main goal of this study was to evaluate whether high values of IT affect osseointegration, implant health, and healing, by highlighting the positive and negative effects of IT > 50 Ncm on peri-implant bone, soft tissues, and long-term stability. This scoping review considered randomized clinical trials, observational studies, and cohort studies. Studies failing to meet the predefined inclusion criteria were excluded from the analysis. The review process adhered to the Preferred Reporting Items for Scoping Reviews (PRISMA-ScR) guidelines. Ultimately, a total of 11 studies were included in the final synthesis. Based on the studies included, the literature suggests that high values of IT guarantee adequate primary stability and better osseointegration. However, high IT is significantly associated with greater marginal bone loss, depending on bone density. Accordingly, IT values > 50 Ncm may provoke greater compressive forces with a negative impact on the jawbone. An elevated strain on the bone can induce necrosis and ischemia, due to an alteration of circulation, which in turn is responsible for marginal bone loss and reduced osseointegration. Lack of osseointegration ultimately leads to an early implant failure. As concerns soft tissue recession, a higher decrease is measured in implants placed with high-insertion torque. Nonetheless, additional clinical trials are warranted to assess long-term outcomes, quantify the incidence of these complications, and explore the impact of emerging clinical variables. Full article

The lower-limb assistance exoskeleton is increasingly being utilized in various fields due to its excellent performance in human body assistance. As a crucial component of robots, the joint is expected to be designed with a high-output torque to support hip and knee movement, and lightweight to enhance user experience. Contrasted with the elastic actuation with harmonic drive and other flexible transmission, the non-elastic quasi-direct actuation is more promising to be applied in exoskeleton due to its advanced dynamic performance and lightweight feature. Moreover, robot joints are commonly driven electrically, especially by a permanent magnet synchronous motor which is rapidly developed because of its compact structure and powerful output. Based on different topological structures, numerous research focus on torque density, ripple torque suppression, efficiency improvement, and thermal management to improve motor performance. Furthermore, the elaborated joint with powerful motors should be controlled compliantly to improve flexibility and interaction, and therefore, popular complaint control algorithms like impedance and admittance controls are discussed in this paper. Through the review and analysis of the integrated design from mechanism structure to control algorithm, it is expected to indicate developmental prospects of lower-limb assistance exoskeleton joints with optimized performance. Full article

Surface-mounted permanent magnet synchronous generators (SPMSGs) are well suited for wind power applications mainly because of their high power density, low cogging torque, and effective thermal management. This study proposes an eccentric Halbach PM array pole shape to enhance the power generation capability of SPMSGs specifically designed for low-speed wind power generation. The topology of the proposed eccentric Halbach PM arrangement is optimized using a genetic algorithm. Two-dimensional finite element simulations indicate that the eccentric Halbach configuration significantly improves flux focusing and magnetic field distribution. Compared to the conventional design, the proposed structure exhibits a substantial increase in electromotive force with reduced total harmonic distortion. Cogging torque is reduced by 48.6%, supporting improved starting and low-speed operation. Under on-load, the proposed design delivers higher average torque with reduced ripple, contributing to smoother operation. At a rated speed, the output power increases by 25%, with consistently higher power generation capability across a wide range of load conditions. Additionally, the proposed generator achieves higher efficiency across all operating speeds. These findings confirm the effectiveness of the eccentric Halbach array configuration in improving the power generation capability of SPMSG, thereby reinforcing its applicability to low-speed wind energy systems aligned with long-term sustainability objectives. Full article

In this study, an axial flux double airgap permanent magnet-assisted synchronous reluctance motor (AF-Pma-SynRM) was designed for electric vehicles (EVs). The AF-Pma-SynRM model employs a forced liquid cooling method (cooling jacket) for a high current density. The model was tested using multi-objective optimization and multi-physics analysis. The AF-Pma-SynRM design has achieved 95.6 Nm of torque, 30 kW of power, and 93.8% efficiency at a 3000 rpm rated speed. The motor exhibits a maximum speed of 10,000 rpm, 253.1 Nm of torque, and 65 kW of output power. This study employs a novel barrier structure for axial motors characterized by fixed outer and inner dimensions, and is suitable for mass production. In the final stage, the motor was cooled using the cooling jacket method, and the average temperature of the winding was measured as 73.83 °C, and the average magnet temperature was 66.44 °C at a nominal power of 30 kW. Also to show variable speed performance, an efficiency map of the AF-Pma-SynRM is presented. Full article

Achieving the appropriate primary stability for immediate or early loading in areas with low-density bone, such as the posterior maxilla, is challenging. A three-dimensional (3D) stabilization implant design featuring a tapered body with continuous cutting flutes along the length of the external thread form, with a combination of curved and linear geometric surfaces on the thread’s crest, has the capacity to enhance early biomechanical and osseointegration outcomes compared to implants with traditional buttressed thread profiles. Commercially available implants with a buttress thread design (TP), and an experimental implant that incorporated the 3D stabilization trimmed-thread design (TP 3DS) were used in this study. Six osteotomies were surgically created in the ilium of adult sheep (N = 14). Osteotomy sites were randomized to receive either the TP or TP 3DS implant to reduce site bias. Subjects were allowed to heal for either 3 or 12 weeks (N = 7 sheep/time point), after which samples were collected en bloc (including the implants and surrounding bone) and implants were either subjected to bench-top biomechanical testing (e.g., lateral loading), histological/histomorphometric analysis, or nanoindentation testing. Both implant designs yielded high insertion torque (ITV ≥ 30 N⋅cm) and implant stability quotient (ISQ ≥ 70) values, indicative of high primary stability. Qualitative histomorphological analysis revealed that the TP 3DS group exhibited a continuous bone–implant interface along the threaded region, in contrast to the TP group at the early, 3-week, healing time point. Furthermore, TP 3DS’s cutting flutes along the entire length of the implant permitted the distribution of autologous bone chips within the healing chambers. Histological evaluation at 12 weeks revealed an increase in woven bone containing a greater presence of lacunae within the healing chambers in both groups, consistent with an intramembranous-like healing pattern and absence of bone dieback. The TP 3DS macrogeometry yielded a ~66% increase in average lateral load during pushout testing at baseline (T = 0 weeks, p = 0.036) and significantly higher bone-to-implant contact (BIC) values at 3 weeks post-implantation (p = 0.006), relative to the traditional TP implant. In a low-density (Type IV) bone model, the TP 3DS implant demonstrated improved performance compared to the conventional TP, as evidenced by an increase in baseline lateral loading capacity and increased BIC during the early stages of osseointegration. These findings indicate that the modified implant configuration of the TP 3DS facilitates more favorable biomechanical integration and may promote more rapid and stable bone anchorage under compromised bone quality conditions. Therefore, such improvements could have important clinical implications for the success and longevity of dental implants placed in regions with low bone density. Full article

In this paper, the concept of symmetry is utilized to optimize the structural parameters and output characteristics of the generator design—that is, the construction and solution of the equivalent magnetic circuit method for the hybrid excitation generator are symmetrical. To address the issues of high excitation loss and low power density in purely electrically excited generators, as well as the difficulty in adjusting the magnetic field in purely permanent magnet generators, a new topology for a built-in permanent magnet and salient-pole electromagnetic hybrid excitation generator is proposed. Firstly, an equivalent magnetic circuit model of the generator is established. Secondly, expressions are derived to describe the relationships between the dimensions of the salient-pole rotor and the permanent magnets and the generator’s no-load induced electromotive force, cogging torque, and air gap flux density. These expressions are then used to analyze the structural parameters that influence the generator’s performance. Thirdly, optimization targets are selected through sensitivity analysis, with the no-load induced electromotive force, cogging torque, and air gap flux density serving as the optimization objectives. A multi-objective genetic algorithm is employed to optimize these parameters and determine the optimal structural matching parameters for the generator. As a result, the optimized no-load induced electromotive force increased from 18.96 V to 20.14 V, representing a 6.22% improvement; the cogging torque decreased from 177.08 mN·m to 90.52 mN·m, a 48.88% reduction; the air gap flux density increased from 0.789 T to 0.829 T, a 5.07% improvement; and the air gap flux density waveform distortion rate decreased from 6.22% to 2.38%, a 39.3% reduction. Finally, a prototype is fabricated and experimentally tested, validating the accuracy of the simulation analysis, the feasibility of the optimization method, and the rationality of the generator design. Therefore, the proposed topology and optimization method can effectively enhance the output performance of the generator, providing a valuable theoretical reference for the design of hybrid excitation generators for vehicles. Full article

Upper limb assistive exoskeletons help stroke patients by assisting arm movement in impaired individuals. However, effective control of these systems to help stroke survivors is a complex task. In this paper, a novel approach is proposed to enhance the control of upper limb assistive exoskeletons by using torque estimation and prediction in a proportional–integral–derivative (PID) controller loop to more optimally integrate the torque of the exoskeleton robot, which aims to eliminate system uncertainties. First, a model for torque estimation from Electromyography (EMG) signals and a predictive torque model for the upper limb exoskeleton robot for the elbow are trained. The trained data consisted of two-dimensional high-density surface EMG (HD-sEMG) signals to record myoelectric activity from five upper limb muscles (biceps brachii, triceps brachii, anconeus, brachioradialis, and pronator teres) during voluntary isometric contractions for twelve healthy subjects performing four different isometric tasks (supination/pronation and elbow flexion/extension) for one minute each, which were trained on long short-term memory (LSTM), bidirectional LSTM (BLSTM), and gated recurrent units (GRU) deep neural network models. These models estimate and predict torque requirements. Finally, the estimated and predicted torque from the trained network is used online as input to a PID control loop and robot dynamic, which aims to control the robot optimally. The results showed that using the proposed method creates a strong and innovative approach to greater independence and rehabilitation improvement. Full article