Search Results (46)

Nowadays, the market for wearable devices and biorobotics is growing rapidly. In active prostheses and exoskeletons, joints are typically driven by electric machines. The critical challenge is balancing the generated torque with the size and mass of the motor, ensuring the overall weight does not hinder the user’s mobility. This paper presents a comprehensive review of high-torque electric machines based on an analysis of 162 publications, primarily from the last decade. The study systematically compares geometric, electrical, and efficiency parameters across various electromechanical converters to identify the optimal limits for bionic applications. Data suggests that an electric machine aiming to align with typical biorobotic requirements would likely fall within an outer diameter of 150 mm, an axial length of 85 mm, and a mass of 1200 g. Furthermore, the required parameters for advanced applications include an efficiency above 95%, a safe nominal voltage of up to 48 V, and the ability to generate torques up to 65 Nm. The analysis highlights that while conventional motors (such as BLDC and PMSM) dominate the market, achieving a torque density exceeding 35–45 Nm/kg—necessary to approach biological muscle capabilities—often requires adopting emerging topologies, such as magnetic gears or Vernier machines. This review provides clear quantitative guidelines for engineers designing optimal drive systems for biorobotics and wearable devices. Full article

The Zeta-Minimizer Theorem (ZMT) provides a complete deductive unification of statistical mechanics, number theory, helical geometry, thermodynamics, and electromagnetism from three primitive axioms alone. Starting with the non-proper Archimedean conical helix and the explicit covariant fugacity Hessian, the universal grand-partition function Z(s) is constructed via the integer-gear rule. This functorially invariant object yields gear occupations, Lyapunov exponents, and interaction parameters that govern all subsequent results. Interface matching and marginal stability λ_2,19 (x_2) = 0 trigger superconductivity at solid–fluid boundaries, while the categorical invariance of Z(s) produces exact magnetic and electric equilibrium curves. The Variational Reaction Rate Theorem then projects the framework onto dynamics, yielding Maxwell’s equations, demystified electrical units as helical torque quantities, and a complete classification of electronic phases. Phonons, Cooper pairing, the superconducting gap, and the full BCS correspondence follow without additional postulates. The same marginal-stability condition reproduces the Casimir effect, the Quantum Hall effect, and the entire 115-year experimental history of superconductivity. Generalization of interface matching to arbitrary solid–liquid pairs and introduction of Variational Anchor Cancellation (VAC) self-organizes a shielded superconducting layer. Finally, the first-principles engineering blueprint of the Radial Helical Gear Condenser (RHGC) delivers a modular, self-regulating device that engineers superconductivity at ambient or near-ambient temperature using only a radial pressure gradient and existing pipeline technology. All predictions are zero-parameter and fully deducible from the three axioms. Full article

This paper presents a systematic optimization methodology for reluctance magnetic gears (RMGs) using genetic algorithms to maximize peak torque within fixed volume constraints. A multi-run parametric study with population sizes ranging from 50 to 150 individuals demonstrates robust convergence toward remarkably similar geometric proportions, with a best torque of 430.15 Nm and minimal variation (0.65%) across different configurations. The optimization redistributes radial dimensions, achieving a 95% torque improvement over uniform distribution by significantly increasing inner rotor teeth thickness by 85% while reducing modulator thickness by 74%. The most significant outcome is the emergence of a consistent design trend across all independent runs, providing general guidelines on how the RMG internal geometry should be arranged to maximize peak torque. Full article

This paper presents an artificial intelligence (AI)-assisted multi-objective topology optimization of a 48 V interior permanent magnet synchronous motor (PMSM) intended for mid-drive e-bike applications. The machine features a 48-slot, 8-pole stator–rotor combination with $\Delta$-shaped three buried magnets per pole, and is coupled to a multi-stage gearbox that adapts its high-speed, low-torque output to a human-scale crank speed. The design problem simultaneously maximizes average torque and efficiency while minimizing torque ripple by varying key stator slot dimensions and magnet geometries. A modular MATLAB–ANSYS Maxwell framework is developed in which finite element simulations are driven by a Bayesian optimization (BO) loop augmented by a large language model (LLM) with retrieval-augmented generation (RAG). The LLM acts as a memory-based agent that proposes candidates, shapes Gaussian Process priors, and incorporates natural language rules expressing qualitative design knowledge. Two AI-assisted trials are compared against a multi-objective Artificial Hummingbird Algorithm benchmark, RAG + BO with and without natural language input. All three methods converge to a similar Pareto region with average torque around 5.4–5.7 Nm, torque ripple of approximately 12.8–14.2%, and efficiency near 93.3–93.6%, suitable for geared e-bike drives. The LLM-guided trial achieves this performance with a 20.1% reduction in simulation expenses relative to the BO baseline and by about 48% compared to the Artificial Hummingbird Algorithm. The results demonstrate that integrating LLM guidance into Bayesian optimization improves sample efficiency while providing interpretable design trends for PMSM topologies tailored for light electric vehicles. Full article

This study presents an optimal design combined with comprehensive multiphysics validation to enhance the torque density of a coaxial magnetic gear (CMG) incorporating an overhang structure. Four high non-integer gear-ratio CMG configurations exceeding 1:10 were designed using different pole-pair combinations, and three-dimensional finite element method (3D FEM) was employed to accurately capture axial leakage flux and overhang-induced three-dimensional effects. Eight key geometric design variables were selected within non-saturating limits, and 150 sampling points were generated using an Optimal Latin Hypercube Design (OLHD). Multiple surrogate models were constructed and evaluated using the root-mean-square error (RMSE), and the Kriging model was selected for multi-objective optimization using a genetic algorithm. The optimized CMG with a 1:10.66 gear ratio achieved a 130.76% increase in average torque (65.75 Nm) and a 162.51% improvement in torque density (117.14 Nm/L) compared with the initial design. Harmonic analysis revealed a strengthened fundamental component and a reduction in total harmonic distortion, indicating improved waveform quality. To ensure the feasibility of the optimized design, comprehensive multiphysics analyses—including electromagnetic–thermal coupled simulation, high-temperature demagnetization analysis, and structural stress evaluation—were conducted. The results confirm that the proposed CMG design maintains adequate thermal stability, magnetic integrity, and mechanical robustness under rated operating conditions. These findings demonstrate that the proposed optimal design approach provides a reliable and effective means of enhancing the torque density of high gear-ratio CMGs, offering practical design guidance for electric mobility, robotics, and renewable energy applications. Full article

This paper presents a comprehensive design approach for optimizing the pole configuration of a coaxial magnetic gear (CMG) structure with an overhang to enhance torque characteristics. Five CMG models were designed, and their characteristics were analyzed. A three-dimensional finite element method analysis was conducted to account for axial leakage flux. To efficiently explore the design space, we utilized an optimal Latin hypercube sampling method to generate experimental points and constructed a kriging-based metamodel owing to its low root-mean-square error. We analyzed torque characteristics across the design variables to identify characteristic trends and performed a parametric sensitivity analysis to evaluate the influence of each variable on the torque. We derived an optimal solution that satisfied the objective function and constraints using the design variables. The characteristics of the proposed model were validated through electromagnetic field analysis, fast Fourier transform analysis of the air-gap magnetic flux density, and structural analysis. The optimal model achieved an average torque of 61.75 Nm, representing a 21.15% improvement over the initial model, while simultaneously reducing the ripple factor by 0.41%. These findings indicate that the proposed CMG design with an overhang effectively enhances torque characteristics. Full article

This paper presents an electromechanical coupling model integrating an equivalent magnetic network (EMN) model of a dual three-phase permanent magnet synchronous motor (DTP-PMSM) with the dynamic model of a helical planetary gear transmission system. Using this model, this study analyzes the dynamic characteristics of an electric drive system, specifically motor phase current, electromagnetic torque, and gear meshing force, under self-fault-tolerant control strategies. Simulation and experimental results demonstrate that the self-fault-tolerant control strategy enables rapid fault tolerance during open-phase faults, significantly reducing system fault recovery time. Meanwhile, compared to the open-phase faults conditions, the self-fault-tolerant control effectively suppresses most harmonic components within the system; only the second harmonic amplitude of the electromagnetic torque exhibited an increase. This harmonic disturbance propagates to the gear system through electromechanical coupling, synchronously amplifying the second harmonic amplitude in the gear system’s vibration response. This study demonstrates that self-fault-tolerant control strategies significantly enhance the dynamic response performance of the electric drive system under open-phase faults conditions. Furthermore, this study also investigates the electromechanical coupling mechanism through which harmonics generated by this strategy affect the gear system’s dynamic response, providing theoretical support for co-optimization electromechanical coupling design and fault-tolerant control in high-reliability electric drive transmission systems. Full article

To collect the energy generated by rotational motion in the natural environment, a piezoelectric electromagnetic hybrid energy harvester (HEH) based on a planetary gear system is proposed. The harvester combines piezoelectric and electromagnetic effects and is mainly used for collecting low-frequency rotational energy. The HEH has a compact structure and contains four sets of piezoelectric energy harvesters (PEHs) and electromagnetic energy harvesters (EMHs) inside. The working principle of the energy harvester is analyzed, its theoretical model is established, and a simulation analysis is conducted. To verify the effectiveness of the design, an experimental device is constructed. The results indicate that the HEH can generate an average output power of 250 mW under eight magnets and an external excitation frequency of 7 Hz. In actual power supply testing, the HEH can light up 60 LEDs and provide stable power supply for the temperature–humidity meter. Full article

A magnetic lead screw (MLS) uses the magnetic field of permanent magnets to convert between linear and rotational motions while achieving a gearing action. This mechanism converts low-speed, high-force linear motion to high-speed, low-torque rotational motion. The MLS is ideal for wave energy applications, where the low-speed oscillatory motion of waves can be converted into usable electrical energy. It harnesses the high-force, low-speed linear motion of waves and converts it into rotational motion for generators, all while maintaining contact-free power transfer, reducing maintenance and machine size compared to linear machines. In this study, two controllers are proposed for an ideal Halbach magnetic lead screw: a proportional-resonant (PR) controller and an observer-based state feedback controller (O-SFC). The proportional-integral (PI) controller is also presented as a benchmark. These controllers are developed based on the linearized model of the ideal Halbach MLS and validated through simulation studies of its non-linear model. Results show that both the PR and O-SFC controllers significantly improve system performance compared to the PI controller, with the O-SFC providing superior performance over both the PR and PI controllers. Full article

This work uses recurrence plots (RPs) to identify nonlinearities and non-stationary conditions in wind turbines. Traditionally, recurrence plots have been applied to vibration or acoustic data; this paper applies them to magnetometer and accelerometer data to compare the sensitivity. The recurrence plots are generated by plotting points in the phase space and identifying those points where the dynamic system returns to a similar configuration, meaning that the state variables are similar to previous conditions. The state variables for the acceleration data are the position and velocity, whereas, for the magnetometer data, they are the magnitude of the magnetic field and its integral. The time series are integrated by combining the shifting principle of harmonic functions and the empirical mode decomposition. The EMD method separates the original signal into several modes, shifts them, and combines them back. The time series were obtained from an accelerometer and a magnetometer mounted in a wind turbine. The results showed that the RP presents different patterns depending on the signal; magnetometer signals identify low-frequency components, such as magnetic field anomalies, and accelerometer signals identify high-frequency components, such as bearings and gears. Full article

Variable frequency drives (VFDs) are widely used in industry as an efficient means to control the rotational speed of AC motors by varying the supply frequency to the motor. VFD signatures can be detected in vibration signals in the form of sidebands (modulations) induced on tonal components (carrier frequencies). These sidebands are spaced at twice the “pseudo line” VFD frequency, as the magnetic forces in the motor have two peaks per current cycle. VFD-related signatures are generally less susceptible to interference from other mechanical sources, making them particularly useful for deriving speed variation information and obtaining a “pseudo” tachometer from the motor’s synchronous speed. This tachometer can then be employed to accurately estimate the speed profile and to facilitate order tracking in mechanical systems for vibration analysis purposes. This paper presents a signal processing technique designed to extract a pseudo tachometer from the VFD signature found in a vibration signal. The algorithm was tested on publicly available vibration data from a test rig featuring a two-stage gearbox with seeded bearing faults operating under variable-speed conditions with no load, i.e., with minimal slip between the induction motor’s synchronous and actual speed. The results clearly demonstrate the feasibility of using VFD signatures both to extract an accurate speed profile (root mean square error, RMSE of less than 2.5%) and to effectively perform order tracking, leading to the identification of bearing faults. This approach offers an accurate and reliable tool for the analysis of vibration in mechanical systems driven by AC motors with VFDs. However, it is important to note that some inaccuracies may occur at higher motor slip levels under heavy or variable loads due to the mismatch between the synchronous and actual speeds. Slip-induced variations can further distort tracked order frequencies, compromising the accuracy of vibration analysis for gear mesh and bearing defects. These issues will need to be addressed in future research. Full article

This study presents a two-dimensional analytical method for fast optimization, taking into consideration the influence of the eddy current in a magnet and iron loss within a coaxial magnetic gear. Subdomain modeling was utilized to obtain vector potentials in the air-gap, magnet, and modulation regions by solving Maxwell’s equations. After that, the magnet, rotor, and modulation losses were predicted and then compared using a finite element method simulation within three topologies with gear ratios ranging from five to six. The authors improved the machine performance, specifically the torque density, by employing a multi-objective function with particle swarm optimization. The flux density obtained using subdomain modeling in just 0.5 s benefits the optimization process, resulting in a torque-density optimal model after around 3 h. A 3/19/16 prototype targeting a low-speed, high-torque, permanent generator application was fabricated to verify the analytical and simulation results. Full article

Induction heating is a clear, cheap, and highly effective technology used for many industrial and commercial applications. Generally, a time-varying magnetic field produces the required heat in the workpiece with a specially designed coil. The efficiency of the heating process depends highly on the coil design and the geometrical arrangement. A detailed and accurate finite element analysis of the induction heating process usually needs to resolve a coupled thermoelastic–magnetic problem, whose parameters values depend on the solution of another field. The paper deals with a shrink-fitting process design problem: a gear should be assembled with an axe. The interesting part of this case study is given the prescribed low limits for critical stress, the temperature of the gear material, and the heat-treated wearing surfaces. A coupled finite-element-based model and a genetic algorithm-based parameter determination methodology were presented. A thermal imaging-based measurement validated the presented numerical model and parameter determination task. The results show that the proposed methodology can be used to calibrate and validate the numerical model and optimize an induction heating process. Full article

The use of renewable energies contributes to the goal of mitigating climate change by 2030. One of the fastest-growing renewable energy sources in recent years is wind power. Large wind generation systems have drawbacks that can be minimized using small wind systems and DC microgrids (DC-µGs). A wind system requires a control system to function correctly in different regions of its operating range. However, real-time analysis of a physical wind system may not be feasible. An alternative to counteract this disadvantage is using real-time hardware in the loop (HIL) simulation. This article describes the implementation of an HIL platform in an NI myRIO 1900 to evaluate the performance of control algorithms in a small wind system (SWS) that serves as a distributed generator for a DC-µG. In the case of an SWS, its implementation implies nonlinear behaviors and, therefore, nonlinear equations, and this paper shows a way to do it by distributing the computational work, using a high-level description language, and achieving good accuracy and latency with a student-oriented development kit. The platform reproduces, with an integration time of 10 µs, the response of the SWS composed of a 3.5 kW turbine with a fixed blade pitch angle and no gear transmission, a permanent magnet synchronous generator (PMSG), and a three-phase full-bridge AC/DC electronic power converter. The platform accuracy was validated by comparing its results against a software simulation. The compared variables were the PMSG currents in dq directions, the turbine’s angular speed, and the DC bus’s voltage. These comparisons showed mean absolute errors of 0.04 A, 1.9 A, 0.7 rad/s, and 9.5 V, respectively. The platform proved useful for validating the control algorithm, exhibiting the expected results in comparison with a lab-scale prototype using the same well-known control strategy. Using a well-known control strategy provides a solid reference to validate the platform. Full article

The construction hoist drive system is a critical component of the construction hoist, and high speed and low vibration noise are essential development directions. In order to improve the NVH level of the construction hoist drive system, this paper carries out research and analysis of construction hoist drive system excitation, establishes the drive system rigid-flexible coupling dynamics model, and completes the establishment of the vibration and noise model of the drive system, simulation analysis, and optimization work. Ansys Motor CAD 2020 was used to establish the parametric model of the asynchronous motor and it was combined with the virtual work method to calculate Maxwell’s electromagnetic force to arrive at the radial electromagnetic force as the main cause of electromagnetic noise. For the mechanical excitation generated by the gearbox, the time-varying stiffness excitation, mesh shock excitation, and transmission error excitation are considered, and the transmission error of helical gears under different working conditions is calculated by combining it with Romax software 2020. The rigid-flexible coupling model of the construction hoist drive system is established. The load distribution analysis of the unit length of the tooth surface is completed for the first- and third-stage helical gears under different working conditions. The primary source of the drive system excitation is the tooth surface bias load. Based on the dynamic response analysis theory of the vibration superposition method, the maximum vibration speed of the drive system was analyzed by Romax. The maximum noise value of 78.8 dB was calculated from the acoustic power simulation of the drive system using Actran acoustic software 2022 in combination with acoustic theory, and the magnetic density amplitude of the stator teeth of the asynchronous motor was optimized based on the microscopic shaping design of the helical gear by Romax. The vibration and noise simulation of the optimized drive system shows that the vibration value is reduced to 0.75 mm/s, and the maximum noise is reduced to 70.2 dB, which is 10.9% lower than before the optimization. The overall NVH level has been improved. The optimization method to reduce the vibration noise of the drive system is explored, which can be used for vibration noise prediction and control during the development of the construction hoist drive system. Full article