Magnomatics’ (MM) innovative magnetic CVT (mCVT) integrates a magnetic planetary gear and a highly efficient control motor/generator to enable a superior power-split HEV powertrain to be realised. A Proof of Concept mCVT has demonstrated excellent efficiency and robustness within a compact package. It has the potential to reduce CO2 emissions from new cars by 1.3Mtonnes p.a. by 2020. Ford UK will provide the specification, technical steer and CAE vehicle studies, MM will design, build and test an mCVT for a passenger car, Arnold Magnetic Technologies (AMT) will manufacture core magnetic components and Romax Technology (RT) will assist with determining optimum HEV architecture and control. A thorough assessment of performance benefits will enable OEMs to assess the market potential, enabling future advanced UK volume manufacturing of components.

This project is part of a plan to bring the manufacture of large generators for offshore wind to the UK. Magnomatics Pseudo Direct Drive (PDD(r)) combines a magnetic gear with a permanent magnet generator. The PDD is very efficient and very reliable with no meshing gear teeth. Independent analysis has shown this provides lower cost of energy. The novel component in this technology is a pole piece rotor (PPR), a cylindrical structure comprising multiple axial steel pole pieces within a non-magnetic composite structure. In operation these pole pieces are subject to massive forces and complex cyclical loads. In previous demonstration units the construction methods used in the PPR were expensive and labour intensive. There are now several alternative concept designs for scaling up the technology but building and testing these at full scale would be very expensive. The PPR for a 15MW generator will be approximately 9m diameter. In this project new instrumentation will be installed in the 500kW CHEG generator and then extensively dynamometer tested to better understand the behaviour of the PPR under wind turbine loads and cycles. The testing carried out at the ORE Catapult will capitalize on previous testing carried out there during the Demo Wind project. Magnomatics will then develop sophisticated computer-based modelling software which can then be used to design robust PPRs including dynamic modelling of the pole piece loads to predict wear and possible erosion of the composite structure. These methods will be validated using the new test data from the ORE Catapult. A virtual product validation will be performed on concept designs. ensuring the PPR achieves the expected product lifetime of 25+ years. Wind turbine generator unit volumes could reach 800 units per annum therefore it would be essential to manufacture the PPR cost effectively. The AMRC, Sheffield, are providing input and support to Design for Manufacture of the PPR to achieve this. Proving this technology provides a credible route to UK construction of direct drive generators for offshore wind leading to annual sales of £1.2bn and dramatically increasing the proportion of UK content in offshore wind farms. This aligns perfectly with UK Industrial Strategy for PEMD and the Offshore Wind Sector deal. The technology can also apply to rail, marine propulsion and industrial drives, improving efficiency and reducing CO2 emissions.

Magnomatics’ PDD® is a new type of direct drive electric motor, optimised for high-torque, low-speed applications, replacing conventional high-speed motor/gearbox systems. It features a non-contacting, lubricant-free magnetic gear which offers significant efficiency and reliability benefits. Due to its ultra-high torque density and high efficiency, the PDD® is particularly suited for in-hub drives for hybrid/EV trucks, busses and construction vehicles, where small size, low energy losses, very high torque capability and robust operation are required. Magnomatics (Lead Partner) have been collaborating with Volvo Powertrain, Kollmorgen and Magnet Applications to realise a PDD® wheel hub drive suitable for a city-bus, municipal commercial vehicle or long-haul truck. A comprehensive design, build and test programme has been undertaken, encompassing full electromagnetic, thermal and mechanical analysis. The resulting 65kW (130kW peak) motor is capable of delivering 4kNm and fits within a standard 22” wheel rim. The performance of the prototype motor has been validated on a dynamometer system at Volvo Technology, showing efficiencies at rated torque and speed in excess of 97%. Magnomatics intend to demonstrate PDD® technology on a hybrid commercial vehicle mule to test the technology as part of a hybrid vehicle powertrain system.

The MAGSPLIT® electronically Continuously Variable Transmission (eCVT) device is a new concept for hybrid vehicle drivetrains. The system comprises a fully integrated magnetic powersplit, and motor/generator. MAGSPLIT offers unparalleled powertrain efficiency and noise and vibration reduction in a very compact system, enabling its use in a greater range of vehicles than is currently achievable and cost effective within existing hybrid drivetrains. These advantages are achieved by the magnetic gearing effect at the heart of MAGSPLIT and all Magnomatics’ products, enabled by the unique Pole Piece Rotor (PPR) component. The achievement of a cost effective, high volume production capability for PPR that retains robustness and high performance is a key element in the success of MAGSPLIT. This project will identify and deliver a production intent PPR using manufacturing advances beyond the current state-of-the-art supporting increased market penetration of MAGSPLIT in a greater number of vehicles in a wider range of platforms. Concurrent component and process design is also expected to benefit both areas and further enhance MAGSPLIT performance.

Awaiting Public Project Summary