Alüminyum Köprü Modülatör Rotor Yapısı Kullanılarak Hız Çarpanlı Manyetik Dişlinin Mekanik Dayanıklılığının Artırılması

Abstract

Elektrikli makinelerin (EM) yüksek hızlarda çalıştırılması, ciddi rotor stresine ve verimlilik kayıplarına neden olur. Eş eksenli hız çarpanlı manyetik dişli (SMMG), düşük hızlı EM'lerin yüksek çıkış dönüş hızlarına ulaşırken verimli bir şekilde çalışmasını sağlayarak, ilgili EM tasarım sorunlarından kaçınılmasını sağlar. SMMG topolojisinde, modülatör rotor olarak da bilinen ferromanyetik kutup parçası (FMP) rotoru, EM'den girdi alan yüksek hızlı çıkış bileşenidir ve bu da yapısal bütünlüğünü kritik hale getirir. Önceki çalışmalar elektromanyetik performansa odaklanmış olsa da, modülatör rotorun aşırı çalışma yükleri altındaki mekanik dayanıklılığı henüz araştırılmamıştır.Bu çalışma, üç modülatör rotor tasarımının yapısal performansını değerlendirmek için 3 boyutlu sonlu elemanlar analizi (FEA) kullanmaktadır: takviyesiz bir taban hattı, polimer dolgulu bir varyant ve yeni bir alüminyum köprü takviyeli yapı. ~83 Nm sabit tork yükü altında 10.800 rpm'ye kadar dönme hızlarında gerçekleştirilen simülasyonlar, alüminyum köprü takviyesinin von Mises gerilimini 458 MPa'dan (takviyesiz) 161 MPa'ya düşürdüğünü, yani %64,85'lik bir azalma sağladığını göstermektedir. Ayrıca, tüm hızlarda 1,6'nın üzerinde bir güvenlik faktörü sağlar ve NSSMC 35H210 kutup malzemesinin akma dayanımı (250 MPa) dahilinde çalışmayı garanti eder. Buna karşılık, takviyesiz ve polimer dolgulu tasarımlar, malzemenin akma sınırını aşan felaket düzeyinde gerilim seviyeleri yaşamıştır. Bu çalışma, temel tasarım kılavuzları sağlamakta ve alüminyum köprü modülatörünün yüksek hızlı uygulamalar için sağlam bir aday olduğunu doğrulamaktadır.

Keywords

• Sonlu elemanlar analizi (FEA)
• Yüksek hızlı uygulamalar
• Manyetik dişliler
• Yapısal güçlendirme

Supporting Institution

Universiti Teknikal Malaysia Melaka (UTeM) ve Kolej Komuniti Bukit Beruang.

Project Number

Fundamental Research Grant Scheme (FRGS), Grant No: FRGS/1/2024/TK08/UTEM/02/3 under Ministry of Higher Education (MoHE), Malaysia

Ethical Statement

Bu araştırmada insan katılımcıları, hayvan deneyleri veya etik onay gerektiren herhangi bir prosedür yer almamıştır.

Thanks

Yazarlar, Mohd Khairol Nizam bin Mohd Anuar'ın Yüksek Lisans çalışmalarını Hadiah Latihan Persekutuan Separa Biasiswa (HLPSB) aracılığıyla desteklediği ve bu araştırmayı Temel Araştırma Hibe Programı (FRGS), Hibe No: FRGS/1/2024/TK08/UTEM/02/3 kapsamında finanse ettiği için Malezya Yüksek Öğretim Bakanlığı'na (MoHE) minnetle teşekkür ederiz. Yazarlar ayrıca araştırma olanakları ve teşvik edici bir akademik ortam sağladıkları için Universiti Teknikal Malaysia Melaka (UTeM) ve Kolej Komuniti Bukit Beruang'a içtenlikle teşekkür eder.

Mechanical Strength Enhancement of a Speed Multiplier Magnetic Gear Using an Aluminium Bridge Modulator Rotor Structure

Abstract

Operating electrical machines (EMs) at high speeds induces severe rotor stress and efficiency losses. A coaxial speed multiplier magnetic gear (SMMG) enables low-speed EMs to operate efficiently while achieving high output rotational velocities, thus avoiding the associated EM design penalties. In the SMMG topology, the ferromagnetic pole piece (FMP) rotor, also known as the modulator rotor, is the high-speed output component receiving input from EM, making its structural integrity critical. While prior studies have focused on electromagnetic performance, the mechanical strength of the modulator rotor under extreme operational loads remains unexplored. This study employs 3D finite element analysis (FEA) to evaluate the structural performance of three modulator rotor designs: an unreinforced baseline, a polymer-filled variant, and a novel aluminium bridge-reinforced structure. Simulations performed at rotational speeds up to 10,800 rpm under a constant torque load of ~83 Nm demonstrate that the aluminium bridge reinforcement reduces the von Mises stress from 458 MPa (unreinforced) to 161 MPa, a 64.85% reduction. It also maintains a safety factor above 1.6 across all speeds and ensures operation within the yield strength (250 MPa) of the NSSMC 35H210 pole material. In contrast, the unreinforced and polymer-filled designs experienced catastrophic stress levels, exceeding the material's yield limit. This work provides essential design guidelines and validates the aluminium bridge modulator as a robust candidate for high-speed applications.

Keywords

• Finite element analysis (FEA)
• High-speed applications
• Magnetic gears
• Structural reinforcement

Supporting Institution

Universiti Teknikal Malaysia Melaka (UTeM) and Kolej Komuniti Bukit Beruang.

Project Number

Fundamental Research Grant Scheme (FRGS), Grant No: FRGS/1/2024/TK08/UTEM/02/3 under Ministry of Higher Education (MoHE), Malaysia

Ethical Statement

This research did not involve human participants, animal testing, or any procedures requiring ethical approval.

Thanks

The authors gratefully acknowledge the Ministry of Higher Education (MoHE), Malaysia, for supporting Mohd Khairol Nizam bin Mohd Anuar’s Master’s studies through the Hadiah Latihan Persekutuan Separa Biasiswa (HLPSB), and for funding this research under the Fundamental Research Grant Scheme (FRGS), Grant No: FRGS/1/2024/TK08/UTEM/02/3. The authors also sincerely thank Universiti Teknikal Malaysia Melaka (UTeM) and Kolej Komuniti Bukit Beruang for providing research facilities and an encouraging academic environment.

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