Magnetic Gear Technologies: A Review

P.M. Tlali, R-J. Wang, S. Gerber

Abstract—This paper reviews the historic and current deve-

lopment of magnetic gear technologies. There has been con-
siderable amount of research and development activities on
magnetic gear technologies in recent years. However, it is still
not clear if this technology is ready for potential industry
applications. The purpose of this paper is to summarize
the historic and current development work of magnetic gear
technologies in an attempt to give readers some insight into the
advantages and disadvantages, challenges, opportunities and
technology readiness.
Index Terms—Magnetic gears, magnetic flux modulation,
permanent magnet, special electrical machines.

I. I NTRODUCTION
EARS and geared machines are widely used in a broad
G spectrum of industry, where the rotational speed of
an input source must be matched to the required rotational
speed of an output load. Mechanical gears are often em-
ployed for this purpose but they are subject to wear, can
overheat, are often damaged in an over-torque situation and
require periodic lubrication and maintenance.
In recent years, magnetic gears (MGs) are increasingly re-
ceiving attention from both research institutions and industry.
Fig. 2. Mechanical and magnetic gear topologies.
A publication histogram on magnetic gear technologies is
given in Fig. 1, where the number of publications including
journals, conferences and patents are summarized. It shows
II. E ARLY DEVELOPMENT OF MAGNETIC GEARS
the increasing research activity after 2000 and especially
in the past decade. It is envisaged that the continuous The first magnetic gear can be traced back to 1901 when
technological development of the magnetic gear will bring Armstrong designed an electromagnetic spur gear [1]. The
it closer to commercial applications. fundamental operating principle of this magnetic gear is very
The concept of an MG was conceived more than a century similar to that of conventional mechanical gears except that
ago. This paper intends to provide a summary and synthesis the force/torque transmission exerted by tooth meshing is
of the important historic work and to discuss the current replaced with the contactless magnetic interaction. Early
status and future development of MG technologies. In the magnetic gear development mainly focused on spur type
following sections, the research and development work done [1]–[8] and worm type [9], [10] topologies. Essentially, a
prior to and after 2000 is classified as early and recent work magnetic gear can be designed according to each available
respectively. topology of its mechanical counterpart. Fig. 2 illustrates
some corresponding gear topologies between mechanical and
80 magnetic gears.
70 There is little success during the early development of
Number of publications

60 MGs. For most early MG topologies, their torque densities

50 simply cannot compete with that of their mechanical coun-
40 terparts. Studies on the magnetic coupling indicated that a
30
higher torque transfer can only be realized when engaging
20
a large number of magnet poles [7], [8], [11], [12]. This
10
implies that the MGs derived from a simple analogy of
0
mechanical gears mostly lead to inferior designs.
A noteworthy concept of an MG [13] was introduced in
the late 1960s, which features three concentric parts, i.e. an
inner magnet rotor, an outer magnet rotor and a flux modu-
Fig. 1. The published work on magnetic gears (1900-2013).
lator between them. Further study on this new MG topology
was done by Laing [14], [15] and Ackermann et al [16], [17].
This work was supported in part by ABB Corporate Research, Sweden The former presented different shapes and arrangements of
and the National Research Foundation of South Africa the modulator while the latter proposed a simple modulator
The authors are with the Department of Electrical and Electronic Engi-
neering, Stellenbosch University, Stellenbosch, 7600, South Africa (e-mail: structure with linking bridges. In addition, Ackermann et al
15894215@sun.ac.za; rwang@sun.ac.za; sgerber@sun.ac.za) [16], [17] described the mathematic relations between the

978-1-4799-4389-0/14/$31.00 ©2014 IEEE 544

numbers of pole-pairs of the permanent magnet (PM) rotors
and the modulator pieces. A unique advantage of this MG
topology is that all PMs are involved in torque transmission,
resulting in a high torque density design.
III. R ECENT DEVELOPMENT OF MAGNETIC GEARS
The last decade has seen a renewed interest in MGs.
This may be attributed to the availability of high energy
density PMs at a reasonable price and more importantly the
new topologies that enable MGs to compete with traditional
mechanical gears in terms of torque density.
A. Torque Dense Magnetic Gear Topologies
Among newly proposed MG topologies, the most sig-
nificant topologies are concentric, harmonic and planetary
magnetic gears as shown in Fig. 3. Although the concentric
Fig. 3. Concentric, harmonic and planetary magnetic gears.
MG may find its root in an early patent by Martin [13],
its high torque capability was first revealed by Atallah et al
in 2001 [18]. The basic operation principle of a concentric
MG is that the ferromagnetic pole-pieces interposed between
the inner and outer PM rotors modulate the magnetic field
such that each rotor “sees” a working space harmonic
corresponding to its own number of poles. The number
of pole-pairs on the inner high-speed and outer low-speed
rotors, ph and pl , and the number of modulator segments,
qm are related by [19]:
qm = ph + pl (1)
With a stationary modulator, the gear ratio Gr is given by:
pl qm − ph qm ωh
Gr = = = −1=− (2)
ph ph ph ωl
where ωh and ωl are the angular speed of the high-speed
and low-speed rotors respectively. The minus sign signifies
that the two rotors rotate in an opposite direction. If the outer
rotor is held still, the gear ratio between the high speed rotor
and rotating modulator is [19]:
qm ωh
Gr = = (3)
ph ωm
where both rotors rotate in the same direction and a slightly
higher gear ratio can be realized.
The harmonic magnetic gears share a similar operating
principle as that of the mechanical harmonic gears. It was
first proposed in [20], while its fundamental theory was
clearly explained and demonstrated in [21]. The operation of
a magnetic harmonic gear relies on a mechanism to produce
time-varying, sinusoidal variation of the air-gap between a
flexible low-speed PM rotor and a rigid PM stator [21],
[22]. The distinct advantages associated with harmonic MGs
are high gear ratios, high torque density and smooth torque
545
transmission [23]. The gear ratio of a harmonic magnetic
gear is given as [21]:
pw
Gr = (−1)k+1 (4)
pl
where pl is the number of PM pole-pairs on the low-speed
rotor and pw is the number of sinusoidal cycles between the
low-speed rotor and stator. The number of PM pole-pairs on
the stator should be p ± pw for maximum torque transfer.
The practical implementation of a harmonic MG is com-
plicated by the need for a flexible PM low-speed rotor.
Alternative configurations were proposed such as the use of
a rigid and eccentrically rotating low-speed rotor [24], and
a dual stage arrangement [21], [23]. However, the structural
complexity of this type of MG remains a deterrent to further
exploitation of this topology.
Planetary MGs received some attention [25]–[28] and
their application in variable inertia devices was demonstrated
in [27]. Similar to their mechanical counterparts, the gear ra-
tio of planetary MGs with a stationary ring gear is governed
by:
ps
Gr = (5)
ps + pr
where pr and ps are the pole-pairs on the magnetic ring
gear and sun gear respectively. The pole-pair relationship
among ring gear, sun gear and planetary gear is given by
ps + 2pp = pr . The merits of planetary MGs include
the capability of three transmission modes, high gearing
ratios and high torque density. However, the mechanical
configuration is also very complicated.
B. State of the Art in Magnetic Gear Technologies
The torque densities of various developed MG tech-
nologies are compared with that of mechanical gears in
Table I. It is clear that the torque dense MG topologies
promise to compete with mechanical gears. Among these
three MG topologies, the concentric MG is mechanically the
least complex. Furthermore, its concentric geometry offers
particular advantages in terms of machine-gear integration
options. This may explain why the concentric-type MG
has received the most attention and is the current focus of
research and development.
TABLE I
T ORQUE DENSITY OF DIFFERENT GEARS [29]
Gear Type Torque density (kNm/m3 )
Mechanical spur gear [30] 100-200
Mechanical helical gear(3G) 50-150
Magnetic worm gear [9] <2
Magnetic bevel gear <5
Magnetic spur gear 10-20
Magnetic harmonic gear(1G) 140-180
Magnetic harmonic gear(2G) 75
Magnetic planetary gear [26] ≈100
Concentric magnetic gear 70-150
IV. C ONCENTRIC MAGNETIC GEAR
A. Design Variations of Concentric MGs
Based on the same operational principle, concentric-type
MGs can also be designed for linear and disc type topologies.
A disc-type concentric MG was proposed in [31] as depicted
in Fig. 4a, which claimed a torque density over 70 kNm/m3 .
Disc-type MGs are well suited for applications where the
isolation of input and output shafts is crucial. Its low-speed
rotor yoke is often made of electrical silicon steel tape
as it is prone to severe core loss [32]. The design of a
linear concentric MG was presented in [33] (Fig. 4b). It
has a tubular structure with outer and inner shorter movers
separated by the ferromagnetic rings along the length of the
gear. Simulation studies showed that a high force density
can be achieved with this linear topology, which is however
sensitive to the axial length of the spacers between the
ferromagnetic rings [34], [35].
(a) (b)
Fig. 4. Concentric MG topologies: (a) disc-type, (b) linear type.
B. Design and Analysis Methods
The design and analysis of MGs involves both electromag-
netic and mechanical analyses. The majority of the published
work is concerned with the electromagnetic design aspects.
Different design analysis approaches have been employed
such as:
• Field solution based analytical models [36]–[39]
• Reluctance network approaches [40], [41]
• Classical electric machine theory [42], [43]
• Numerical methods (Finite Element Method)
While the analytical approaches are time efficient and
can provide some physical insight into the electromagnetic
solutions, the inherent limitations such as the inability to
account for saturation and intricate geometries make them
less favorable in the design and optimization of MGs.
Although the reluctance network approach is not widely
used, it demonstrated the capability of modeling the end-
field leakages of MGs [41]. Numerical methods such as FEM
account for material nonlinearity, give accurate magnetic
field distribution inside the MGs, and have been extensively
applied in the design and analysis of MGs.
In the finite element (FE) analysis of electrical machines,
the standard practice is to apply 2D FE modeling and
make use of geometric symmetry to further reduce the
complexity of the FE model. Usually concentric MGs do
not exhibit periodic symmetry, thus requiring full FE models
to be simulated. This will inevitably make 2D FE modeling
computationally expensive, let alone 3D FE modeling.
One common problem experienced by many researchers is
that 2D FE analysis overestimates the performance of MGs
by a significant margin (up to 40%) [39], [44]–[47], while
3D FE is shown to give accurate prediction [48]. This is
due to the fact that 2D FE models ignore the 3D end-effects
within a magnetic gear. The mechanism of these 3D end-
effects within MGs are studied in [47], [49]. Fig. 5 shows
546
the effect of the modulator thickness on the maximum torque
of an MG [49]. Both 2D and 3D FE results confirm the
existence of an optimum thickness corresponding to the stall
torque of the MG. Despite the visible discrepancy, both 2D
and 3D results show the same tendency. While it may be
subject to further proof and verification, it appears that 2D
FEM remains a viable tool in the design analysis of MGs,
especially when optimization is required.
Fig. 5. The variation of stall torque with modulator thickness of a MG (2D
FE: dashed, 3D FE: solid) [49].
C. Design Aspects of the Flux Modulator
The flux modulator is the key to the operation of concen-
tric type MGs. It operates as either a low-speed rotor (high
torque) or the mechanical earth of an MG so that its me-
chanical integrity is a major concern. Different mechanical
linkage options are evaluated in [43], which shows that the
internally connected modulator has the least impact on the
torque capability of an MG. This is in a good agreement with
[45], [47], which further reveals the benefits of thin internal
mechanical bridges such as loss reduction and suppression
of undesirable harmonics. Jian et al [50] proposed the use
of high temperature superconductor (HTS) materials for
modulator pole-pieces, which can significantly reduce the
modulator thickness and also the end effects. The effect of
the stack length of the modulator has been investigated in
[47], [51], which show that maximum stall torque can be
obtained when the modulator has the same stack length as
that of both rotors.
D. Design Aspects of Inner and Outer Rotors
The PMs on the inner rotor are subjected to large cen-
trifugal forces during high-speed operation, thus methods
of securing PMs on the rotor need careful consideration.
Inner rotor designs with both interior [43] and spoke-type
PM configurations [44] were considered. Both configurations
showed significant reduction of torque capability when com-
pared with the surface-mounted PM configuration.
Different magnet pole arrangements of the outer rotor
have also been reported [46], [52]–[54] as illustrated in
Fig. 6. An interesting design is proposed in [46] as shown in
Fig. 6b, which reduces PM material by introducing salient
leakage poles while still maintaining high torque density.
Considering the current high PM cost, there were also
attempts to use more affordable PMs such as ferrite magnets
[55].

Fig. 6. Different magnet pole arrangements on the outer rotor, where (a)
surface-mounted, (b) leakage pole [46], (c) flux concentration [54], (d)
halbach array [53].
E. Cogging and Ripple Torque
A detailed study on the cogging torque composition was
presented in [56]. Cogging torque reduction techniques such
as step skew was evaluated in [48]. As an indication of the
severity of cogging torque, the cogging torque factor fc first
introduced in [57] is often used in the design of MGs, which
is defined as follows:
2pq
fc = (6)
LCM(p, q)
where p is the number of pole-pairs on one of the PM
rotors, q represents the number of modulator pole-pieces,
LCM stands for the least common multiple. For the lowest
cogging torque, a unity cogging factor is preferred. Fig. 7
illustrates the relationship between the gear ratio and key
gear parameter combinations for p = 3. It can be observed
that the lowest cogging factor is associated with fractional
gear ratios, which is in good agreement with [58], [59].
Fig. 7. The relationship between the gear ratio and key gear parameter
combinations (p = 3) [60].
F. Influence of MG Parameters on Torque Capability
The influence of design parameters (such as modulator
geometry, pole counts of rotors, gear ratios and PM thick-
ness) on the peak torque capacity of MGs was investigated in
[61], which shows the necessity to conduct multi-parameter
based analysis as the single-parameter sweeping analysis has
limited value. The studies reported in [61] (2D FE) and [49]
(3D FE) confirm that for an MG with fixed outer diameter,
there exists an optimum gear ratio where torque capacity
reaches a maximum.
To mitigate the end-effects of MGs, it was proposed in
[44] that longer stack lengths should be used for MGs.
However, as explained in [62], severe deflection of the
modulator is likely to happen with long stack lengths. It
547
has been shown in [49] that aspect ratio has the greatest
impact on the end-effects of MGs and that a critical aspect
ratio exists, above which the 3D end-effects are significantly
reduced.
To avoid operating an MG close to its unstable region, the
rated torque of the MG should be less than its stall torque.
A load factor defined as the percentage of the MG’s stall
torque can be incorporated in the design procedure.
G. Operational Features and Possible Solutions
The inherent overload protection characteristic of MGs
may present operating challenges for certain applications.
When subjected to an overload condition, pole-slipping
occurs in MGs that completely decouples the rotors; hence
torque transmission is halted until the input side re-engages.
As a remedy, automatic pole-slip detection is necessary for
a quick recovery [63], [64], otherwise MGs need to be
designed with a larger safety factor.
In addition, MGs are characterized by a lower torsional
stiffness coefficient than mechanical gears [64]–[68]. They
can suffer from undesired oscillations under rapid load
change, which implies that they are not suitable for servo
drive applications. Both passive and active methods have
been proposed to address this issue. One passive oscillation
suppression strategy is to add damper windings on the high
speed rotor [66], [67], which can reduce the settling time
by more than 80% [67]. The effectiveness of the damping is
clearly shown in Fig. 8. However, insertion of rotor damper
windings decreases the stall torque rating and efficiency of
MGs [66], [67]. Another approach to alleviate the oscil-
lations uses feedback control sensors to actively monitor
the position or speed of both rotors [63], [65]. Control
algorithms are applied to quickly stabilize the system after
any disturbance.
Fig. 8. Transient performance of an MG: (a) without rotor damper windings
(b) with rotor damper windings [67].
H. Variable Gear Ratio Transmission
Similar to mechanical planetary gears, the gear ratio of
concentric MGs can be varied if the stationary element
is allowed to rotate. A compact magnetic continuously
variable transmission (m-CVT) was described in [69], [70],
which employs an inverse MG structure, i.e. with an outer
high-speed rotor. The speed/torque output is controlled by
regulating the high-speed rotor.
 (a) Coupled/decoupled inner-stator configuraton (b) Outer-stator configuraton
Fig. 9. Topologies of magnetically geared machines.
V. M AGNETICALLY GEARED MACHINES
Advances in magnetic gear technology led to the deve-
lopment of a new class of electrical machine: magnetically
geared machines (MGMs). These machines house a mag-
netic gear integrated with a PM machine in the same volume.
In this way, the system torque density is increased beyond
what can be achieved with a cascaded configuration.
A. Topologies
The concept of an integrated magnetically geared elec-
trical machine was first described by Venturini in 1993
[71]. The two most prominent topologies of MGMs, shown
in Fig. 9a and Fig. 9b, were proposed in [72], [73] and
in [74]. The topology in Fig. 9a can be classified as an
MGM with an inner-stator whereas the one in Fig. 9b can
be classified as an MGM with an outer-stator. The inner-
stator topology can further be classified as either a coupled
or decoupled configuration, illustrated by the left and right
halves in Fig. 9a respectively. Another possible topology
was presented in [75] where it is proposed that a winding
be placed between the modulator segments. This type of
topology, illustrated in Fig. 9c, can be referred to as a wound
modulator magnetically geared machine.
The inner-stator topology is perhaps the most natural way
of integration, especially in the decoupled case since the
spaces occupied by the magnetic gear and electrical machine
are completely separate. The decoupled configuration will
have superior flux-weakening capabilities compared to the
coupled configuration due to its higher inductance [76]. This
can be an important consideration for applications such as
traction drives. On the other hand, the coupled configuration
generally has higher torque density because it does not re-
quire a thick high-speed rotor yoke. One major disadvantage
of the inner-stator topology is the high level of mechanical
complexity. The machine has four concentric components,
three air-gaps and two rotors rotating at different angular
velocities. Thus, the mechanical construction of this machine
is challenging. Despite the difficulties, several prototypes of
inner-stator MGMs have been realized [77]–[79].
The outer-stator topology has reduced mechanical com-
plexity compared to the inner-stator topology because the
outer magnets are attached directly to the inner surface of
the stator. In this way, the number of air-gaps is reduced to
two. It has been demonstrated that a torque density greater
than 60 kNm/m3 can be achieved [74], [80]. One study has
found that the outer-stator MGM does not perform as well
as the inner-stator topology in terms of torque density for a
small machine [81].
548
(c) Wound modulator configuration.
Besides the radial configurations, such as those displayed
in Fig. 9, disc [60] and linear configurations can also be
realized.
B. Design
Magnetically geared machines contain two systems in a
single volume (the MG and the PM machine) of which the
torque/power capability can be maximized independently.
An optimal design of an MGM must ensure that the MG’s
torque capability is well matched with that of the PM
machine [82]. Ideally, this means the machine’s stator must
be capable of converting all the input mechanical torque via
the gear into electrical power for generator operation, or in
the case of a motor, the gear must be able to transfer all the
stator torque without slipping. It is sensible to have the stator
designed for a torque capacity slightly below the gear’s stall
torque since the machines rated operating torque must be
below the stall torque. In this regard, the stator load factor
[83] defined below, is a useful concept.
Ts0 Gr
γs = (7)
Tm 0
In (7), Ts0 is the rated stator torque and Tm0
is the modulator
stall torque. The stator load factor is a measure of the balance
between the torque capacity of the PM machine and the MG
and forms part of the design specification as determined by
the prospective application.
VI. V ERNIER - TYPE MACHINES
Researchers have proposed other machine topologies de-
rived from MGMs that do not feature a full magnetic
gear. The similarity between these machines and vernier
machines, such as the one shown in Fig. 10a, has been
described in [84]. In the machine proposed in [84]–[87] the
high-speed PM rotor of the inner-stator MGM topology is
omitted (Fig. 10b). In this case the purpose is to inherit
the high torque density of MGMs while reducing the me-
chanical complexity. This topology allows greater freedom
in the stator configuration compared to conventional vernier
machines, but it has an extra component which is expected to
degrade performance. Alternatively, in [88], [89] the outer-
stator topology is modified by omitting the PMs on the
surface of the stator and choosing the number of stator slots
so as to maintain the magnetic gearing action (Fig. 10c).
This topology largely overcomes the problem of possible
demagnetization.
An important motivation behind these machines is the
reduced usage of magnets and mechanical complexity. How-
ever, the power factor, the torque density or both will be
compromised compared to MGMs.

(a) (b) (c)
Fig. 10. Vernier type machines.
VII. O PPORTUNITIES AND CHALLENGES
Mechanical gears have been widely used in industry and
their maintenance burdens and performance limitations are
known issues. In the wind power industry alone, gearbox
failures account for the largest amount of downtime, main-
tenance and loss of power generation. There are needs in
the market for new gear transmission technologies that are
more efficient, reliable and require little maintenance.
In comparison with mechanical gears, MGs offer advan-
tages such as contactless torque transfer, lower maintenance,
inherent overload protection and physical isolation between
input and output shafts. They are well suited to a variety
of industry applications such as mining, renewable energy
systems [90]–[92], marine propulsion systems, aerospace
technology, and automotive applications [73], [76], [79],
[93]. Within gearbox market segments, planetary gearboxes
appear to be the fastest growing product sub-segment. Great
opportunities exist for concentric MGs to compete in this
market segment.
The current high price of rare earth PMs present signifi-
cant challenges to the development of MGs as this inevitably
increases the costs of MGs. Considering the relatively com-
plex mechanical structure of MGs, their manufacturability
need to be improved. Since there are no reasonably sized
MGs in practical operation, the claimed advantages of MGs
are still to be proved.
VIII. C ONCLUSIONS
In this paper, the historic and current development of
magnetic gear technologies have been discussed with a
specific focus on the concentric-type MG. The distinct merits
of magnetic gear technology are explored together with the
challenges associated with this technology.
MGs potentially have high efficiency and reliability due
to their contact-less operation, intrinsic overload protection
and little to no maintenance. Magnetically geared machines
have emerged as a new class of electrical machine with high
torque density. Several topologies have been proposed and
further research is needed to ascertain their merits.
Magnetic gear technology is still in its infancy and more
practical validation is desired to firmly establish its readiness
to the industrial world. The relatively complex structure and
design process of MGs and MGMs, together with the price
of PMs, imply high manufacturing costs. The advantages
that this technology could bring are significant and warrant
further development.
549
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Pushman M. Tlali (M0 14) was born in Leribe, Lesotho in 1987. He
received his BEng in Electrical and Electronic Engineering at Stellenbosch
University, South Africa in 2012. He is currently pursuing his MScEng
degree in the field of electrical machines. His research interests are in the
optimal design of magnetically geared electrical machines.
Rong-Jie Wang (M0 00-SM0 08) received the PhD(Eng) degree from Stel-
lenbosch University in 2003. He is currently an Associate Professor in the
Department of Electrical and Electronic Engineering of Stellenbosch Uni-
versity. His research interests are computer-aided design and optimization
of electric machines, computational electromagnetics and thermal modeling
of electric machines. He has published more than 50 journal and conference
papers and was a co-author of the monograph Axial Flux Permanent Magnet
Brushless Machines (2nd ed., Springer 2008).
Stiaan Gerber (M0 13) was born in Bellville in South Africa on February
20, 1986. He received his BEng (cum laude) in the field of Electrical and
Electronic Engineering with Computer Science at Stellenbosch University
in 2008 and his MScEng (cum laude) in 2011. He is currently studying
towards his PhD in the field of electrical machines, with specific focus
on magnetically geared electrical machines. His main interests in the
engineering field are electrical machine design, numerical optimization,
renewable energy power generation and finite element methods.