This article has been accepted for publication in a future issue of this journal, but has not been

fully edited. Content may change prior to final publication. Citation information: DOI 10.1109/TMAG.2017.2707066, IEEE
Transactions on Magnetics

> Intermag2017: FS-08. Paper ID.: MAGCON-17-03-0473.R2 < 1

A NEW ELECTRIC MAGNETIC-GEARED MACHINE FOR ELECTRIC

UNMANNED AERIAL VEHICLES
Chunhua Liu 1*, Senior Member, IEEE, Jincheng Yu 1, and Christopher H.T. Lee 2
1
School of Energy and Environment, City University of Hong Kong, HKSAR, China
2
Research Laboratory of Electronics, Massachusetts Institute of Technology, Cambridge, USA

This paper proposes a new electric magnetic-geared (EMG) machine, which artfully incorporates the magnetic gear into an outer-
rotor inserted-PM machine, purposely for electric unmanned aerial vehicle (e-UAV) application. The proposed EMG machine artfully
shares the sandwiched-rotor for both the PM machine and the magnetic gear. As a result, the proposed machine can run in the high
speed and high power for propelling the e-UAV. The design details, operation principles, static characteristics, and machine
performances, as well as the propulsion performances of the proposed machine, are elaborated and discussed. The finite element
method (FEM) is utilized to verify the validity of the machine design and performances, with emphasis on the e-UAV application.

Keywords—Magnetic-geared machine, gearing effect, permanent-magnet machine, unmanned aerial vehicle (UAV).

Recently, a new concept of magnetic gear, which enjoys the

I. INTRODUCTION
NMANNED AERIAL VEHICLES (UAV), in recent years, has
U attracted more attentions due to the ease manipulation,
high cost-effectiveness, wide application ranges, and pilot
safety [1],[2]. Various types of UAVs have been developed
and proposed for complicated and tough missions, such as
data acquisition, forest fire detection, rescue and search
mission, and so on [3],[4]. Typically, the UAVs still rely
mainly on the combustion engines for propulsion [5]. In the
meantime, the electric UAV (e-UAV), which employs the
electric machine drive as the major power source, has become
one of the most attractive applications in aviation industry.
The e-UAV possesses the distinct merits of high efficiency,
high reliability, full-electricity, flexible controllability, and
low pollution. All these advantages drive a tendency in UAV
development, especially for short-distance missions.
In order to fulfill the requirements for the e-UAV
applications, the electric machine for e-UAVs should achieve
the features of tight structure and light weight for saving the
space and mass. In addition, it should provide the high power
density under medium-high speed operation [1],[5]. According
to these criteria, both brushed and brushless machines are
basically suitable candidates for e-UAVs. Undoubtedly, the
brushed dc machines enjoy the merits of simple control, while
it suffers from lower reliability for high-precision e-UAVs. On
the other hand, the induction machines and permanent-magnet
machines, as the most promising brushless machine candidates,
are also quite suitable for e-UAVs. Even though all these
machines consist of their own merits for e-UAV propulsion,
few of them can directly fulfill the requirement for the high-
speed operation, especially up to 8000 rpm or even higher [6].
In this situation, special machine designs have to be employed
for the high-speed running, while the mechanical gear is a
very promising strategy for the high-speed operation.
Manuscript received March 10th, 2017; revised April 20th, 2017.
Corresponding author: Chunhua Liu (e-mail: chualiu@eee.hku.hk).
Color versions of one or more of the figures in this paper are available
online at http://ieeexplore.ieee.org.
Digital Object Identifier (inserted by IEEE).
distinct merit of non-physical contact, has been presented [7],
[8]. Compared to mechanical gears, magnetic gears possess
the definite merits of minimum acoustic noise, no frictional
loss, inherent overload protection, free from maintenance, and
high reliability [9][10]. Thus, by integrating the electric
machine with the magnetic gear, a new type of machines so-
called as the magnetic-geared machines, are proposed for low-
speed applications. In particular, these machines are highly
favorable for wind power generation and electric vehicle
propulsion [11]-[13].
The purpose of this paper is to present a new topology of
electric magnetic-geared (EMG) machine, which is suitable
for high-speed e-UAV propulsion. The e-UAV configuration
with the proposed machine and the theoretical analysis of the
machine topology will be elaborated and discussed. The
validity of the proposed EMG machine is proved through the
finite element method (FEM).
II. SYSTEM CONFIGURATION OF E-UAV
Fig. 1 shows the propulsion system of the proposed e-UAV.
The proposed system consists of the control center, power
converter, energy storage, and the proposed EMG machines.
The control center is the core of the e-UAV, while it has the
responsibility for data collection, route control, task execution
and management, and emergency treatment. In addition, the
control center manages the normal operation of power
converter, energy storage, and the machine drives. Meanwhile,
the energy storage such as the battery can provide the power to
the EMG machines via the power converter. The power
converter obeys the instructions from the control center, in
order to control the machine drives and the energy distribution.
The EMG machines are installed in both wings to drive the
propellers and to provide the driving powers for the e-UAV.
The proposed e-UAV adopts the high-speed direct-drive
propulsion system, so that the merits of direct-drive and
precise control can be achieved. It should also be noted that he
inherent direct-drive feature retains the propulsion system free
from maintenance, wears and tears, such that the efficiency

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This article has been accepted for publication in a future issue of this journal, but has not been fully edited. Content may change prior to final publication. Citation information: DOI 10.1109/TMAG.2017.2707066, IEEE
Transactions on Magnetics
> Intermag2017: FS-08. Paper ID.: MAGCON-17-03-0473.R2 <
and reliability of the e-UAV propulsion system can be
improved significantly. Furthermore, the electric machines
offer the advantage of lighter weight and higher power density,
as compared with the combustion engine counterparts.
Fig. 1. Proposed e-UAV system with new EMG motors.
Fig. 2. Topology of proposed EMG machine.
The key features of the proposed e-UAV system with the
new EMG machines can be summarized as follow:

With the full-electricity configuration, the proposed system
is very compact and robust.

The high-speed direct-drive propulsion system has the merit
of simple and direction configuration, which is capable for
the reliable and precise control of the machine drives.

The proposed electric propulsion configuration provides the
high-power mass ratio, which vastly improves the loading
capability of the e-UAV system.

Although the magnetic-geared machine is usually used for
low-speed high-torque occasions, it still has the big
potential for high-speed applications. The key of design is to
reasonably arrange PM poles and iron steels so that the iron
loss and magnet loss are acceptable for high-speed operation.
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2

Comparing to the combustion engine, the electric machines
offer the advantage of higher fuel efficiency and lower
acoustic noise.

The proposed EMG machines offer high flexible
controllability, such that the e-UAV can enjoy better fault-
tolerant capability.

The machine drives can be controlled independently so that
the total power can be regulated flexibly.
III. MACHINE DESIGN AND OPERATION PRINCIPLE
A. Machine Design
The proposed EMG machine, which incorporates a PM
machine with a coaxial magnetic gear, is shown in Fig. 2. The
proposed machine artfully shares the sandwiched-rotor for
both the magnetic gear and the electric machine. The electric
machine adopts the outer-rotor topology, i.e., the PM is
inserted in the rotor with the circumferential magnetization
and the armature winding is located in the stator. Meanwhile,
the magnetic gear adopts a regular coaxial design. Hence, the
proposed topology can fully utilize the machine space to
increase the power density significantly for e-UAV propulsion.
Since the proposed EMG machine is derived from the
magnetic-geared machine, the number of pole-pairs in the
space harmonics of the flux density distribution can be
described as follow [11]-[14]:
pi = npo + kN s (1)
npo (2)
ωi = − ωo
npo + kN s
where n = 1,3,5,K, ∞, k = 0, ±1, ±2,K , ±∞, N s is the number
of modulation ring iron segments, pi and po are the number
of inner and outer rotor pole pairs respectively, ωi and ω o are
the rotational speed of inner and outer rotor, and the minus
notations in (2) refer to the opposite direction of the inner and
outer rotors. By choosing the combination of n = 1
and k = −1 , the largest space harmonic component can be
obtained. Hence, the high-to-low speed gear ratio Gr is
expressed as:
Gr = po − N r po (3)
The modulation ring is designed to be stationary, while the
outer rotor and the inner rotor rotate in opposite directions.
Taking the requirement of e-UAV application into account,
pi =24, po =3, N s =27, Gr =8, ω o =8000 rpm, and ωi =1000
rpm are selected for the proposed topology.
The coupled inner stator contains 18 slots, with the single-
layer three-phase concentrated windings. The inner rotor
consists of 24 pole-pair PMs with the circumferential
magnetization. The outer rotor consists of 3 pole-pair PMs
with the radial magnetization. Hence, the modulation ring
comes up with 27 poles as the sandwiched form between two
rotors. With respect to the magnetic gearing effect, the
absolute value of rotation speed ratio between the inner and
outer rotor is the reciprocal of the gear ratio, which equals
− 3:24. The minus notation of the gear ratio indicates that the
This article has been accepted for publication in a future issue of this journal, but has not been fully edited. Content may change prior to final publication. Citation information: DOI 10.1109/TMAG.2017.2707066, IEEE
Transactions on Magnetics
> Intermag2017: FS-08. Paper ID.: MAGCON-17-03-0473.R2 <
inner and outer rotors have opposite rotating directions. If the
speed of the inner rotor is set to be 1000 rpm, the relevant
speed of outer rotor should be equal to 8000 rpm. As a result,
the proposed machine can achieve the high-speed
requirements for e-UAV operation. It should be noted that the
immobilization of the modulation ring would be similar with
the magnetic-geared wind generator or other applications [14].
The polyester is filled in the air part of the modulation ring,
which forms an entirety for installation.
It should be noted that the PMs in the inner rotor are
inserted in the rotor slots with circumferential magnetization.
This PM arrangement increases the mechanical integrity of the
machine and reduces the tearing of PM materials. The
employment of high-energy-density magnets definitely
improves the machine torque and power densities. In addition,
the magnetization strategy can also integrate the advantages of
radial and circumferential magnetization. The flux pattern of
the proposed machine is shown in Fig. 3 and it can illustrate
the flux modulation feature and the bipolar characteristics.
Fig. 3. Flux patterns of proposed EMG machine.
Fig. 4. Theoretical waveforms of BLAC conduction scheme.
B. Operating Principle
First, since the e-UAV is often employed for complex and
tough missions, such as the forest fire detection, inspection in
constrains locations, search and rescue missions, it requires
very high reliability and fault-tolerability. The proposed e-
UAV adopts two machines from both wings to drive the two
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3
propellers. Hence, the dual-drive scheme increases the
flexibility and reliability of the e-UAV system. For instance, if
one machine experiences any fault conditions during the
mission execution processes, the remaining one can still keep
the e-UAV in the sky as remedial operation.
Second, the proposed EMG machine inherits the high-speed
characteristic based on the magnetic gearing effect. Its
operating principle is very similar to the conventional PM
brushless machine. To be specific, the sinusoidal armature
current is injected with is 90° lagging with respect to the flux-
linkage. This conduction scheme is well-known as the
brushless AC (BLAC) scheme as shown in Fig. 4. The BLAC
scheme addresses the features of high efficiency, high power
output and low torque ripple, which can be a suitable
conduction scheme for the e-UAV propulsion.
Third, two propulsion EMG motors can coordinate for
operation. For instance, both motors can work in the rated
situation for the optimal running of e-UAV. Also, one motor
can work in the rated situation while the other can work in half
rated torque output due to some situations. It means that two
motors can provide the desired torque for e-UAV propulsion
even under some faults.
IV. PERFORMANCE ANALYSIS
The FEM-based design optimization strategy is adopted in
the machine design and analysis, and it is performed by the
commercial software, the JMAG-Designer. The basic
characteristics of the proposed EMG machine can be
addressed with the help of electromagnetic analysis, while the
machine performances are presented and analyzed.
Consequently, the proposed characteristics of the EMG
machine can be verified.
A. Machine Characteristics
The key design parameters of the proposed EMG machine
are shown in Table I. The diameter of the proposed machine
core is 220mm, while for some other special applications, the
EMG machine can be designed with larger sizes. Hence, the
higher power output can be achieved.
The magnetic field distribution of the proposed EMG
machine is presented in Fig. 5. It can be found that the flux
lines are in symmetrical pattern. The corresponding airgap
flux density versus the rotor position is given in Fig. 6. It can
be seen that the middle airgap consists of the highest flux
density. It should be noted that all three airgap densities fulfill
the design requirement of density with 1 T. Furthermore, the
flux-linkage of the EMG machine is shown in Fig. 7. As
expected, the flux-linkage illustrates the bipolar patterns, such
that the proposed EMG machine can produce higher power
density than its unipolar counterpart does. In addition, the rms
values of the no-load EMF under various inner rotor speeds
are shown in Fig. 8. The results show the output voltages are
directly proportional to the operating speed. In particular, the
output voltages vary from 750 V to 1800 V, in corresponding
to the inner rotor speed from 600 rpm to 1400 rpm.
This article has been accepted for publication in a future issue of this journal, but has not been fully edited. Content may change prior to final publication. Citation information: DOI 10.1109/TMAG.2017.2707066, IEEE
Transactions on Magnetics

> Intermag2017: FS-08. Paper ID.: MAGCON-17-03-0473.R2 < 4

TABLE I.
KEY PARAMETERS OF PROPOSED EMG MACHINE
Item Value
Number of phases 3
Outer radius of outer rotor 110 mm
Inner radius of outer rotor 93.8 mm
Outer radius of inner rotor 78.6 mm
Inner radius of inner rotor 64.6 mm
Airgap length 0.6 mm
Stack length 80 mm
Rated gear inner-rotor speed 1000 rpm
Rated gear outer-rotor speed 8000 rpm
Number of outer-PM pole-pairs 3 (c)
Number of inner-PM pole-pairs 24 Fig. 6. Airgap flux density of the proposed EMG machine. (a) Inner airgap. (b)
Number of modulation ring irons 27 Middle airgap. (c) Outer airgap.
Number of stator slots 18

Fig. 7. Flux-linkage of the proposed EMG machine.

No-load EMF (V)

Fig. 5. Magnetic flux distribution of proposed EMG machine.

Inner Airgap flux density(T)

Fig. 8. RMS values of no-load EMFs under different inner rotor speed.

B. Machine Performance
The machine performance is mainly the torque features,
which is used to evaluate the driving performance for e-UAVs.
First, the cogging torque is evaluated as shown in Fig.9. The
evaluation is just derived from the inside PM machine,
(a) whereas the outer rotor and the modulation ring of the gear are
kept stationary. In this way, it can reflect the damping nature
of the proposed machine. It can be seen that the cogging
torque is significantly small due to the multipole PM design of
the inner rotor. Also, it indicates that after the PM machine
integrates with the magnetic gear, the torque ripple would be
small.
Second, the torque-angle relationship for the inner rotor and
the outer rotor is given in Fig. 10, and the result can give
information of the torque transmission capability of the
magnetic gear. When the outer rotor is kept at standstill, the
inner rotor is rotated step by step under the rated conditions.
(b) Then, the corresponding torque-angle curve of the inner rotor
can be obtained. Similarly, the torque-angle curve of the outer
rotor can be calculated based on the same methodology. It can
be found that the torque-angle curves are quite sinusoidal, and

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This article has been accepted for publication in a future issue of this journal, but has not been fully edited. Content may change prior to final publication. Citation information: DOI 10.1109/TMAG.2017.2707066, IEEE
Transactions on Magnetics

> Intermag2017: FS-08. Paper ID.: MAGCON-17-03-0473.R2 < 5

the maximum torque values denote the pull-out torques. To be

specific, the pull-out torques of the inner rotor and the outer
rotor are 248 Nm and 48Nm, respectively. According to the
machine size listed in Table I, the torque density of the inner
rotor and the outer rotor are 78.3 kNm/m3 and 15.1 kNm/m3,
respectively. The results show the torque densities of the
proposed EMG machine are significantly larger than the
standard electric machine, whose typical value is around 10
kNm/m3 [15]. Because of the larger number of PM pole-pairs,
Fig. 10. Torque-angle relationships of the outer and inner rotors.
the inner rotor can provide smoother torque than the outer one.
In addition, as deduced in the mathematical model, there is a 140
180° phase difference between the two torque-angle curves. 70
Outer
In the third place, the average torque outputs of the inner 0

Torque(Nm)
rotor and the outer rotor of the proposed EMG machine under
-70
the rated conditions are shown in Fig. 11. It can be found that
the outer and inner rotors both consist of very smooth torque -140
Inner
waveforms with the corresponding average torque outputs of -210
236 Nm and 42 Nm, respectively. As a result, the magnetic -280
gearing effect of the proposed EMG machine can be verified. 0 60 120 180 240 300 360
Forth, the power loss of the proposed machine is revealed Angle(degree)

by FEM calculation, which is performed by calculation and
simulation as shown in Table II. It can be seen that as
expectation, the eddy current loss would be the largest one
with the high-speed operation and up to 2184W. The total
power losses are around 3414W. Even though, the motor
efficiency is still up to 91.2%, which is high enough for
practical application. In addition, the power loss for thermal is
not significant for the proposed machine, which is not capable
to bring a high temperature increase. Also, the machine two
rotors inherently play the role of fans for the help of thermal
dissipation. Furthermore, since the proposed machine is used
for e-UAV operation, the temperature in air is normally low.
Thus, the thermal issue of the proposed machine would not be
a big challenge.
TABLE II
POWER LOSSES OF PROPOSED M ACHINE
Item
Copper loss (W)
Hysteresis loss (W)
Eddy current loss (W)
PM loss (W)
Other loss (W)
Power efficiency (%)
Fig. 11. Steady torque outputs of the proposed EMG machine.
C. E-UAV Performance
When two proposed EMG machines are installed in the side
wings of e-UAV, both of the machines can provide
satisfactory power to drive the propellers. The key machine
performances for the e-UAV application are listed in Table II.
It can be found that the EMG machine can provide the output
power of 35.2 kW under the rated conditions. As a result, two
machine drives can provide the power up to 70 kW and this
power level is fairly high for the e-UAV. In addition, the
proposed motor has the power factor of 0.88, which is smaller
than that of 0.97 [16]. Since the proposed motors are used for
e-UAV, the power converter normally has the large
redundancy due to the high requirement of reliability. So, the
power factor is high enough for e-UAV application.
In the meantime, the different power combinations between
Value
two EMG machines are shown in Fig. 12. The results show
127
344 that each of the machine drives can provide different output
2184 powers under various control strategies. If one of the two
506 machines undergoes any fault conditions, the e-UAV can still
253
91.2 achieve the power of 52.8 kW to sustain the normal operation.
Therefore, it can be expected the proposed system can
increase the reliability and safety for the e-UAV applications.

TABLE III
Torque(Nm)

MACHINE PERFORMANCES FOR E-UAV APPLICATION

Item Value
Cogging torque in inner rotor 0.025 Nm
Average torque in inner rotor 236 Nm
Average torque in outer rotor 42 Nm
Power of the inner/outer rotor 35.2 kW
Total Power of the e-UAV 70.4 kW

Fig. 9. Cogging torque in the inner rotor.

0018-9464 (c) 2016 IEEE. Personal use is permitted, but republication/redistribution requires IEEE permission. See http://www.ieee.org/publications_standards/publications/rights/index.html for more information.
This article has been accepted for publication in a future issue of this journal, but has not been fully edited. Content may change prior to final publication. Citation information: DOI 10.1109/TMAG.2017.2707066, IEEE
Transactions on Magnetics

> Intermag2017: FS-08. Paper ID.: MAGCON-17-03-0473.R2 < 6

magnetic-geared machines,” IEEE Tran. Magn., vol. 52, no. 7, pp.

Fig. 12. Power combinations between two EMG motor drives under different
cases for e-UAV.
V. CONCLUSION
In this paper, a new direct-drive EMG machine, which can
operate at high-speed and provide the high power output, is
proposed. This machine artfully integrates the inserted-PM
machine with the magnetic gear together based on the coaxial
structure. Moreover, the proposed machine is proposed for e-
UAV propulsion. The e-UAV configuration, the machine
design details, the machine operating principle and the
machine performances are elaborated and discussed. The
results show that the proposed EMG machine is a very
promising candidate for the e-UAV application.
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ACKNOWLEDGMENT
The work described in this paper was supported by a grant
from the Research Grants Council of the Hong Kong Special
Administrative Region, China [Project No. CityU 21201216].

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