Optimal Design of a Coaxial Magnetic Gear Pole Combination Considering an Overhang

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.