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The paper presents an analysis of local and global forces acting on the ferromagnetic material of a modulator in a co-axial magnetic gear, taking several design variants and the impact of loading into account. The analyses include a modulator with cores manufactured from a soft-magnetic composite material and two variants made from electrical steel with laminations stacked in different directions. Variations of local forces acting on individual pole pieces of the modulator are analyzed at different loads, showing that the force spectra are subject to significant variation with an increasing load. The presented magnetostatic analyses are extended by structural analysis that provides estimation of stress and displacement for the modulator assembled from additively manufactured acrylonitrile butadiene styrene (ABS)-plastic parts. The analysis carried out for the least favorable design case of the magnetic circuit of the modulator shows that an application of the technology is significantly restricted by the magnetic gear torque volumetric density. Some changes to the modulator mechanical design are proposed in the paper to mitigate the drawbacks of this technology.

On-Load Characteristics of Local and Global Forces in Co-Axial Magnetic Gear with Reference to Additively Manufactured Parts of Modulator