Investigation on the Torque to Mass Ratio of Synchronous Magnetic Couplings

This paper provides a comprehensive analysis of the torque to mass ratio for a wide range of synchronous permanent magnetic coupling geometries. The study aims to compare optimized magnetic couplings with commercially available flexible disc couplings to evaluate their relative performance and viability for various torque transmission applications. Both coaxial magnetic coupling (CMC) and axial magnetic coupling (AMC) designs are considered. Different combinations of dimensional parameters are explored to optimize the torque to mass ratio for each target peak torque value using an analytical design tool and validated with 2D magnetostatic finite element analysis. Results indicate that while the optimized CMC design achieves a torque to mass ratio of 160.13 Nm/kg, it remains less competitive compared to the 315.2 Nm/kg ratio of an equivalent Mayr®Roba®-DS flexible disc coupling. Our findings suggest that although MCs offer benefits such as misalignment tolerance and reduced vibration, their application is more suited to scenarios where these advantages outweigh the lower torque to mass ratio. This research provides valuable insights into the design and application of magnetic couplings in automotive and aerospace systems.