Non-Contact, Lubrication-Free Magnetic Gear Integrated Motor Generator for Reduced Maintenance, Increased Survivability, Extended Range, and Enhanced Payload Capacity of Autonomous Vehicles

FluxWorks aims to increase the manufacturing readiness level (MRL) to 5 for the modulator and magnet rotor subassemblies of the coaxial magnetic gear and demonstrate technology readiness level (TRL) 5 through drive cycle testing of a high fidelity prototype in a simulated course on a dynamometer, all while building the transition roadmap to bridge to cross the technology valley of death.Ā First, FluxWorks will manufacture 2x tactical vehicle-relevant coaxial magnetic gears (CMG) and analyze experimental performance, formally conducting factory acceptance testing.Ā Simultaneously, FluxWorks will develop 2xĀlarger CMG prototype while developing a scalable manufacturing readiness assessment before shipping the gear to BAE Systems for testing at their Sterling Heights facility. Success of this effort will be indicated by the following milestones: Manufacturing plan delivered including an affordable solution for identified need with acceptable technology risk, scope, and complexity, affordability targets have been identified, and technology development plans, time, funding, and other resources match understood customer needs. Prototyping and end item development strategy for next step Technology Development phase focused on key technical risk areas identified. The high-fidelity tactical prototype slip torque, measured by FluxWorks, is within ▒10% of the simulated value.Ā The measured losses are within ▒20% of the simulated values.Ā An industry standard factory acceptance testing (FAT) procedure has been developed and utilized to explain the variation in performance between units.Ā Electromagnetic leakage measured is acceptable radially beyond the gear during any operating condition, and thermal and vibro-acoustic signature characterization complete. A Manufacturing Readiness Assessment will be conducted to measure maturity, associated costs, risks and to provide the basis for manufacturing maturation and risk management.Ā Engineering and production will identify high risk processes and create mitigation solutions to achieve a seamless transition to production. A detailed plan for commercialization and technology transition plan has been delivered and serves as a green light/red light to guide further funding through SBIR CATALYST, Phase III with specific acquisition personnel identified, or other means. The technology demonstrator is capable of meeting rated peak power at 2200 rpm (high speed side) on the BAE Systems, Platforms and Services Sector Sterling Heights Mobility Electrical Test Lab Dynamometer when exposed to test chamber maximum temperature conditions. The measured losses are within ▒20% of the simulated values, thermal- and vibro-acoustic signature preliminary characterization is complete.Ā Post-processed experimental results applied to full-scale magnetic gear design to yield large-scale recovery vehicle-relevant performance; potential system level benefits to communicated to BAE Systems and Army leadership.Ā