Magnetic gears transmit torque via non-contact electro-magnetic coupling, which eliminates mechanical contact and significantly reduces wear, backlash, and noise compared to traditional mechanical gears. These benefits make magnetic gears particularly appealing for high-precision, high-reliability applications. However, achieving both high torque density and high gear ratios necessitates an optimized structural design that promotes efficient magnetic flux distribution while minimizing leakage and saturation. This study focuses on a hollow-type magnetic gear for collaborative robots that offers a high gear ratio. It employs topology optimization in conjunction with finite element analysis (FEA) to enhance torque density and efficiency. Key design variables, such as the geometry of the ferromagnetic core and the arrangement of permanent magnets, were optimized to increase average torque and reduce torque ripple and electro-magnetic losses. A prototype based on the optimized model was fabricated, and its performance was validated using a conventional direct torque measurement system. Experimental results were compared with simulation predictions to evaluate accuracy and analyze loss characteristics. The findings demonstrate the effectiveness of the proposed optimization approach and provide practical guidelines for designing high-efficiency magnetic gears suitable for advanced drive systems, including electric mobility and renewable energy applications.

The aim of this research was to investigate the torque performance of the motor in an electric vehicle depending on the rotor shape and air gap. The research focused on numerical comparison of torque performance of new rotors based on the average torque and torque ripple rate, which appeared according to the number and placement of permanent magnets. This research was numerically analyzed by MAXWELL V21.1. Average torque values in cases 1, 2, and 3 were increased, but vibration and noise in cases 1 and 3 were increased as the torque ripple rate increased. Considering the average torque and torque ripple rate, the torque performance of case 2 was the most optimal. Compared with Model N, the average torque of case 2 was increased by 9.1% and the torque ripple rate was reduced by 1.5%. The torque performance according to the size of air gap was compared with the basic model of case 2, which showed the best performance. An air gap of 0.7 mm applied to Model N showed the best torque performance. An additional magnet on case 2 and air gap of 0.7 mm provided the best torque performance and improved the driving motor performance for motor durability.