Gearboxes are critical for reducing the mass of drivetrains but the lubrications that they require struggle with extremely cold and dusty environments. Magnetic gears (MGs) are a promising noncontact alternative that does not require lubrication; however, existing topologies either struggle to achieve high gear ratios (coaxial MGs) or suffer from reliability and efficiency limitations (cycloidal MGs). The proposed patented Flux Angle Mapping MG relies on an entirely new operating principle, which offers the potential to achieve the key performance parameter (KPP) goals listed below: (A) Min. ambient temperature actuator operation in hard vacuum without supplementary heating (°C) (B) Average total efficiency in a lunar permanently shadowed region (%) (C) Magnetic actuator life in dust-free environment (Output Cycles) The state-of-the-art and goals for these KPPs are given in Table I of the Technical Volume and are listed on the briefing chart. The high-level technical objectives of this project are to research and evaluate FAM MGs. The deliverables are a final technical report including a transition and commercialization plan. The first technical objective will be the use of parametric multi-physics simulation models to evaluate the suitability of FAM magnetic gears MGs for use in cold and dusty environments and to design a FAM MG technology demonstrator with the following specifications: >208 N·m slip torque >43:1 gear ratio >55 N·m/kg total mass torque density of the gearbox alone >2 rpm low-speed shaft speed >90% efficiency The second technical objective will be the development and testing of a proof-of-concept magnetic gear prototype with the same specifications listed above. This prototype will demonstrate the feasibility of FAM magnetic gears and calibrate and validate the aforementioned simulation models. The third objective is to develop a transition and commercialization plan, including a detailed plan to achieve TRL 6 in Phase II and TRL 9 by 2028. Anticipated
Benefits: The proposed technology is potentially applicable for rover wheels, solar arrays, gimbals, ISRU (drills, buckets, etc.), and robot arms for nearly all planetary exploration missions, including missions to the Lunar surface, Lunar Gateway, Mars, Europa, Titan. Moreover, this magnetic gearbox technology is also potentially useful for deep space applications, such as the James Webb telescope. The proposed technology is potentially useful for several applications outside of NASA, such as advanced air mobility flight control surface actuators and backlash free backdrivable high-precision robotics actuators.
