N102-115 TITLE: Magnetic Gears for Utility Actuation Gearbox Applications

TECHNOLOGY AREAS: Air Platform

ACQUISITION PROGRAM: PMA-299 H-60 Helicopter Program

RESTRICTION ON PERFORMANCE BY FOREIGN CITIZENS (i.e., those holding non-U.S. Passports): This topic is "ITAR Restricted." The information and materials provided pursuant to or resulting from this topic are restricted under the International Traffic in Arms Regulations (ITAR), 22 CFR Parts 120 - 130, which control the export of defense-related material and services, including the export of sensitive technical data. Foreign Citizens may perform work under an award resulting from this topic only if they hold the "Permanent Resident Card", or are designated as "Protected Individuals" as defined by 8 U.S.C. 1324b(a)(3). If a proposal for this topic contains participation by a foreign citizen who is not in one of the above two categories, the proposal will be rejected.

OBJECTIVE: Develop and demonstrate an airworthy magnetic gear-based gearbox suitable for utility actuation winch applications.

DESCRIPTION: Modern rotary wing aircraft have a number of utility winching/reeling systems for cargo, rescue, and sensor deployment applications. Degradation or failure of these systems through wear of gear teeth can cause serious mission, reliability, maintenance, and logistical impacts. Magnetic gears afford the opportunity to provide speed and torque multiplication similar to a traditional geared gearbox or transmission, but by using magnetic attraction between rotating members rather than actual physical contact as between gear teeth. It may be possible to greatly reduce, or potentially eliminate, lubrication requirements compared to existing traditional gearboxes. A magnetic gear-based gearbox for winch applications could increase reliability and mission availability by reducing or perhaps eliminating wear-related gearbox failures attributable to traditional tooth-to-tooth contact.

The primary set of challenges is to develop and test a magnetic gear-based gearbox system for winch applications capable of meeting the weight, envelope, stiffness, hysteresis, and torque and speed-multiplication requirements associated with small utility actuation gearboxes. Applications range from large winches with intense duty cycles and high loads such as used on the H-60 and H-53 helicopters, to smaller rescue hoist winches on various other naval helicopters. The compatibility of magnetic gear technology with providing reliable operation in a difficult thermal, vibration and potentially corrosive maritime aviation environment is believed to be a challenge as well.

PHASE I: Determine the feasibility of developing proposed concept for aircraft applications including volume, weight, and performance.

PHASE II: Develop, fabricate and demonstrate a prototype magnetic gear design for an applicable gearbox system. Define test objectives and evaluate through performance and qualification-type testing.

PHASE III: Transition the concept to H-60 helicopter and other applicable platforms that can utilize a magnetic gear-based winch gearbox system.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: A magnetic gear-based winch gearbox system would have direct application to winching/reeling systems on commercial aircraft such as search and rescue aircraft, Police/Security helicopters, logging operation aircraft, and off-shore oil rig aircraft operation. Other potential applications include industrial control and heavy equipment used in construction and mining operations. Indirect application of the technology to other non-winch gearbox systems appears feasible, and could be even broader to perhaps encompass commercial aircraft utility systems of many types as well as aviation propulsion gear-based gearbox systems with demands for high-inherent reliability/minimal maintenance.

REFERENCES:
1. Atallah, K., Calverlay, S. D., & Howe, D., (2004 May). High-performance magnetic gears. Science Direct � Journal of Magnetism and Magnetic Materials, 272-276, Supplement 1, E1727-E1729. doi:10.1016/j.jmmm.2003.12.520

2. Atallah, K., Wang, J., Mezani, S., & Howe, D. (2001, July). A novel high-performance magnetic gear. IEEE Transactions on Magnetics, 37(46), 2844-2846. http://www.jstage.jst.go.jp/article/ieejias/126/10/126_1352/_article

3. P.O.Rasmussen, P. O., Andersen, T. O., Joergensen, F. T., & Nielsen, O. (2005, May-June) Development of a high performance magnetic gear. IEEE Trans. on Industry Applications. 41(3), 764 � 770. http://ieeexplore.ieee.org/xpls/abs_all.jsp?arnumber=1433001&tag=1

KEYWORDS: Magnetic Gear; Winch; Gearbox; Mine Sweeping; Utility Actuation; Rescue Hoists

** TOPIC AUTHOR (TPOC) **

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