Design Optimization and Manufacturing of High-performance MLS for WEC

Wave energy is a promising renewable resource, requiring efficient mechanisms for energy conversion. The magnetic lead screw (MLS), functioning as a trans-rotary magnetic gear, offers a robust, contact-free actuation solution characterized by high thrust force density, inherent overload protection, and environmental benefits. These qualities make it well-suited for wave energy conversion (WEC) systems. Among various MLS configurations, the conventional permanent magnet (PM) type is widely adopted for its high efficiency and simpler structure. However, due to its complex geometry and high cost, the manufacturing of helical PMs faces challenges. The design optimization of the MLS is investigated and an innovative oblique cutting method is introduced for helical PM manufacturing. Compared to the conventional approach, this proposed method not only enhances manufacturing efficiency, but also improves the material utilization rate of PMs, minimizing waste as much as possible. This article provides design guidance for high-performance magnetic transmission devices in WEC systems, offering significant engineering application value.