Development of a Contactless Electromagnetic Clutch for Efficient Torque Transmission

Abstract

Conventional mechanical clutch systems rely on friction-based contact surfaces to transmit torque between rotating shafts. Although widely used in automotive and industrial machinery, such systems suffer from frictional losses, mechanical wear, heat generation, and frequent maintenance requirements. To address these limitations, this paper presents the design, modelling, and experimental evaluation of an electromagnetic contactless torque transmission system capable of transferring torque without direct mechanical contact. The proposed system utilizes electromagnetic coupling generated by energized solenoid coils and permanent magnets to produce a controllable magnetic field across a small air gap between the driving and driven plates. The prototype system consists of a DC motor, electromagnetic coil assembly, slip ring mechanism, neodymium magnets, and an electronic control circuit that regulates torque transmission through electrical excitation. Experimental testing demonstrates that the system achieves smooth engagement and disengagement with minimal vibration and reduced frictional losses compared with conventional clutch mechanisms. Results indicate that torque transmission can be controlled effectively by varying the coil excitation current, allowing precise control of rotational power transfer. The proposed system significantly reduces mechanical wear, noise, and maintenance requirements. The developed prototype demonstrates the feasibility of electromagnetic contactless torque transmission for applications in electric vehicles, industrial automation systems, robotic drive mechanisms, and precision machinery.