Question:

What are the advantages/disadvantages of using adjustable air-gap magnetically

coupled drives instead of conventional electronic adjustable speed drives?

Answer:
The MagnaForce adjustable coupling was extensively studied under a Bonneville Power
Administration contract. Their 1995 report "Testing and Evaluation of the MagnaForce
Adjustable Coupling" demonstrates that the adjustable coupling technology has evolved
into a high efficiency design. Coupling efficiencies of 98-99% are achieved at low torque
conditions, although they do drop to as low as 94% under high load/extended torque
conditions.
A later development, the adjustable speed/adjustable air gap MagnaDrive coupling was
extensively studied by the Northwest Energy Efficiency Alliance. Their October 2005 report "
MagnaDrive: Market Progress Evaluation Report" (913K Adobe Acrobat .pdf) examines
magnetic couplings rated at 50 hp, 100 hp, and 200 hp in direct-coupled pump and fan
installations. The MagnaDrive couplings are compared with throttling or baffling
systems to provide flow control as well as electronic adjustable speed drives. All
systems are evaluated with respect to control capability, power consumption, power
factor, total harmonic distortion, vibration, noise, and temperature changes. The
researchers found that the magnetic couplings are up to 30% more efficient than the
baffled fan control and up to 44% better than the pump throttling control. The
MagnaDrive couplings are less energy efficient than the electronic variable speed drive
(VSD) system, achieving an average of 62% of the VFD fan energy savings and 65%
for pumps. The 2008 NEEA "Long Term Monitoring and Tracking Report on 2008
Activities" (pp. 19-27) provides more discussion on this topic
MagnaDrive literature indicates that, since 1999, their couplings have been installed at
a number of Northwest sites including applications involving HVAC systems, bag house
fans, farm pumps, irrigation pumps, and belt press feed pumps. Their variable
speed/variable air gap design was shown to provide energy savings of 633,300
kWh/year at a 250 hp centrifugal pump motor at Ponderay Newsprint. This
demonstration project was developed as a Northwest Energy Efficiency Alliance Case
Study. MagnaDrive received a U.S. Department of Energy NICE3 grant to demonstrate
their variable speed/variable air gap coupling on 500 to 1,500 hp motors at four
industrial sites.
Additional advantages of the MagnaDrive coupling include:

Vibration isolation (due to the motor and load not being coupled)
Laser alignment unnecessary
Soft start and stop capabilities
Load seizure protection

No wearing parts
Potential reduction in system maintenance
Does not produce harmonic distortion (no reactors, harmonic filters, or isolation transformers are
necessary)
Allows for thermal shaft expansion
Does not require replacement of existing motor with an inverter-duty motor (does not cause motor
insulation failure or bearing pitting)
Does not induce additional motor heating or service factor de-rating
Does not require bypass circuitry
Elimination of control valves and louvres
Can be cost-effective in applications involving high voltage motor power supply (where conventional
VSDs are cost-prohibitive).

Disadvantages include the space requirements of the drive and the fact that users
achieve only about two-thirds of the energy savings that are obtainable with a
conventional electronic VSD.