Experimental Validation of a Modified Halbach Array for Improved Electrodynamic Suspension Efficiency

In this work, we present an experimental validation of a modified Halbach array magnet configuration for passive electrodynamic suspension (EDS) systems. The study builds upon previous research that indicated improved lift-to-drag performance and reduced power consumption by altering the span (fill factor) of horizontally magnetised magnets in a Halbach array. A custom rotating test rig was developed to measure both magnetic field distributions and levitation/braking forces for several Halbach array configurations with varying magnet width ratios. Six magnet array packs were tested, featuring different fill factors (0.125, 0.5, 0.875), magnet lengths, and wavelengths. The experimental results show good agreement with 3D finite-element simulations across a range of speeds (0–85 m/s) and air gaps, confirming that non-classical Halbach arrays (with a fill factor ≠ of 0.5) can achieve higher energy efficiency. In particular, configurations with extreme fill factors produced lower magnetic drag for the same lift force, yielding a higher lift-to-drag ratio and a reduced magnetic friction coefficient. These findings validate the proposed modified Halbach arrangement and demonstrate that adjusting the horizontal magnet span can indeed reduce the power requirements of EDS maglev systems. The novelty of this work lies in the combined numerical–experimental assessment of mixed-length Halbach array configurations, revealing previously unreported scaling effects between magnet width ratio and force stability in short-stroke applications.