Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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HIGH EFFICIENCY AC DC ELECTRIC MOTOR, ELECTRIC POWER GENERATING SYSTEM
WITH VARIABLE SPEED, VARIABLE POWER, GEOMETRIC ISOLATION AND HIGH
EFFICIENCY CONDUCTING ELEMENTS.
FIELD
[001] The disclosed invention relates to a high efficiency electric motor and
generator which can
operate at variable speeds and using various types of electric power input.
More particularly, the
present invention is related to configuration of components of an electric
machine including
construction of poles, shielding, geometric configuration, use of
superconductive materials, and
specialty materials in coils in the stator and rotor to reduce electromagnetic
drag from the magnetic
reaction force created by the load current which opposes the rotation of the
armature.
CROSS REFERENCE TO RELATED APPLICATIONS
[002] The present application claims priority to International Application No.
PCT/US2012/069449
HIGH EFFICIENCY ELECTRIC GENERATOR WITH ELECTRIC MOTOR FORCES filed
December 13, 2012, which claims priority from U.S. Provisional Application No.
61/630,600 filed
December 15, 2011, the contents of both of which are incorporated herein by
reference. The present
application further claims priority to: U.S. Provisional Application No.
61/688,668, entitled HIGH
EFFICIENCY VARIABLE SPEED VARIABLE POWER INPUT ELECTRIC MOTOR AND
APPLICATIONS, filed May 18, 2012; U.S. Provisional Application No. 61/688,669,
entitled
ELECTRIC POWER GENERATING SYSTEM FOR GENERATION OF ALTERNATING
CURRENT (AC) AND/OR DIRECT CURRENT (DC) AND APPLICATIONS, filed May 18, 2012;
and U.S. Provisional Application No. 61/852,304, entitled ELECTRIC POWER
GENERATING
SYSTEM UTILIZING A UNIQUE STATOR, ROTORS, WINDING AND SHIELDING
,
MECHANISMS ALONG WITH SUPERCONDUCTIVE COILS AND GRAPHENE
CAPACITORS TO IMPROVE EFFCIENCY, filed March 15, 2013,
BACKGROUND
[003] An electric power generator consists of two main parts: A stator and a
rotor. The stator is
generally made of laminated iron or other ferro-magnetic material and contains
long slots having a
certain depth and in which wire coils are wound in such a fashion to allow
electric power to be
generated when magnetic fields emanating from the rotor move past the coils.
The rotor contains a
specific arrangement of magnets, with generally wound armature electro-magnets
whose strength is
governed by the amount of current flowing in the armature windings. When the
rotor spins inside the
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stator, the moving magnetic fields from the rotor induce a current in the
stator windings thus
generating what is referred to as electrical power.
[004] The energy required to spin the rotor is typically applied by a drive
unit of some kind, such as
an electrical drive motor, diesel or other fossil fuel motor, steam turbine or
the like. At typical
efficiencies, only 20% of the energy input by the drive motor is devoted to
creating electrical power.
[005] The remaining 80% is dissipated by magnetic drag, or braking forces,
that develop between
the rotor and the stator. When current is applied to a load from a
conventional generator, a magnetic
force or braking force is created by the flow of the load current in the
generator conductors that
opposes the rotation of the generator armature. If the load current in the
generator conductors
increases, the drag associated with the reaction force increases. More force
must be applied to the
armature as the load increases to keep the armature from slowing. Increasing
drag and increasing
load current leads to decreasing conversion efficiency and can eventually lead
to destructive
consequences for generator equipment. The generators and structures in
accordance with
embodiments described herein are designed and constructed such that these
destructive drag forces
are eliminated.
[006] As noted, an ordinary electric motor consumes large amounts of electric
power due to
electromagnetic drag. The greater the mechanical load, the more power is
consumed and the greater
is the electromagnetic drag. Electric motors are designed today to consume
approximately 746 watts
of electric power for each horsepower produced. It is estimated that if the
electromagnetic drag
forces were removed, the electric motor would be significantly more efficient,
such as potentially
400 ¨ 500% more efficient.
SUMMARY
[007] The electric motor/power cogeneration unit of embodiments eliminates or
reduces
electromagnetic drag and generates electric power offthe opposite ends ofthe
lateral motor pole
irons. These lateral pole irons are described in great detail in application
"Solid State Rotary Field
Electric Power CoGeneration Unit PCT/IB2010/000039."
[008] The more load applied to the motor shaft, the more increased current
flows through the motor
which increases the amount of drag in a classic electric motor. However, this
is not the case with the
motor of in embodiments. The current flow and frequency through the lateral
pole irons is controlled
by a solid state excitation control system. The wire carrying the load current
is wound onto
appropriate cast-iron or laminated lateral steel pole irons which are placed
in direct proximity to the
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coil slots of the power cogeneration induction coils which are wound into the
appropriate slots of
the laminated steel generator frame. The cogeneration induction coils are
formed of multiple coils
per group with multiple groups being used as needed. The wound lateral pole
iron coils form direct
current (DC) electromagnetic poles which are wound such that they each, when
activated, fire as
needed north or south in sequence in a clockwise or counterclockwise fashion.
The sequencing and
rotational direction is controlled byan attached computer programmable logic
center and solid state
coil direct current excitation system. This system is more efficient and more
flexible than an
alternating current (AC) system.
[009] The wound lateral pole iron coils fire in sequence into each slot of the
superior portion of the
power generation induction coils. The central ends of these electromagnetic
poles are seated into
slots of a non-ferromagnetic conductor ring which is fixed to the laminated
steel generator by a
support means. These central ends of the electromagnetic poles are flush with
the inner surface of the
ring. The laminated steel motor/generator frame is encased in by example, a
circular housing which
is attached to end bells which contain bearings (ball bearings or roller
bearings or the like). The roller
bearings support a non-ferrous armature which contains permanent magnetic rods
or electromagnetic
members which are strategically placed into closed cavities, which closely
approximate the outer
radius of the armature portion. With respect to the permanent magnetic rotor
or electromagnetic
rotors of the armature, approximately 180 of the member is north pole charged
or south pole
charged and the other 180 will be of the opposite charge.
[0010] The cavities, which contain the magnetic bars or electromagnetic rotor
members are held by a
containment means and are supported by roller bearings and shielded by a
laminated stainless steel
mu metal cylinder. The cylinder is open to the peripheral surface of the
stator by a 45 opening to
allow interaction with the opposite magnetic pole of the lateral pole iron. As
the stator is activated,
the field rotates in a sequential clockwise or counterclockwise fashion,
attracting the opposite poles
of the armature. The three pole irons represented by example fire in sequence
and in parallel with the
other eleven pole iron groups. Therefore, the sequence for 50 Hz operation is
for the 3 lateral pole
irons to fire repetitively for 6.66 milliseconds (ms). The maximum magnetic
pole strength is reached
in five ms following DC excitation and requires five ms to collapse once DC
excitation has ceased.
When the poles are activated, the armature pole nearest the activated wound
pole irons is attracted.
The pole iron reaches magnetic peak intensity in five ms and collapses in five
ms releasing the
magnetic polar attraction of the pole iron. The collapsing pole pushes current
in the opposite
direction. This collapsing current is channeled through a solid state
switching circuit and is stored in a
battery system.
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[0011] The power from the battery is then used to parallel with the DC power
supplies which are
used to excite the lateral pole iron coils on following cycles. The armature
magnetic rotating poles
cannot repel the stator pole irons due to the freewheeling design. The
sequence for 60 Hz operation is
to fire repetitively for 5.55 ms. However, this is a multiple speed electric
motor which is computer
controlled and operates from a DC power supply which can be powered by either
AC or DC and in
the case of AC, can utilize either single phase, two phase, three phase or the
like by the use of the
correct power supply, or by the use of each leg of a polyphase electric supply
along with, and in
conjunction with, a power neutral or ground neutral. The sequential firing of
the north-south
sequence of the stator poles generates power in the power generation induction
coils just as a
magnetic spinning armature generates power. The sequential firing of the poles
also spins the
armature thereby generating mechanical power or motor power onto the motor
shaft. As the load on
the shaft increases, the current flow in the stator coils increases, thereby
increasing the amount of
power generated in the cogeneration coils. This arrangement allows the motor
to operate more
efficiently since the electromagnetic drag has been mostly eliminated.
[0012] The cogeneration component allows removal of power off the induction
coils and thereby
allows less impedance to current flow to neutral and to ground as is well
demonstrated in
application "Solid State Rotary Field Electric Power CoGeneration Unit;
PCT/IB2010/000039". The
cogenerated power from the unit is fed back to the solid state coil DC
excitation system where it is
used to excite the stator lateral pole iron coils in parallel, along with the
power system and batteries
in which power is stored from the collapsing pole coils. The rotor magnetic
poles may be composed
of electromagnetic components as well as by the rotary permanent magnetic
components and the
rotary permanent magnetic components may be stabilized by electromagnetic pole
stabilizing
inserts.
[0013] Various exemplary embodiments are discussed and described herein
involving aspects of an
electric machine, such as an electric motor and power cogeneration unit that
produces power with
high efficiency and low electromagnetic drag forces. Accordingly, an exemplary
method for
reducing drag in an electric motor ¨ power cogenerator can include forming a
series of wound
lateral pole irons around the inner periphery of a stator as is fully
described in application "Solid
State Rotary Field Electric Power CoGeneration Unit. PCT/IB2010/000039". The
stator is further
provided with slots around the inner periphery that contain induction
windings. First, ends of the
lateral pole irons extend into the slots and are supported by a lateral pole
iron support structure
forming a circular opening that is concentric with the inner periphery of the
stator. Second, end of
the lateral pole iron extend toward the circular opening. Stator inserts
containing free-wheeling
permanent magnet inserts, or wound electromagnetic inserts, can be distributed
along an outer
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periphery of a rotor inserted into the circular opening of the lateral pole
iron support structure. The
free-wheeling permanent magnet inserts can be inserted into cavities along the
outer periphery of
the rotor and can each include a pair of pole sections with a first magnetic
polarity and a second
magnetic polarity. The pole sections can be made, for example, from neodymium,
samarium-cobalt
or the like. The windings of the lateral pole irons can be sequentially
energized so as to provide a
moving field such that a torque is applied to rotate the rotor, and pole
sections of the free-wheeling
permanent magnet inserts which are free to rotate into alignment with ones of
the second ends of the
lateral pole irons to increase a flux density in the lateral pole iron, the
first ends of the lateral pole
irons inducing a current flow into the induction windings.
[0014] The stator, the support structure, and the rotor can be divided into N
equally spaced sectors,
which can be twelve in embodiments described herein, by radii emanating from a
common center
point on a common central longitudinal axis. The freewheeling permanent magnet
inserts can be
inserted into positions along the outer periphery of the rotor. Based on the
distribution of the
sectors and the like, N/2 groups of two of the N equally spaced sectors can be
established. First ones
of the lateral pole iron windings in first ones of the sectors in the N/2
groups can be wound such that
the first lateral pole irons have a first magnetic polarity. Second ones of
the lateral pole irons in that
sector also have pole iron windings of the first polarity of the sectors in
the N/2 groups and can be
wound such that the second lateral pole irons have a first magnetic polarity.
It will be appreciated
that the slots, lateral pole irons and freewheeling permanent magnet inserts
are axially aligned along
a respective lengthwise axis thereof such that a lengthwise axis of the
freewheeling permanent
magnet inserts is in normal alignment with a depthwise axis of the slots and
lateral pole irons.
[0015] The freewheeling permanent magnet inserts magnetically shielding within
the rotor such that
flux generated thereby is directed into the second ends of the lateral pole
irons so as to minimize
flux leakage and magnetic drag and to increase the magnetic flux coupling
thereinto. The
freewheeling permanent magnet inserts can further be inserted into respective
openings provided in
the rotor that are arranged in lengthwise alignment with the slots and lateral
pole irons. The
openings correspond to a longitudinal opening of the slots and provide
magnetic communication
with the corresponding second ends of the lateral pole irons that are
disposed, for example, within
or near the slots. The sequential energizing of the windings of the lateral
pole irons includes
bringing first ones of the freewheeling permanent magnet inserts into
alignment such as though the
self initiated freewheeling action thereof with the first ones of the second
ends of the lateral pole
irons such that the torque is provided to rotate the rotor, the first ones of
the freewheeling
permanent magnet inserts maintain the alignment, for example, during at least
a portion of the
rotation with the first ones of the second ends of the lateral pole irons. As
the rotor rotates past the
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second ends of the lateral pole irons and the alignment is maintained, a
maximum flux density
associated with the moving field is also maintained so as to induce a maximum
current flow in the
induction windings and reduce a magnetic drag associated with the rotation.
[0016] In accordance with embodiments, the electromagnetic assembly for an
electric motor and
power cogeneration can be provided and includes, for example, a stator having
a plurality of slots on
a stator periphery of an inner stator opening thereof A plurality of lateral
pole irons can be coupled
to the stator such that first ends of the plurality of lateral pole irons are
coupled to respective ones
of the plurality of the slots as is described in application "Solid State
Rotary Field Electric Power
CoGeneration Unit. PCT/IB2010/000039". The slots in the lateral pole irons can
be aligned along
with a lengthwise and depthwise axis. The plurality of lateral pole irons can
be supported by a
support structure that is positioned within the inner stator opening on a
common central axis. The
support structure has a support structure opening in the center thereof The
stator and the support
structure can have a substantially circular shape and can therefore be
arranged in a concentric fashion.
The lateral pole irons have windings and second ends directed toward the
support structure opening.
A rotor can be positioned within the support structure opening and can have a
plurality of cavities on
a rotor outer periphery. The rotor can be coupled to a central shaft and can
have a plurality of
freewheeling permanent magnet inserts inserted into the cavities. Each of the
cavities has an opening
capable of being positioned adjacent to the second ends of the lateral pole
irons. Each of the plurality
of freewheeling permanent magnet inserts can have a pair of magnetic pole
sections having a first
magnetic polarity and a second magnetic polarity. The pole sections can be
made from neodymium,
samarium-cobalt or the like depending on the application. Each of the
freewheeling permanent
magnet inserts are capable of rotating about a longitudinal axis. In some
embodiments, the pole
section can be electromagnets such as wound armature electromagnets.
[0017] Windings of the plurality of lateral pole irons are sequentially
energized to create a moving
field and to apply a torque on the rotor causing a rotation of the shaft. The
freewheeling permanent
magnet inserts can rotate into alignment with the second ends of energized
ones of the lateral pole
iron and can free-wheel in order to maintain alignment as the rotor and the
field rotates so as to
provide maximum flux density in the lateral pole iron and induction windings
in a corresponding
one of the plurality of slots to induce a current flow therein. The stator,
the support structure and
the rotor can be divided into N equally spaced sectors by radii emanating from
a common center
point on a common central longitudinal axis an activation circuit coupled to
the windings of the
lateral pole iron can apply a pulsed DC current in sequence in an alternating
north-south-north
sequence or in any other functional sequence consistent with the concepts
described herein. The
sequencing and rotational direction is controlled by a computer, programmable
logic center, and a
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solid state DC excitation system. This system is more efficient and more
flexible than an alternating
current (AC) system. As the stator is activated, the field rotates in a
sequential clockwise or
counterclockwise fashion attracting the opposite poles of the armature. In the
example presented
there are twelve pole iron groups. One solid state excitation card with three
channels per card is
employed in exciting the pole irons for each group. All twelve excitation
cards function in parallel.
The three pole irons represented in each group segment fire in sequence and in
parallel with the other
eleven pole iron groups. This sequential firing spins the rotor at the desired
speed by the lateral pole
irons.
[0018] Each of the plurality of lateral pole irons can be disposed
respectively above each of the
plurality of the slots such that the induction coil windings disposed in the
plurality of slots are
exposed to a concentrated amount of moving magnetic flux generated when the
windings of the
lateral pole irons are energized and a magnetic circuit is completed by the
freewheeling permanent
magnet inserts and/or the electromagnetic inserts. The plurality of
freewheeling permanent magnet
inserts are further capable of rotating in a synchronized relation with the
magnetic field such that
when the windings of the lateral pole irons are sequentially energized, the
freewheeling permanent
magnet inserts are rotated into alignment with the second ends of the lateral
pole iron so as to
provide maximum flux density in the induction windings to induce a current
flow therein and to
reduce magnetic drag on the rotor.
[0019] In an embodiment, each of the plurality of freewheeling permanent
magnet inserts is
contained within a containment sleeve that shields the rotor from magnetic
fields produced by each
of the freewheeling permanent magnet inserts. The containment sleeve is made
from alternating
layers of mu metal austenitic steel and/or carbon steel or other like steel.
The containment sleeve can
contain one or more bearings to support rotation of the containment sleeve and
the contained
permanent magnet insert member.
[0020] In accordance with an aspect, a method is disclosed for reducing drag
in an electric generator
that includes a change in geometric design and placement of the rotors in
relation to the stator coils
along with a system of magnetic shielding which results in very minimal
interaction of the rotor
magnetic fields with the destructive magnetic fields of the stator when the
generator is connected to
an electric load. This radical redesign includes distributing first numbers of
slot rotor pairs along the
outer periphery of a first stator section having induction windings
accommodated in slots. Second
numbers of the slot rotor pairs can be distributed along the outer periphery
of a second stator section
having induction windings accommodated in slots. The slots of the first stator
section and the second
stator section are axially aligned along a lengthwise and depthwise access.
The "outer" periphery of
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the second stator section can also correspond to an "inner circumference"
where reference is made to
a circular or other suitable shape stator embodiment. The inner periphery of
the first stator section
and the inner periphery of the second stator section are adjacent to each
other. The first members and
second members of the slot rotor pairs include slot rotors having at least one
pair of wound armature
pole sections of a first and second magnetic polarity. The first and second
members of the slot rotor
pairs can be rotated in a synchronized manner such that a first one of the
pole sections of the first
member having the first magnetic polarity and a second one of the pole
sections of the second
member having the second magnetic polarity are aligned with the slots to
provide maximum flux
density in the induction windings to induce a current flow therein. The first
member and the second
member of the respective slot rotor pairs are aligned with the aligned slots
of the first stator section
and the second stator section along respective lengthwise axis of the first
and second members and
the slots such that the lengthwise axis of the first and second members are in
normal alignment with
the depthwise axis of aligned slots.
[0021] The first and second members can be magnetically shielded such that
flux generated by the
first and second members is directed only into the slots so as to minimize
flux leakage and magnetic
drag resulting from interaction of the rotor pairs with the stator magnetic
fields. The first members
and the second members shielding means can be inserted into respective
openings provided in the
first and second stator sections. The respective openings can be arranged in
lengthwise alignment
with the slots, to partially shield the first and second members and can be
provided with a
longitudinal opening corresponding to a longitudinal opening of the slots in
order to provide
magnetic communication with the corresponding longitudinal openings of the
slots and ultimately to
the windings disposed therein.
[0022] The opening in the first and second stator sections opening which are
approximately 45 to
180 openings. The openings are necessary to accommodate the stator coil
winding process. After
the first and second member rotor shields are in place, the openings are
closed by placement of
laminated electrical steel shield covers. This 360 laminated shielded rotor
tunnel provides equal
attraction for the magnetized rotors for 360 of rotation. In operating
conditions, a magnetic bearing
effect is provided, thereby eliminating drag between the magnetized rotor
poles and the stator iron.
[0023] The first and second members of the slot rotor pairs can be rotated
about their axis in
opposite directions over the slots such that the net torque generated by the
polar force interaction
between the first and second members is approximately zero and in specific
cases can be a high net
negative torque. Accordingly as the first one of the pole sections of the
first members having the first
magnetic polarity is rotated over a slot in a first direction, the second one
of the pole sections of the
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second member can be sequenced such that it presents the second magnetic
polarity opposite the first
magnetic polarity in order to maximize the flux density in the aligned slots.
The second one of the
pole sections is being rotatable in a second direction opposite the first
direction to form a magnetic
circuit between the first and second magnetic polarities. The first angle in
certain instances can be
timed to yield usable motor effects. The first and second members can be
driven in a synchronized
manner that includes turning on an excitation current in an armature of the
first one of the pole
sections of the first member having the first magnetic polarity at an instant
in time when the first one
of the pole sections is positioned in a correct proximity to a slot in a first
direction. An excitation
current in an armature of the first one of the pole sections of the first
member having the first
magnetic polarity at an instant in time when the first one of the pole
sections is positioned in correct
proximity to a slot in a first direction. An excitation current in an armature
of the second one of the
pole sections of the second member having the second magnetic polarity can be
similarly turned on.
Alternating current (AC) can be generated when both the first and second
members of the slot rotor
pairs are provided with appropriate alternating first and second magnetic
polarities. Direct current
(DC) may be generated from the same slot rotor pairs when the first slot rotor
pair of the pair
generates only a first polarity and the second slot rotor pair generates only
a second polarity. This
allows changing the generator from AC to DC by changing direction of the
excitation currents in
appropriate poles, which may be accomplished by a programming change in the
excitation PLC
controller. The first and second members can be shielded such that flux
generated when an excitation
current is supplied to the armatures of the first and second members is
directed substantially towards
the slots. The induction winding can be connected for alternating current,
direct current and in
single-phase or three-phase, high wye or low wye, however a delta connection
is not prohibited.
[0024] In accordance with another exemplary aspect, an electromagnetic
assembly for an electric
generator can be provided that includes a dual stator having a first stator
section and a second stator
section. A first polarity of slots are arranged on an outer periphery of the
second stator section.
Again, as noted herein above, with respect to a closed geometric arrangement
stator the outer
periphery of the second stator section can refer to an "inner circumference."
Respective inner
peripheries of the first and second sections are disposed in adjacent relation
and can include a back
iron disposed there between to improve magnetic coupling through the slots.
Each of the first and the
second polarity of slots are aligned along a lengthwise and depthwise axis to
form slot pairs, each of
the polarity of the slots having induction coil windings disposed therein. The
assembly can further
include slot rotor pairs associated with the slot pair. Each of the slot rotor
pairs has a first slot
member disposed in aligned relation with one of the first polarity of slots
and a second slot rotor
member disposed in aligned relation with one of the second polarity of slots
corresponding to the
slot pair. Each slot rotor member has at least a pair of magnetic poles with
one of the pair of
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magnetic poles having a first magnetic polarity and another of the pair of
magnetic poles having a
second magnetic polarity. Each slot rotor member is capable of rotating about
a longitudinal axis.
The slot rotor pairs are disposed along the slot pairs such that the induction
coil winding disposed in
the slot pairs are exposed to magnetic flux generated by the slot rotor pairs.
Each slot rotor member
can be provided with a shield having an opening portion over the slots to
direct the flux into the slots
but minimize external flux leakage. In addition, a shield section can be
provided for shielding
magnetic flux from the first and second slot rotor members and end teeth
portion of the first stator
section and the second stator section. The shielding can be made from mu
metal. The first slot rotor
member and the second slot rotor member are capable of rotating such that when
magnetic flux of
one of the magnetic poles of the first polarity associated with the first slot
rotor member is directed
to a corresponding first slot of the slot pair, magnetic flux of an associated
one of the magnetic poles
of the second polarity associated with the second slot rotor member is
directed to a corresponding
second slot of the slot pair such that induction coil winding disposed in the
first and second slots are
exposed to increased magnetic flux and leakage of the magnetic flux is
minimized. In one
embodiment, the first polarity of slots can include 48, but not limited to 48,
wire slots, and the
second polarity of slots can include 48, but not limited to 48, wire slots.
Each of the first stator
section and the second stator section can have a substantially circular shape
where the first stator
section and the second stator section are concentric about a longitudinal axis
of the dual stator.
Alternatively, the first stator section and the second stator section are
planer. In another embodiment,
the first polarity of slots includes four wire slots, and the second polarity
of slots can include four
wire slots. Each of the first stator sections and the second stator section
can have a substantially
square shape with the wire slots located in the corners of the square, where
the first stator section
and the second stator section are concentric about a longitudinal axis of the
dual stator. This last
embodiment is preferred in that it affords geometric isolation from the
magnetomotive poles in the
stator which greatly reduces the drag forces between the stator and magnetized
rotors. The first
polarity of slots and the second polarity of slots may contain up to 12 wire
slots each without
significant increase in drag forces.
[0025] An excitation circuit can be provided that applies an excitation
current to the first slot rotor
member and the second slot rotor member so as to generate the magnetic flux
when the one of
magnetic poles of the first polarity associated with the slot rotor member is
rotated into alignment
with a corresponding first slot of the slot pair and to generate the magnetic
flux when the associated
one of the magnetic poles of the second polarity associated with the second
slot rotor member is
rotated into alignment with a corresponding second slot of the slot pair. The
excitation circuit can
further remove the excitation current from the first slot rotor member and the
second slot rotor
member in order to remove the magnetic flux at an instant when the one of the
magnetic poles of the
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first polarity associated with the first slot rotor member is rotated out of
alignment with the
corresponding first slot of the slot pair, and to remove the magnetic flux at
an instant when the
associated one of the magnetic pole of the second polarity associated with the
second slot rotor
member is rotated out of alignment with the corresponding second slot of the
slot pair. A diode
circuit can be provided for transmitting a current generated when the magnetic
flux collapses
forming current flow in the opposite direction, from the first and the second
slot rotor members to a
battery. The excitation circuit can include a commutator circuit (either
mechanical or solid state)
associated with the first and second slot rotor members, the commutator
circuit selectively coupling
one of the first and second slot rotor members to the excitation current as
the appropriate ones are
rotated into alignment.
[0026] Various exemplary embodiments are discussed and described herein
involving aspects of an
electric machine, such as a generator that produces power with high efficiency
and very low
electromagnetic drag. The relevance of this elimination of drag to its uses
and applications along
with the use of superconductor coils are presented and discussed.
[0027] In accordance with an aspect, a method is disclosed for reducing drag
in an electric generator
that includes a change in geometric design and placement of the rotors in
relation to the stator
magnetic poles such that the stator magnetic poles that are created by the
flow of load current in the
generator are geometrically isolated from the rotor cavities and are shielded
by a system of magnetic
shielding as well as a unique winding which provides electromagnetic shielding
and canceling of the
effective stator magnetic poles secondary to electrical load currents in the
stator winding. The
physical shielding consists of metallic mu metal shielding and electromagnetic
shielding around the
rotor cavity. Further shielding is provided by the unique winding pattern in
the rotor cavity portion
of the stator. Further reduction in magnetic interaction between the rotor
magnetic poles and the
potential stator magnetic poles is accomplished by the further uniqueness of
the stator winding
patterns which consists of bi-directional current flow in adjacent windings
during load current flow
which neutralizes destructive effective magnetic polarity of the stator. This
shielding and geometric
isolation of the rotors from the potential stator magnetic poles, created by
the stator induction
windings, results in very minimal magnetic flux linkage of the rotor magnetic
fields with the
destructive magnetic fields of the stator when the generator is connected to a
full electric load. This
radical design alteration from standard generators includes distributing first
members of slot rotor
pairs along the outer periphery of a first stator section having induction
windings accommodated in
slots in the inner periphery of the rotor pair cavities. The slots are
multiple axially aligned slots
which are skewed by one stator slot tooth width or slot pitch. This skewing of
the slots is utilized to
reduce the air gap permeance harmonics caused by the slots as the rotors
rotate past the wire slots.
11
CA 02873973 2014-11-18
Second members of the rotor pairs along the outer periphery of a second stator
section having
induction windings accommodated in slots in the inner periphery of the slot
rotor pair cavities. The
slots are multiple axially aligned slots which are skewed from the axis by one
slot tooth width or one
slot pitch to reduce the air gap permeance harmonics which are caused as the
rotors rotate the
magnetic flux passed the wire slots. The slots of the first stator section and
the second stator section
are axially aligned with a skew by one stator slot tooth width or one slot
pitch, along a lengthwise
and depth-wise access. The "outer" periphery of the second stator section can
also correspond to an
"inner circumference" where reference is made to a circular or other suitable
shaped stator
embodiment. The "inner periphery" of the first stator section and the "inner
periphery" of the second
stator section are adjacent to each other. The first members and the second
members of the slot rotor
pairs include slot rotors having at least one wound armature pole section
which is excited by a solid
state excitation with a gating mechanism which allows the entire rotor pole
section of the wound
armature to alternate between a first and second magnetic polarity. The first
and second members of
the slot rotor pairs can be rotated in a synchronized manner such that a first
magnetic polarity and a
second magnetic polarity are aligned with the slots to provide maximum flux
density in the induction
windings to induce a current flow therein. The first member and the second
member of the
respective slot rotor pairs are aligned with the skewed, aligned slots of the
first stator section and the
second stator section along respective lengthwise axes of the first and second
members and the slots
such that the lengthwise axes of the first and second members are in normal
alignment with the
depth-wise axes of the aligned slots.
[0028] The first and second members can be magnetically shielded such that the
flux generated by
the first and second members is directed into the induction wire slots with
minimal interaction
among the rotor pairs and/or the stator magnetic field. The first members and
the second members
shielding is accomplished by two means. First, a mu metal shielding means is
installed at strategic
locations to separate the rotor magnetic fields among the rotors and from the
stator magnetic fields.
Second, the unique rotor cavity and stator induction windings provides a net
zero magnetic flux
interaction or flux linkage between the magnetic fields of the rotors and the
stator.
[0029] The rotor pair cavity openings in the first and the second stator
sections are only sufficient to
accommodate the stator coil winding process. After the winding process is
complete, the openings
are closed by placement of removable laminated stator sections. This 360
laminated tunnel along
with skewing of the stator slots provides equal flux linkage between the
magnetized rotors and the
stator iron for the entire 360 of rotation. In operating conditions a
magnetic bearing effect is
provided thereby eliminating drag between the magnetized rotor poles and the
stator iron due to
irregular flux linkage and resultant air gap harmonics.
12
CA 02873973 2014-11-18
[0030] The first and second members of the slot rotor pairs with first and
second polarities can be
rotated about their axis in opposite directions over the slots such that the
net torque generated by the
polar forces (i.e. flux linkage) interaction between the first and second
members is approximately
zero. The first and second members can be driven in a synchronized manner that
includes turning on
an excitation current in an armature of the first one of the magnetized poles
of the first member
having a first magnetic polarity at an instant in time when the first member
is driven in a first
direction. An excitation current in an armature of the second member having a
second magnetic
polarity can be similarly turned on. Alternating current (AC) can be generated
when both the first
and second members of the slot rotor pairs are provided with appropriate
alternating first and second
magnetic polarities. Direct current (DC) may be generated from t he same slot
rotor pairs when the
first slot rotor of the pairs generates only a first polarity and the second
slot rotor pair generates only
a second polarity. This allows changing the generator from AC current to DC
current by changing
direction of the excitation currents in appropriate poles, which may be
accomplished by a
programming change in the excitation PLC (Programmable Logic Center)
controller. The induction
windings can be connected for AC current, DC current and in single-phase or 3-
phase "high-wye" or
"low-wye", however a Delta connection is not prohibited. The frequency of the
generated power
may be changed by altering the speed of the first and second members of the
slot rotor pairs.
[0031] In accordance with another exemplary aspect, an electromagnetic
assembly for an electric
generator can be provided that includes a dual stator having a first stator
section and a second stator
section. A first polarity of rotor cavities are arranged on an outer periphery
of the first stator section.
A second polarity of rotor cavities are arranged on the outer periphery of the
second stator section.
Again, as noted herein above, with respect to a closed geometric stator
arrangement, the outer
periphery of the second stator section can refer to an "inner" circumference.
Respective inner
peripheries on the first and second sections are disposed in adjacent relation
and can include a back-
iron of any desired dimension disposed there between to improve magnetic
coupling through the
induction wire slots. Each of the first and second polarity rotor cavities are
aligned along a
lengthwise axis and contain induction wire slots which are skewed the distance
of a slot pitch or
width of a slot tooth, aligned along a lengthwise and depthwise axis. Each of
the slots have
induction coil windings disposed therein. The assembly can further include
slot rotor pairs within the
rotor cavities. Each slot rotor has an alternating magnetic pole, alternating
between 360 of first pole
and 360 of second pole. Each slot rotor member is capable of rotating about a
longitudinal axis. The
slot rotor pairs are disposed along the slot pairs such that the induction
coil windings disposed in the
rotor cavities of the stator are exposed to magnetic flux generated by the
slot rotor pairs. Each slot
rotor member can be provided with a magnetic shield placed in appropriate
slots separating the rotor
cavities from the stator magnetic poles. The shielding can be made from mu
metal.
13
CA 02873973 2014-11-18
[0032] In one embodiment, the first polarity of slots are contained in four
rotor cavities, the second
polarity of slots are contained in four rotor cavities. Each of the first
stator section and the second
stator sections can have a substantially square shape, but not confined to
square shape, with the rotor
cavities located in the corners of the square, where the first stator section
and the second stator
section are concentric about a longitudinal axis of the dual stators. This
last embodiment is preferred
(but not restrictive) in that it affords geometric isolation from the
magnetomotive poles in the stator,
thereby greatly reducing the drag forces between the stator and the magnetized
rotors. The first
polarity of slots and the second polarity of slots may contain up to 48 wire
slots, but not limited to
48, each without increasing the drag forces.
[0033] The slots are wired such that the 360 of slots are wound in a counter-
clockwise direction and
are lapped by 360 of slots wound in a clock-wise direction. Therefore, the
induced north pole
cancels the induced south pole, thereby electromagnetically isolating the
rotor magnetic fields from
the induced potential stator magnetic fields.
[0034] An excitation circuit can be provided in one embodiment that applies an
excitation current to
the first slot rotor member and the second slot rotor member so as to generate
the magnetic flux
when one of the magnetic poles of the first polarity associated with the slot
rotor member is rotated
into alignment with a corresponding first slot of the slot pair and to
generate the magnetic flux when
the associated one of the magnetic poles of the second polarity associated
with the second slot rotor
member is rotated into alignment with a corresponding second slot or series of
slots of the slot rotor
cavity pair. The excitation circuit can further remove the excitation current
from the first slot rotor
member and the second slot rotor member in order to move the magnetic flux in
an instant when the
one of the magnetic poles of the first polarity associated with the first slot
rotor member is rotated
out of alignment with the corresponding first slot of the multiple slot pairs,
and to remove the
magnetic flux at an instant when the associated one of the magnetic poles of
the second polarity
associated with the second slot rotor member is rotated out of alignment with
the corresponding
second slot of the slot pair. A diode circuit can be provided for transmitting
a current generated
when the magnetic flux collapses forming current flow in the opposite
direction from the first and
the second slot rotor members to a battery. The excitation circuit can include
a commutator circuit
(either mechanical or solid state) associated with the first and slot rotor
members, the commutator
circuit selectively coupling one of the first and second slot rotor members to
the excitation current as
the appropriate ones are rotated into alignment. In other embodiments the
magnetic pole or poles of
the first slot rotor member and the second slot rotor member may be supplied
with a constant
excitation current or may be activated in such a fashion that the entire 360
circumference of the
rotor may alternate between first magnetic polarity and second magnetic
polarity.
14
CA 02873973 2014-11-18
[0035] In a preferred embodiment, the first and second rotors are unipolar
(i.e. north-pole,
alternating with south-pole) for the entire 360 circumference of the first
and second rotors of the
rotor pair. The unipolar circuit excited by a solid state switching system
which allows all of the rotor
windings to be switched in alternating directions i.e. switch the entire rotor
from north pole to south
pole and south pole to north pole. This unique design allows the program PLC
or commutator circuit
which controls the excitation circuit which can apply an excitation current to
the first slot rotor
member and the second slot rotor members so as to generate the magnetic flux
in the one of the
magnetic poles of the first polarity associated with the slot rotor member 50
times per second (50
Hz) or 60 times per second (60 Hz) regardless of the position of the rotor in
rotational space and to
generate the magnetic flux when the associated one of the magnetic poles of
the second polarity
associated with the second slot rotor member is applied with an excitation
current thereby generating
a magnetic flux of opposite polarity such that magnetic coupling occurs
through each slot and the
intervening back-iron and stator coils. This unique embodiment allows the
generator rotors to be
operated at any speed with the frequency being controlled by the excitation
circuit rather than being
controlled by the speed of the rotors. This design allows flexibility in power
output by increasing
and decreasing the speed of the rotor without alternating the frequency. For
example, a generator
operated at 3,000 rpm can double the power output by increasing the operating
speed to 6,000 rpm
or more, also decreasing the power by bringing the power as low as desired by
progressively
decreasing the speed of the rotor but maintaining the frequency by timed
excitation of the rotor coils.
If the conductor material with very low resistance to electron flow is
employed (a room temperature
superconductor) such as a graphene coded magnet wire, is used to wind both the
stator and the rotors
significant increase in power output can be realized for the same power input.
Alternatively, a
generator one-fifth or one-tenth the size would generate the same power output
while using the
superconductor coils.
[0036] Various configurations are presented in the prior art, but none
approach the issues of
reducing magnetic drag as in the present disclosure. For example, in U.S.
Patent Application
Publication No. 2011/0221298 to Calley et al., an electrical device is
disclosed with a tape wound
core laminate rotor. Calley fails to teach shielding a magnetized element from
the adjoining stator
surface, and fails to teach exposing only small segments of the side iron and
the wire slots to the
magnetic fields generated by rotor elements. Calley further fails to teach
geometric isolation of the
rotor from the stator induction magnetic poles which are created when the
induction coils are closed
to a load. Calley further fails to teach wire slots containing two coils, one
coil wound north pole and
one wound south pole. As the coils are closed to a load during power
generation, the north pole
cancels the south pole and south pole cancels the north pole, thereby removing
the electromagnetic
drag forces from the stator. Calley further fails to teach that these
cancelling poles, when wound
CA 02873973 2014-11-18
around a 360-degree circumference within the stator-rotor cavity, produce a
neutral electromagnetic
shielding effect around the rotors. Still further, Calley fails to teach the
desirability on alternating
pulsed unipole, which provides a consistent flux linkage in the stator iron
for a full 360-degrees of
rotation.
[0037] Other systems are presented in the prior art. For example, in U.S.
Patent No. 7,608,967 to
Durham et al., a single field rotor motor is disclosed. Durham however, fails
to teach improving the
efficiency of a variable speed electric motor and removing electromagnetic
drag by sequentially
firing a series of DC electromagnetic members in sequential sectors in
parallel; and fails to teach that
the members interact with freewheeling permanent magnetic rotor inserts or
electromagnetic rotor
inserts along the outer periphery of the rotor. Durham fails to teach a north
pole-south pole
activation, synchronized with activation of a lateral pole iron controlled by
an excitation or
activation system or circuit. Durham further fails to teach sequential,
repetitive energizing of the
windings of lateral pole irons in each sector of a stator, with each sector
firing in parallel so as to
provide a moving magnetic field to generate torque applied to rotate the rotor
and permanent or
electromagnetic pole sections of the rotor magnetic inserts which rotate into
alignment with ones of
the second ends of the lateral pole irons to increase flux linkage with
lateral pole irons, with first
ends of the lateral pole irons inducing a current flow in the stator induction
windings as in the
disclosed invention.
[0038] Other prior art systems exist to accomplish various objectives but none
address the problem
of reducing magnetic drag.
[0039] Therefore, it is an object to present a method and apparatus for
reducing the electromagnetic
drag in an electric motor to thereby improve efficiency and simultaneously
cogenerate electric
power which is available for any appropriate use including powering the stator
pole excitation
system.
[0040] It is an additional object to present a method and apparatus by which
electromagnetic poles
are constructed and activated in the proper sequence by a computer controlled
solid state DC
excitation system.
[0041] It is a further object to present exemplary freewheeling armature
magnetic poles to reduce
drag by freely moving into and maintaining an aligned position with the
electromagnetic poles of a
stator system to reduce drag and increase magnetic flux coupling.
[0042] It is an additional object to present exemplary induction coils
activated by wound lateral
16
CA 02873973 2014-11-18
pole iron and to thereby generate power as the motor/generator produces
mechanical energy on an
exemplary motor shaft.
[0043] It is a further object to demonstrate the use of AC, DC and/or any
phased power to power the
pole excitation DC power supplies such that the motor cogeneration system may
be adaptable to any
available power supply.
[0044] It is an additional object to reveal a method of frequency excitation
which allows ease of
variable speed operation. The sequence of excitation of the lateral pole irons
for 50 Hz operation is to
excite each pole sequentially for 6.66 ms and 5.55 ms for 60 Hz operation.
However, this is a
multiple speed motor which has a computer controlled excitation system and has
a wide range of
operating speeds which are possible with very little drag, high efficiency and
cogeneration of
electric power which may be used to parallel feed the stator pole excitation
system.
[0045] It is an additional object to demonstrate the use of an embodiment in
which a high efficiency
electric motor is used to drive a standard efficiency electric generator to
produce a net increase in
electric power output. It is a further object to demonstrate the use of a high
efficiency electric
motor and a high efficiency electric generator to produce a greater net
increase in electric power
output.
[0046] It is an object therefore to provide distributed slot rotor pairs that
rotate in a close proximity
to aligned wire slots disposed around the circumference of a dual stator of an
electric power
generator.
[0047] It is a further object to demonstrate a means to complete an
intensified magnetic circuit and
place maximum flux into the wire slots using slot rotor pairs.
[0048] It is an additional object to demonstrate the use of
unipolar/alternating polarity rotor pairs
such that the frequency and type of current (AC or DC) may be controlled by a
computer controlled
rotor excitation system.
[0049] It is an additional object to reveal the use of individual 3-phase
electric motors to drive each
rotor with all rotors being controlled by a common variable speed drive.
[0050] It is a further object to reveal the structure of laminated electrical
steel shield covers to
provide a uniform steel environment to encapsulate the rotors to cause a
magnetic bearing effect
without polarizing drag occurring in said laminated steel covers.
17
CA 02873973 2014-11-18
[0051] It is a further object to release energy which would be consumed by
electromagnetic drag
forces, as electric power by specific geometric location and shielding of
distributed slot rotor pairs in
a high efficiency generator.
[0052] It is an additional object to demonstrate the use of the high
efficiency generator as part of a
stand-alone electric power plant.
[0053] It is a further object to reveal the use of the high efficiency
generator to power an electric
power grid.
[0054] It is an additional object to reveal the use of the high efficiency
generator to power an
automobile/power generation plant.
[0055] It is a further object to reveal the use of the automobile/power
generation plant to power
homes, businesses and the power grid while the automobile units are not being
utilized as motive
devices.
[0056] It is an additional object to reveal the use and method of the high
efficiency generator to
power trains.
[0057] It is a further object to reveal the use and method of powering boats
and other water craft
with the high efficiency generator.
[0058] It is an additional object to reveal the use and method of powering
buses and trucks with the
high efficiency generator.
[0059] It is a further object to reveal the use and method of powering
airplanes and other flying
machines with the high efficiency generator.
[0060] It is an additional object to reveal a testing protocol for testing the
efficiency of the high
efficiency generator and comparing it to the efficiency of a standard electric
power generator.
[0061] It is an object therefore to provide distributed slot rotor pairs but
not confined to pairs that
rotate in a close proximity to aligned and skewed wire slots disposed around
the circumference of a
dual stator of an electric power generator. It is a further object to provide
equally spaced wire slots
for 360'in the rotor cavities with narrow openings into larger slots which
contain wound magnet
wires. This arrangement aids in the control of permeance harmonics.
[0062] It is an additional object to provide a skew in the slot alignment
equal to at least the width of
18
CA 02873973 2014-11-18
the tooth between the slots sufficient to control permeance harmonics in the
air space between the
magnetized rotors and the stator iron of the rotor cavities.
[0063] It is a further object to demonstrate a means to complete an
intensified magnetic circuit and
place maximum flux into wire slots, the side iron, the stator tooth and back
iron using slot rotor
pairs.
[0064] It is an additional object to demonstrate the use of unipolar,
alternating polarity rotor pairs
such that the frequency and type of current (AC or DC) may be controlled by a
computer control
rotor excitation system.
[0065] It is a further object to reveal a double shoe rotor which can function
as a dipole or unipole
rotor.
[0066] It is an additional object to reveal a mid-rotor shielding mechanism
which allows each of two
shoe poles outer surface polarities to form flux linkage with the inner
opposite pole adjacent to the
shaft.
[0067] It is a further object to reveal a double shoe rotor which can function
as a clean, full strength
unipole rotor with only two leads. These two leads float(+-) (-+)i.e.
alternate between positive and
negative leads by a switching mechanism in the excitation boards.
[0068] It is an additional object to =reveal the mechanism and design of the
stator such that energy
input is released as usable electric power which would otherwise be dissipated
or consumed by
electromagnetic drag forces.
[0069] It is a further object to reveal the method by which the rotor magnetic
forces are separated
from the stator induction magnetic forces by specific geometric location and
shielding of the
distributed slot rotor pairs as well as by the unique winding pattern of the
stator which effectively
shields and cancels significant magnetic poles in the stator.
[0070] It is an additional object to reveal a testing protocol for testing the
efficiency of the high
efficiency generator and comparing it to the efficiency of a standard electric
generator.
[0071] It is a further object to reveal a 3-phase electric generator which can
operate as 3-phase or
single-phase by electromagnetically changing the stator output hookup and the
rotor magnetic
polarity from a first pole to a first and second pole, all via computer
programming.
[0072] It is an additional object to reveal a 3-phase electric generator which
can operate as 3-phase,
19
CA 02873973 2014-11-18
single-phase, AC or DC and at 50 Hz, 60 Hz, or any other desired frequency by
changing the system
through a computer program with a slaved PLC and solid state switching through
electromagnetic
switching gear.
[0073] It is a further object to reveal a physical geometric separation of the
different rotor cavities
(stators) without deviating from the teachings.
[0074] It is an additional object to reveal a 3-phase generator which operates
without computer
assistance nor a solid state excitation system without deviating from the
teachings.
[0075] It is a further object to reveal the use of a very low electrical
resistance conductor wire to
wind both the stator and the rotors with significant increase in power output
to an electrical load.
[0076] It is an additional object to reveal the use of individual 3-phase
electric motors to drive each
rotor with all rotors being controlled by a common variable speed drive.
[0077] It is a further object to reveal the methods for the release of energy
which would be
consumed or dissipated by electromagnetic drag forces, this methodology being
specific geometric
location and shielding of distributed slot rotor pairs in a high efficiency
generator.
[0078] It is an additional object to reveal the use of superconductor
material, with very low
resistance to electron flow, to wind both the stator and the rotors of the
unit and thereby increase the
power output by a significant amount.
[0079] It is a further object to utilize high conductivity or superconductive
material, such as
grapheme, to aid in the function of the unit as a stand-alone, power plant.
[0080] It is an additional object to demonstrate the use of the high
efficiency generator as part of a
stand-alone electric power plant.
[0081] It is a further object to reveal the use of the high efficiency
generator to power an electric
power grid.
[0082] It is an additional object to reveal the use of the high efficiency
generator to power an
automobile/mobile power generation plant.
[0083] It is a further object to reveal the use of the automobile/power
generation plant to power
homes, businesses, and the power grid while the automobile units are not being
utilized as motive
devices.
CA 02873973 2014-11-18
[0084] It is an additional object to reveal the use and method of the high
efficiency y generator to
power trains.
[0085] It is a further object to reveal the use and method of powering boats
and other watercraft with
the high efficiency generator.
[0086] It is an additional object to reveal the use and method of powering
buses and trucks with the
high efficiency generator.
[0087] It is a further object to reveal the use and method of powering
airplanes and other flying
machines with the high efficiency generator.
[0088] It is an additional object to use graphene and/or other original unique
substances as
superconductors, high capacity capacitors and super-efficient ferromagnetic
materials to enhance
electromagnetic induction with smaller physical size and lighter weight
generating devices.
BRIEF DESCRIPTION OF THE DRAWINGS
[0089] In order that embodiments may be fully and more clearly understood, by
way of non-
limitative examples, the following description is taken in conjunction with
the accompanying
drawings in which like reference numerals designate similar or corresponding
elements, regions and
portions and in which:
[0090] FIG. lA is a diagram illustrating a lateral view of an exemplary rotor
containment unit and
end bells in accordance with one or more embodiments;
[0091] FIG. 1B is a diagram illustrating a lateral view of an exemplary stator
and leads in
accordance with one or more embodiments;
[0092] FIG. 2A is a diagram illustrating a lateral view of an exemplary rotor
containment unit
revealing slip rings, bearing rest and rotor magnet stabilizing coils and end
bells in accordance with
one or more embodiments;
[0093] FIG. 2B is a diagram illustrating a lateral view of an exemplary stator
and leads in accordance
with one or more embodiments;
[0094] FIG. 3A is a diagram illustrating a lateral view of an exemplary rotor
containment unit
revealing slip rings, bearing rests, electromagnetic pole inserts and end
bells in accordance with one
or more embodiments;
21
CA 02873973 2014-11-18
[0095] FIG. 3B is a diagram illustrating a lateral view of an exemplary stator
and leads in accordance
with one or more embodiments;
[0096] FIG. 4A is a diagram illustrating a lateral view of an exemplary rotor
containment unit
containing and end bell with slip ring brush support means, slip ring, bearing
rest and
electromagnetic pole inserts in accordance with one or more embodiments;
[0097] FIG. 4B is a diagram illustrating a lateral view of an exemplary rotor
containment unit
revealing an end bell with a cutaway of a view of a slip ring brush support
means, slip ring, bearing
rest and electromagnetic pole inserts in accordance with one or more
embodiments;
[0098] FIG. 5 is a diagram illustrating a cross-sectional end view of an
exemplary stator and stator
insert portion including a rotor and exemplary freewheeling permanent magnetic
inserts and lateral
pole irons along with windings and leads to support a solid state DC stator
pole excitation
sequencing system in one or more embodiments;
[0099] FIG. 6 is a diagram illustrating a cross-sectional end view of an
exemplary stator and stator
insert portion including a rotor and exemplary freewheeling permanent magnetic
inserts along with
permanent magnetic stabilizing coils and lateral pole irons along with winding
and leads to support a
solid state DC stator pole excitation sequencing system in one or more
embodiments;
[00100] FIG. 7 is a diagram illustrating a cross-sectional end view of an
exemplary stator and stator
insert portion including a rotor and exemplary electromagnetic rotor pole
inserts with power leads
along with lateral pole iron without windings in one or more embodiments;
[00101] FIG. 8 is a diagram illustrating a cross-sectional end view of an
exemplary stator and stator
insert portion including a rotor and exemplary electromagnetic rotor pole
inserts with power leads
along with lateral pole irons with windings and leads to support solid state
DC stator pole excitation
sequencing system in one or more embodiments;
[00102] FIG. 9 is a diagram illustrating a cross-sectional end view of an
exemplary stator and stator
insert portion including a rotor and exemplary electromagnetic rotor pole
insert with power leads
along with lateral unwound pole irons and stator power generating coils in one
or more
embodiments;
[00103] FIG. 10A is a diagram illustrating a lateral view of an exemplary
unwound lateral pole iron
in accordance with one or more embodiments;
22
CA 02873973 2014-11-18
[00104] FIG. 10B is a diagram illustrating an end view of an exemplary unwound
lateral pole iron in
accordance with one or more embodiments;
[00105] FIG. 11A is a diagram illustrating a lateral view of an exemplary
copper magnet wire
wound lateral pole iron in accordance with one or more embodiments;
[00106] FIG. 11B is a diagram illustrating an end view of an exemplary copper
magnet wire wound
lateral pole iron in accordance with one or more embodiments;
[00107] FIG. 12A is a diagram illustrating a lateral and end view of an
exemplary unwound iron
pole piece of an electromagnetic rotor pole magnet stabilization inserts in
accordance with one or
more embodiments;
[00108] FIG. 12B is a diagram illustrating a lateral and end view of an
exemplary copper magnet
wire wound iron pole piece of an electromagnet rotor pole magnet stabilization
insert in
accordance with one or more embodiments;
[00109] FIG. 13A is a diagram illustrating a lateral and end view of an
exemplary wound iron pole
piece of an electromagnetic rotor pole insert in accordance with one or more
embodiments;
[00110] FIG. 13B is a diagram illustrating a lateral and end view of an
exemplary copper magnet
wire wound iron pole piece of an electromagnetic rotor pole insert in
accordance with one or more
embodiments;
[00111] FIG. 14A is a diagram illustrating a lateral oblique view of a carbon
steel ¨ mu metal
laminated sleeve in a pole cavity of the rotor in accordance with one or more
embodiments
[00112] FIG. 14B is a diagram illustrating a lateral oblique view ofthe carbon
steel ¨ mu metal
laminated sleeve with opening for flux linkage with aelectromagnetic rotor
pole magnet
stabilizing insert in a pole cavity in accordance with one or more
embodiments;
[00113] FIG. 15 is a diagram illustrating a lateral superior oblique view of a
pole magnet
[00114] structure housed in acarbon steel ¨ mu metal sleeve contained within
cavities in the
periphery of the rotor in accordance with one or more embodiments;
[00115] FIG. 17 is a diagram illustrating a high efficiency electric motor
driving a standard
efficiency electric generator coupled with a hydrogen generator and a hydrogen-
driven standard
drive engine in accordance with one or more embodiments;
23
CA 02873973 2014-11-18
[00 1 1 6] FIG. 18 is a diagram illustrating a high efficiency electric
driving motor, a standard
efficiency electric generator, and a bank of energy storage devices in
accordance with one or more
embodiments;
[00117] FIG. 19 is a diagram illustrating a high efficiency electric motor
driving a standard
efficiency electric generator and interacting with a hydro storage system
utilizing a water pump, a
water storage reservoir, and gravity flow through generator turbine system in
accordance with one
or more embodiments;
[00118] FIG. 20 is a diagram illustrating an exemplary configuration for the
magnification of
electric power through a high efficiency electric motor driving an electric
generator of lower
efficiency than the electric drive motor in accordance with one or more
embodiments;
[00119] FIG. 21A is a diagram illustrating an exemplary wound dual stator
machine having dual
electromagnetic slot rotors inserted into shielded recesses in accordance with
one or more
embodiments;
[00120] FIG. 21B is a diagram illustrating exemplary three-phase winding
connections of a wound
dual stator machine in accordance with one or more embodiments;
[00121] FIG. 21C is a diagram illustrating an exemplary wound stator machine
in accordance with
in one or more alternative embodiments;
[00122] FIG. 21D is a diagram illustrating exemplary three-phase winding
connections of a wound
stator machine in accordance with in one or more alternative embodiments;
[00123] FIG. 21E is a diagram illustrating an exemplary three-phase internal
race winding of a
wound stator machine in accordance with in one or more alternative
embodiments;
[00124] FIG. 22 is a diagram illustrating a dual pole embodiment of an
exemplary dipole
electromagnetic slot rotor including pole windings, mu metal shielding, wire
slot, side iron and back
iron flux linkage between the north and the south pole;
[00125] FIG. 23 is a diagram illustrating a dual pole embodiment of an
exemplary unipole
alternating lead electromagnetic slot rotor including pole windings, mu metal
shielding, wire slot
containing conductors, side iron and back iron and flux linkage between the
north and south pole;
[00126] FIG. 24 is a diagram illustrating a single pole embodiment of an
exemplary alternating lead
electromagnetic slot rotor including pole windings, mu metal shielding, and
laminated steel around
24
CA 02873973 2014-11-18
the rotors with a laminated steel mu metal shield cover;
[00127] FIG. 25 is a diagram illustrating an exemplary cross section of a
slot, stator, rotors, mu
metal shields and mu metal shield covers of one or more embodiments;
[00128] FIG. 26 is a diagram illustrating a depiction of a cross-section of a
24 slot stator, rotors, mu
metal shields and mu metal shield covers of one or more embodiments;
[00129] FIG. 27 is a diagram illustrating a unipolar rotor and slip ring of
one or more embodiments;
[00130] FIG. 28 is a diagram illustrating a cross section of an exemplary
stator, a stator iron, rotor
windings, unipolar rotors, mu metal shields, and laminated steel mu metal
shield covers of one or
more embodiments;
[00131] FIG. 29 is a diagram illustrating an end view projection of an
exemplary stator, rotor drive
motors and a variable speed drive unit in one or more embodiments;
[00132] FIG. 30 is a schematic block diagram illustrating an exemplary control
and testing system
for a high efficiency generator and standard generator in one or more
embodiments;
[00133] FIG. 3lis a diagram illustrating an oscilloscope trace of an
excitation current and voltage
from an exemplary activation circuit in one or more embodiments;
[00134] FIG. 32 is a diagram illustrating an exemplary configuration for
magnifying electric power
including a standard electric motor driving an exemplary high efficiency
electric generator in one or
more embodiments;
[00135] FIG. 33 is a diagram illustrating a high efficiency electric
generator, a hydrogen generator
and a hydrogen-driven engine in one or more embodiments;
[00136] FIG. 34 is a diagram illustrating a high efficiency electric
generator, a standard efficiency
electric driving motor, and a bank of energy storage devices in one or more
embodiments;
[00137] FIG. 35 is a diagram illustrating a high efficiency electric
generator, a standard efficiency
electric driving motor, and a hydraulic system with a nitrogen accumulator as
a short term stored
energy supply in one or more embodiments;
[00138] FIG. 36 is a diagram illustrating a high efficiency electric
generator, a standard efficiency
electric driving motor, and a hydro storage system utilizing a water pump, a
water storage reservoir
CA 02873973 2014-11-18
and gravity flow through a generator turbine system in one or more
embodiments;
[00139] FIG. 37 is a diagram illustrating an automobile using a high
efficiency generator as a motive
source in one or more embodiments;
[00140] FIG. 38 is a diagram illustrating an automobile using a high
efficiency generator both as a
motive source and as a power source in one or more embodiments;
[00141] FIG. 39 is a diagram illustrating a train engine using a high
efficiency generator in one or
more embodiments;
[00142] FIG. 40 is a diagram illustrating a water craft using a high
efficiency generator in one or
more embodiments;
[00143] FIG. 41 is a diagram illustrating a bus using a high efficiency
generator in one or more
embodiments;
[00144] FIG. 42 is a diagram illustrating an aircraft using a high efficiency
generator in one or more
embodiments;
[00145] FIG. 43 is a diagram illustrating a transport truck using a high
efficiency generator in one or
more embodiments;
[00146] FIG. 44 is a diagram illustrating a superior oblique projection of an
exemplary arrangement
in one or more embodiments;
[00147] FIG. 45 is a diagram illustrating an exemplary laminate of a main
stator section and middle
stator section prior to formation of wire slots in one or more embodiments;
[00148] FIG. 46 is a diagram further illustrating an exemplary laminate of a
main stator section,
middle stator section and outer stator section prior to formation of wire
slots in one or more
embodiments;
[00149] FIG. 47 is a diagram illustrating a cross-sectional view of a stator
and rotors including an
exemplary laminate of the main stator section, middle stator section and outer
rotor cavity corners
with skewed stator induction coil wire slots and dipole rotor laminates in one
or more embodiments;
[00150] FIG. 48 is a diagram illustrating a cross-sectional view of a stator
and rotors including an
exemplary laminate of the main stator section, middle stator section and outer
rotor cavity corners
26
CA 02873973 2014-11-18
with skewed stator induction wire slots wired in the outer rotor cavities and
dipole rotor laminates in
an exemplary single- phase embodiment and other embodiments;
[00151] FIG. 49 is a diagram illustrating a cross-sectional view of a stator
and rotors including an
exemplary laminate of the main stator section, middle stator section and outer
rotor cavity corners
with skewed stator induction wire slots with magnet wire coils in the inner
and outer rotor cavities
and dipole rotor laminates in an exemplary single-phase alternating current
(AC) embodiment and
other embodiments;
[00152] FIG. 50 is a diagram illustrating a cross-sectional view of a stator
and rotors including an
exemplary laminate of the main stator section, middle stator section and outer
rotor cavity corners
with skewed stator induction wire slots with magnet wire coils in the inner
and outer rotor cavities,
and dipole rotor laminates with dipole magnet wire windings in an exemplary
single-phase AC
embodiment and other embodiments;
[00153] FIG. 51 is a diagram illustrating a cross-sectional view of a stator
and rotors including an
exemplary laminate of the main stator section, middle stator section and outer
rotor cavity comers
with skewed stator induction wire slots, and rotor laminates in one or more
embodiments;
[00154] FIG. 52 is a diagram illustrating a cross-sectional view of a stator
and rotors including an
exemplary laminate of the main stator section, middle stator section and outer
rotor cavity comers
with skewed stator induction wire slots, rotor laminates with a center mu
metal shield forming an
operational rotor in one or more embodiments;
[00155] FIG. 53 is a diagram illustrating a cross-sectional view of a portion
of a stator in one or
more embodiments;
[00156] FIG. 54 is a diagram illustrating a cross-sectional view of a middle
stator in one or more
embodiments of FIG. 53;
[00157] FIG. 55 is a diagram illustrating a cross-sectional view of a pre-
assembly of stator
components in one or more embodiments;
[00158] FIG. 56 is a diagram illustrating a cross-sectional view of an
assembled stator laminate in
one or more embodiments;
[00159] FIG. 57 is a diagram illustrating a cross-sectional view of an
assembled stator laminate
including representative outer stator windings and leads in one or more
embodiments;
27
CA 02873973 2014-11-18
[00160] FIG. 58 is a diagram illustrating a cross-sectional view of an
assembled stator laminate
including inner stator section, main laminate and outer stator section, and
representative inner stator
windings and leads in one or more embodiments;
[00161] FIG. 59 is a diagram illustrating exemplary rotor sets operated by
individual drive motors in
synchronized operational control using a variable speed drive in one or more
embodiments;
[00162] FIG. 60 is a diagram illustrating a cross-sectional view of a rotor
laminate including a rotor
laminate, a shaft cross-section and a mu metal shield in one or more
embodiments;
[00163] FIG. 61 is a diagram further illustrating a cross-sectional view of a
rotor laminate including
a rotor laminate, shaft cross-section, mu metal shield and a representative
pole winding with leads in
one or more embodiments;
[00164] FIG. 62 is a diagram illustrating a cross-sectional view of rotor
cavities in one or more
embodiments;
[00165] FIG. 63 is a diagram illustrating a cross-sectional view of rotor
cavities contained in a
support means in one or more embodiments;
[00166] FIG. 64 is a diagram illustrating a side view of a longitudinal series
of standard generator
housings retrofitted in one or more embodiments;
[00167] FIG. 65 is a schematic diagram illustrating a layout of an exemplary
load testing system of
an exemplary generator in one or more embodiments;
[00168] FIG. 66 is a schematic diagram illustrating a portion of electrical
wiring of the load testing
system of FIG 65 in one or more embodiments;
[00169] FIG. 67 is a schematic diagram illustrating a portion of the
electrical wiring for a stand-
alone power producing high efficiency generator in one or more embodiments;
[00170] FIG. 68 is a schematic diagram illustrating exemplary input power
supply wiring for two
standard single-phase generators and a stand-alone high efficiency generator;
and
[00171] FIG. 69 is a schematic diagram illustrating exemplary output power
wiring for two standard
single-phase generators and a stand-alone high efficiency generator.
DETAILED DESCRIPTION
28
CA 02873973 2014-11-18
[00172] In accordance with various exemplary embodiments discussed and
described herein and by
way of brief summary, an exemplary high efficiency motor unit eliminates or
greatly reduces
electromagnetic drag as it also generates electric power from the opposite end
of the motor lateral
pole irons. The conductors carrying the current load, in connection with
various and exemplary
embodiments, can be wound onto cast-iron or laminated steel pole pieces,
hereinafter referred to as
lateral pole irons, which are then placed in direct proximity to the coil
slots of the power
cogeneration induction coils, which are wound into slots of the laminated
steel stator of the
motor/generator frame. The cogeneration induction coils can be formed of
multiple coils per group
with multiple groups being used as needed.
[00173] The wound coils on the lateral pole irons form electromagnetic poles
wound such that three
or more north pole wound lateral pole irons fire in sequence in a clockwise or
counterclockwise
fashion into each slot of a portion of the power generation induction coils.
Each lateral pole iron is
wound with a separate conductor such that the individual pole irons may be
fired separately in
sequence from a solid state lateral pole iron excitation system. The coils of
the lateral pole irons
associated with adjacent portions can be wound in opposite directions to
establish alternating
magnetic field polarities of the associated poles. The south pole wound
lateral pole irons can also fire
in sequence in a clockwise fashion. It should be noted that each of the
lateral pole irons can be
arranged such that one end portion thereof is seeded into a respective one of
the slots and the other
end portion toward the center of the machine are seeded into slots of a non-
ferrous ring which can
be fixed to the laminated steel generator by a support means as in "Solid
State Rotary Field Electric
Power CoGeneration Unit PCT/1B2010/000039". The center oriented ends of the
lateral pole irons
are flush with the inner surface of the ring.
[00174] In another general aspect, the laminated steel generator frame is
encased within a circular
housing to which end bells containing roller bearings, a ball bearing or the
like can be attached. The
roller bearings can support a non-ferrous mechanism which contains
freewheeling permanent magnet
inserts placed into, for example, closed lubricant-filled cavities arranged
around the outer radius of
the non-ferrous mechanism attached to the shaft. The freewheeling permanent
magnet inserts may
be sequentially and synchronously aligned with the firing of the polarizing
circuits of the lateral pole
irons. This alignment mechanism of the freewheeling magnets allows more
effective magnetic
coupling between the freewheeling permanent magnetic inserts and the
sequentially magnetized
lateral pole irons. The alignment mechanism may consist of wound
electromagnetic inserts placed
radially from each freewheeling magnetic insert such that the insert fires
synchronously with the
lateral pole iron thereby aligning the freewheeling permanent magnet insert to
hold in the proper
orientation.
29
CA 02873973 2014-11-18
[00175] In an exemplary aspect, a first 1800 of the freewheeling permanent
magnet insert is
constituted of a north pole charged permanent magnet, and the other 180 is
constituted of a south
pole charged permanent magnet. Cavities, such as lubricant-filled cavities,
can contain the
freewheeling permanent magnet inserts, which are held by a containment means
and supported by
roller bearings or the like. The inserts can further be shielded by a cylinder
constituted of a shield
having alternating laminations of carbon steel, stainless steel and mu metal.
The shielded cylinder
has a 45 opening to the peripheral surface of the stator so as to allow
interaction and magnetic
coupling with the opposite magnetic pole of the lateral pole iron. The
shielded cylinder may also
have a 45 opening 180 opposite the peripheral surface of the non-ferrous
rotor to allow interaction
and magnetic coupling between the electromagnetic stabilizing insert and the
freewheeling
permanent magnet insert.
[00176] As the stator is electrically activated, such as through passing and
excitation current
through the windings of the individual lateral pole iron, the magnetic field
generated thereby
rotates sequentially in each segment of the pole iron of three or more north
pole wound, then south
pole wound and sequential repeating through twelve or more groups, having an
overall field
polarity that in the case of the freewheeling permanent magnet inserts
attracts the opposite poles. In
the case ofthe freewheeling magnet inserts with stabilization coil inserts,
the stabilization coil fires
at the same instant as the corresponding lateral pole iron, but with opposite
polarity. Therefore, if
the lateral pole iron generates north pole, the freewheeling magnet south pole
is attracted to the
lateral pole iron and it is stabilized by south pole generated by the
stabilization coil insert. In the
instance of an exemplary electromagnet rotor pole insert, the computer
excitation system may
sequence the electromagnetic rotor pole insert with opposite polarity to the
corresponding lateral
pole iron coil polarity for the sequential rotation past three or more lateral
pole iron coils in a
segment.
[00177] The computer excitation system switches the polarity ofthe
electromagnetic rotor pole
insert as the rotor rotates from the last lateral pole iron of the group to
the first lateral pole iron of
the next group. This rotation of the rotor from one lateral pole iron sector
to the next lateral pole
iron sector requires 10 ¨ 12 ms and the time required to change polarity is 10
ms (5 ms for one pole
to collapse and 5 ms to reach peak polarity with the second pole following DC
excitation.) This
sequence repeats around the 360 rotation thereby spinning the rotor, creating
torque and
revolutions per minute therefore horsepower is created.
HP= (Torque(ft*lbs) x rpm)/5252
For instance, a 3000 rpm motor of this example requires that the lateral pole
irons each be fired in
CA 02873973 2014-11-18
sequence every 6.6 ms and in the case of a 3600 rpm motor of this example
requires that the lateral
pole irons each be fired in sequence every 5.55 ms. Therefore, in this
example, a segment of three
lateral pole irons is activated [pole iron #1 (6.6 ms) #2 (6.6 ms) #3
(6.6ms) #1 (6.6 ms) #2
(6.6 ms) #3 (6.6 ms) #1 (6.6 ms) etc.] Each segment is excited by an
excitation board
containing three channels. The channels fire sequentially by way of example
every 6.6 ms or every
5.5 ms or other sequencing speeds to vary the speed of rotation of the motor.
[00178] Since the magnetic poles of the stator and rotor are sequenced,
minimal to no drag forces
are encountered. The rotating poles of the freewheeling permanent magnet
inserts and
electromagnetic inserts are spaced such that when a pole of one insert is
aligned over, for example,
the center of a first north pole wound lateral pole iron in a coil group, a
pole of a next insert is dead
center over a first south pole wound lateral pole iron of the group. The
sequential firing of the north
pole- south pole sequence of the lateral pole irons of the stator generates
power in the power
generation induction coils just as a magnetic spinning armature generates
power. The sequential
firing of the lateral pole irons also spins the armature thereby generating
mechanical power on the
motor shaft. The cogeneration component removes power from the induction coils
and thereby
allows less impedance in current flow to neutral and/or to earth ground as
observed in patent "Solid
State Rotary Field Electric Power CoGeneration Unit. PCT/IB2010/000039". The
cogenerated
power may be used to provide a parallel power source to the excitation boards
for the lateral pole
irons, the electromagnetic rotor pole inserts and the electromagnetic
stabilization inserts for the
freewheeling magnets.
[00179] The above overview is exemplary in nature to provide a brief overview.
A better
understanding is provided herein below in the description that accompanies the
figures. With
reference to FIG. lA thereof, basic components of an exemplary high efficiency
motor are shown. A
stator 15 can accommodate a rotor 6 having in this example cavities that hold
stator inserts 4 and that
have openings 7 that allow magnetic coupling with flux which permeates the
opening 7. The stator
inserts 4 accommodate freewheeling permanent magnet inserts 5. The rotor
mechanism can be
coupled to a shaft 8, which can be the power drive shaft of one exemplary high
efficiency motor.
Specifically, rotor 6 inside a stator 15 see FIG. 1B. Stator 15 can contain
slots, coils, and wound
lateral pole irons as will be described in greater detail hereinafter. A shaft
8 can be placed through
an opening lin end bells 2 that can accommodate, for example, a bearing or
similar support
mechanism. A common central axis 8j (FIG. 2A) can extend through the shaft 8
and can be a common
point of reference for the rotor 6, the stator 15, and a support structure for
lateral pole irons that will
be described in greater detail hereinafter. The unit can be bolted together
through holes 3 in each
bell. Input power to the unit can be attached by connecting leads from the
solid state DC excitation
31
CA 02873973 2014-11-18
board through excitation input leads 16, 17, and 18 (each lead contains at
least 4 excitation circuit
leads) and through a neutral ground lead 19. The output power leads 13 and 14
from power
generating coils can be attached to the power board for supplying the rotor
electromagnetic poles
and/or the pole stabilization electromagnetic inserts and/or any appropriate
distribution circuit.
[00180] An alternate embodiment by way of an example is shown in FIG. 2A. This
embodiment
reveals a greatly improved method for maximizing flux linkage between the
rotor magnetic poles
and the wound lateral pole irons as will be further described later. In this
embodiment a stator 15
can accommodate a rotor 6 having cavities that hold rotor inserts 4 and that
have openings 7 that
allow flux linkage with the wound lateral pole irons. The rotor inserts 4
accommodate freewheeling
permanent magnets 5. The magnetic stabilization inserts 8f are placed between
the freewheeling
magnet inserts and the shaft for purposes of stabilizing the freewheeling
magnets at the appropriate
time and to improve torque by better alignment of the freewheeling magnet
poles with the wound
lateral pole irons for better flux linkage. The rotor mechanisms can be
coupled to a shaft 8 which
can be the power drive shaft of the high efficiency motor. A bearing rest 8g
may be provided which
fits into bearing 8i in end bell 2. The rotor shaft 8 may be fitted with a
slip ring assembly 8k. Ring 8c
may be connected to lead 8h which is connected to an eddy current rod which
makes electrical
contact as it goes through all laminates of the rotor in two locations 1800
opposing one another. Slip
ring 8d is connected to lead wire 8a which is one side of a floating, or
alternating, (+) (-) lead which
is shifted or alternated by a gating mechanism within the solid state
excitation boards. Slip ring 8e is
connected to lead wire 8b, which is the matching lead of 8a, therefore, is the
opposite lead of the coil
lead and is also a floating, alternating(+) (-) lead which is shifted by a
gating mechanism within the
solid state excitation boards. Specifically, rotor 6 can be placed inside a
stator 15 shown in FIG. 2B.
Stator 15 can contain slots, coils, and wound lateral pole irons as will be
described in greater detail
hereinafter.
[00181] An additional alternate embodiment by way of example is seen in FIG.
3A. This
embodiment reveals a greatly improved method ofestablishing sequential flux
linkage between
rotor electromagnetic pole inserts 8j and the wound lateral pole irons of the
stator as will be further
described later. Inthis embodiment a stator 15 can accommodate a rotor 6
having cavities that hold
stator inserts 4 which house rotor electromagnetic pole inserts 8j. Stator
inserts 4 have openings 7
that allow flux linkage in sequential fashion between rotor electromagnetic
pole inserts 8j and the
lateral pole irons. The rotor inserts accommodate rotor electromagnetic pole
inserts 8j. The rotor
mechanism can be coupled to a shaft 8 which can be the power drive shaft of
this embodiment of the
high efficiency motor. A bearing rest 8g may be provided which fits into
bearing Bi in end bell 2.
The rotor shaft 8 may be fitted with a slip ring assembly 8k. Ring 8c may be
connected to lead 8h
32
CA 02873973 2014-11-18
which is connected to an eddy current rod which makes electrical contact as it
goes through all
laminations of the rotor in two locations 180 opposing one another. The slip
ring &1 is connected to
lead wire 8a which lead wire is one side of a floating, or alternating(+)(-)
lead arrangement which is
alternated by a gating mechanism within the solid state excitation boards.
Slip ring 8e is connected
to lead wire 8b which is the matching lead of 8a, therefore, is the opposite
lead of the coil lead is also
a floating, or alternating,(+)(-) lead which is shifted by a gating mechanism
within the solid state
excitation board. Specifically rotor 6 can be placed inside a stator 15, shown
in FIG. 3B. Stator 15
can contain slots, coils, and wound lateral pole irons as will be described in
greater detail later in
this application.
[00182] By way of further explanation of an exemplary component of one or more
embodiments,
FIG. 4A reveals a slip ring brush holder containment means 8s which is bolted
to end bell 2 by bolt
mechanism 8q. Power cable 81 exits 8s through port 8t from slip ring brush
holder containment
means 8s. Leads 8m (+) (-), 8n (+)(-)and rotor eddy current ground 8p are
attached to slip ring
brushes 8o in FIG. 4B. Slip ring brushes 8o, in operating mode, are configured
so as to make contact
with slip ring 8k. Lead 8p discharges eddy currents from the stator to earth
ground. Leads 8m and 8n
alternate between(+) (-) and (-) (+). This switching mode is accomplished by a
switching gating
mechanism in the computer /PLC (Programmable Logic Center) controlled
excitation boards.
[00183] The switching to accommodate alternating polarity requirements of the
rotor
electromagnetic pole inserts and rotor magnetic stabilization inserts of
exemplary embodiments by
way of reference to several exemplary embodiments rotor 6 (FIG. 1A, FIG. 2A
and FIG. 3A) is
constructed of non-ferromagnetic material.
[00184] A more detailed understanding of the structure of the stator assembly
can be gained with
reference to FIG. 5. Therein, a cross-sectional end view of laminated stator
iron 31, laminated pole
irons 34, and rotor 6 is shown. Containment sleeves 4 can accommodate
freewheeling permanent
magnetic inserts 5 therein. Laminated stator iron 31 can contain open wire
slots 25 which are
insulated and can contain the power induction coils 29 as will be described in
greater detail
hereinafter. The stator 31 and associated lateral pole iron support structure,
for illustration and
description purposes, can be divided into sectors such as sector A-L and
allocated with a number of
slots 25 which are three slots per sector in the present example FIG.5. Each
sector can contain a
series of slots associated with a number of lateral pole irons having lateral
pole iron windings wound
of a particular magnetic polarity. As the lateral pole irons are excited,
through DC current activation
of the lateral pole iron windings in a sequential fashion, a moving magnetic
field is developed.
[00185] Dividing each set of two sectors is a support segment 26. A support
segment 26 that can be
33
CA 02873973 2014-11-18
attached to and can support lateral pole iron containment ring 21, which in
turn, can support the
inner ends of the lateral pole iron 34 are coupled to, contained in, inserted
into, adjacent to,
magnetically coupled to, or the like, respective ones of the open wire slots
25. While the other end
of the lateral pole irons 34 are illustrated as being inserted into, it will
be appreciated that other
configurations are possible that position the ends of the lateral pole irons
over the slots to allow flux
generated within the lateral pole irons to be coupled with the side iron and
back iron of slot 25 and
into the windings 29. Rotor 6 is positioned on shaft 8 and contains rotor
inserts 4, which as noted,
are configured to contain freewheeling magnet inserts 5, within a magnetically
shielded containment
means that includes a roller bearing support housed in containment sleeve that
consists of
laminations of mu metal and carbon steel or the like with an opening in at
least one location and in
this instance on the periphery.
[00186] A more detailed understanding of an alternate embodiment and its
assembly can be gained
with reference to FIG. 6. Therein, in a cross-sectional end view, laminated
stator iron 31, laminated
lateral pole irons 34 and rotor 6 are shown. Containment sleeves 4 can
accommodate freewheeling
permanent magnet inserts 5 there within. Laminated stator iron 31 can contain
open wire slots 25
which are insulated and can contain power induction coils 29 as will be
described in greater detail
hereinafter. The stator 31and associated lateral pole iron support structures
for illustration and
description purposes, can be divided into sectors such as sectors A-Land
allocated with a number of
slots 25 which are three slots per sector in the present example FIG. 6. Each
sector can contain a
series of slots that are associated with a number of lateral pole irons having
lateral pole iron
windings wound in a particular magnetic polarity. As the lateral pole irons
are excited via DC
current activation of the lateral pole irons windings in a sequential fashion,
a moving magnetic field
is developed.
[00187] Dividing each of two sectors is a support segment 26 that can be
attached to and can
support lateral pole iron containment ring 21, which in turn, can support the
inner ends of the
lateral pole irons 34 which are coupled to, contained in, inserted into,
adjacent to, magnetically
coupled to, or the like, respective ones of the open wire slots 25. While the
other end of the lateral
pole irons 34 are illustrated as being inserted into, it will be appreciated
that other configurations are
possible that position the ends of the lateral pole irons over the slots to
allow flux generated within
the lateral pole irons to be coupled with the side iron and back iron of slots
25 and thus into the
windings 29, thereby, generating voltage and/or current flow in windings 29.
Rotor 6 is positioned
on shaft 8 and contains rotor inserts 4, which as noted, are configured to
contain freewheeling magnet
inserts 5 within a magnetically shielded containment means that includes a
roller bearing support
housed in containment sleeve that consists of laminations of mu metal and
carbon steel or the like
34
CA 02873973 2014-11-18
with an opening in the periphery to allow magnetic coupling between the
freewheeling magnetic
pole and the excited lateral pole iron. The laminated containment sleeve has a
second opening 180
diagonally across from the first opening, the second opening being on the
shaft side of the laminated
containment sleeve to allow flux coupling between the freewheeling magnetic
poles and the
freewheeling permanent magnet stabilizing coils 30, in which, by way of
example, when the lateral
pole iron is activated north pole the stabilizing coil in direct alignment and
proximity to the adjacent
freewheeling magnet is activated south pole at the same instant. Therefore,
the relationship is as
follows: Lateral pole iron (north pole), freewheeling magnet (south pole)
facing the lateral pole iron
and freewheeling magnet (north pole) facing the stabilizing coil 30, as the
stabilizing coil is activated
(south pole).
[00188] A more detailed understanding of an alternate embodiment and its
assembly can be gained
with reference to FIG.7. Therein, in a cross-sectional end view, laminated
stator iron 31, lateral pole
irons 34 and rotor 6 are shown. Containment slot 32a can accommodate
electromagnetic rotor pole
inserts 32. North pole ¨ south pole alternating leads are shown by way of
example by 35 ¨ 36, 37 ¨
38. The programmable excitation circuit switches north pole to south pole to
north pole to south pole
etc. every other segment as is seen in FIG. 6., segments A-L. The polarity of
the electromagnetic pole
insert changes polarity as it passes from one segment to the next segment
passing over support
segment 26. The electromagnetic pole insert maintains the same polarity for a
complete segment and
in this example three lateral pole irons, but is not limited to three. At a
rotational speed of 3600
rpm's the travel time from, for example, segment or sector A to segment or
sector B (FIG. 6, FIG. 7,
and FIG. 8) is approximately 10 ms. The time required for the excited poles,
and the electromagnetic
pole inserts, to magnetically collapse and reach peak magnetic flux again is
approximately 10 ms.
Therefore, the pole will collapse as it leaves one segment, for example,
segment A and reach
maximum magnetic flux of the opposite polarity as it reaches segment B. In
this example of FIG. 7,
laminated stator iron 31can contain open wire slots 25 which are insulated and
can contain power
induction coils 29 FIG. 8. The stator 31 and associated lateral pole iron
support structure, for
illustration and description purposes, can be divided into sectors such as
sector A-Land allocated
with a number of slots 25, which are three slots per sector in the present
example in FIG. 7. Each
sector can contain a series of slots that are associated with a number of
lateral pole irons having lateral
pole iron windings, wound in a particular magnetic polarity (FIG. 7 and FIG.
8).
[00189] As the lateral pole irons are excited through direct current
activation of the lateral pole iron
windings in a sequential fashion, a moving magnetic field is developed.
Dividing each set of two
sectors is a support segment 26 that can be attached to and can support
lateral pole iron containment
ring 21, which in turn, can support the inner ends of the lateral pole irons
34 which are coupled to,
CA 02873973 2014-11-18
contained in, inserted into, adjacent to, magnetically coupled to, or the
like, respective ones of the
open wire slots 25. While the other ends of the lateral pole iron 34 are
illustrated as being inserted
into, it will be appreciated that other configurations are possible that
position the ends of the lateral
pole irons over the slots to allow flux generated within the lateral pole
irons to be coupled with the
side iron and back iron of slots 25 and thus into the windings 29 (FIGS. 5, 6,
8 and 9) thereby
generating voltage and/or current flow in said windings 29.
[00190] Rotor 6 is positioned on shaft 8 and contains electromagnetic rotor
pole insert 32. The
electromagnetic pole inserts 32 are locked in place by a slotted locking
mechanism housed in
containment slot 32a which can accommodate electromagnetic rotor pole inserts
32. The
electromagnetic rotor pole inserts 32 are flush with the peripheral surface of
rotor 6, to allow
magnetic coupling between the expanded peripheral portion of electromagnetic
rotor pole insert 32
and the inner ends of the lateral pole irons. The wound lateral pole irons in
each sector fire
sequentially for 6.6 ms in the case of rotational speeds of 3,000 rpm and 5.55
ms in the case of
rotational speeds of 3,600 rpm and at the appropriate sequence and rate for
faster and slower speeds.
[00191] The pole irons are either north pole wound or south pole wound for a
given sector and
alternate as for example sector (A) - south pole, sector (B) -north pole,
sector (C)-south pole,
sector (D) ¨ north pole, sector (E)- south pole, sector (F) ¨ north pole,
sector (G)- south pole,
sector (H) ¨ north pole, sector (I) ¨ south pole, sector (J) ¨ north pole,
sector (K) ¨ south pole, and
sector (L)- north pole. The lateral pole irons fire in sequence and in
repetitive fashion in for
example for three lateral pole irons per sector, every 6.6 ms or at other
appropriate speeds as for an
additional example, in sector (A), the sequence is as follows: 51, (6.6 ms) -
752 (6.6 ms) -7 53 (6.6 ms)
-7 51(6.6 ms) -7 etc. The sequence described in the example for sector (A)
above is repeated,
simultaneously with sector (A) as well as in sectors (B), sector (C), sector
(D), sector (E), sector (F),
sector (G), sector (H), sector (I), sector (J), sector (K), and sector (L).
[00192] In FIG. 8 an example is illustrated in sector (A) during the
sequential south pole firing of 51,
52, and 53, the electromagnetic rotor pole insert is excited north pole by the
solid state excitation
system such that the sequential rotary movement of the south pole magnetic
flux in the lateral pole
iron coupled with the north pole flux of the electromagnetic rotor pole insert
32 to induce a rotary
motion with the appropriate torque in rotor 6 which is transferred to a
rotational mode through
rotor shaft 8. As a further example in FIG. 8 in sector (B) during sequential
firing of N1, N2 and N3
the electromagnetic rotor pole insert is excited south pole by the solid state
excitation system such
that the sequential rotary movement of the magnetic flux in the lateral pole
iron coupled with the
south pole of the electromagnetic rotor pole insert 32 to induce a rotary
motion with torque in
36
CA 02873973 2014-11-18
rotor 6 which is transferred to a rotational load through rotor shaft 8.
Electromagnetic rotor pole
inserts 32 are powered or excited through lead pairs of as an example lead
wires 35 and 36 as well as
pairs 37 and 38. These pairs of lead wires are "floating" leads utilized by
all 12 electromagnetic rotor
pole inserts. The lead wires are alternatively fed current from the excitation
board such that they
alternate polarity(+) -7 (-)and (-) -7 (+).
[00193] A further detailed understanding of an exemplary embodiment and its
assembly and
function can be gained with reference to FIG. 8. Therein, in a cross-sectional
end view laminated
stator iron 31, lateral pole irons 34 (FIG. 7 and FIG. 8) and rotor 6 are
shown. Containment slot 32a
(shown and labeled in FIG. 7) can accommodate electromagnetic rotor pole
inserts 32 (FIG. 7). North
pole/south pole alternating leads are shown by way of example by 35 ¨ 36 and
37 ¨ 38. The
programmable excitation circuit switches north pole -7 south pole -7 north
pole -7 south pole -7 etc.
i.e. the polarity switches as it passes over the next segment in its rotation
as it passes segments A ¨ L.
The polarity ofthe electromagnetic pole insert changes as it passes from one
segment to the next
segment passing over support segment 26. The electromagnetic pole insert
maintains the same
polarity for a complete segment or sector and then this example three (3)
lateral pole irons, but not
limited to three (3). At a rotational speed of 3,600 rpm the travel time from,
for example, segment
or sector A to segment or sector B is approximately 10 ms. The time required
for the excited poles,
of the electromagnetic pole inserts to collapse when current is discontinued
and to reach peak
magnetic flux again when current is fed from the opposite direction is
approximately 10 ms.
Therefore, the pole will collapse as it leaves one sector or segment, for
example sector or segment A
and reach maximum magnetic flux of the opposite polarity as it reaches sector
or segment B. it is
obvious to anyone schooled and skilled in the art that timing manipulation of
the beginning of
excitation of the rotor in the above examples may be m anipulated to reach
maximum torque and
minimum drag.
[00194] Inthis example of FIG. 8 laminated stator iron 31 can contain open
wire slots 25 which are
insulated and can contain power induction coils 29. The stator 31 and
associated lateral pole iron
support structure, for illustration and description purposes, can be divided
into sectors such as
sector A-Land allocated with a number of slots 25 which are three slots per
sector in the present
example FIG. 8. Each sector can contain a series of slots that are associated
with a number of lateral
pole irons having lateral pole iron windings wound in a particular magnetic
polarity FIG. 8. As the
lateral pole irons are excited through direct current activation of the
lateral pole iron windings, in
sequential fashion, a moving magnetic field is developed.
[00195] Dividing each set of two sectors is a support segment 26 that can be
attached to and can
37
CA 02873973 2014-11-18
support lateral pole iron containment ring 21, which in turn, can support the
inner ends of the
lateral pole irons 34 which are coupled to, contained in, inserted into,
adjacent to, magnetically
coupled to, or the like, respective ones of the open wire slots 25. While the
other end of the lateral
pole iron34 are illustrated as being inserted into, it will be appreciated
that other configurations are
possible that position the ends of the lateral pole irons over the slots to
allow flux generated within
the lateral pole irons to be coupled with the side iron and back iron of slots
25 and thus into the
windings 29 (FIGS. 5, 6, 8 and 9) thereby generating voltage and/or current
flow in said windings 29.
[00196] Rotor 6 is positioned on shaft 8 and contains electromagnetic rotor
pole inserts 32. The
electromagnetic rotor pole inserts 32 are locked in place by a slotted locking
mechanism housed
within the containment slot 32a (FIG. 7) which can accommodate electromagnetic
rotor pole inserts
32. The central end of the electromagnetic rotor pole inserts 32 are flush
with the peripheral surface
of rotor 6 to allow magnetic coupling between the expanded peripheral portion
of electromagnetic
rotor pole inserts 32 and the inner ends of the lateral pole irons. The wound
lateral pole irons in each
sector fires sequentially for 6.66 ms in the instance for example in the case
of rotational speed of
3,000 rpm and 5.55 ms in the example of rotational speeds of 3,600 rpm and at
the appropriate
sequence and speeds for faster or slower rotational speeds. The lateral pole
irons are either north
pole wound or south pole wound for a given sector and alternate from sector to
sector, as for
example, sector (A) - south pole, sector (B) ¨ north pole, sector (C) -south
pole, sector (D) ¨ north
pole, sector (E)- south pole, sector (F) ¨ north pole, sector (G)- south pole,
sector (H) ¨ north pole,
sector (1)- south pole, sector (J) ¨ north pole, sector (K) ¨ south pole, and
sector (L) ¨ north pole.
The lateral pole irons fire in sequence and in repetitive fashion in for
example for three lateral pole
irons per sector, every 6.6 ms or at other appropriate speeds as for an
additional example, in sector
(A), the sequence is as follows: Sl, (6.6 ms) -752 (6.6 ms) -7 53 (6.6 ms) -7
51(6.6 ms) -7 etc.
[00197] The sequence described in the example for sector (A) above is
repeated, simultaneously with
sector (A) as well as in sectors (B), sector (C), sector (D), sector (E),
sector (F), sector (G), sector (1-1),
sector (I), sector (J), sector (K), and sector (L). In FIG. 8 as an example in
sector (A) during the
sequential south pole firing of Sl, 52, and 53, the electromagnetic rotor pole
insert is excited north
pole by the solid state excitation system which is triggered by the signal
from an end coder on the
rotor shaft such that the sequential rotary movement of the magnetic flux in
the lateral pole iron
sector (A) couples with the north pole of the electromagnetic= rotor pole
insert 32 to induce a
rotary motion with the appropriate resultant torque in rotor 6 which is
transferred to a rotational
load through rotor shaft 8. As a further example in FIG. 8 in sector (B)
during sequential firing of
N1, Ni, N3 the electromagnetic rotor pole insert is excited south pole by the
solid state excitation
system such that the sequential rotary movement of the magnetic flux in the
lateral pole iron
38
CA 02873973 2014-11-18
couples with the south pole of the electromagnetic rotor pole insert 32 to
induce a rotary motion
with torque in rotor 6 which is transferred to a rotational load through rotor
shaft 8.
Electromagnetic rotor pole inserts 32 are powered or excited through lead
pairs as example lead
wires 35 and 36 as well as pairs 37 and 38. The pairs of leads by example are
"floating" leads utilized
by all 12 electromagnetic rotor pole inserts. The lead wires are alternatively
fed current from the
solid state excitation boards such that they alternate polarity, e.g. from (+)
to (-) and from (-) to (+).
[00198] A further detailed understanding of an exemplary embodiment and its
assembly and
function can be gained with reference to FIG. 9, in which a cross-sectional
end view, laminated stator
iron 31, lateral pole irons 34, and rotor 6 are shown. Containment slot 32a in
rotor 6 can
accommodate electromagnetic rotor pole inserts 32. The north pole/south pole
alternating leads are
shown by way of example by 37 ¨ 38. The programmable excitation circuit
switches north pole 7
south pole -?north pole -?south pole etc., i.e. the polarity switches as it
passes over the next segment
in its rotation as it passes segments A- L. The polarity of the
electromagnetic pole insert changes as
it passes from one segment to the next segment passing over support segment
26. The timing of the
pole reversal is dictated by a rotor encoder which signals the PLC onboard the
excitation card. The
electromagnetic pole insert maintains the same polarity for a complete segment
and in this
example three (3) lateral pole irons, but not limited to three (3), at a
rotational speed of 3,600
rpm the travel time for example segment (A) to segment (B) is approximately 10
ms. The time
required for the excited magnetic pole, of the electromagnetic pole inserts to
collapse when
current is off and to again reach peak magnetic flux when current is fed from
the opposite
direction is approximately 10 ms. Therefore the pole will collapse as it
leaves one segment for
example, segment (A) and reaches maximum magnetic flux of the opposite
polarity as it reaches
segment (B).
[00199] In this example of FIG. 9 laminated stator iron 31 can contain open
wire slots 25 which
are insulated and can contain power induction coils 29. Dividing each set of
two sectors is a
support segment 26 that can be attached to and can support lateral pole iron
containment ring
21, which in turn can support the inner ends of the lateral pole irons 34,
which are coupled to
contained in, inserted into, adjacent to, magnetically coupled to, or the
like, respective ones of
the open wire slots 25. These configurations may position the ends of the
lateral pole irons over
the slots to allow flux generated within the lateral pole irons to be coupled
with the side iron,
and back iron of slots 25 and thus into winding 29 thereby generating voltage
and/or current
flow in said windings 29. The power induction coils 29 are connected in series
with jumper
wires 39, 39a, 39b, 39c, and 39d connecting the "out lead" of each coil to the
"in lead" of the
next coil. For example, the "in leads" and "out leads" are designated by
consecutive circled
39
CA 02873973 2014-11-18
numbers 1-12. As shown in FIG. 9, in sector L-A circle 2 is connected via
jumper wire 39 to
circle 3 lead in sector B ¨ C. This hookup arrangement can be continued in a
clockwise
fashion until all coils are connected in series with remaining leads 33 (+)and
33a (-).These
leads 33 and 33a may be used to parallel power to the solid state excitation
system.
[00200] Further understanding and its assembly and function can be gained with
reference to
FIG. 10A and 10B, which is a diagram illustrating a lateral view of an
exemplary unwound
lateral pole iron 41. Section 45, the pole iron is defined by a boundary of
cross member 46
which attaches to the lateral pole iron containment ring. The stator
attachment means is
represented by 42, 43, and 44. This piece forms a groove mechanism which by
example may be
fitted onto the tooth area of stator 31 FIG. 9. FIG. 10B is an end view of the
unwound lateral
pole iron 41.
[00201] Further understanding and its assembly and function can be gained with
reference to
FIG. 11A and 11B. FIG. 11A shows wound lateral pole iron 41 with winding 47
which may
be wound clockwise for a south pole production and counterclockwise for a
north pole
production. Leads 47a and 47b may be activated as positive or negative leads
to produce the
desired polarity.
[00202] Additional understanding and its assembly and function can be gained
with reference to
FIG. 12A, which is a diagram illustrating a lateral and end view of an
exemplary unwound iron
pole piece of an electromagnetic rotor pole magnet stabilization insert 52.
Section 50 the pole
coil area is defined by a boundary of cross members area 51and49. An
interlocking slot 48 is
revealed which locks iron pole piece 52 in place in rotor 6.
[00203] For further understanding and its assembly and function, one can refer
to FIG. 12B,
which is a diagram illustrating a lateral and end view of an exemplary wound
iron pole piece of
an electromagnetic rotor pole magnet stabilization insert 52. Winding 53 is
made of electrical
magnet wire wound onto insulated pole iron 50. The coil boundaries are
established by cross
members 49 and 51. Interlocking slot 48 is revealed in the end view. Leads 54
and SS are
"floating" leads which may be positive or negative for switching from north
pole to south pole
and from south pole to north pole. This switching function is controlled by a
gating
mechanism which is contained in the solid state excitation boards.
[00204] Additional understanding, its assembly and function can be gained when
one refers to
FIG. 13A, which is a diagram illustrating a lateral and end view of an
exemplary unwound iron
pole piece of an electromagnetic rotor pole insert S8. Section 60, the pole
coil area is defined
CA 02873973 2014-11-18
by a boundary of cross member 61 and interlocking complex 56, 57, and 59 FIG.
13B reveals.
Coil 62 which is wound on insulated iron 6 contains two lead wires 62a and
62b. These leads
each may be either positive or negative for switching from north pole to south
pole and south
pole to north pole. This switching function is controlled by a gating
mechanism which is
contained in the solid state excitation boards which may be used to excite the
electromagnetic
rotor pole insert 58.
[00205] Further understanding and its assembly and function can be gained with
reference to
FIG. 14A, which is a diagrammatic representation of a lateral oblique view of
the carbon
steel/mu metal laminated sleeve which is pressed into the pole cavity of the
rotor in
accordance with one or more embodiments. In an embodiment, the length of the
sleeve can
correspond to the width of an exemplary rotor, such as 8 inches in the present
example.
However, the length could be longer or shorter depending upon the particular
application. The
laminations are constituted of non-magnetic or magnetic carbon steel and
nickel-iron alloy
such as mu metal. While mu metal provides excellent shielding properties, it
is relatively soft
compared to steel, which, while providing a degree of shielding is stronger
than the mu metal.
Therefore the laminations combining steel and mu metal provides excellent
strength and
magnetic shielding properties. In the event that a magnetic steel is used, the
mu metal still
provides excellent magnetic shielding properties. The insert represented in
FIG. 14B can be
pressed into a cavity, machined or laser cut into the rotor 6 laminates or
solid material block.
The laminated sleeve 65 can be provided with an opening 64 and 64a as shown in
FIG. 14B to
allow the magnetic flux fields associated with the freewheeling permanent
magnet inserts 4 to
have unobstructed interaction and magnetic coupling with an end of a lateral
pole iron, such as
lateral pole iron 34. A bearing support 63 can be provided and can be formed
for example, as a
groove in the sleeve which gives additional structural support and provides a
guide for the
bearings of the rotor insert 4.
[00206] A lateral oblique of rotor insert 4, which is housed in the above
described laminated
steel/mu metal sleeve, is shown in FIG. 15. Each of the sleeves and all of the
assemblies pertinent
thereto can be arranged along and rotate about a longitudinal axis 69b. The
magnet containment
means 4 is constructed of non ferro-conductive material such as carbon fiber
or austenitic steel
or the like. Through open slot or opening 68, permanent magnets 69 and 71 can
be exposed for
example, the lateral pole iron ends as described above and can form flux
linkage between the
permanent magnets and the magnetized lateral pole irons. Permanent magnets 69
and 71 can be
constituted of, for example, neodymium, samarium-cobalt, or similar quality
high energy
product magnetic bodies. Permanent magnet 71 can be bonded to a thin ferro-
conductive sheet
41
CA 02873973 2014-11-18
70b with the north pole facing the outer surface of the containment means.
Permanent magnet
69 can be bonded to thin ferro-conductive sheet 70b with the south pole facing
the outer surface
of the containment means. An appropriately sized layer of mu metal can be used
to form shield
70 and 70a, which can be bonded to the lateral surface of the permanent magnet
69, sheet 70b
and permanent magnet 71. The magnet support 4 can be attached inside the above
described
laminated sleeve 65 FIG. 14 and can provide rotation via ball bearing or
roller bearings such that
the magnet support means 4 may be turned freely without significant mechanical
drag.
[00207] FIG. 16 is an end view of the rotor insert 4, including freewheeling
magnet inserts 69
and 71 contained within the containment means 75, which in turn, can be
contained within
laminated sleeve 65. The rotor insert 4 can be contained within cavities that
are formed in the
periphery of the rotor 6 as described herein above. In FIG. 16 mu metal
cylinder 66 is bonded
to carbon steel cylinder by bonding glue 66a. The laminated structure 65 is
stabilized by
bonding rivets 67.
[00208] Further understanding and its assembly and function can be gained by
reference to
FIG.17, which is a diagram illustrating a high efficiency electric motor, a
hydrogen generator, a
hydrogen driven standard drive engine and a standard electric power generator.
In the example
a 20 hp internal combustion engine 77 can be configured to drive a standard
efficiency electric
generator 76, which in turn, drives a hydrogen generator 83, which thereby
provides hydrogen
to hydrogen storage tank 82 and feeds the hydrogen engine 77 through conduit
79. Water
which is formed from hydrogen combustion drains through conduit 84 into water
reservoir 87
and in turn supplies hydrogen generator 83 with water through conduit 85. An
electric power
generating system is provided by utilizing a series of high efficiency
electric motors which are
driving standard efficiency electric generators. The 20 hp hydrogen fueled
internal combustion
engine can be operated through control panel 78.
[00209] The standard efficiency generator 76 which is driven by hydrogen
fueled internal
combustion engine 77 supplies for example 13.05 Kw to hydrogen generator 83 as
well as 1.85
Kw through electrical conduit 80 to 10 hp high efficiency electric motor 88
that drives a 7.46
Kw electric generator 89 for supplying 3.76 Kw of electric power to the
electric power grid 99
through conduit 97 and transformer 98. The generator 89 further supplies
approximately 1.85
Kw of electric power through electrical conduit 90 to 10 hp high efficiency
electric motor 86 which
drives standard efficiency electric generator 92 which feeds through conduit
93 hydrogen generator
83 with an additional 7.46 Kw of electric power which provides a total of
20.51 Kw of electric
42
CA 02873973 2014-11-18
power to the hydrogen generator 83. The generator 89 further supplies
approximately 1.85 Kw of
electric power through conduit 91to 10 hp high efficiency electric motor 95
which drives generator
94 which in turn supplies 7.46 Kw of electrical power to power grid 99 through
electrical conduit 96
and transformer 98.
[00210] While the above described embodiment allows for the generation of
additional power
through powering a standard efficiency generator by high efficiency motors and
diversion of a
portion of the power output to additional high efficiency drive motors, in
alternative embodiments
storage devices can be used to store a portion of the surplus generated as a
result of the gains in
efficiency.
[00211] Additional understanding may be gained by reference to FIG. 18, which
illustrates an
exemplary interaction of a standard efficiency electric generator 106 with a
high efficiency electric
driving motor such as 108 through a bank of batteries, capacitors, electric
energy storage devices or
the like such as storage devices 110 and 111. In the present example high
efficiency 10 hp electric
motor 108 can drive a 7.46 Kw standard efficiency generator 106 through shaft
105. The generator
106 supplies 3.76 Kw through electrical conduit 112 to a full wave bridge
rectifier 109. The direct
current energy output from the full wave rectifier is then stored in storage
devices 110 and 111,
while output stored power or a combination of storage power and converted
power, depending on
demand level, through electrical conduit 114 to variable frequency drive or
inverted, which supplies
high efficiency motor 108 through conduit 113. In addition, generator 106 puts
out about 1.85 Kw
of electric power through conduit 107 to high efficiency electric motor 103
which drives standard
efficiency generator 104 which puts out about 7.46 Kw to power grid 100
through conduit 102.
Additionally generator 106 puts out about 1.85 Kw through conduit 115 to high
efficiency electric
motor 116 which drives standard efficiency generator 118, which puts out 7.46
Kw to power grid
100 through conduit 101. The net output to the grid occurs as a result of a
multiplier effect from
high efficiency motors driving standard lower efficiency generators.
[00212] Further understanding may be gained by reference to FIG. 19, which is
a diagram
illustrating a high efficiency electric driving motor and a standard
efficiency electric generator along
with a hydro storage system utilizing a motor, pump, water storage reservoir,
and gravity flow
through a generator turbine system. Water tower storage tank 132 can provide
water to turbine 133
that flows, for example, under gravitational pressure. Turbine 133 can drive
normal efficiency
generator 134 which feeds 5.61 Kw back to high efficiency motor and pump 138
for pumping waste
water that has passed through the turbine 133, from receiving reservoir 138
back to water tower
43
CA 02873973 2014-11-18
reservoir 132 through water conduit 131. The generator 134 can also send
remainder of its output
power or 1.85 Kw of electric power through electrical conduit 135 to 10 hp
high efficiency electric
motor 139. Electric motor 139 drives generator 140 which generates 7.46 Kw of
electric power to
the power grid through electrical conduit 141.
[00213] It will be appreciated that by supplying an illustrative 7.46 Kw to
the power grid 119 at a
cost of 7.46 Kw, the hydro power configuration can perpetuate additional
electric systems due to a
combined multiplier effect associated with various efficiency gain stages. For
example, considering
the 7.46 Kw input to power grid 119 from generator 140, electric 10 hp high
efficiency motor takes
1.85 Kw of power from the power grid 119 through electrical conduit 122 to
power a high efficiency
motor 125 which drives a 7.46 Kw standard efficiency generator 124
constituting a gain stage. A
resulting output of 3.76 Kw of power is supplied back to the power grid 119
through electrical
conduit 123. The generator 124 also supplies 1.85 Kw of electric power to high
efficiency electric
motor 128a and 1.85 Kw of electric power to high efficiency electric motor 128
respectively through
electrical conduits 126 and 127. Electric motors 128a and 128 are configured
to drive 7.46 Kw
generator 129 and 7.46 Kw generator 130 constituting additional gains. Power
output of generators
129 and 130 is transmitted to the power grid 119 through electrical conduits
120 and 121.
[00214] An additional understanding may be gained by reference to FIG. 20,
which is a diagram
illustrating an exemplary configuration for magnification of electric power
through a high efficiency
electric motor driving a standard efficiency electric generator. Electric
power is initially taken from
the power grid 142 in an illustrative amount of approximately 1.85 Kw through
electrical conduit
145, such as a wire conductor, busbar, or the like, to drive 10 hp high
efficiency motor 147. Motor
147 is configured to drive a standard efficiency electric generator such as
generator 149 through
shaft 146 to produce an illustrative 7.46 Kw of electric power. In the
example, approximately 3.76
Kw of output from generator 149 can be fed back to the power grid while
approximately 1.85 Kw is
fed to each of two 10 hp high efficiency drive motors 151and153 respectively,
through electrical
conduits 150 and 148 from generator 149 constituting a net gain due to a
multiplier effect. High
efficiency electric motor 151in turn drives another electric generator to
generate 7.46 Kw of energy
to feed back to the power grid through conduit 144. Electric motor 153 drives
electric generator 154
to generate 7.46 Kw of power to feed back to the power grid through electrical
conduit 143. The
operation of high efficiency electric motors 151 and 153 to drive standard
generators constitute
another stage of gain due to a multiplier effect.
[00215] Further accordance with various exemplary embodiments discussed and
described herein,
44
CA 02873973 2014-11-18
motor reaction force may be reduced and eliminated in an embodiment whereby a
series of rotatable,
bipolar, quadrapolar or unipolar electromagnets, electrical armatures, rotors
and the like, can be
disposed or otherwise inserted on their axis into recesses in a stator which
recesses may be
completely surrounded by laminated electrical steel. The recesses can be
shielded and positioned
over each wire slot of the generator such that wire slots in the correct
pattern to mimic a central
single 4 pole rotor of a conventional generator. Conversely the preferred
embodiment provides
recesses in a stator in which the rotors may be inserted which are
geometrically isolated from the
center of the magnetic poles which form in the stator as the stator coils are
connected to a load, as an
increasing current flows through the stator coils. This geometric isolation
reduces the interaction
between the rotor and stator magnetic fields and in combination with mu metal
shielding greatly
reduces or eliminates the motor reaction force or electromagnetic drag. The
maximum flux density is
obtained in accordance with an embodiment whereby the wire slots on an inner
stator circumference
and an outer stator circumference are each provided with slot rotors forming
an exemplary dual slot
rotor. Also dual stator configuration is provided such that the stator side
iron and back iron are
exposed to both rotors to allow the desired magnetic coupling between the
rotors and through the
power generation slots to generate the desired magnetic movement across the
conductors in the wire
slots.
[00216] The following detailed description provides an understanding of
embodiments as illustrated
and described herein below. A high efficiency generator is provided that
shields or separates the drag
creating magnetic forces, between the rotors and the stator, from one another
so that upwards of 80%
of the driving energy which conventionally is consumed and/or dissipated by
magnetic drag is
converted to electric power.
[00217] In accordance with embodiments as will be described in greater detail
in connection with
the illustrations below, the classic rotor armature and stator have been
replaced by a laminated
electrical steel dual stator having a stator section with an outer
circumference and a stator section
with an inner circumference. Each stator section has, in one example, 48 wire
slots that are
magnetically coupled with individual slot rotors of corresponding slot rotor
pairs. The corresponding
slots from the inner and outer stator sections are aligned with each other and
a ferrous back iron is
preferably disposed between the stator sections to increase the flux coupling.
In a preferred
embodiment each stator section has, in a second example, 8 wire slots that are
geometrically spaced
in the corner of a square or rectangle or the like and are magnetically
coupled with individual slot
rotors of corresponding slot rotor pairs. The corresponding slots from the
inner and outer stator
CA 02873973 2014-11-18
sections are aligned with each other and a ferrous back iron and small segment
of side iron is
preferably disposed between the stator sections to increase the flux coupling.
In another preferred
embodiment, each stator section has, in a third example, 24 wire slots that
are geometrically spaced
in the corner of a square or rectangle of the stator and are magnetically
coupled with individual slot
rotors of corresponding slot rotor pairs. The corresponding slots from the
inner and outer stator
sections are aligned with each other and a ferrous back iron and small segment
of side iron is
preferably disposed between the stator sections to increase the magnetic flux
coupling.
[00218] The slot rotors can be constituted of, for example, two pole, four
pole or preferably one pole
(unipolar rotor) with a floating lead controlled by a solid state excitation
system. The rotors are
wound armature poles with associated slip rings and bearing mechanisms. The
slot rotors are
positioned in close proximity to the wire slots in order for each rotor of the
slot rotor pairs to form a
closed magnetic circuit through both slots. It should be noted that one of the
slot rotors in the slot
rotor pair rotates clockwise and the other rotates counterclockwise in order
for the proper magnetic
flux to be delivered to the wire slots in the case of the two pole and four
pole. However the direction
of rotation is not as critical in the case of the unipolar rotor, however
rotation of the two rotor pairs
in the opposite direction is preferable.
[00219] Each slot rotor armature of the slot rotor pair can be energized and
the individual rotor
assembly can be rotated to provide alternating fields of north and south pole
magnetic flux field
energy into the open wire slots and side iron in the stator and this flux
field will magnetically couple
with the side iron and back iron and/or with the opposite slot rotor of the
slot rotor pairs. Each of the
slot rotors in the slot rotor pair is rotated such that a pole of one slot
rotor makes up a complete
magnetic flux circuit with the corresponding opposite pole of the other slot
rotor of the slot rotor pair
thereby directing a maximum amount of magnetic flux into the stator slots
containing the induction
coils. The magnetic poles are activated with DC current via a brush and solid
state or mechanical
commutator apparatus or other appropriate mechanism such that the magnetic
poles are obtained
only as they pass over the wire slots in the case of multi-pole rotors.
However, in the case of the
unipole rotor the pole is activated north 50 times per second and south 50
times per second (50 Hz)
or north 60 times per second and south 60 times per second (60 Hz) or any
other appropriate timing
for other desired frequencies. In other operational modes, the rotor can be
excited all north and/or all
south pole to generate DC current. Since the opening of the mu metal laminated
shield is precisely
positioned over the wire slot and are positioned such that a small portion of
side iron is exposed,
only a focused but intense window of magnetic flux permeates the side iron,
the induction coils and
46
CA 02873973 2014-11-18
back iron. Therefore the shielding and geometric isolation allows only minimal
to no
electromagnetic drag upon the slot rotors.
[00220] The slots in the outer circumference and inner circumference are
aligned. The magnetic
poles of each individual member of the pair of slot rotors rotate in a
coordinated fashion respectively
over the inner and outer aligned slots such that, for example, as a north pole
of one of the pair of
rotors rotates over one slot of the inner slot, a south pole of the other of
the pair of rotors rotates over
the outer slot. Thus, the dual rotors can be sequenced such that they present
opposite poles to
corresponding slots in the inner and outer stators respectively thereby making
up a magnetic circuit
between the north pole and south pole as they rotate past one another. The
resulting magnetic circuit
generates a high flux density into the slots on both the inner and outer
stators and into the shared side
iron, back iron, and cuts across the slot induction coils thereby generating
power. In the instance of
AC (alternating current) the rotor poles alternate north pole then south pole
in each of the
corresponding rotor pairs, but maintain the sequencing of the dual rotors such
that they present
opposite poles to corresponding slots in the inner and outer stators
respectively. In the instance of
direct current (DC), the rotor pairs remain of one polarity either north or
south, but maintaining the
sequence of the dual rotors such that they present opposite poles to
corresponding slots in the inner
and outer stators respectively.
[00221] In an exemplary bipolar slot rotor, one of the two pole sections is
north pole charged and the
opposite section is south pole charged. In one embodiment, the north pole
section can be constituted
by a 120 section and the south pole can be constituted by an opposite 120
section with a 60
neutral zone between poles on each side thereof. In another embodiment the
rotor is unipolar i.e. the
entire rotor is north pole for half of the frequency cycle, then the current
flow is reversed via the
excitation controller and the entire rotor becomes south pole i.e. north pole
then south pole for 360 .
Pole sections can be shielded with mu metal shielding. Each of the slot rotor
arrangements are
preferably contained in a longitudinal cylindrical cavity that is located in a
close proximity to and
extends lengthwise along the opening of the winding slots. The slot rotor
mechanism, including a mu
metal shield can be contained within a laminated steel cylinder. The steel
cylinder is a partial
cylinder so as to allow installation of the stator windings and is closed by
use of a laminated steel mu
metal shield cover. The cylinder has an opening that corresponds and is in
communication with the
opening of the stator wire slot. An opening along the length of the steel
cylinder can be in alignment
with a slot or opening along the length of the mu metal shield to allow
magnetic coupling between
the slot rotor and the winding slot side iron, back iron and the corresponding
rotor of the rotor pairs.
47
CA 02873973 2014-11-18
[00222] It will be appreciated that the slot rotors may be fashioned, for
example, as wound
electromagnetic armatures that are positioned as pairs of rotors around the
circumference of a dual
wound stator. Different numbers of slot rotor pairs can be used preferably in
even numbers such as 4
or 8 slot rotor pairs, which is by way of example and different numbers of
slot rotor pairs can be
used. An individual slot rotor armature may be made by fashioning a series of
laminated steel pole
pieces upon a shaft in a manner similar to that of a conventional generator
armature. Completed pole
pieces may be wound in a conventional manner with insulated wire to suitable
winding
specifications for the operating demands of the generator. Power can be
applied to the armatures via
a control system.
[00223] To drive the shafts of the slot rotor mechanism, a central gear
mechanism may be employed
at one end of the individual slot rotor shafts over the inner and/or outer
circumference of the stator.
As the slot rotor pairs and their respective armatures are rotated on both
sides of the stator in a
synchronized manner by the gear mechanism, power can be generated with greatly
reduced drag as
compared with a single, central rotating armature of a conventional generator.
[00224] In another preferred embodiment in the case of a unipolar (single
north pole and followed
by a single south pole for 360 of the surface) rotor, the shafts of the slot
rotor mechanism may be
driven by employing a single three phase motor at one end of the individual
slot rotor shafts over the
inner surface and/or outer circumference of the stator. The slot rotor motors
are controlled by a
single variable speed drive. As the slot rotor pairs are rotated on both sides
of the stator in a
synchronized manner, power can be generated with greatly reduced drag as
compared with a single,
central rotating armature of a conventional generator.
[00225] Power generation in accordance with the reduced electromagnetic drag
provided by various
embodiments discussed and described herein can result in, for example, a four
to five-fold increase
in electrical energy output with the same mechanical or kinetic energy input.
With an exemplary
mechanical input of, for instance, one horsepower provided by an electric
drive motor driving the
exemplary gear mechanism, one horsepower of mechanical energy may potentially
generate more
than the conventional limits. Therefore, as the conventional one horsepower
electric motor, or
system of electric drive motors utilizing 746 watts, drives the slot rotors,
the generator may
potentially generate additional usable energy.
[00226] The process of electrical power generation can be thought of as a
process by which input of
kinetic energy, for example, is used to move a magnetic field. The resulting
moving magnetic field
48
CA 02873973 2014-11-18
moves across the conductor wires in the stator induction wire slots of the
electric generator, causes
an electrical voltage in the coils of the generator and when the coils are
connected to an electrical
load causes an electrical current to flow in the coils of the generator. The
electrical current flowing
in the stator coils creates a magnetic field by virtue of the physical
construction of the coils and the
laminated steel in which they are wound. The newly created magnetic field in
the stator iron
increases in strength as electric power increasingly drawn from the generator
and is approximately
equal and opposite polarity to the original source of the magnetic field. The
stator field interacts with
the original source of the magnetic field in the rotor which ends up
dissipating the kinetic energy
input to the system. Therefore, it may appear that kinetic energy is being
converted into electrical
energy. In fact the kinetic energy is only eliciting electrical energy which,
by virtue of design of the
conventional generator, is dissipating the kinetic energy by acting in the
opposite direction to the
original kinetic energy.
[00227] The problem associated with such energy dissipation is a fundamental
problem of generator
design rather than a practical necessity of the generating process. A change
in generator design can
eliminate the unwanted byproduct of back electromotive force (EMF) and
subsequent
magnetomotive force without affecting the generating process. The input of
kinetic energy is no
longer related to electrical output. In accordance with various embodiments,
an electrical generator
system can be provided in which a conventional magnetically polarized
generator rotor is replaced
by a series of distributed slot rotors having magnetic poles affixed over and
in close proximity to
each wire slot. In order to isolate the magnetic flux and direct it to the
slots, slot rotors are
geometrically placed away from the center of the stator magnetic poles created
by the induction
current and the said slot rotors can be shielded with, for example, mu metal,
which can be an
annealed metal of 75% nickel, 15% iron, plus copper and molybdenum.
[00228] A stator in accordance with the embodiments discussed and described
herein can contain
wire slots on the inner circumference as well as the outer circumference. In
should be noted however
that, by use of the terms "inner" and "outer", illustrative reference is made
to a circular shaped stator
embodiment. It will be appreciated and should be emphasized that the dual
stator need not be
circular and can be linear or planar, or can be of a semi-circular or other
functional shape and have
dual stator sections with the same effect of the embodiment specifically
illustrated and described
herein. In such an embodiment where the stator is not circular, the terms
"inner circumference" and
"outer circumference" can be replaced by terms such as "first outer periphery"
and "second outer
periphery". Further, since an exemplary stator in various embodiments is
described herein as dual
49
CA 02873973 2014-11-18
stator arrangement, the first outer periphery and second outer periphery can
include the stator surface
containing the slot rotors. The respective inner peripheries of the stator
sections can be adjacent to
and can face each other either directly or with an intervening member such as
a segment of side iron
and back iron or the like.
[00229] The slots in the outer circumference and inner circumference are
aligned. The magnetic
poles rotate over both aligned slots such that as a north pole rotates over
one slot, the pole over the
aligned slot is sequenced such that it presents a south pole rotating in the
opposite direction thereby
making up a magnetic circuit between the north pole and south pole as they
rotate past one another.
This magnetic circuit generates a very high flux density into the slots on
both the inner and outer
radius and into the side iron and shared back iron. Each of the magnetic
bodies is constructed of
wound inductive magnetic armatures. The size of the magnetic wound inductive
armature is not
limited but is sized to be compatible with the stator size. The unique design
which may be unipolar,
dipolar or quadrapolar is powered by a DC current supply which activates pole
coils through a brush
and slip ring mechanism or an appropriate inductive transfer mechanism such
that the magnetic
poles are only activated as they are rotated over the unshielded wire slots.
The armature mechanism
is separated from the back EMF (and related magnetomotive force) by mu metal
shield cylinders
which surround the electromagnetic armature mechanism. These cylinders are
only open to the wire
slots of the stator. The shielded electromagnetic poles are rotated by a
transmission mechanism or
individual slot rotor motors which effectively exposes the wire slots to a
high density moving
magnetic field over and through the slots of the induction coils of the
stator. The magnetic poles of
the armature mechanism are only activated as they rotate over the wire slots.
With the proper stator
winding and pole activation sequence, clean 3-phase, 2-phase and single phase
and direct current
may be generated. The attributes of a generator in accordance with
embodiments, allows generators
of practically unlimited size with unlimited application to be constructed.
[00230] The immediate and obvious applications include a stand-alone power
generation system for
point of use electric power needs, stand-alone power generation plant, power
magnification at
substations, powering motive devices such as automobiles, trains, boats,
ships, buses, trucks, planes
and any other use for which convenient power is needed.
[00231] In accordance with various exemplary embodiments discussed and
described herein, and by
way of brief summary, an exemplary electric power generation process is
disclosed whereby a high
efficiency generator can be used to generate electric output with enhanced
efficiency.
CA 02873973 2014-11-18
[00232] Exemplary embodiments make use of a new paradigm of efficiency in
which kinetic energy
input onto the shaft of an electric power generator in accordance with
exemplary embodiments
yields additional electric energy output from the generator leading to an
enhanced generation factor.
Output of the generator is fed back to the driver motor or motors through an
interface such as a full
wave rectifier- battery- inverter (UPS/Uninterruptible Power Supply) or other
similar device or
interface, additional usable power is generated by example and not limiting.
[00233] Paradigm shift is a term first coined by Thomas Kuhn is his book
entitled "The Structure of
Scientific Revolutions" published in 1962. The term is used to reference a
change in basic
assumptions within the ruling theory of science. The current assumption
concerning electric energy
generation by rotating machinery based electric power generators, are based
upon historical
observations from electromotive machines. The classic observations are based
on a particular design
of the generator and result in paradigms in which only 20% of the kinetic
energy input onto the shaft
of the generator is used to generate electric power, when operating at full
load. The remaining 80%
is dissipated by competing destructive magnetic forces within the generator
resulting from sub-
optimum generator design. The high efficiency generator described in
accordance with embodiments
in the present and related patent applications (as noted in cross-reference to
related co-pending
applications) has been redesigned to reduce the 80% kinetic energy loss from
the destructive
magnetic forces completely or almost completely. At a full load, a high
efficiency generator, for
example, as described herein, requires approximately 24% of the energy
required to drive a classic
generator at full load. Accordingly, it is possible to generate the same
amount of energy in
accordance with a higher efficiency paradigm using approximately one-fourth
the kinetic energy
input that would be required with conventional paradigms.
[00234] A driver motor operating in accordance with one energy paradigm and a
generator to which
the driver motor is coupled, operating according to another higher efficiency
paradigm in creating a
net usable energy output is not operating in violation of laws of physics.
Rather, the gains are
associated with the fact that power generated by operating a driver motor
which in accordance with a
lower efficiency paradigm transmits kinetic energy through a physical driver
shaft into a generator
which operates in accordance with a higher efficiency paradigm, thereby
expanding the amount of
usable energy.
[00235] The above gains do not violate the laws of thermodynamics, rather the
phenomenon
suggests a need for supplementary laws. For example, it might be stated that
when a generator driver
motor operating in accordance with a lower energy efficiency paradigm is used
to drive an electric
51
CA 02873973 2014-11-18
power generator through a physical and/or mechanical connection operating in
accordance with a
higher efficiency paradigm or vice versa, whereby the driver motor operating
in accordance with a
higher efficiency paradigm than the generator, an expansion in the amount of
available usable
energy generated by the system is the result, due to the multiplier effect
associated with the
difference in efficiency between the driver and the generator. Based on the
gains, the driver motor
may be powered by a portion of the generated excess power through a suitable
interface and the
remaining output may be used for other desired purposes. The above described
phenomenon requires
a disparity between the efficiency of the generator and the driver motor
resulting from, for example,
1) a normal efficiency driver motor and a high efficiency generator or 2) a
high efficiency driver
motor and a normal efficiency generator.
[00236] The generator system herein described requires an energy storage
interface placed between
the generator and the driving motor can supply the energy for the drive motor.
Suitable systems for
energy storage can include batteries, capacitors, hydraulic systems with a gas
accumulator, a hydro
storage/pump/turbine system, a hydrogen generator with hydrogen powered
turbine, or an internal
combustion engine and the like. Interaction with an existing power grid can
also be used thereby
creating a magnifier effect. In addition to the above stand-alone power plant
application and
interaction with the electric power grid, many other applications become
evident.
[00237] The power generation system herein described may be installed
underneath the hood of an
automobile to power the automobile through the use of electric traction motors
in the wheel hubs, or
on the axle, or other parts of the drive train. The power plant contained in
the automobile may be
used to power the locomotion of the automobile and/or may be used to plug-in a
conductor from the
automobile power plant into an input point in a home garage to power the home
and the grid. It may
also be utilized to plug into other stations in parking lots, parking deck,
parking garage, curbside and
the like to send power to the grid. The automobile power plant can generate AC
single-phase or
three-phase current as well as DC current. These changes in functions are
programmable from the
onboard computers.
[00238] The power generation plant herein described may also power trains,
boats, ships, buses,
trucks, airplanes and any other function which requires power. All of the
applications may also have
a secondary function to power the electric power grid.
[00239] With reference now to the figures, FIG. 21Ashows an end view of an
exemplary
embodiment involving a dual laminated steel stator 2001with 96 armature
mechanisms, or slot rotors
52
CA 02873973 2014-11-18
as described herein, which form 48 slot rotor pairs. The slot rotor pairs,
such as is exemplified by
outer slot rotor 2002 and inner slot rotor 2010 are shown positioned over wire
slots 30 of the outer
stator race and wire slots 2116 of the inner stator race of stator 2001. In
the present embodiment, the
outer race slots of laminated steel stator lcontains a series of 48 slots,
which are accompanied by slot
rotor pairs. Slot rotor activation and advancement is such that 4 magnetic
poles and 4 magnetic voids
rotate around the circumference of the dual stator unit.
[00240] It will further be appreciated that, with reference to FIG. 21A,the
outer race slots contain
induction coils associated with a 3-phase generator. In FIG. 21A, the phases
are shown as follows:
the first phase 12, the second phase 14 and the third phase 13. The various
phase coils can be
connected using a wye connection such as a "low wye" or a "high wye"
connection. The inner race
slots can also contain induction coils of a three-phase generator wherein the
first phase 2015, the
second phase 2017 and the third phase 2016 which can also use a wye connection
such as a "low
wye" or "high wye". The rotating north -south - north - south pole energy is
separated by areas of
magnetic void between each pole as is represented in FIG. 21A. In one
embodiment, the four pole
electromagnetic dual slot rotors 2002 in the outer race and electromagnetic
slot rotors 2010 in the
inner race are only turned on, energized or excited as they rotate past the
wire slots, the depiction
represents activation by the outlined magnetic poles. The dual slot rotors
2002 represented in FIG.
21A may be four pole electromagnetic slot rotors, or two pole electromagnetic
rotors or unipole
electromagnetic rotors. The unipole is pulsed 60 times per second north and 60
times per second
south for 60 Hz current and pulsed 50 times per second north and 50 per second
south for 50 Hz
current generation.
[00241] To better understand the exemplary dual stator and slot rotor pair
structure and operation, a
description is provided that encompasses each magnetic section of the stator
and the slot rotors
during an instant of rotation. The term covered as used herein below refers to
various states whereby
a particular slot rotor pole is in full or partial alignment with the
underlying wire slot as it rotates by
and past the slot. Each slot is shown with a corresponding slot number shown
inside the slot in
brackets such [1] through [48]. With reference again to FIG 21A, as can be
seen, slot [45] is covered
by a north pole which can be energized or otherwise activated as is
represented by a solid state of the
pole coloring nearest the slot in the case of the quadrapole. In the case of
the preferred embodiment,
the unipole, the entire rotor would be colored when turned on as in this
example. Proceeding
counterclockwise, slot [46] is covered by an activated magnetic pole or as in
slot [47], [48], [1], [2],
[3], and [4]. An indication that all eight wire slots are receiving magnetic
flux from the activated slot
53
CA 02873973 2014-11-18
rotor is provided by the solid state of the pole coloring or shading. The arc
2018 refers to the span of
north pole #1. Continuing counterclockwise on FIG. 21A, the rotors 4 covering
slots [S], [6], [7], [8]
are not excited and therefore are not emitting any magnetic flux as is
indicated by the outline or
unshaded/uncolored state of the pole coloring.
[00242] Next excitation of south pole #1 begins, the slot rotors that cover
slots [9], [10], [11], [12],
[13], [14], [15], and [16] are excited as is indicated by the solid state of
the pole coloring. The arc 19
refers to the span of south pole #1. Continuing counterclockwise, the slot
rotors that cover slots [17],
[18], [19] and [20] are not excited and therefore are not emitting any
magnetic flux as is indicated by
the outlined state of the pole covering. Next, excitation for north pole #2
begins. The rotors that
cover slots [21], [22], [23], [24], [25], [26], [27] and [28] are excited as
is indicated by the solid state
of the pole coloring or shading. The arc 20 refers to the span of north pole
#2. Continuing
counterclockwise in FIG. 21A, the rotors covering slots [29], [30], [31], and
[32] are not excited and
therefore not emitting any magnetic flux as is indicated by the outline state
of the pole coloring or
shading. Next excitation of south pole #2 begins. The rotors which cover slots
[33], [34], [35], [36],
[37], [38], [39] and [40] are excited as is indicated by the solid state of
the pole coloring or shading.
The arc 2021 refers to the span of south pole #2. Continuing counterclockwise
in FIG 21A, the
rotors covering slots [41], [42], [43] and [44] are not electrically excited
and therefore are not
emitting any magnetic flux as is indicated by the outlined state of pole
coloring.
[00243] When the pole rotors 2003 and 2009 begin to rotate in a synchronous
fashion, four spans of
actively excited slot rotors and corresponding magnetic poles distributed
around the outer and inner
circumference of the stator each occupy approximately 60 of the total stator
circumference. The
active spans are interspaced with four magnetically void segments
corresponding to the slot rotors
that are not actively excited that each occupy approximately 30 of the stator
circumference. It
should also be noted that in accordance with the embodiments, the dual slot
rotors rotate in opposite
directions such that the poles rotating over the inner slots 2116 and the
outer slots 2030 are
synchronized. When the poles are in position, they can be turned on
simultaneously such that the
north pole flux lines from one are synchronized with the south pole flux lines
from the other and
magnetic coupling is completed there between. The resulting magnetic flux
excites the stator
induction coils while experiencing very little resistance due to counter EMF
produced as the
magnetic arc transverses the circumference of the stator. The rotational
torque of the slot rotors
approximates that of the separation forces in a mechanical gear system.
[00244] It will be appreciated that in order to control the application of the
current to the various slot
54
CA 02873973 2014-11-18
rotor armatures, various means can be used both to synchronize rotation and
energize the slot rotor
armatures. For example, commutator arrangements can be used to selectively
apply current to the
slot rotor armatures at the appropriate time as the slot rotors synchronously
rotate about their
respective axis. Alternatively, the application of current can be controlled
by a computer, processor,
controller or other suitable logic device as would be appreciated to control
the application of current
to the slot rotor armatures and to accomplish current control for output
voltage and current
regulation purposes. Such a controller can make corrections at a rate much
higher than the rotational
rate of the slot rotors and thus can apply a degree of high resolution control
that would be more
difficult with the commutator arrangement. Also including in any such rotation
and excitation
control circuit is a current recovery circuit. As the current in the slot
rotors is turned off, the
excitation field in the rotor collapses sending a pulse of current in the
opposite direction, which is
returned to a battery through a diode circuit such that a reduced amount of
power is consumed by the
excitation of the slot rotors.
[00245] In accordance with various exemplary embodiments, and in particular, a
48 slot
embodiment, all of the slot rotors in the outer race and inner race of the
stator can be connected in a
permanent positional relationship through the transmission which is driven by
a driver motor or
other driving element. The synchronous rotation of the outer race slot rotors
and the inner race slot
rotors allows the generation of an arc of induction flux across the aligned
wire slots of the outer race
and in the inner race. The synchronization is such that at any one instant, 8
slot rotor pairs generate
an arc of north pole flux in 8 corresponding slots of the outer race and an
arc of south pole flux in 8
aligned slots in the inner race. The physical makeup of the slot rotors and
the induction coils in the
outer race and the inner race are identical. However, it will be noted that
rotational relationship of
the inner slot rotors to the inner race slots is offset by 90 as, by example,
but not confined to90 ,
compared to the rotational relationship of the outer slot rotors to the outer
race slots.
[00246] With further reference to an embodiment, for example, as depicted in
FIG. 21A, it is noted
that the 3 phase induction of the outer race are wound in the same fashion as
the 3 phase induction
coils of the inner race slots, however north pole #1 (22) is rotated 90
counterclockwise when
compared to the north pole #1 (18) of the outer race. It will be further noted
an exemplary mu metal
magnet shield 2008 is shown, for illustrative purposes, as being placed over
the inner race slot rotor
of slot #4 as is the shielding 2006 over the outer race slot rotor of slot #4.
In accordance with an
embodiment, though not shown, the shielding will be placed over each of the 96
rotors of both the
inner race and outer race to minimize flux leakage between the rotors and the
stator sections.
CA 02873973 2014-11-18
[00247] As previously noted, an exemplary generator can be configured for 3
phase, 2 phase, single
phase alternating current (AC) and direct current (DC) power generation. In
the present example, a 3
phase AC current implementation is shown. Accordingly, a depiction of the
internal wiring
connections of the 3 phase 4 pole 12 coil generator is shown in FIG 21B for
both the outer race
windings and the inner race windings. As would be readily appreciated by one
skilled in the art, the
illustrated hookup is referred to as a "high wye" connection. More
specifically, in a "high wye"
connection, each phase can be configured to include two winding circuits which
may be connected
in series and produces 480 volts or the like. Alternatively, the two of the
winding circuits may be
connected in parallel and can be referred to as a "low wye" connection. While
a "low wye"
configuration produces 240 volts, the current output can be doubled as
compared with the "high
wye" such that the power output is the same for each hookup. These same hookup
arrangements may
produce different voltages in other sizes of generator depending upon the
winding and flux into the
slots, however this example is illustrative and not confining.
[00248] Following the phase circuits from the power output leads through the
circuits to the neutral
"wye" connection for the outer race windings and the inner race windings, and
with initial reference
to the outer race, phase A leg 2033 includes coil group 2038 wound in a
counterclockwise or north
pole (N) direction. Input is at circle 1(D) and output is circle 4. The output
lead 2069 connects with
coil group 2041, wound in a clockwise or south pole (S) direction with an
input at circle land output
at circle 4. The output lead 2072 connects with coil group 2044, wound in a
counterclockwise (N)
direction with an input at circle 7 and an output at circle 10. The output
2075 connects with coil
group 2047 wound in a clockwise (S) direction with input at circle 7 and
output at circle 10. The
output lead 2078 connects with lead 2066 at the central "wye" connection 2062
with the other two
phases.
[00249] Phase B leg 2035 includes coil 2040 wound in a counterclockwise (N)
with an input at
circle 2 and an output at circle 5. The output lead 2071connects with coil
group 2043 which is
wound in a clockwise direction (5) with an input at circle 2 and output on
circle 5. The output lead
2074 connects to coil group 2046 wound in a counterclockwise (N) direction
with an input at circle 8
and an output at circle 11.The output lead 2077 connects to coil group 2049
which is wound in a
clockwise (S) direction with an input at circle 8 and an output at circle 11.
The output lead 2080
connects with lead 2067 making up a portion of the "wye" connection at 62.
[00250] Phase C leg 2035 connects to coil group 2042 wound in a
counterclockwise (N) direction
with an input at circle 3 and an output at circle 6. The output lead 2073
connects to coil group 2045
56
CA 02873973 2014-11-18
wound in a clockwise (S) direction with an input at circle 3 and an output at
circle 6. The output lead
2076 connects to coil group 2048 wound in a counterclockwise (N) direction
with an input at circle 9
and an output at circle 12. The output lead 2079 connects to coil group 2039
wound in a clockwise
(S) direction with an input at circle 9 and output at circle 12. The output
lead 2070 connects to
conductor 2068 which forms the third leg of the "wye" connection 2062.
[00251] With reference now to the inner race windings, phase A2 leg 2034
connects to coil group
2050 wound counterclockwise (N) direction with an input at circle land an
output at circle 4. The
output lead 2081connects to coil group 2053 wound in a clockwise (S) direction
with an input at
circle land output at circle 4. The output lead 2084 of the two coil groups
connects to coil group
2056 wound in the counterclockwise (N) direction with an input at circle 7 and
an output at circle
10. The output lead 2087 connects to coil group 2059 wound in a clockwise (S)
direction with an
input at circle 7 and an output at circle 10. The output lead 2090 connects to
conductor 2063 which
connects with the "wye" connection 2062 with the other two phases.
[00252] Phase B2 leg 2036 connects with coil group 2052 wound in a
counterclockwise (N)
direction with an input at circle 2 and an output at circle 5. The output lead
2083 connects to coil
group 2055 wound in a clockwise (S) direction with an input at circle 2 and an
output at circle 5. The
output lead 2086 connects to coil group 2058 wound in a counterclockwise (N)
direction with an
input at circle 8 and an output at circle 11. The output lead 2089 connects to
coil group 2061wound
in a clockwise (S) direction with an input at circle 8 and an output at circle
11.The output lead 2090a
connects to neutral lead 2064 which connects to the "wye" connection 2062.
[00253] Phase C leg 2038 connects with coil group 2054 wound in a
counterclockwise (N) direction
with an input at circle 3 and an output at circle 6. The output lead 2085
connects to coil group 2057
wound in a clockwise (S) direction with an input at circle 3 and an output at
circle 6. The output lead
2088 connects to coil group 2060 wound in a counterclockwise (N) direction
with an input at circle 9
and an output at circle 12. The output lead 2091connects to coil group
2051wound in a clockwise (S)
direction with an input at circle 9 and an output at circle 12.The out lead
2082 connects to conductor
2065 which forms a third leg of the "wye" connection 2062.
[00254] With the above described spacing of the inner race windings and the
outer race windings
and the internal connections, three phase power can be generated with the
phase legs separated
electrically by 120 , when an exemplary four pole rotating magnetic field with
60 of coverage of
the stator with each pole and a 30 segment of no magnetic field between each
60 pole is employed
57
CA 02873973 2014-11-18
and rotated at the proper speed from the dual slot rotors of the described
embodiments.
[00255] With reference to FIG 21C, a depiction of the actual coil groups which
are represented
diagrammatically in FIG 21B is shown. The input and output wires for each
wound coil group in
FIG 21C correspond to the same numbers as represented in FIG 21B.The
correspondence can be
described as follows: Phase A coil group #1 input wire #1-2092, output wire #2-
2093; Phase C coil
group #1 input wire #3-2115, output wire #4-2094; Phase B coil group #1 input
wire #5-2095, output
wire #6-2096; Phase A coil group #2 input wire #7-2097, output wire #8-2098;
Phase C coil group
#2 input wire #9-2099, output wire #10-2100; Phase B coil group #2 input wire
#11-2101, output
wire #12-2102; Phase A coil group #3 input wire #13-2103, output wire #14-
2104; Phase C coil
group #3 input wire #15-2105, output wire #16-2106; Phase B coil group #3
input wire #17-2107,
output wire #18-2108; Phase A coil group #4 input wire #19-2109, output wire
#20-2110; Phase C
coil group #4 input wire #21-2111, output wire #22-2112; Phase B coil group #4
input wire #23-
2113, output wire #24-2114.
[00256] It will be appreciated that the above detailed description provides
the ability to easily
transpose the internal hookup diagram shown in FIG 21B to an actual exemplary
wire hookup of
wound three phase coils of an embodiment. The winding depicted in FIG 21D, as
in FIG 21B, is a
three phase four pole winding with four coil groups per phase and are
counterclockwise lap wound.
[00257] With reference to FIG 21D, Phase A leg 3092 is connected to coil group
3038-A wound in a
counterclockwise (N) direction with an input at circle land an output at
circle 4. The output lead
3093 connects to coil group 3041-A which is wound in a clockwise (S) direction
with an input at
circle land an output at circle 4. The output lead of these two coil groups
3097 connect to coil group
3044-A wound in a counterclockwise (N) direction with an input at circle 7 and
an output at circle
10. The output lead 3104 connects to coil group 3047-A wound in a clockwise
(5) direction with an
input at circle 7 and output at circle 10. The output lead 3109 makes up in
the "wye" connection
3062 with the other two phases.
[00258] Phase B leg 3095 connects with coil group 3040-B wound in a
counterclockwise (N)
direction with an input at circle 2 and an output at circle 5. The output lead
3096 connects to coil
group 3043-B wound in a clockwise (S) direction with an input at circle 2 and
an output at circle 5.
The output lead 3101 connects to coil group 3046-B wound in a counterclockwise
(N) direction with
an input at circle 8 and an output at circle 11.The output lead 3108 connects
to coil group 3049-B
wound in a clockwise (S) direction with an input at circle 8 and an output at
circle 11. The output
58
CA 02873973 2014-11-18
lead 3113 connects to a portion of the "wye" connection 3062.
[00259] Phase C leg 3099 connects to coil group 3042-C wound a in a
counterclockwise (N)
direction with an input at circle 3 and an output at circle 6. The output lead
3100 connects to coil
group 3045-C wound in a clockwise (S) direction with an input at circle 3 and
an output at circle 6.
The output lead 3105 connects to coil group 3048-C wound in a counterclockwise
(N) direction with
an input at circle 9 and an output at circle 12. The output lead 3112 connects
to coil group 3039-C
wound in a clockwise (S) direction with an input at circle 9 and an output at
circle 12. The output
lead 3115 connects to "wye" connection 3062.
[00260] FIG. 21E illustrates an internal race winding of the stator 2117 with
a three phase four pole
clockwise lap winding with four coils per phase. The slots 2116 contain slot
insulation as well as
insulation between the phase coils. Phase A coils 2120 are depicted in blue,
Phase C coils 2119 are
depicted in brown, and Phase B coils 2118 are depicted in red.
[00261] Although the forgoing depiction discussed four pole slot rotors, the
preferred embodiment is
a unipole rotor. The unipolar rotor is wound such that the entire 360 rotor
surface is either north
pole or south pole depending upon the direction of the current flow through
the windings. The
unipolar rotor has only two leads and the direction of current flow is
controlled by a gating
mechanism within the solid state excitation cards.
[00262] FIG 22 is a depiction of a cross-section of a dipole slot rotor pair
and stator segment.
Laminated steel stator segment representing outer circumference segment 4134
and inner
circumference segment 4124 of the dual stator slots. The outer circumference
slot 4131and the inner
circumference slot 4125 contain conductors which make up the induction coils
of the outer
circumference induction windings and the inner circumference induction
windings. The back iron
consists of common laminate steel 4134a and 4124a which are common to both the
outer
circumference slot 4131and the inner circumference slot 4125. Outer
circumference slot rotor 4141
rotates on shaft 4140 which is driven by a gear and transmission mechanism or
individual slot rotor
variable speed motor. Slot pole rotor 4141south pole is generated by copper
wire coil 4138 as DC
current is fed into coil through a slip ring to conductor 4142 and current
returns through conductors
4137 to slip ring and power supply which is controlled by sequencing solid
state excitation boards.
[00263] Slot pole rotor 4141north pole is generated by copper wire coil 4136
as a DC current is fed
into the coil through a slip ring to conductor 4143 and current returns
through conductor 4135 to slip
59
CA 02873973 2014-11-18
ring and power supply which is controlled by a sequencing solid state
excitation board. Inner
circumference slot rotor 4127 rotates on shaft 4119 which is driven by a gear
and transmission
mechanism or an individual slot rotor variable speed motor. Slot pole rotor
4122 south pole is
generated by copper wire coil 4128 as a DC current is fed into the coil
through a slip ring to
conductor 4129 and the current returns through conductor 4123 to slip ring and
power supply which
is controlled by sequencing the solid state excitation boards. Slot pole rotor
4122 north pole is
generated by copper wire coil 4117 or a DC current is fed into the coil
through a slip ring to
conductors 4118 and the current returns through conductor 4120 to slip ring
and power supply which
is controlled by sequencing via the solid state excitation boards. As the
sequencing system rotates
the dual rotors, north pole in one rotor and south pole in the opposite rotor
facing the dual stator
slots, magnetic coupling occurs between the two poles (North+-+ South) through
the air, the side
iron 4132 and 4124 as well as the back iron 4134a and 4124a. This magnetic
flux 4133, 4130 and
4126 pushes electrons in the appropriate direction and generates significant
voltage. The side iron
and back iron greatly enhances the magnetic coupling and thereby enhances
power production. The
rotor magnetic poles are shielded and separated from the stator inductive
poles by mu metal shield
4139 on the outer circumference and shield 4121 on the inner circumference.
[00264] FIG 23 is a diagram illustrating a dual pole embodiment of an
exemplary unipolar
alternating lead (alternates North pole+-+ South pole) electromagnetic slot
rotor including pole
windings, mu metal shielding around the rotors and further illustrating a wire
slot containing
conductors along with side iron and back iron to enhance the flux linkage
between the north and
south pole rotors such that the moving magnetic flux permeates the conductors
contained within the
wire slots. The outer circumference rotor 4158 of the slot rotor pair rotates
on shaft 4148 in close
proximity to wire slot 4155 which is contained in laminated steel stator outer
circumference 4156.
Rotor 4158 is shielded from the stator inductive poles by geometric location
and mu metal shield
4161. The inner circumference rotor 4146 of the slot rotor pair rotates on
shaft 4148 in close
proximity to wire slot 4152 which is contained in laminated steel stator inner
circumference 4151.
Unipolar rotors 4158 and 4146 are lap wound with a single coil with a span
which allows the
greatest flux density. The unipolar rotors as described herein are lap wound
with a single coil and 2
leads (an alternating(+) positive and(-) negative lead). The solid state
excitation system reverses the
direction of current flow in the leads every other excitation cycle, such that
the rotor which exhibits
north pole for 360 then south pole 360 . Therefore the frequency is
controlled by the excitation
system and generated power frequency is independent of the speed of the rotor.
As will be seen in
FIG 24 the mu metal shields 4161 and 4144 are preferably surrounded by
laminated electric steel
CA 02873973 2014-11-18
such that a magnetic bearing effect aids in stabilizing the rotors at high
speed. This laminated steel
tunnel is homogenous for 3600 of rotation, and without magnetic poling
therefore no drag occurs
secondary to attraction of the rotor poles spinning within the laminated steel
tunnel. When the inner
circumference stator rotor is activated south pole, the outer circumference
slot rotor is activated
north pole. The magnetic flux generated between the north pole and south pole
allows magnetic
coupling through the air gap along with the side iron and shared back iron.
Magnetic flux 4155
couples with magnetic flux 4152 through back iron 4153 and permeates the
conductors in wire slot
4154 and 4150. Thereby, creating voltage which becomes electric power when the
coils are
connected to an electric load and current begins to flow.
[00265] FIG 24 is a diagram illustrating the formation of the closed laminated
steel tunnel formed on
the outer stator circumference. This is a depiction of a single outer stator
circumference rotor single
pole embodiment of an exemplary alternating lead (north +-+ south)
electromagnetic slot rotor
including pole windings, mu metal shielding and laminated steel around the
rotors with a laminated
steel mu metal shield cover which forms uniform laminated steel around the
unipole rotor giving a
magnetic bearing effect. Laminated steel stator segment 4172 contains wire
slot 4171which contains
induction coil wire 4170 which are put into the slot through slot opening
4169. Rotor 4173 is a
unipolar rotor with a continuous lap wound coil 4145 with only two leads in
which the current flow
direction is controlled by a switching mechanism in the excitation cards. The
rotor contains eddy
current discharge rods 4174 and 4164. The rotor is rotated on shaft 4148 and
is rotated by a gearing
mechanism or a single driver, variable speed motor. The rotor is surrounded by
mu metal shield
4166 and is retained by laminated electrical steel mu metal shield cover 4162
which is attached to
the stator by retention rod 4163.
[00266] FIG 25 is a diagram illustrating a depiction of a cross section of an
8 slot stator, rotor, inner
mu metal shield covers, outer mu metal shield covers of a preferred
embodiment. Laminated stator
cross section 4177 contains outer circumference rotor cavities 4229 and inner
circumference stator
cavity 4228. The outer circumference rotor cavities contain induction wire
slots 4184. The inner
circumference rotor cavities contain induction wire slots 4183. The rotor
cavities are lined with mu
metal shields with openings in the shield over the wire slots. The outer
circumference rotor cavities
contain mu metal shields 4144, the inner circumference rotor cavities contain
mu metal shields
4144a. Laminated stator 4177 contains support post holes 4179, air ventilation
holes 4233 and
torsion bolt holes 4176 and mu metal shield covers. Outer circumference mu
metal shield covers
4162 are made of laminated steel, laminated in the same orientation as the
stator. The texture of
61
CA 02873973 2014-11-18
shield covers 4162 in the FIG 25 appear different to the stator, however this
difference is only to
contrast the shield covers to the stator. The mu metal shield covers are held
in place by retention
bolts 4163 which attach to the stator iron in slot 4175. The inner
circumference mu metal shield
covers 4180 are in one piece of laminated steel, which is laminated in the
same orientation as the
stator laminates. The said inner circumference mu metal shield contains a
ventilation hole 4181and
attaches to stator laminate 4177 via attachment means 4178. The laminated
stator 4177 presents in
the area of each induction wire slot a region of functional side iron 4232
which is not covered by the
mu metal shields by intentional design. Shared back iron 4231 is present
between the outer
circumference rotor slot 4229 and the inner circumference rotor slot 4228. In
one example of the
functioning of the stator rotor mechanism in FIG 25 which represents one of
the two north- south
cycles of the unipolar rotor. Rotor (1) and Rotor (S) forms magnetic flux
linkage across the side iron,
wire slots and shared back iron. Similar flux linkages occur between Rotor (2)
and Rotor (6), Rotor
(3) and Rotor (7) and Rotor (4) and Rotor (8). When these rotors are rotated
by a transmission or
individual slot rotor motors with the proper magnetic flux density, speed and
north - south
excitation, power is generated in the induction coils in slots 4184 and 4183.
[00267] There are 4 outer stator circumference slots and 4 inner stator
circumference slots. The
induction coils are lap wound and connected in series for the outer
circumference coils and for the
inner circumference induction coils. The power output is single phase AC in
this particular
arrangement. If 3 stators are employed in which the rotors in the separate
stators are fired 120 out of
phase with one another and the neutral leads from each stator are connected
together, 3 phase power
will be produced. If the rotors are continuously rotated with the same
polarity DC (direct current)
will be produced. The rotors 4182 rotate on shaft 4148 in a bearing
containment means and are
rotated by a transmission and drive motor or eight individual rotor drive
motors driven by a common
variable speed drive. The structure as depicted in FIG 25 completely
eliminates any electro-magnetic
drag either by destructive flux linkage between any stator components
including the induced stator
poles, which occur when the induction coils are connected to an electric load.
The kinetic energy
required to drive the system is the same in the unloaded state, loaded state
or at variable loads. The
only energy required is that required to turn the mechanical mechanism.
[00268] FIG 26 is a diagram illustrating a depiction of a cross section of a
24 slot stator, rotor, inner
mu metal shield covers, and outer mu metal shield covers of a preferred
embodiment. Laminated
stator cross section 4177 contains outer circumference rotor cavities 4229 and
inner circumference
rotor cavities 4228. The outer circumference rotor cavities contain induction
wire slots 4184, 4185
62
CA 02873973 2014-11-18
and 4186. The inner circumference rotor cavities contain induction wire slots
4183, 4187 and 4188.
[00269] The rotor cavities are lined with mu metal shields with openings in
the shield over the wire
slots. The outer circumference rotor cavities contain mu metal shields 4144,
the inner circumference
rotor cavities contain mu metal shields 4144a. Laminated stator 4177 contains
support post holes
4179, air ventilation holes 4230, torsion bolt holes 4176 and mu metal shield
covers. Outer
circumference mu metal shield covers 4162 are made of laminated steel,
laminated in the same
orientation as the stator. The texture of shield covers 4162 in FIG 26 appears
different to the stator,
however this difference is only to contrast the shield covers by way of
differentiation to the stator.
The mu metal shield covers are held in place by retention bolts 4163 which
attaches to the stator iron
in slot 4175.
[00270] The inner circumference mu metal shield covers 4180 are in one piece
of laminated steel,
which is laminated in the same orientation as the stator laminates. The said
inner circumference mu
metal shield cover contains a ventilation hole 4181and attaches to stator
laminates 4177 via
attachment means 4178. The laminated stator 4177 presents in the area of each
induction wire slot a
region of functional side iron 4232 which is not covered by the mu metal
shields by design. Shared
back iron 4231 is present between the outer circumference rotor slots 4229 and
in the inner
circumference rotor slots 4228.
[00271] In one example of the functioning of the stator rotor mechanism in FIG
26 is noted that the
activation of the rotors are electrically 180 out of phase when compared to
FIG 25. This example in
FIG 26 represents the opposite south - north cycles of the unipolar rotor.
Rotor (1) and Rotor (5)
forms a magnetic flux linkage across the side iron, wire slots and shared back
iron. Similar flux
linkages occurs between Rotor (2) and Rotor (6), Rotor (3) and Rotor (7) and
Rotor (4) and Rotor
(8). When these rotors are rotated by a transmission or individual slot rotor
motors with the proper
magnetic flux density, speed along with north - south excitation, electric
power is generated in the
induction coils in slots 4184, 4185, 4186, 4183, 4187 and 4188. There are 12
outer circumference
stator slots and 12 inner circumference stator slots. The induction coils are
lap wound and connected
in series for the outer circumference induction coils and for the inner
circumference induction coils.
The power output is single phase AC in this particular arrangement. If 3
stators are employed in
which the rotors in the separate stators are fired 120 out of phase with one
another and the neutral
leads from each stator are connected together, 3 phase AC power will be
produced. If the rotors are
continuously rotated with the same polarity, DC (direct current) will be
produced. The rotors 4182
rotate on shaft 4148 in a bearing containment means and are rotated by a
transmission and drive
63
CA 02873973 2014-11-18
motor or eight individual rotor drive motors all driven by a common variable
speed drive. The
structure as depicted in FIG 26 completely eliminates any electromagnetic drag
either by destructive
flux linkages between any stator components including the induced stator poles
which occur when
the induction coils are connected to an electric load. The kinetic energy
required to drive the system
is the same in the unloaded state, loaded state or at variable loads. The only
energy required is that
required to turn the mechanical mechanism.
[00272] FIG 27 is a diagram illustrating a unipolar rotor and slip ring of a
preferred embodiment.
Rotor body 4146 is made of laser cut disc of 0.34mm annealed electrical steel
which is stacked on a
jig, pressed and dipped in motor insulation varnish. The shaft 4148 is then
pressed into the
laminates. Slip ring 4189 is placed on shaft 4148. Eddy current rods 4164 are
pressed through the
entire length of the laminates and permanently attached at each end of the
rods. The rods are
electrically connected to the slip ring through conductors 4164a. The rotor is
then insulated and
wound with insulated copper magnet wire in a lap wound fashion with the
greatest possible coil
span. The two leads 4188 are connected to the N/S slip rings.
[00273] FIG 28 is a depiction of a cross section of a stator of one of the
preferred embodiments
revealing the stator iron, stator windings, unipole rotors, mu metal shields
and mu metal shield
covers. This cross section of stator 4177 reveals major geometric and
shielding issues which allow
the generator to operate with little to no drag forces i.e. low positive
torque. It is good to place torque
of this machine into the proper perspective. It will be noted that at constant
speed, the generator shaft
torque is the only variable in relation to horsepower (HP) required to turn
the generator shaft at
constant speed such that the proper speed and in the case of a 2 pole or 4
pole proper frequency is
maintained. However in the case of the unipole, the frequency is determined by
the excitation boards
and not altered by speed.
[00274] HP= Torque (FT lbs) x Speed (rpm)/5252
[00275] A computer model of an exemplary generator in embodiments, reveals
that this generator
requires essentially the same torque to turn the shaft in the electrically
loaded and unloaded state
and/at various loads. The mechanical forces are related to mechanical
resistance (i.e. torque)
required to turn the mechanical mechanism and to compensate for the attraction
of the magnetic
rotors to the iron in the rotor cavities of the stator 4228 and 4229. However,
in the case of this
preferred embodiment, the unipolar rotor and the laminated electrical steel mu
metal shields
completely remove these attraction forces. The unipolar rotors and homogenous
stator laminated
64
CA 02873973 2014-11-18
steel rotor cavities 4228 and 4229 in combination function as a drag-free
magnetic bearing of sorts.
The other dominant forces which bring about very low electromagnetic drag
secondary to stator
electric load forces are the geometric positioning of the rotors some distance
removed from stator
magnetic poles 44a, 44b, 44c and 44d. Due to this geometric isolation of the
rotor magnet from the
stator magnetic field along with mu metal shielding 4144 around all rotors,
the rotor magnetic forces
are isolated from the stator magnetic forces. The stator coils associated with
inner-outer lead pairs
circle 1-2, circle 3-4, circle 5-6, circle 7-8, circle 9-10, circle 11-12,
circle 13-14, circle 15-16 are lap
wound and connected in series or in parallel. It is apparent from the figure
that there is an inner
stator winding and an outer stator winding. As will be noted the inner
circumference stator windings
are opposite in polarity to the outer circumference stator windings. The
opposite polarity between
inner circumference of the stator and outer circumference of the stator allows
for flux linkage in the
area of the support post 4179, which focuses magnet flux away from the rotor
cavities 4229 and
4228. This design characteristic also decreases any flux linkage that may
occur between the rotor
magnetic poles and the stator induced magnetic poles.
[00276] FIG 29 is a depiction of a superior oblique projection of a preferred
stator revealing the
rotor drive motors which are all controlled by a single variable speed drive.
This projection reveals
the stator 4177 which is supported by end support members 4190. Induction
coils 4196 are revealed
on the proximal end of the stator. Outer circumference rotors 4146 are
revealed as are the outer
circumference rotor mu metal shield covers 4162. The support plates 4190 are
held in place and
support the stator via torque support means 4197. The rotors are rotated at
the desired speed via
individual slot rotor motors 4193. The motors are supported by support frame
4194. The motors are
powered by a variable speed drive 4191 through conductor cables 4192.
[00277] FIG 30 is a depiction of a schematic of the control and testing system
for the high efficiency
generator and comparison to standard generators. The high efficiency generator
is operated by a
computer controlled system with master control, programmable logic centers and
solid state rotor
excitation system. The efficiency of the generator is determined by monitoring
power input wall
supply 4213 which enters power box 4216, where voltage, amperage and wattage
into the system are
measured. The output from generator 4210 (HEG) is fed via conduit 4200a to
generator junction
panel 4218. A voltage meter and current loop inside the Generator Junction
Panel are connected to
display screen on the master control panel 4217. Conductor 4200 carries power
to the programmable
load cell control panel. Power is sent to the load panel via a computer
program cycle or manually.
The load in increased until voltage drop on the system occurs. The two
reference generators are
CA 02873973 2014-11-18
tested in the same manner. That is total power input is measured and total
power output to the load
cell is measured. In the case of the two kW single phase generator 4205, it is
driven by an electric 3
phase motor 4206 which is controlled by a variable speed drive 4191. Power
output is then measured
by the load bank controller panel meters as circuits are opened through
conduit 4223 to load cell
4198. Total power input from wall 4213 is measured and recorded from the power
box 4216 via volt,
amp, watt meters as it passes through the power box en route to a variable
speed drive (VSD) 4191.
[00278] In the case of the 25 kW single phase generator 4208, it is driven by
an electric 3 phase
motor 4207 which is controlled via the VSD 191. Power output is then measured
by the load bank
controller panel meters as circuits are opened through conduit 4223 to load
cell 4198. Total power
input from wall 4213 is measured and recorded from power box 4216 via volt,
watt, amp meters as it
passes through the power box en route to the VSD.
[00279] The HEG 4210 in FIG 30 is an illustrative representation only. More
details may be
presented in the preceding figures. The driver motor 4209 is controlled by the
VSD which receives
an input single from a rotor encoder through a PLC (programmable logic center)
to control speed. A
position sensor on one of the rotor end shafts sends a signal to the
excitation controller panel which
sends a signal to the solid state excitation board which triggers the
excitation board to send a DC
electrical pulse at the proper time to the coils of the wound electric rotor
(FIG 27). Power input and
output are measured in the same manner as in the case of generators 4205 and
4208. The power for
the HEG can come either/or from the wall 4213 or from the Uninterruptible
Power Supply 4211.
[00280] FIG 31 is a diagram illustrating an oscilloscope tracing of the
excitation current and voltage
from two of the excitation cards which power the rotor coils. Tracing 4224
represents the voltage
tracing which in this illustration is on for 180 of the rotational cycle.
Tracing 4225 represents the
amperage from the same 180 firing angle. Tracing 4226 represents the voltage
from a second card
and 4227 represents the amperage from the same card.
[00281] FIG 32 is a diagram illustrating an exemplary configuration for the
magnification of electric
power through a standard electric motor driving an electric generator of
higher efficiency than the
electric drive motor. Electric power is initially taken from the power grid
4228 in an illustrative
amount of approximately 7.46 kW through electrical conduit 4231, such as a
wire conductor, busbar
or the like to drive motor 4233 having an illustrative rating of 10 hp. Motor
4233 is configured to
drive a high efficiency (HE) generator such as generator 4235 through a shaft
4232 to produce an
illustrative 25 kW of electric power. In the example, approximately 10.08 kW
of output of generator
66
CA 02873973 2014-11-18
4235 can be fed back to the power grid, while approximately 7.46 kW is fed to
each of two 10 hp
drive motors 4237 and 4239 respectively, through electrical conduit 4236 and
electrical 4234 from
generator 4235 constituting a net gain due to the multiplier effect (ME)
between the first high
efficiency generation stage and the subsequent high efficiency generation
stage. Electric motor 4237,
in turn, drives another HE generator 4238 to generate 25 kW of energy to feed
back to the power
grid through electrical conduit 4230. Electric motor 4239 drives HE generator
4240 to generate 25
kW of power to feed back to the power grid through electrical conduit 4241 and
electrical conduit
4229. The operation of HE generators 4238 and 4240 constitute a second stage
of gain due to the
multiplier effect ME.
[00282] FIG 33 is a diagram illustrating a high efficiency electric generator
HE, a hydrogen
generator, and a hydrogen driven standard drive engine. In the example, a 20
hp internal combustion
engine 4243 can be configured to drive HE electric generator 4242, which in
turn, drives a hydrogen
generator 4250, to thereby provide electric power through the feedback
utilization of the efficiency
gains. The 20 hp hydrogen-fueled internal combustion engine 4243 can be
operated through control
panel 4244 and fueled by hydrogen generator 4250 and contained in storage tank
4249 through the
hydrogen conduit line 4245 into hydrogen-fueled internal combustion engine
4243. The hydrogen-
fueled internal combustion engine 4243 drives 50 kW HE generator 4242 that
feeds approximately
20 kW of power through electrical conduit 4248 to the hydrogen generator 4250
which in turn,
supplies, for example, gaseous hydrogen or the like, to the hydrogen storage
tank 4249 from which
the hydrogen is supplied to the hydrogen-fueled internal combustion motor
4243.
[00283] HE generator 4242 supplies an additional 20 kW of power via electrical
conduit 4246 to the
power grid 4266 via transformer 4265. HE generator 4242 supplies 7.46 kW of
electric power via
electrical conduit 4247 to a 10 hp electric motor 4255 that drives a 25 kW HE
generator 4256 for
supplying approximately 10 kW of power to the electric power grid 4266 via
electric conduit 4264
and transformer 4265. HE generator 4256 further supplies approximately 7.46 kW
to drive motors
4253 and 4262, respectively, through electrical conduits 4257 and 4258
constituting a net gain due to
the multiplier effect (Me). The 10 hp drive motors 4253 and 4262 drive 25 kW
generators 4259 and
4261, which, in turn, supply 25 kW of electric power via electrical conduit
4260 to the electric
power grid 4266 via transformer 4265 constituting an additional gain due to
the multiplier effect
(ME). HE generator 4261 sends 25 kW of electric power via electrical conduit
4263 to the electric
power grid 4266 via transformer 4265.
[00284] While the above described embodiments allow for the generation of
additional power
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CA 02873973 2014-11-18
through diversion of a portion of the HE generator output, in alternative
embodiments storage
devices can be used to store a portion of the surplus power generated as a
result of the gains in
efficiency.
[00285] FIG 34 illustrates the exemplary interaction of a HE electric
generator, such as HE
generator 4274, with a standard efficiency, electric driving motor such as
motor 4276, through a
bank of batteries, capacitors, electrical energy storage devices or the like
such as storage devices
4278 and 4279. In the present example electric motor 4276 can be a 10 hp 3
phase standard
induction motor driving a 25 kW HE generator 4274 through shaft 4273. HE
generator 4274
supplies10.08 kW through electrical conduit 80 to a full wave bridge rectifier
4277. The direct
current energy output from the full wave rectifier is then stored in storage
devices 4278 and 4279,
which output stored power, or a combination of stored power and converted
power, depending on
demand level, through electrical conduit 4282 to a variable frequency drive
4277a which can
convert the stored DC power to a square wave DC which is recognized as AC as
it drives a 10 hp 3
phase motor 4276 through electrical conduit 4281. HE generator 4274 outputs
about 7.46 kW of
power to 10 hp motors 4271and 4284 through electrical conduit 4275 and 4283
respectively. Two 10
hp motors 4271 and 4284 drive HE generators 4272 and 4286 which each put out
25 kW through
electrical conduit 4270 and 4285 respectively to the electric power grid or
for use at the point of
generation constituting a stage of gain due to the multiplier effect Me.
[00286] FIG 35 is a diagram illustrating a HE generator, a standard efficiency
electric driving motor,
and a hydraulic system with a nitrogen accumulator as a short term storage
energy supply. FIG 35
illustrates an exemplary interface between a HE electric generator such as HE
generator 4293, a
standard efficiency electric drive motor, a hydraulic system and a nitrogen
accumulator which serves
as a short term storage energy supply. HE generator 4293, which is a 3 phase
150 kW electric
generator, can output 100 kW of power through phase legs 4287, 4288, and 4289
to a load point or
can be fed to the electric power grid. The remaining power can be fed back and
used both in variable
frequency drive 4298a and rectifier 4314 to facilitate generation as will be
described in greater detail
hereinafter constituting stages of gain due to the multiplier effect (Me).
[00287] It will be noted that generator 4293 is driven by hydraulic motor 4290
that receives
hydraulic power, in the form of pressurized hydraulic fluid supplied through
hydraulic conduit 4292
from, for example, a hydraulic storage and pressure tank 4302 which contains a
nitrogen
accumulator 4302a. The nitrogen accumulator is pressurized by pressure pump
4309 which is driven
by DC motor 4308 to supply pressurized nitrogen gas to pressure tank 4302
through gas conduit
= 68
CA 02873973 2014-11-18
4304. In response to sensed pressure levels in the nitrogen accumulator 4302a,
DC power lines 4309
and 4310 of a motor power supply circuit can be opened and closed by nitrogen
accumulator 4302a
pressure switch 4303 through electric conduit 4305. DC motor 4308 is powered
from battery 4312,
for example, when the power lines 4309 and 4310 are switched on. Battery 4312
can be charged via
leads 4306 and 4313 from full wave bridge rectifier 4314 which is powered from
phase leg LI
through electrical conduit 4295 and neutral 4294. Hydraulic pressure tank 4302
can be charged by
pressurized hydraulic fluid entering through the hydraulic conduit 4301 and
pressurized by
mechanical pressure pump 4300, which receives return hydraulic fluid from
hydraulic motor 4290
through hydraulic conduit 4291. Mechanical pressure pump 4300 can be driven by
variable speed
electric motor 4299, which is powered through variable frequency drive 4298a
with 20 kW of the 3
phase power conducted from HE generator 4293 through 3 phase electrical
conduits 4296, 4297 and
4298.
[00288] FIG 36 is a diagram illustrating a HE electric generator, a standard
efficiency electric
driving motor, and a hydro storage system utilizing a motor pump, water
storage reservoir and
gravity flow through a generator turbine system. Water tower storage tank 4328
can provide water to
turbine 4329 that flows, for example, under gravitational pressure. Turbine
4329 can drive a 25 kW
HE generator 4330 which feeds 17.54 kW of 3 phase power back to water pump
4333 for pumping
waste water that has passed through turbine 4329, from receiving reservoir
4334 back to the water
tower reservoir 4328 through water conduit 4327. HE generator 4330 can also
send the remainder of
its output power, or 7.46 kW of electric power to 10 hp motor 4335 through
electrical conduit 4331.
Electric motor 4335 drives generator 4336, which generates 25 kW of electric
power to the power
grid 4315 through electrical conduit 4337 constituting a stage of gain due to
the multiplier effect
(Me). It will be appreciated that by supplying an illustrative 25 kW to the
power grid 4315, at a cost
of 7.46 kW, the hydro power configuration can perpetuate additional electric
systems due to the
combined multiplier effects (Me) associated with various efficiency gain
stages. For example,
considering the 25 kW input to power grid 4315 from HE generator 4336,
electric 10 hp motor 4321
takes 7.46 kW of power from the power grid 4315 through electrical conduit
4318 to power a 25 kW
HE generator 4320 constituting a gain stage. A resulting output of 10.08 kW of
power is supplied
back to the power grid 4315 through electrical conduit 4319. HE generator 4320
also supplies 7.46
kW of electric power to electric motor 4324 and 7.46 kW of electric power to
electric motor 4338
respectively, through electrical conduits 4322 and 4323. Electric motors 4324
and 4338 are
configured to drive 25 kW HE generator 4325 and 25 kW HE generator 4324
constituting additional
gain stages. The power output of HE generators 4325 and 4326 is transmitted to
the power grid 4315
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CA 02873973 2014-11-18
through electrical conduits 4316 and 4317.
[00289] FIG 37 is a diagram illustrating an automobile which utilizes the HE
(high efficiency)
generator. The HE generator in various embodiments may be used in an
automobile to provide the
motive force as one application but not limited to only that application. The
HE generator may be
placed underneath the hood or bonnet 4343 and reserve the trunk or boot 4339
for objects of
transport. The HE generator may alternatively be placed in the trunk or boot
4339 and reserve the
area underneath the hood or bonnet 4343 for objects of transport. The HE
electric power generator
could move the vehicle via traction motors in the drive train or directly in
the wheel 4340 and 4342.
[00290] FIG 38 is an illustration of an automobile which in this application
utilizes the HE generator
both as a motive source and to power a home, office and/or power grid from a
plug-in device in the
garage, commercial garage, street parking, parking lot and the like. The
automobile utilizing the HE
generator which is housed underneath the hood 4343 of the automobile with
traction motors in the
wheels 4349 and 4342 which provides the motive force. The automobile of FIG 38
is parked inside a
garage, carport or the like 4348. The automobile is in the non-motive mode
with the HE generator in
the power output mode for either single phase or 3 phase to be compatible with
the desired
application. Power conduit cable 4352 is plugged into receptacle 4353. Conduit
4354 carries power
to the power meter 4351 input to the house, where power is fed to the house,
office and the like
through conduit 4349 and to the electric power grid through conduit 4350.
[00291] FIG 39 is a diagram illustrating a train engine device which utilizes
the HE generator for
locomotion and other power needs of the train. Since trains in current use
operate by using diesel
power to power electric generators and the trains are moved by electric
traction motors 4347, the
conversion only requires installation of the generator in the areas currently
occupied by diesel
engines and diesel fuel storage tanks, such as, but not limited to, areas in
the engine of FIG 39
designated as 4345 and 4346.
[00292] FIG 40 is a diagram illustrating a water craft which utilizes the HE
generator. The craft
shown in FIG 40 is by example only and not limiting. The application is
applicable to boats of all
sizes, and modes of operations such as small craft, ships, submarines and the
like. The boat of FIG
40 is operated on electric power generated by diesel engines which power
electric generators. The
HE generator would replace the diesel powered generators in area 4344 by way
of example but not
limited to this area.
CA 02873973 2014-11-18
[00293] FIG 41 is a diagram illustrating a bus or similar vehicle which
utilizes the HE generator.
The HE generator is placed in area 4357 or 4355. The electric power provides
locomotion via
electric traction motors in the wheels 4356 or elsewhere in the power train.
Power is also provided
for other needs of the bus.
[00294] FIG 42 is a diagram illustrating an aircraft or similar flying machine
or like vehicle which
utilizes the HE generator. The HE generator is placed in an area 4359, for
example, but not limited
to this area. The power generated may be used to power electric propellers or
to compress ambient
air which is fed into the electric hot sections of a jet flying craft to
provide thrust. The compressed
air may be augmented by water which is fed into the "hot sections" where both
the compressed air
and water expands under the intense heat of the hot sections thereby providing
thrust.
[00295] FIG 43 is a diagram illustrating a transport truck or similar vehicle
which utilizes the HE
generator to provide locomotion and other power needs. The HE generator may
be, by example,
placed underneath the hood 4361, the area currently occupied by diesel or
other internal combustion
engines. This locomotion is by example and not limiting. The vehicle is
powered by traction motors
in the wheels or elsewhere on the drive train 4362 by example. The remaining
power needs of the
vehicle are also supplied.
[00296] While embodiments have been described and illustrated, it will be
understood by those
skilled in the art and technology concerned that many variations or
modifications in details of
design or construction may be made without departing from the present
invention. For example,
while high efficiency motors are described herein as powering standard
efficiency electric
generators, in an alternative embodiment, a high efficiency electric generator
can be driven with a
standard efficiency electric motor and thereby produce net increases in
electric power output to the
efficiency gains of the high efficiency configuration. If a high efficiency
electric motor drives a
high efficiency electric generator, even greater gains may be realized.
Further, while standard
motors are described herein as powering HE generators, in an alternative
embodiment, a standard
efficiency electric generator can be driven with a HE electric motor and
thereby produce net
increases in electric power output to the efficiency gains of the HE
configuration.
[00297] It is apparent to anyone schooled in the art that the technology
described herein has
numerous applications in addition to the power generation applications just
described.
[00298] In accordance with various exemplary embodiments discussed and
described herein, rotor
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CA 02873973 2014-11-18
reaction force i.e. electromagnetic drag may be reduced and eliminated in an
embodiment whereby a
series of rotatable, bipolar, quadrapolar or unipolar electromagnetic s,
electrical armatures, rotors,
and the like, can be diagnosed or otherwise inserted on their axis into
recesses in a stator in which
recesses may be completely surrounded by slots containing laminated electrical
steel which is wound
with coils of magnet wire or the like. The preferred embodiment provides
recesses in a stator in
which the rotors may be inserted which are geometrically isolated from the
center of the magnetic
poles which form in the stator as the stator coils are connected to an
electrical load, as an increasing
current flows through the stator coils. This geometric escalation reduces the
interaction between the
rotor and rotor magnetic field and in combination with unique winding patterns
along with mu metal
shielding greatly reduces or eliminates the motor reaction force or
electromagnetic drag. The
maximum induction flux density in the stator iron is obtained in accordance
with an embodiment
whereby the wire slots on an inner stator circumference and on an outer stator
circumference are
each provided with slot rotors forming an exemplary dual slot rotor pair. Also
dual stator
configuration is provided such that the stator side iron and back iron are
exposed to both rotors to
allow the desired magnetic coupling between the rotor iron and the stator iron
to generate the desired
magnetic movement across the conductors in the wire slots.
[00299] The following detailed description provides an understanding of
embodiments as illustrated
and described herein below. The high efficiency generator is provided that
shields, cancels or
separates the drag creating magnetic forces between the rotors and stator,
from one another so that
upwards of 80% of the driving energy which conventionally is consumed and/or
dissipated by
electromagnetic drag is converted to electric power.
[00300] In accordance with embodiments as will be described in greater detail,
in connection with
the illustrations below, the classic rotor armature and stator have been
replaced by a laminated
electrical steel dual stator having a stator section with an outer
circumference and stator sections
with an inner circumference. Each stator section has slotted rotor cavities as
in one example the rotor
cavities are geometrically spaced in a corner of a square or rectangle or the
like and are magnetically
coupled to the stator iron. The stator iron of the rotor cavities may contain
for example 18 wire slots
which may be wound such that when an electric load is applied to the
generator, lap coils in each
slot section carry current in opposite directions, thereby canceling any
destructive stator load poling.
[00301] Each slot rotor armature can be energized and the individual rotor
assembly can be rotated
to provide alternating fields of north and south pole magnetic flux field
energy into the open wire
slots and side iron in the stator and this flux field will magnetically couple
with the side iron and
72
CA 02873973 2014-11-18
back iron of the stator. The magnetic poles are activated with DC current via
a slip ring/brass and
solid state or mechanical commentator apparatus or other appropriate mechanism
such that the
magnetic poles are activated either continually or in pulsed fashion. In other
operational modes, the
rotor can be excited all north pole and/or all south pole to generate DC
current.
[00302] In an exemplary bipolar stator cavity rotor, one of the two pole
sections is north pole
charged and the opposite section is south pole charged. In one embodiment, the
north pole section
can be 180 and the south pole can be constituted by an opposite 180 section.
In another
embodiment, the rotor is unipolar i.e. the entire rotor is north pole for half
of the frequency cycle,
thus the current flow is reversed via the excitation controller and the entire
rotor becomes south pole
i.e. north pole then south pole for 360 . Pole sections can be shielded with
mu metal shielding
behind the back iron. Each of the slot rotor arrangements are preferably
contained in a longitudinal
cylindrical cavity that is located in a close proximity to and extends
lengthwise along the opening of
the stator winding slots. The slot rotor mechanism, including mu metal back
shielding can be
contained within a laminated electrical slotted steel cylinder of the rotor.
The steel cylinder is a
partial cylinder so as to allow installation of the stator windings and is
closed by use of a removable
slotted laminated electrical steel stator section. The cylinder has an opening
that corresponds and is
in communication with the opening of the stator wire slots.
[00303] It would be appreciated that the slot rotors may be fashioned, for
example, as wound
electromagnetic armatures or permanent magnet armatures that are positioned as
pairs of rotors
around the circumference of a dual wound stator. Different numbers of slot
rotor pairs can be used
preferably in even numbers such as 4, 8, etc. slot rotor pairs, which is by
way of example and
different numbers of slot rotor pairs or numbers unpaired can be used. An
individual slot rotor
armature may be made by fashioning a series of laminated steel pole pieces
upon a shaft in a manner
similar to that of a conventional generator armature. Completed pole pieces
may be wound in a
conventional manner with insulated wire to suitable winding specifications for
the operating
demands of the generator. Power can be applied to the armatures via a control
system.
[00304] To drive the shafts of the rotor mechanism, a central gear mechanism
may be employed at
one end of the individual slot rotor shafts over the inner and/or outer
circumference of the stator. As
the slot rotor pairs are rotated on both sides of the stator in a synchronized
manner by the gear
mechanism, power can be generated with greatly reduced drag as compared with a
single, central
rotating armature of a conventional generator.
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CA 02873973 2014-11-18
[00305] In another preferred embodiment in the case of a unipolar (single
north pole and followed
by a single south pole for 3600 of surface) rotor, the shafts of the rotor
mechanism may be driven by
employing a single 3-phase motor at one end of the individual slot rotor
shafts over the inner surface
and/or outer surface of the stator. The slot rotor motors are controlled by a
single variable speed
drive. As the slot rotor pairs are rotated on both sides of the stator in a
synchronized manner, power
can be generated with greatly reduced drag as compared with a single, central
rotating armature of a
conventional generator.
[00306] A stator in accordance with the embodiments discussed and described
herein can contain
wire slots around the periphery of the cavities on the inner circumference as
well as the outer
circumference. It should be noted however that, by use of the terms "inner"
and "outer", illustrative
reference is made to a circular shape stator embodiment. It will be
appreciated and should be
emphasized that the dual stator need not be circular and can be linear or
planar, or can be of a semi-
circular or other functional shape and have dual stator sections but not
confined to dual stator
sections with the same effect of the embodiment specifically illustrated and
described herein. In
such an embodiment where the stator is not circular, the terms "inner
circumference" and "outer
circumference" can be replaced by terms such as "first outer periphery" and
"second outer
periphery". Further, since an exemplary stator in various embodiments is
described herein as a dual
stator arrangement, the first outer periphery and second outer periphery can
include the stator surface
containing the slot rotors. The respective inner peripheries of the stator
sections can be adjacent to
and can face each other either directly or with an intervening member such as
a segment of side iron
and back iron or the like.
[00307] With reference to the figures, FIG. 44 shows a superior oblique
projection of one
embodiment. Driver motor 5001 is configured to be placed on support plate 5002
which is attached
to frame 5003, driver rotor shafts 5008, through transmission 5004 to open
rotors 5026 which
transverse stator cavity 5021which contains wire slots 5041, which contains
stator windings. Stator
5007 and 5007a are held in place by support posts 5011 which contain torque
bolts. The two stators
are supported upon frame 5015. The rotor shafts in stator 5007 drive the rotor
shafts in stator 5007a
via a spline coupling 5009. End supports 5012, 5013, and 5014 along with
transmission wall support
the stators and rotors. The DC current to the rotors is transferred via
brushes and slip rings 5020.
[00308] With reference to FIG. 45 a cross-sectional view is presented of a
stator laminate without
stator inductor wire slots. The main stator laminate section 5006 is connected
to the center section
5025. Rotor cavities are further shown including outer cavity 5021 and inner
cavity 5022, and torque
74
CA 02873973 2014-11-18
bolt hole 5024 in support post hole 5023. FIG. 46 illustrates the addition of
outer laminated stator
pieces 5028 which attach the main laminate 5006 and closes an outer cavity
5021.
[00309] FIG. 47 is a diagram illustrating laminates of one embodiment. The
illustrated laminate may
be used for a single-phase 28 slot generator. Slotted outer laminate 5028
attaches to main laminate
5006, which attaches to a center slotted laminate 5025. Dipole rotor laminates
5028 are depicted in
rotor cavities #1, #2, #3, #4, #5, #6, #7, and #8. The dipole rotor laminates
5028 are contemplated
for single-phase AC operation.
[00310] FIG. 48 is a diagram illustrating the cross-section of a generator
constructed of laminates,
for example, as shown in FIG. 44. The outer rotor cavities 5021are wound with
single-phase coils.
The winding pattern in the present and other embodiments may be configured to
cancel magnetic
drag in the area of the induction slots by lapping north pole and south pole
winding coils; e.g. coil
5031 is wound as a north pole, coil 5032 is wound as a south pole, coil 5033
is wound as a north
pole, and coil 5030 is wound as a south pole. The above described arrangement
places the center of
the stator induction magnetic pole midway between the rotors in stator iron 6,
e.g. in a position that
is advantageously geometrically removed from the rotors.
[00311] FIG. 49 is a diagram illustrating the cross-section of a generator
constructed of laminates as
in FIG. 47 and FIG. 48. The outer rotor cavities 5021are wound with single-
phase coils. The winding
pattern cancels magnetic drag forces in the area of the induction slots by
lapping north pole and
south pole winding coils. Coil 5031 is north pole wound, coil 5032 is south
pole wound, coil 5033 is
north pole wound and coil 5030 is south pole wound. The inner rotor cavities
5022 are wound with
single-phase coils. The winding pattern cancels magnetic drag forces in the
area of the induction
slots by lapping north pole and south pole winding coils. Coil 5034 is south
pole wound, coil 5035 is
north pole wound, coil 5036 is south pole wound and coil 5037 is north pole
wound, therefore the
inner and outer coil winding patterns cancel the "effective" inductive poling
in the stator. This pole
cancellation and geometric isolation removes only effective load drag forces
on this generator.
[00312] FIG. 50 is a further depiction of the generator cross-section of FIG.
48 and FIG. 49, and
depicts the rotor winding 5038 which is employed in the dipole rotor 5029.
[00313] FIG. 51 is a further depiction of the generator cross-section of FIG.
48, FIG. 49 and FIG.
50, and depicts a different rotor laminate 5039. This rotor contains a slot
5040 for a mu metal shield
that diverts the magnetic field from the rotor pole to close a flux circuit
back to the pole face rather
CA 02873973 2014-11-18
than penetrating through the shaft to the opposite pole to complete the
magnetic circuit. The mid-
shaft shielding provided by the mu-metal shield allows the use of a functional
unipolar rotor having
the same first pole or second pole, e.g. N or S pole, continuously throughout
3600 of the rotor
surface.
[00314] FIG. 52 is a further depiction of the generator stator and rotors of
FIG. 51 in an exemplary
single-phase arrangement, with a unipole rotor alternating first polarity and
second polarity for AC
power. The windings are also as in FIG. 50 wound in such a fashion to cancel
load induction polarity
in the stator which is a major factor in load drag forces.
[00315] FIG. 53 illustrates a cross-sectional view of one embodiment, which
when utilized in the
generator may be operated as the single-phase or 3-phase or as a DC generator.
This embodiment
contains 18 induction wire slots per stator rotor cavity. Mu metal shielding
5044 is advantageously
placed behind the back iron. The stator induction coils must be in the cavity
prior to placement of the
previously described outer sections 5028 and center section 5025 as
illustrated in FIG. 54. After the
sections are attached together, the coils are placed in insulated slots.
[00316] FIG. 54 illustrates the stator center section 5025 with induction wire
slots 5041 and mu
metal shields 5044.
[00317] FIG. 55 illustrates the three stator laminate sections 5006, 5025 and
5044. The sections are
separated prior to placing the stator induction coils into the rotor cavities.
Once the coils are in place,
section 5044 is attached to section 5006. Section 5025 is then attached to
section 5006. The coils
may then be placed in the insulated slots.
[00318] FIG. 56 is a view of stator of FIG. 55 with the stator sections
assembled but without the
induction windings having been placed in the slots. Mu metal shields 5044
dispersed in vital
locations behind the back iron.
[00319] FIG. 57 is a view of the stator laminates of FIG. 55 and FIG. 56 with
3-phase winding in
rotor cavities 5021. The windings are as is shown in FIG. 49, e.g. wound such
that electromagnetic
drag forces are cancelled by coils that are in the same sector but with
current running in the opposite
direction. In the illustrated 3-phase example, Phase 1 in and out leads
include circled numbers- (1),
(2), (3), (4), (5), (6), (7) and (8). Phase 2 in and out leads include circled
numbers (9), (10), (11),
(12), (13), (14), (15) and (16). Phase 3 in and out leads include circled
numbers (17), (18), (19), (20),
(21), (22), (23) and (24). An exemplary generator with the above described
configuration may
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CA 02873973 2014-11-18
operate with a dipole rotor at 50 or 60 Hz and may be connected in series
and/or in parallel.
[00320] FIG. 58 is a view of the stator laminates of FIG. 12 and FIG. 13 with
3-phase windings in
rotor cavities 5022. The windings are as is shown in FIG. 49, e.g. wound such
that electromagnetic
drag forces are cancelled by coils that are in the same sector but with
current running in the opposite
direction. This is a 3-phase winding. Phase 1 in and out leads include circled
numbers - (25), (26),
(27), (28), (29), (30), (31) and (32). Phase 2 in and out leads include
circled numbers -(33), (34),
(35), (36), (37), (38), (39) and (40). Phase 3 in and out leads include
circled numbers - (41), (42),
(43), (44), (45), (46), (47) and (48).
[00321] FIG. 59 is a depiction of the single rotor drive motors 5046
positioned on a support stand
5047 driven by a variable speed drive 5049 through cable 5048.
[00322] FIG. 60 is a depiction of a laminate 5039 of a unipole/dipole rotor
with mu metal shield slot
5040 which deflects the magnetic pole from either pole to avoid N/5 cancelling
effects when
operated as a unipole.
[00323] FIG. 61 is a depiction of a laminate 5039 of a unipole/dipole rotors
with winding 5038 and
leads 5055, 5056, 5057, 5058 and Mu metal shield slot 5040.
[00324] FIG. 62 is a depiction of 4 standard stators 5059, 5060, 5061, and
5062 which may be
retrofitted such that the windings 63 may be wound according to the above
described teachings.
[00325] FIG. 63 depicts a generator system for an exemplary commercial
embodiment. The standard
generator stators 5059, 5060, 5061, and 5062 of FIG. 62 may be retrofitted and
supported by a
support frame 72 composed of a lightweight material. The stators 5059, 5060,
5061, and 5062 may
be connected by wire coil conduits 5068, 5069, 5070 and 5071, with similar
conduits (not shown) on
the opposite end to accommodate the backside of the coil loop. Removable
segments 5064, 5065,
5066, and 5067 are removed to allow introduction of the coils during the
winding process and are
wound in the same manner as the stator in Figures 48, 49, 50, 51, and 57.
While a coil associated
with one of the coil phases is illustrated, it will be appreciated that coils
for the remaining phases
may also be wound and placed in the stators 5059, 5060, 5061, and 5062. After
the phase windings
are completed, connected, tied down, dipped and baked, rotors may be inserted
and end bells may be
attached. Individual driver motors, such as those shown in FIG. 59 may be
attached to the end bells.
Slip rings and brushes may be coupled to the shaft on the opposite ends of
double shafts as part of
the rotor excitation mechanism as shown in FIG. 64, which is a depiction of an
assembly of standard
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CA 02873973 2014-11-18
stators in retrofit stage to be wound according to any of the above described
teachings.
[00326] FIG. 64 illustrates an embodiment whereby a number, such as 12, of
retrofitted standard
generator housings shown as stators 5060, 5061, 5073, 5074, 5075, and 5076 may
be supported by a
lightweight support structure. Conduit ports 5077, 5078, 5079, 5080, 5081,
5082, 5083, 5084, 5085,
5086, 5087 and 5088 are provided, which may accommodate wiring for winding
coils and coil
groups that passes between stators 5060, 5061, 5073, 5074, 5075, and 5076, and
including those not
shown. End bells may be used to support rotors and shafts. Spline couplings
5095, 5096, 5097 and
5098 connect the shafts between the individual units. Slip rings and brush
mechanisms 5089,5090,
5091, 5092, 5093 and 5095 may be utilized to carry an excitation current to
the rotors windings. The
illustrated embodiment may use unipole rotors, therefore each gang of four
housings in a system
with 12 retrofitted housings, will represent one phase of a 3-phase generator.
[00327] FIG. 65 represents the details of a layout for exercising a test
protocol to certify operation as
a stand-alone power plant and to compare to standard generators.
[00328] FIG. 66 further illustrates the details of a layout for exercising a
test protocol to certify
operation as a stand-alone power plant and to compare to standard generators.
[00329] FIG. 67 further illustrates the details of a layout for exercising a
test protocol to certify
operation as a stand-alone power plant and to compare to standard generators.
[00330] FIG. 68 further illustrates the details of a layout for exercising a
test protocol to certify
operation as a stand-alone power plant and to compare to standard generators.
[00331] FIG. 69 further illustrates the details of a layout for exercising a
test protocol to certify
operation as a stand-alone power plant and to compare to standard generators.
78
