Compact high-efficiency, low-reverse torque electric power generator driven by a high efficiency electric drive motor
11196331 · 2021-12-07
Inventors
Cpc classification
H02K11/30
ELECTRICITY
H02K31/00
ELECTRICITY
H02K11/0094
ELECTRICITY
H02K99/00
ELECTRICITY
International classification
H02K11/30
ELECTRICITY
H02K11/00
ELECTRICITY
Abstract
A generator with reduced reverse torque which may be used as a singular, point of use, compact electric generator that produces power with high efficiency and very low reverse torque. The generator comprising a stator having slots and stator coils and a series of slot rotors placed in relation to the stator coils such that minimal destructive interaction is caused between magnetic fields of each rotor and induced magnetic fields of the stator when the power generator is connected to an electric load with at least a portion of that power being sent to a storage device where a portion of the stored power is provided to excitation circuitry utilized to re-excite a motor to drive the slot rotors.
Claims
1. A power generator, comprising: a stator having slots and stator coils; and a series of slot rotors placed in relation to the stator coils such that minimal destructive interaction is caused between magnetic fields of each rotor and induced magnetic fields of the stator when the power generator is connected to an electric load, wherein each slot rotor comprises a rotor placed in a respective rotor cavity having at least one of the slots; wherein first members of the slot rotors are distributed along the outer periphery of a first stator section having induction windings accommodated in the slots; wherein the first members of slot rotors contain permanent magnets that have a first magnetic polarity on 360° of the external face of the slot rotors, and a second polarity on 360° of the inner face and adjacent to a shaft of the slot rotors.
2. The power generator of claim 1, further comprising: the slots of the first stator section are axially aligned along a lengthwise and depthwise axis.
3. The power generator of claim 1, wherein the slot rotors are distributed along the outer periphery alternating in polarity from the first magnetic polarity to the second magnetic polarity.
4. The power generator of claim 1, wherein the slot rotors are configured such that the first pole having the first magnetic polarity and the second pole having the second magnetic polarity are located in geometrically adjacent corners of the stator body.
5. The power generator of claim 4, wherein the first side of a stator armature coil is excitable by the first magnetic polarity while a second side of the same stator armature coil is excitable by the second magnetic polarity such that a moving flux density is provided in the induction windings to induce a DC current to flow therein.
6. The power generator of claim 3, further comprising a drive wheel for rotation of the slot rotors.
7. The power generator of claim 6, wherein the drive wheel comprises a non-ferromagnetic disc containing two static magnets on the outer periphery separated by 180°.
8. The power generator of claim 7, wherein the magnetic disc is mounted on a central drive shaft by use of a bearing mechanism.
9. The power generator of claim 8, further comprising a plurality of DC electromagnets spaced a predetermined number of degrees apart and in proximity to the edge of the magnetic disc.
10. The power generator of claim 9, wherein the DC magnets are placed on the outer periphery of the magnetic disc such that north pole faces the outer periphery and south pole the inner periphery for each static magnet separated by 180° on the face of the disc.
11. The power generator of claim 9, further comprising a programmable logic center (PLC) and relays, wherein the plurality of electromagnets are excitable by the relays which are controlled by the programmable logic center (PLC).
12. The power generator of claim 11, wherein each relay is operable to close a DC power circuit to two of the electromagnets distributed 180° apart from each other next to the circumference of the magnetic disc.
13. The power generator of claim 12, wherein the programmable logic center (PLC) is configured such that one relay is exited for a predetermined duration followed by a rotational excitation in the remaining relays, each being excited for the predetermined duration.
14. The power generator of claim 13, wherein the excitation in sequence allows the disc to spin at a speed of 10 milliseconds per rotation or 6,000 rpm.
15. The power generator of claim 6, wherein the drive wheel is connected to a central shaft which is also connected to a non-ferromagnetic cog wheel.
16. The power generator of claim 15, wherein the cog wheel on the central shaft meshes with a smaller cog wheel on the shaft of each of the four rotors.
17. The power generator of claim 16, wherein of the cog wheel is set to a predetermined ratio to the smaller cog wheels.
18. The power generator of claim 1, wherein the stator coils include three coil sets.
19. The power generator of claim 18, wherein coils within each coil set are connected in series for generating DC power.
20. The power generator of claim 13, wherein the PLC is programmed to pulse a signal to a relay which in turn closes the DC circuit for the predetermined duration in series.
21. The power generator of claim 20, wherein the PLC is powered by a common battery which also powers an electrical load.
22. The power generator of claim 21, further comprising an on-off switch which breaks the circuit from the common battery to the PLC.
23. The power generator of claim 21, further comprising a MOSFET transistor, which opens the circuit when the common battery is fully charged and closes the circuit when the common battery needs additional charge.
24. The power generator of claim 21, further comprising a transistor voltage regulator that controls the voltage from the power generator to the common battery.
25. The power generator of claim 1, wherein the stator is constructed of laminated electrical steel, or laminated graphene, or a combination of laminated electrical steel and laminated graphene.
26. The power generator of claim 1, wherein the stator coils are made of copper, aluminum, graphene, and/or ceramic.
27. The power generator of claim 1, wherein the stator has a substantially square shape, with rotor cavities located in the corners of the square, where the stator section is concentric about the longitudinal axis.
28. The power generator of claim 1, wherein the slots are wired such that 360° of slots are wound in a counter clockwise direction and are lapped by 360° of slots wound in a clockwise direction between the two adjacent rotor cavities.
29. The power generator of claim 28, wherein the lapped winding is such that an induced north pole cancels an induced south pole thereby electromagnetically isolating the rotor standing magnetic pole from the induced potential stator magnetic pole.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The accompanying drawings, which are incorporated in and constitute part of this specification, and together with the description, illustrate and serve to explain the principles of the exemplary embodiments disclosed herein. In the drawings:
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DETAILED DESCRIPTION
(10) Embodiments herein include systems and methods. At least some disclosed methods may be executed, for example, by at least one processor that receives instructions from a non-transitory computer-readable storage medium. Similarly, systems consistent with the present disclosure may include at least one processor and memory, and the memory may be a non-transitory computer-readable storage medium. As used herein, a non-transitory computer-readable storage medium refers to any type of physical memory on which information or data readable by at least one processor may be stored. Examples include random access memory (RAM), read-only memory (ROM), volatile memory, nonvolatile memory, hard drives, CD ROMs, DVDs, flash drives, disks, and any other known physical storage medium. Singular terms, such as “memory” and “computer-readable storage medium,” may additionally refer to multiple structures, such a plurality of memories and/or computer-readable storage mediums. As referred to herein, a “memory” may comprise any type of computer-readable storage medium unless otherwise specified. A computer-readable storage medium may store instructions for execution by at least one processor, including instructions for causing the processor to perform steps or stages consistent with an embodiment herein. Additionally, one or more computer-readable storage mediums may be utilized in implementing a computer-implemented method. The term “computer-readable storage medium” should be understood to include tangible items and exclude carrier waves and transient signals.
(11) Embodiments of the present disclosure provide numerous advantages over prior systems and methods. For example, 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 elimination of the drag to its uses and applications is presented and discussed. For example, embodiments of the present disclosure provide systems and methods for a generator design virtually free of reverse torque due to a number of design changes when compared to a conventional electric rotary generator. These design features, including Geometric Isolation, Singular Stator Winding Pattern, Shielding, and Unique Rotor Design, are explained next.
(12) Geometric Isolation: Each stator armature induction coil can be located in two separate rotor cavities, such that only one side of a stator coil is in close proximity to a first magnetized rotor, while the opposite side of the coil is in close proximity to a second magnetized rotor. Both rotors are outside of a closed induction loop. Reverse torque of a conventional generator may be formed when a single rotor excites both sides of a stator coil, one being at least one north pole and the other at least one south pole. Based on Lenz's Law, there is an induced current in a closed loop if the magnetic flux through the loop is changing. The direction of the induced current is such that the induced magnetic field opposes a change in flux. In the case of the present disclosure, however, the magnetic field of the rotor is geometrically removed and isolated from a magnetic axis or center line of a stator magnetic pole. Therefore, reverse torque does not occur to any significant extent due to this geometric separation of the would-be opposing magnetic poles.
(13) Singular Stator Winding Pattern: A stator armature may be wound with lapping coils in wire slots such that a direction of current flow in the lapping coils is identical in all slots of an individual rotor cavity. However, as the coils exit stator induction slots, the coils are physically wound in opposite directions thereby creating opposite magnetic polarities and effectively canceling available magnetic polarity which may otherwise form a small amount of reverse torque.
(14) Shielding: A stator armature iron also contains a series of mu metal shields between wire slots, which allow flux linkage between narrow segments of side iron and back iron and a uni-pole rotor flux such that an armature coil inductive power generation may be attained. However, no significant reverse torque is developed.
(15) Unique Rotor Design: The modified pole rotor is a singular uni-polar (functioning as a single-pole) rotor. The rotor does not exhibit a detectable magnetic center pole or center line which could tend to line up on small magnetic poles of the stator and thereby develop some counter torque. The first and second magnetic poles can be permanent fixed poles on 360° of rotor surface.
(16) In accordance with an aspect of the disclosed generator, a method is disclosed for reducing drag in an electric generator that includes a unique geometric design of the stator and placement of a unique series of uni-polar rotors in relation to the stator coils along with a system of magnetic shielding which results in minimal destructive interaction of the rotor magnetic fields with the magnetic fields of the stator when the generator is connected to an electric load. The design includes distributing first members of slot rotors along the outer periphery of a first stator section having induction windings accommodated in stator slots. The slots of the first stator section are axially aligned along a lengthwise and depthwise axis. The first members of slot rotors contain permanent magnets that have a first magnetic polarity on the 360° external face of the rotor and the second magnetic polarity on the inner face adjacent to the rotor shaft. The slot rotors distributed along the outer periphery are distributed in alternating polarity from first magnetic polarity to second magnetic polarity. The slot rotors may be rotated in such manner that the first pole having a first magnetic polarity and the second pole having a second magnetic polarity are located in geometrically adjacent corners of the stator, such that a first side of a stator armature coil is excited by a first magnetic polarity, a second side of a stator armature coil is excited by a second magnetic polarity such that maximum moving flux density is provided in the induction windings to induce a DC current to flow therein. The rotor magnetic fields are magnetically shielded such that magnetic drag resulting from magnetic interaction between the rotors and stator is minimized.
(17) According to some embodiments, the present disclosure presents a method and apparatus for reducing the electromagnetic drag in a miniature electric generator to improve efficiency and simultaneously allow a constant power supply for miniature applications, such as cellular phones, smart phones, computers, implantable medical devices, and the like.
(18) In an embodiment of the current disclosure, distributed slot rotors rotate in a close proximity to aligned wire slots disposed around the circumference of a miniature stator of an electric power generator.
(19) According to an embodiment, means are revealed to provide a uni-polar permanent magnetic rotor in order to place maximum flux into the wire slots of the stator.
(20) According to some embodiments of the current disclosure, the structure of laminated steel and/or graphene or other suitable material is used in a stator such that a uniform ferro magnetic environment is created surrounding the uni-polar magnetic rotor.
(21) According to some embodiments of the current disclosure, the high efficiency generator demonstrates the release of energy which would otherwise be consumed by electromagnetic drag forces by specific geometric location and shielding of distributed slot rotors in the generator.
(22) Some embodiments of the current disclosure reveal an alternating lap winding pattern of the stator to shield the uni-polar rotors from the magnetic fields of the stator when the generator is connected to an electrical load.
(23) Some embodiments of the current disclosure reveal the use of the small high efficiency generator as part of a stand-alone, high efficiency electric power source for cellular phones and other electronic information devices.
(24) Some embodiments of the current disclosure provide distributed slot rotors that rotate in a close proximity to align and skew wire slots disposed around the circumference of a stator of a miniature power generator.
(25) Some embodiments of the current disclosure provide equally spaced wire slots for 360° in the rotor cavities with narrow openings into larger slots which contain wound magnetic wire. This arrangement aids in the control of permeance harmonics.
(26) Some embodiments of the current disclosure provide a skew in the slot alignment equal to at least the width of 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 cavity.
(27) Some embodiments of the current disclosure 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 uni-polar slot rotors.
(28) Some embodiments of the current disclosure demonstrate the use of uni-polar rotors, with one side of each coil excited by the first polarity and the second side of the coil excited by the second polarity such that DC current is generated.
(29) Some embodiments of the current disclosure 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.
(30) Some embodiments of the current disclosure reveal the method by which the rotor magnetic forces are separated from the stator induction magnetic forces by specific geometric locations and shielding of the distributed slot rotors as well as by the unique winding pattern of the stator which effectively shields and cancels significant magnetic poles in the stator.
(31) Some embodiments of the current disclosure reveal the use of a very low electrical conductor wire to wind both the stator and the rotors with significant increases in power output to an electrical load.
(32) Some embodiments of the current disclosure reveal 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 rotors in a high efficiency generator.
(33) Some embodiments of the current disclosure reveal the use of superconductor material with very low resistance to electron flow to wind the stator of the unit and thereby increase the power output by a significant amount.
(34) Some embodiments of the current disclosure utilize high conductivity or superconductive materials such as but not limited to graphene or ceramic or other high temperature superconductors to aid in the function of the unit of a stand-alone power source for all applications.
(35) Some embodiments of the current disclosure reveal the use of the high efficiency generator to power electronic notebooks, laptop computers, desktop computers, e-readers, electronic tablets, and the like.
(36) Some embodiments of the current disclosure reveal the use of the high efficiency generator to power implantable medical devices.
(37) Some embodiments of the current disclosure reveal the use of the high efficiency generator to power any and all small power applications.
(38) Some embodiments of the current disclosure use graphene and/or other substances or materials as superconductors, high-capacity capacitors, and super efficient ferro magnetic materials to enhance electromagnetic induction with small physical size and lighter weight generating devices.
(39) In accordance with various exemplary embodiments discussed and described and by way of brief summary, an exemplary high efficiency mini electric generator unit eliminates or greatly reduces electromagnetic drag or reverse torque so that upwards of 80% of the driving energy which conventionally is consumed and/or dissipated by magnetic drag is converted to electric power. In accordance with the embodiment as will be described in greater detail in connection with the illustrations below, the classic rotor or armature and stator have been replaced by a laminated electrical steel or laminated graphene stator. The stator section has, in one example, 18 wire slots that are magnetically coupled with individual slot rotors in adjacent corners of the stator. In a preferred embodiment, the stator section has, 18 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 adjacent slot rotors.
(40) The slot rotors can be constituted of, for example, a permanent magnetic uni-pole for 360° of their outer surfaces. The slot rotors are positioned in close proximity to the wire slots in order for each rotor to form a closed magnetic circuit with the stator slot tooth, side iron, and back iron in order to allow maximum moving magnetic flux across the induction coils. Therefore, the shielding, geometric isolation, and winding patterns allow only minimal to no electromagnetic drag upon the slot rotors.
(41) To drive the shafts of the slot rotor mechanism, a central gear wheel mechanism may be employed at one end of the individual slot rotor shafts over the inner or outer circumference of the stator. As the slot rotors are rotated on both sides of the stator by the central gear mechanism, the step-up speed from the central gear to the rotor shaft has an increased speed of 10-fold or 1:10 gear speed ratio and power can be generated with greatly reduced drag as compared with a single central rotating armature of a conventional generator.
(42) The shafts of the slot rotor mechanisms may be driven by employing an electric high efficiency motor which is driven by multiple isolated magnetic poles in electromagnets which are sequenced by a programmable logic center (PLC) and relay mechanism such that magnetic drag or reverse torque on the driver mechanism does not exist. Power generation in accordance with the reduced electromagnetic drag provided by various embodiments discussed and described herein can result in, for example, 4 to 5-fold increase in electrical energy output with the same mechanical or kinetic energy input.
(43) Reference will now be made in detail to the exemplary embodiments implemented according to the disclosure, the examples of which are illustrated in the accompanying drawings.
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(45) The stator is of appropriate thickness and is constructed of laminated electrical steel, laminated graphene, or like material. The stator wire is, for example, copper, aluminum, graphene, or high temperature super conductor material such as ceramic. In a preferred embodiment the stator section can have substantially a square shape, but not confined to a square shape, with the rotor cavities located in the corners of the square, where the stator section is concentric about the longitudinal axis. The embodiment is preferred, but not restrictive, in that in affords geometric isolation from the magneto-motive poles in the stator thereby reducing the drag forces between the stator and the magnetized rotors.
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(47) The stator slot windings as shown in
(48) The stator slot windings as shown in
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(53) As noted above, slot rotors 33, 34, 35, 36 distributed along the outer periphery alternate geometrically between first magnetic polarities to second magnetic polarities. The rotors are rotated by a drive wheel which is driven by a direct current motor device system. The motor device system includes thin non-ferro magnetic disc drive wheel 41, containing two static magnets 41M in the outer periphery 180° separated. The disc is mounted on central drive shaft 6(3). The disc can be rotated at 3,000 rpm, but not limited to 3,000 rpm, by energized electromagnets 42-49 mounted upon the support structure, for example, laminate 40. There are eight, but not limited to eight, electromagnets 42-49 spaced 45° apart in proximity to the edge of disc 41 with the south poles S adjacent the periphery of disc 41. Static magnets 41M on the outer periphery of driver disc 41 are placed such that north pole faces the outer periphery and the rotating south pole S fields generated by electromagnets 42-49. The south pole S of each magnet 41M faces the inner periphery of disc 41. When two of the electromagnets 42-49 180° apart are excited for 5 milliseconds in sequence, 360° of rotation occurs in 20 milliseconds or 3,000 rpm.
(54) The eight electromagnets 42-49 are excited by four relays 61-64 which are controlled by PLC 57 illustrated in
(55) Drive wheel 41 in
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