Electromechanical battery
11641140 · 2023-05-02
Assignee
Inventors
- Jonathan Forrest Garber (Hillsborough, CA, US)
- Frank Levinson (Tiburon, CA, US)
- Andre Adams (Tiburon, CA, US)
Cpc classification
F03G3/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H02K11/21
ELECTRICITY
Y02E60/16
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
H02K5/10
ELECTRICITY
H02K11/0141
ELECTRICITY
International classification
F03G3/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H02K11/01
ELECTRICITY
Abstract
The present invention relates to an electromechanical battery comprising a single pole-pair Halbach array of permanent magnets incorporated into an annular flywheel, which together comprise a rotor assembly, a means for levitating the rotor assembly using a “double-lift” attractive magnetic levitator under active control, and a means for actively stabilizing the spinning rotor assembly by interaction with the fringe fields of the Halbach array.
Claims
1. An electromechanical battery comprising: a rotor assembly comprising: a. a vertical columnar single pole-pair Halbach array of permanent magnets that define a central through-hole, the array having an upper end, a lower and, and essentially planar top and bottom surfaces, wherein the planar top and bottom surfaces are perpendicular to a longitudinal axis of the columnar array, wherein, the Halbach array has a substantially uniform unidirectional magnetic field in the central through-hole and nonuniform fringe magnetic fields with radial and vertical components at its top and bottom surfaces; b. an annular flywheel coupled to the Halbach array; c. a stator disposed within the through-hole of the Halbach array and substantially centered on the longitudinal axis of the array; d. windings disposed within the stator; and e. a coil at the upper end and a coil at the lower end of the Halbach array, wherein the coils interact with the fringe magnetic fields; a sensor that detects changes in radial position of the rotor assembly when the rotor assembly is levitated; and a radial controller in communication with the sensor wherein, upon receiving radial position data from the sensor, the radial controller directs current through the coils to affect the radial position of the rotor assembly.
2. The electromechanical battery of claim 1, wherein the sensor comprises: a light source that directs a beam of light at a longitudinal edge of the rotor assembly such that a portion of the beam is blocked by the rotor assembly; and a detector positioned on the opposite side of the rotor assembly from the light source wherein the detector senses changes in the quantity of light that passes by the longitudinal edge of the rotor assembly due to changes in the radial position of the rotor assembly and transmits that information to the controller.
3. The electromechanical battery of claim 1, comprising: at least two assemblies of permanent magnets, each assembly comprising one or more magnets, each assembly being fixedly coupled to a framework that surrounds the rotor assembly, the one or more magnets of each assembly being disposed to exert levitating force on the rotor assembly.
4. The electromechanical battery of claim 3, wherein: each assembly of magnets extends in a plane that is orthogonal to the longitudinal axis of the rotor assembly; and one assembly of magnets is disposed above the center of gravity of the rotor assembly and the other assembly of magnets is disposed below the center of gravity of the rotor assembly, wherein: the assemblies of permanent magnets generate sufficient magnetic force to levitate the rotor assembly against gravity while, in addition, passively affecting the centration of the rotor assembly.
5. The electromechanical battery of claim 4 wherein the assemblies of magnets are disposed equidistantly above and below the center of gravity of the rotor assembly.
6. The electromechanical battery of claim 5, wherein two assemblies of magnets are used.
7. The electromechanical battery of claim 3, comprising: a sensor that detects changes in the vertical position of the rotor assembly when the rotor assembly is levitated; and a vertical controller in communication with the sensor wherein, upon receiving vertical position data from the sensor, the vertical controller directs current through the control coils to affect the vertical position of the rotor assembly.
8. The electromechanical battery of claim 1, wherein the battery is disposed in an air-tight housing.
9. The electromechanical battery of claim 1, further comprising a permeable component to isolate the fringe magnetic fields from interaction with other magnetic fields.
10. An electromechanical battery comprising: a rotor assembly comprising: a. a vertical columnar single pole-pair Halbach array of permanent magnets that define a central through-hole, the array having an upper end, a lower and, and essentially planar top and bottom surfaces, wherein the planar top and bottom surfaces are perpendicular to a longitudinal axis of the columnar array, wherein, the Halbach array has a substantially uniform unidirectional magnetic field in the central through-hole and nonuniform fringe magnetic fields with radial and vertical components at its top and bottom surfaces; b. an annular flywheel coupled to the Halbach array; c. a stator disposed within the through-hole of the Halbach array and substantially centered on the longitudinal axis of the array; and d. windings disposed within the stator; at least two assemblies of permanent magnets, each assembly comprising one or more magnets, each assembly being fixedly coupled to a framework that surrounds the rotor assembly, the one or more magnets of each assembly being disposed to exert levitating force on the rotor assembly via levitation magnetic fields; each assembly of magnets extending in a plane that is orthogonal to the longitudinal axis of the rotor assembly; and one assembly of magnets being disposed above the center of gravity of the rotor assembly and the other assembly of magnets being disposed below the center of gravity of the rotor assembly, wherein: the assemblies of permanent magnets generate sufficient magnetic force to levitate the rotor assembly while, in addition, passively affecting the centration of the rotor assembly.
11. The electromechanical battery of claim 10, wherein the battery is disposed in an air-tight housing.
12. The electromechanical battery of claim 11, wherein a vacuum is created in the air-tight housing.
13. The electromechanical battery of claim 12, wherein heat generated within stator windings is transported to the air-tight housing.
14. The electromechanical battery of claim 10, wherein: the rotor assembly comprises at least one material of construction selected from: carbon fiber, glass fiber, basalt fiber, aramid fiber, silica fiber, and wherein: said material of construction is disposed in the form of a composite material.
15. The electromechanical battery of claim 10, further comprising a permeable component to isolate the levitation magnetic fields from interaction with the nonuniform magnetic field and the fringe magnetic fields.
16. An electromechanical battery comprising: a rotor assembly comprising: a. a vertical columnar single pole-pair Halbach array of permanent magnets that define a central through-hole, the array having an upper end, a lower and, and essentially planar top and bottom surfaces, wherein the planar top and bottom surfaces are perpendicular to a longitudinal axis of the columnar array, wherein, the Halbach array has a substantially uniform unidirectional magnetic field in the central through-hole and nonuniform fringe magnetic fields with radial and vertical components at its top and bottom surfaces; b. an annular flywheel coupled to the Halbach array; c. a stator disposed within the through-hole of the Halbach array and substantially centered on the longitudinal axis of the array; d. windings disposed within the stator; and the electromagnetic battery further comprising first and second attractive levitator magnet assemblies, wherein one of the attractive levitator magnet assemblies is disposed above the center of gravity of the rotor assembly and the other attractive levitator magnet assembly is disposed below the center of gravity of the rotor assembly.
17. An electromechanical battery as in claim 16 wherein: the first and second attractive levitator magnet assemblies generate sufficient magnetic force to levitate the rotor assembly against gravity while, in addition, passively affecting the centration of the rotor assembly.
18. An electromechanical battery as in claim 16 further comprising a first control coil located above the center of gravity of the rotor assembly and a second control coil located below the center of gravity of the rotor assembly, to control a radial position of the rotor assembly.
Description
DESCRIPTION
Brief Description of the Figures
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DISCUSSION
(12) It is understood that, with regard to this description and the appended claims, reference to any aspect of this invention made in the singular includes the plural and vice versa unless it is expressly stated or unambiguously clear from the context that such is not intended. For instance, a reference to a “sensor” in the singular includes two or more sensors.
(13) As used herein, any term of approximation such as, without limitation, near, about, approximately, substantially, essentially and the like, mean that the word or phrase modified by the term of approximation need not be exactly that which is written but may vary from that written description to some extent. The extent to which the description may vary will depend on how great a change can be instituted and have one of ordinary skill in the art recognize the modified version as still having the properties, characteristics and capabilities of the word or phrase unmodified by the term of approximation. In general, but with the preceding in mind, a numerical value herein that is modified by a word of approximation may vary from the stated value by ±15%, unless expressly stated otherwise.
(14) As used herein, the use of “preferred,” “preferably,” “more preferred,” “presently preferred” and the like refers to preferences as they existed at the time of filing of this patent application.
(15) As used herein, an “electromechanical battery,” sometimes referred to in the relevant literature as a “motor-generator,” also sometimes referred to as a “flywheel”, refers to a device that stores energy in a rapidly rotating rotor assembly and releases that energy as electrical energy as the rotor slows down. Previous manifestations of such batteries are revealed in U.S. Pat. Nos. 5,705,902, 6,566,775, 6,858,962, 7,679, 247, each of which is incorporated by reference, including drawings, as if fully set forth herein. These and other publications describe in detail the use of a Halbach array that is coupled to a flywheel that is made to rapidly spin and thereby store energy for eventual conversion to electrical as the flywheel spins down. As such, it is not considered necessary to recite herein all of the basic elements of a Halbach array electromechanical battery as such can be readily gleaned from the cited references as well as numerous other patent references and technical articles. The import of the present invention lies in its use of novel technology to stabilize the electromechanical battery's rotating assembly using an extremely low expenditure of energy and stabilizing the rotating assembly substantially about its inertial rotational axis, maximizing energy storage and conversion efficiencies, single charge lifetime and overall operational lifetime of the battery.
(16) As used herein, a “rotor assembly” or “rotor” refers to a construct comprising at least the following elements: a. columnar single pole-pair Halbach array 5,
(17) As used herein, a “Halbach array” refers to a specialized arrangement of permanent magnets as known and understood in the art wherein the magnets augment the magnetic field inside the through-hole of the arrangement while essentially cancelling the magnetic field on the exterior. A top view of a columnar Halbach array is shown in
(18) Key to this aspect of the invention are two fixed coils, one being located at or near one end of the Halbach column and the other being located at or near the other end of the Halbach column. The coils are disposed so as to be capable of interacting with the two fringe fields of the Halbach array. Thus, the coils may be located anywhere in the through-hole so long as the aforesaid interaction is possible. It is presently preferred, however, that the two coils be disposed inside and at either end of stator 10 such that first coil 12, shown in
(19) In addition to the rotor and stator elements 4, 10, respectively, an electromechanical battery of this invention includes a sensor, the function of which is to detect changes in the radial position of the rotor assembly when the rotor assembly is levitated. The sensor would, of course, be capable of detecting the radial position of the rotor assembly when it is not levitated, but such is of little consequence to the instant invention. In addition to detecting the position of the rotor assembly when levitated, the sensor is capable of detecting changes in the position of the rotor assembly when it is levitated and rotating. In fact, it is this last function of the sensor that is, at present, of most importance to this aspect of the invention. In electromechanical batteries, the flywheel is often spinning extremely rapidly. Thus, inherent resonance frequencies of the various parts of the battery when spinning and the high speed at which the flywheel is rotating can result in negative effects on the battery such as, without limitation, fatigue and construction material failure. This aspect of the present invention minimizes and potentially eliminates such adverse events.
(20) Once the sensor has detected changes in the radial position of the rotor assembly, it transmits that information to a controller with which it is in communication and the controller, in turn, directs a current through the coils that are at least partially within the fringe magnetic fields thereby interacting with those fields and generating reaction forces on the rotor assembly.
(21) While virtually any manner of sensor can be used for the above purpose and any and all such sensors are within the scope of this invention, it is presently preferred that the sensor comprises a light source and change in light intensity detector. This is shown in
(22) A further aspect of this invention relates to fine-tuning the levitation of the rotor assembly. An added benefit of the novel mechanism for doing so is a passive positive effect on centration of the rotor assembly on its longitudinal (vertical) axis of rotation. This aspect of the invention uses at least two assemblies of permanent magnets. While it will be evident from the discussion that follows how the technique discussed would apply when using more than two assemblies of magnets, this description will be directed solely to the presently preferred embodiment which is the use of just two assemblies of magnets. While the following discussion refers to an embodiment in which one magnet of each assembly of levitation magnets is fixed to the rotor assembly, it discloses and applies equally to the levitation magnet assembly of
(23) In
(24) The use of magnets to offset the gravimetric weight of rotor assemblies/flywheels has long been known in the art. Commonly used configurations for vertical-axis flywheels, however, differ from that of this invention in that, in the art, either repulsive arrays are preferred, or else an attractive array is used near the top of the rotor, while a secondary array at the bottom is either absent entirely, or configured to interact in repulsion. The problem with this is that, when in repulsive mode, magnets are radially divergent; that is, they push each other away and to one side or another. With regard to an electromechanical battery, this inherent tendency to diverge necessitates additional methods to achieve and maintain rotor assembly stability around its axis of rotation. Generally, rotor assembly stability imposes tight constraints on rotor mass balance to limit imbalance forces. This, then, requires more expensive rotor manufacturing procedures. Even then, it is well-known that rotor mass distribution often changes during operation. In the short term, rotor mass distribution may change as the rotor expands nonuniformly during spin-up. Over the long term, rotor mass distribution may change as rotor materials creep due to prolonged exposure to radial and circumferential stresses at high rotation speeds. In addition, rotor mass distribution may change suddenly as the result of limited material failure under rotational stress. In contrast to prior art, the instant invention can overcome these limitations.
(25) With reference to
(26) By employing two levitators both of which act in attractive mode, each levitator exerts a passive radial centering force, referred to herein as “centration” on the rotor and thus requires no compensation for radial divergence effects inherent in repulsive levitators. The weak radial restoring force permits large radial clearances between the rotor assembly and adjacent stationary structure, which allows rotation approximating that which would result from a rotor spinning purely according to its inertial mass distribution without radial constraint. This enhanced clearance in turn accommodates changes in the rotor assembly/flywheel mass distribution due to spin-up/spin-down nonuniform strains, material aging and local microstructural failures. In addition, the two pairs of levitation magnets in attractive mode present essentially identical characteristics with respect to development of hardware production and assembly and can simplify control software design. These and other advantages of the “double-lift” design with both pairs of levitating magnets being in attractive mode will become clear to those skilled in the art based on the discussion herein and knowledge of the shortcomings of alternative suspension systems.
(27) It is also an aspect of this invention that magnet supporting elements 77 are L-shaped with the leg of the L facing downward toward and aligned with a projection upward from magnet supporting elements 78. While magnet supporting elements 77 and 78 may be constructed of any material of sufficient strength to perform their support function, it is presently preferred that magnet supporting elements 77 and 78 be constructed of a high magnetic permeability material. An example, without limitation, of such a material would be a ferromagnetic material such as steel. This is equally applicable to elements 215 and 219 of
(28) To deliver the above advantages, the double-lift design of the instant invention requires active control of the vertical position of the rotor assembly/flywheel of this invention. This is accomplished by the inclusion of control coils 90 and 91, shown in
(29) The sensor for detecting changes in vertical position of rotor assembly 50 is similar to the sensor for detecting radial divergence of rotor assembly 50. Again, any type of sensor that will achieve the result described below can be used and is within the scope of this invention. It is presently preferred, however, that the sensor comprises a light source and change in light intensity detector. This is shown in
(30) It should be noted that, while the above double-lift mechanism for levitating a rotor assembly/flywheel is described as an addition to the earlier described device comprising means for controlling radial displacement of the rotor assembly, it is possible and is an aspect of this invention that the double-lift mechanism may be used without radial displacement control, the result being a device with active vertical placement control only.
(31) The flywheel of an electromechanical battery of this invention may be appended to the rotor assembly in at least two distinct ways. The flywheel mass may be contiguous with and directly connected to the Halbach array. This is shown in
(32) Another aspect of this invention is a device for attenuating detrimental magnetic field interactions within an electromechanical battery. Electromechanical batteries such as that of this invention use permanent and electromagnets to generate powerful magnetic fields that may interfere with one another. For example, the magnetic fields used for the motor/generator of a flywheel-based electromechanical battery may interfere with the magnetic fields generated for systems such as those described above for vertical positioning. To attenuate these interferences, an element made of magnetically permeable material may be interposed between a magnetic field and those locations from which it is desired that a magnetic field be excluded or, at least, its intensity at the location be diminished. The permeable element provides a preferential path for magnetic flux thereby diminishing residual magnetic force that might detrimentally affect another element of the overall electromechanical battery system. Any type of highly magnetically permeable material may be used but it is presently preferred that the material be ferromagnetic and have a magnetic permeability of at least 2000. This would, it is anticipated, enhance the stable operation of all elements of the system. Such an element is shown in
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PRIOR ART CITED
(34) U.S. Pat. No. 7,876,010 U.S. Pat. No. 7,679,247 U.S. Pat. No. 6,858,962 U.S. Pat. No. 6,566,775 U.S. Pat. No. 5,705,902 Merritt, Bernard T, RF Post, Gary R Dreifeurst, and DA Bender. “Halbach Array Motor/Generators-A Novel Generalized Electric Machine.” Halbach Festschrift Symposium, Feb. 3, 1995. Shafai, Beale, S Beale, P LaRocca, and E Cusson. “Magnetic Bearing Control Systems and Adaptive Forced Balancing.” Control Systems, IEEE 14, no. 2 (1994): 4-13.