SPIRAL HELIX ELECTROMAGNETIC LINEAR PULSE MOTOR

Abstract

A spiral helix electromagnetic linear pulse motor includes a rotor, having a driveshaft; a first spiral magnetic core surrounding the rotor; linear electromagnetic assemblies surrounding the rotor, each having wire coils; and a second magnetic core; the wire coils surrounds the second magnetic core; linear support beams; connection joints; the linear support beams and linear electromagnetic assemblies alternate in positions around the rotor, thereby encompassing the rotor; the connection joints secures the linear support beams to the linear electromagnetic assemblies; a linear magnetic pulse travels down the linear electromagnetic assemblies parallel to the first magnetic core; the traveling of the linear magnetic pulse rotates the rotor; and rotation of the rotor creates rotational mechanical energy to be transferred via the driveshaft.

Claims

1. A spiral helix electromagnetic linear pulse motor, comprising: a plurality of linear support beams; a plurality of linear array electromagnetics secured to the plurality of linear support beams; a rotor, having: a driveshaft that extends a length of the plurality of linear support beams; a spiral ferromagnetic core spiraling the rotor, the spiral ferromagnetic core having a plurality of electromagnetic assemblies, each of electromagnetic assemblies are offset at a radial angle relative to each other and secured to the driveshaft; and a plurality of connection joints; wherein rotation of the rotor creates rotational mechanical energy to be transferred via the driveshaft.

2. The motor of claim 1, wherein each of the plurality of linear electromagnetic assemblies is a stator.

3. (canceled)

4. (canceled)

5. The motor of claim 1, wherein the second ferromagnetic core is a laminated electrical steel sheet.

6. The motor of claim 1, wherein the first ferromagnetic core is a permanent magnet assembly.

7. The motor of claim 1, wherein the rotor further comprises: one or more center connection reinforcement plates; and one or more laminated connection tabs; wherein the one or more center connection reinforcement plates and the one or more laminated connection tabs are configured to secure a rotor assembly together.

8. The motor of claim 1, wherein each of the plurality of linear support beams comprises: a central I beam; and a plurality of connection tabs configured to secure the support beam to one or more of the plurality of linear electromagnetic assemblies.

9. The motor of claim 8, wherein each of the plurality of linear support beams comprises: one or more reinforcement flanges secured to and configured to reinforce the central I-beam.

10. The motor of claim 1, further comprising: a motor face plate, having: a plurality of attachment slots configured to secure to the plurality of linear support beams; a connection flange configured to connect to the driveshaft; and a shaft thrust plate configured to bear a main thrust.

11. The motor of claim 10, wherein the motor face plate further comprises: a plurality of secondary attachment slots configured to secure to the plurality of linear electromagnetic assemblies.

12. The motor of claim 10, further comprising: an expansion joint configured to secure to the motor face plate, the expansion joint having: assembly; a universal connection joint configured to allow alignment flex in a motor one or more rotor drive shaft bolted slip joints configured to provide a means to assemble and disassemble the motor assembly; and one or more expansion connection centering devices configured to allow expansion of the motor assembly; wherein the expansion joint is configured to provide a means to connect the motor of claim 10 with a second motor having the same features and function as the motor of claim 10; and wherein the expansion joint provides a means to increase an overall length and power of the motor assembly.

13. The motor of claim 12, further comprising: one or more absolute optical position encoders configured to digitally control the movement of electromagnetism.

14. The motor of claim 12, further comprising: one or more spiral helix motor pedestal supports.

Description

DESCRIPTION OF THE DRAWINGS

[0014] The novel features believed characteristic of the embodiments of the present application are set forth in the appended claims. However, the embodiments themselves, as well as a preferred mode of use, and further objectives and advantages thereof, will best be understood by reference to the following detailed description when read in conjunction with the accompanying drawings, wherein:

[0015] FIG. 1 is an oblique view of a spiral helix electromagnetic linear pulse motor in accordance with a preferred embodiment of the present application;

[0016] FIG. 2 is a side view of a partially assembled motor with the top and bottom linear arrays installed and the Spiral Helix Rotor Array of FIG. 1;

[0017] FIG. 3 is a top view of a linear electromagnet assembly of FIG. 1;

[0018] FIG. 4 is a bottom view of a linear electromagnet assembly of FIG. 1;

[0019] FIG. 5 is a side view of a linear electromagnet assembly of FIG. 1;

[0020] FIG. 6 is an end view of a linear electromagnet assembly of FIG. 1;

[0021] FIG. 7 is an end view of a magnetic core template for the electrical steel lamination cutout form use to create the magnet core from FIG. 6;

[0022] FIG. 8 is end view of a rotor electromagnet assembly in accordance with the present application;

[0023] FIG. 9 is a side view of the rotor electromagnet assembly of FIG. 8;

[0024] FIG. 10 is a top view of the rotor electromagnet assembly of FIG. 8;

[0025] FIG. 11 are template views for the electrical steel lamination cutout forms use to build the magnet core of the rotor electromagnet assembly of FIG. 10;

[0026] FIG. 12 is an isometric view of the rotor assembly of FIG. 8;

[0027] FIG. 13 is a cross sectional view of a support beam in accordance with the present application;

[0028] FIG. 14 is a side view of the support beam of FIG. 13;

[0029] FIG. 15 is a top view of the support beam of FIG. 13;

[0030] FIG. 16 is a bottom view of the support beam of FIG. 13;

[0031] FIG. 17 is an end view of an end of the support beam of FIG. 13;

[0032] FIG. 18 is a side view of the end of FIG. 17;

[0033] FIG. 19 is a bottom view of the end of FIG. 17;

[0034] FIG. 20 is a top view of the end of FIG. 17;

[0035] FIG. 21 is a cross sectional view of an assembly of a spiral helix electromagnet arrays on a rotor shaft in accordance with the present application;

[0036] FIG. 22 is a top cross sectional view of an assembly of a spiral helix permanent magnet arrays on a rotor shaft in accordance with the present application;

[0037] FIG. 23 is a view of a motor bearing housing face in accordance with the present application;

[0038] FIG. 24 is a side view of a connection expansion joint for use with the spiral helix electromagnetic linear pulse motor of FIG. 1;

[0039] FIG. 25 is a side view of a partially assembled motor of FIG. 1;

[0040] FIGS. 26a-d are side views of a partially assembled motor of FIG. 1 showing the angle rotation of the spiral helix magnet array in accordance with the present application;

[0041] FIG. 27 is a simplified diagram of a Digital Control Commutator;

[0042] FIG. 28 is a simplified chart of a Digital Control Commutator contact sequence in accordance with the present application;

[0043] FIG. 29 is a simplified operations chart in accordance with the present invention; and

[0044] FIG. 30 is a an end view of an operating motor in accordance with the present invention.

[0045] While the systems and methods of use of the present application is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the invention to the particular embodiment disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present application as defined by the appended claims.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0046] Illustrative embodiments of the system and method of use of the present application are provided below. It will of course be appreciated that in the development of any actual embodiment, numerous implementation-specific decisions will be made to achieve the developer's specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.

[0047] The system and method of use in accordance with the present application overcomes one or more of the above-discussed problems commonly associated with conventional electromagnetic motors. Specifically, the present invention provides a means to increase power capacity without increasing the thermal signature, or limiting the potential output power, while allowing current manufacturing capabilities the ability to create the construct. These and other unique features of the system and method of use are discussed below and illustrated in the accompanying drawings.

[0048] The system and method of use will be understood, both as to its structure and operation, from the accompanying drawings, taken in conjunction with the accompanying description. Several embodiments of the system are presented herein. It should be understood that various components, parts, and features of the different embodiments may be combined together and/or interchanged with one another, all of which are within the scope of the present application, even though not all variations and particular embodiments are shown in the drawings. It should also be understood that the mixing and matching of features, elements, and/or functions between various embodiments is expressly contemplated herein so that one of ordinary skill in the art would appreciate from this disclosure that the features, elements, and/or functions of one embodiment may be incorporated into another embodiment as appropriate, unless described otherwise.

[0049] The preferred embodiment herein described is not intended to be exhaustive or to limit the invention to the precise form disclosed. It is chosen and described to explain the principles of the invention, and its application and practical use to enable others skilled in the art to follow its instructions.

[0050] Referring now to the drawings, wherein like reference characters identify corresponding or similar elements throughout the several views, FIGS. 1 and 2 depict an oblique view, and a side view of a spiral helix electromagnetic linear pulse motor 101 in accordance with a preferred embodiment of the present application. It will be appreciated that motor 101 overcomes one, or more of the above-listed problems commonly associated with conventional electromagnetic rotational motor systems.

[0051] In the contemplated embodiment, motor 101 includes one or more motor units 103, 105 connected by one or more expansion joints 111, 113. It should be appreciated that the expansion joints allow for motor 101 to be modular and increase linearly in size, thereby increasing the power of motor 101. In the preferred embodiment, each unit includes a plurality of linear electromagnetic assemblies 119.

[0052] In FIGS. 3-7, various views of an example of a linear electromagnetic assembly 300 is shown. Assembly 300 can include a plurality of wire coils 301 configured to surround a ferromagnetic core 303. Assembly 300 further includes one or more Digital Control Commutator(s) 302 configured to control the electrical energy flow associated with motor 101. It is contemplated that the ferromagnetic core 303 can be composed of a laminated electrical steel sheet. Assembly 300 can further include one or more connection tabs 304 for securing to a plurality of support beams (shown in FIGS. 13-16). Each assembly 300 further includes a curved face 305 configured to match the curvature of a rotor. Assembly 300 further includes a plurality of bolts 306 configured to hold assembly 300 together.

[0053] In FIGS. 8-12, various views of a rotor assembly 800 used in motor 301 are shown. Assembly 800 includes a plurality of coils 801 surrounding a ferromagnetic core 803 and a rotor 802, with optional hollow rotor core implementation 8010. Assembly 800 further includes one or more center connection reinforcement plates 804 and one or more laminated connection tabs 805 joining the rotor electromagnet assembly together, and one or more bolts 806 configured to hold assembly 800 together. Assembly 800 can further include one or more reinforcement end plates 807 configured to provide a means for the lamination connection tabs to join the rotor electromagnet assembly together. In FIGS. 11, 8 and 9 indicate the template for the electrical steel cutting pattern for the laminated core with and without a connection tab.

[0054] In FIGS. 13-20, various views of a linear array support beam 1300 are shown. Support beam 1300 includes a central I-beam or equivalent structure 1301 and one or more electromagnet assembly connection points 1302 having a plurality of bolt holes 1303. The connection points and bolt holes are configured to provide a location to attach a plurality of support beams and the plurality of linear electromagnetic assemblies together around a central rotor. The assemblies further include top end connection points 1702 and bottom end connection points 1703. Each beam can further include a reinforcement flange 1704 and additional bolt holes 1705 for securing the support structure together.

[0055] In FIG. 21, a cross sectional view of an assembly 2100 of the plurality of linear electromagnetic assemblies and the plurality of support beams is shown. As depicted, assembly 2100 includes alternating support beams 2101 and electromagnetic assemblies 2102 attached by connection joints 2103. This arrangement surrounds a rotor shaft 2105 and rotor shaft electromagnets 2106. The rotor includes one or more connection joints 2107. Assembly 2100 includes a plurality of Digital Control Commutator(s) 2104, further discussed in FIG. 27.

[0056] In FIG. 22, a cross sectional view of an assembly 2200 of the plurality of linear electromagnetic assemblies and the plurality of support beams is shown, wherein assembly 2200 includes a permanent magnet rotor shaft 2206 as well as the features discussed above and associated with assembly 2100, including the alternating support beams 2201 and electromagnetic assemblies 2202 being connected by connection joints 2203 and a plurality of Digital Control Commutator(s) 2204. In addition, assembly 2200 includes one or more connection joints 2207 of a rotor shaft 2205.

[0057] In FIG. 23, an interior view of a faceplate 2300 for use with motor 101 is shown. Faceplate 2300 includes one or more connection attachment slots 2301 configured to secure to the plurality of support beams and one or more connection attachment slot support tabs 2302 configured to further secure the attachment slots to the support beams. Plate 2300 includes a plurality of bolts 2303, 2304 for further securing the assembly together. Plate 2300 includes a main thrust bearing shaft thrust plate 2305 and a drive shaft rotor connection flange 2306 with optional hollow core driveshaft shown.

[0058] In FIG. 24, an example of an expansion joint 111 is shown. Expansion joint 111 includes a universal connection joint 2401 configured to provide the motor with length flex points. One or more rotor drive shaft bolted slip joints 2402, are configured to provide a means for assembling and disassembling the motor units of FIGS. 1 and 2. One or more expansion connection centering mechanisms 2403 are configured to allow for expansion of joint 111. It is contemplated that mechanism 2403 can be a spring, hydraulic, or of pneumatic components. Joint 111 can further include one or more expansion connection joint free movement spaces 2404. Expansion joint 111 further includes one or more connection points 2405 configured to secure to the plurality of linear array support beam ends and one or more spiral helix rotor electromagnet commutator brush supports 2406. In addition, joint 111 can include one or more rotor driveshaft absolute optical position encoders 2407 and one or more spiral helix motor pedestal supports 2408.

[0059] In FIG. 25, a partially assembled motor 2500 in accordance with the present invention is shown. Motor 2500 includes a linear array electromagnet 2501 and a spiral helix array electromagnet 2502. In addition, motor 2500 includes one or more rotor drive shaft absolute optical position encoders 2503 configured to control the movement of electromagnetism. In the preferred embodiment, motor 2500 further includes a spiral helix rotor electromagnet commutator brush support 2504. A linear support beam 2505 is shown, as well as a drive shaft rotor main support bearings 2506, drive shaft rotor thrust bearings 2507, rotor drive shaft bolted slip joints for assemble and disassembly 2508, and a spiral helix motor pedestal support 2509.

[0060] In FIGS. 26a-d, partially assembled views of a four section motor 2600 are shown. It should be noted that dashed lines 1-4 indicate points of joining the various views of motor assembly 2600. The figures show a complete rotation of the spiral helix electromagnet array for the full 360 degrees of rotational coverage. In these figures, 2604 and 2605 depict the spiral electromagnetic surface at the beginning of 0 degrees rotation to 90 degrees rotation, 2606 depicts the spiral electromagnetic surface at 90 degrees rotation, 2607 depicts the spiral electromagnetic surface at 180 degrees rotation, 2608 depicts the spiral electromagnetic surface at 180 degrees rotation, 2609 depicts the spiral electromagnetic surface at 270 degrees rotation, 2610 depicts the spiral electromagnetic surface at 270 degrees rotation, and 2611 depicts the spiral electromagnetic surface at 360 degrees rotation.

[0061] FIGS. 27 and 28 depict diagrams of a Digital Control Commutator (DCC) used in motor 100. The DCC is designed to connect direct current to an electromagnet, reverse the direct current flow from one direction to the opposite direction, and control the power flow while under direct digital control. The DCC includes three basic parts, a digital control stepper motor 2709, a rotational absolute angle detection sensor 2706, and a commutator 2716, while working in conjunction with a closed loop current flow detection sensor used as an electrical contact brush failure indicator 2820, and includes one or more DC current carbon metallic or equivalent contact brushes 2702. The DCC energizes a direct current ferromagnetic core electromagnet 2701, Lines 2703 indicate splitting open the commutator cylinder 2705 for a plainer view. Lines 2704 indicate the bi-rotational direction of cylinder 2705. Commutator cylinder 2705 includes a non-conductive cylinder with conducting metallic inserts in a specific pattern to allow current flow to energized, de-energize, and reverse polarity as commutator 2705 rotates. The DCC includes a power and signal connection 2707 for optical absolute encoder, and a power and control input 2708 for the stepper motor. In addition, the DCC can include multiple connections 2710-2715 for directing current flow.

[0062] In FIG. 28, rows 2817 and 2819 of commutator contacts provide electrical connections for the direct current to flow in opposite directions from one another. Row 2818 of commutator contacts is a non-connection null row configured to provide a non-connection stop/delay position for the commutator.

[0063] The stepper motor is rotated under digital feedback control to energize an electromagnet with precise digital timing signals to create current flow in one direction, and then reverse the current flow in the opposite direction with precise digital control timing signals, additionally it has the ability to remain stationary in any current flow or non-current flow position.

[0064] The commutator is composed of a core material that has conducting metallic inserts in a pattern that creates segmented metallic rings around the commutator core. The segmented rings are aligned to create parallel axial rows. The six segmented rings form two groups of three contact rings each. One group of contact rings is aligned to match the DC current input and output brushes, and the contact brush for one electromagnet coil lead wire and the other group of contact rings is aligned to match the DC current input, output brushes, and the contact brush for the other electromagnet coil lead wire.

[0065] The rows have three patterns as following, one row has six insert segments with no interconnections 2818, and thus does not provide a closed electrical connection. Two rows have four insert segments with two pairs of segments creating two closed electrical connections (2817, 2819) and thus current can flow through them. Those two groups of row patterns are alternated back and forth to create an alternating reversing current flow path, with the frequency of current reversal, and current supply, digitally controlled by rotational speed, rotational angle position, and rotational direction.

[0066] FIG. 29 depicts an operational sequence chart associated with the present invention. Chart represents a spiral helix motor section that has been cut open, and laid out flat on a plain. The rectangle boxes represent the outside electromagnet linear arrays. (L1-L12) The ovals represent the underlying spiral helix magnet arrays. The spiral helix magnet arrays represented by the ovals, are rotating from the top, down to the bottom of the chart. The spiral helix magnet array creates a full time uninterrupted magnetic field. The magnetic polarity does not change, so the magnetic fields can be generated by constantly energized electromagnets, or permanent magnets. When the ovals representing the spiral helix magnet arrays reach the bottom of the chart they will reappear back at the top of the chart and the cycle repeats.

[0067] The letter number combination on the left side indicated by (L1-L12) signifies Linear array 1, Linear array 2, . . . , Linear array 12. The linear electromagnet arrays form the linear magnetic pulse by energizing, de-energizing, and reversing polarity in linear sequence. The letter number combination across the bottom of the figure (R1-R9) represent rings of electromagnets around the rotor formed by the linear electromagnet arrays. At position (L1:R1) the rectangle box contains an X, which indicates the electromagnet is de-energized. At position (L2:R1) the rectangle box contains an , which indicates the electromagnet is energized, South pole. At position (L4:R1) the rectangle box contains an +, which indicates the electromagnet is energized, North pole. At position (L3:R1) the rectangle box contains oval dashed lines representing the rotor magnet directly aligned with the linear electromagnet ring.

[0068] The electromagnetic sequenced pulse traverses from the right side of the chart, to the left side of the chart. The pulse is created by the Digital Control Commutator(s)(DCC) (FIGS. 27, 28) energizing the electromagnets on the linear arrays in timed sequence to magnetically attract, and magnetically repulse, the magnets on the spiral helix magnet array. The timing of the sequence, and magnetic pulse, is dependent on the require operating performance of any given moment during operations. That is all under the control of the digital operating system. As the spiral magnet array rotates, the linear electromagnet arrays creates motion by magnetically interacting in the following ways: At position (L3:R1), the rotor magnet is directly opposite the linear array magnet, and in that position the linear electromagnet is de-energized as the DCC rotates the contacts to the reverse polarity position. The length of time the linear magnet is de-energizes is dependent on the spiral helix motors current operating parameters, though the time is usually as short as possible while the rotor is revolving. The spiral helix magnet remains constant with the negative(south) magnetic polarity. The position (L2:R1), shows the negative(south) polarity repulsing the rotor magnet before it has been de-energized. The position (L4:R1), shows the positive(north) polarity electromagnet attracting the spiral helix rotor negative(south) polarity.

[0069] As the spiral helix rotor magnet turns past the direct linear electromagnet opposing position, at the position (L3:R2), the linear electromagnet is energized with a negative(south) polarity, repulsing the spiral helix magnet negative(south) polarity. At position (L4:R2), the linear electromagnet is energized with a positive(north) polarity attracting the spiral helix magnet negative(south) polarity. At position (L3:R3), the linear electromagnet is energized with a negative(south) polarity, with the spiral helix magnet at midpoint between linear array(L3:R3) and linear array(L4:R3), it repulses the spiral helix magnet negative(south) polarity. At position (L4:R3), the linear electromagnet is energized with a positive(north) polarity attracting the spiral helix magnet negative(south) polarity. At position (L3:R4), the linear electromagnet is energized with a negative(south) polarity, it repulses the spiral helix magnet negative(south) polarity. With the spiral helix magnet almost rotated to the direct opposite position to the linear array(L4:R4), the linear electromagnet at position(L4:R4) is energized with a positive(north) polarity attracting the spiral helix magnet negative(south) polarity. All the spiral helix rotor magnets go through the same sequence as the positive(north) and negative(south) electromagnetic pulses travel down each linear electromagnet array. All magnetic polarities are dependent upon the design characteristics of the specific motor implementation.

[0070] In FIG. 30, an end view of an operating motor is shown, wherein a ring of electromagnets is represented by R1.

[0071] One of the unique features believed characteristic of the present invention is that in order to make a more powerful motor, is to simply increase the length of the motor. The diameter of the motor does not need to increase with increasing power, but only the length. It is done by using standardized components, while being built with linear, assembly line construction methods. A change required for longer or shorter motors though, is that the curve of the spiral helix magnet array needs to be changed to match the designed length of the motor. The designed voltage, and/or amps, and/or motor diameter, can remain constant for Spiral Helix Motors of different designed output power levels. The average energy density and thermal loads, does not increase with increasing power output levels. The motor output power capability, is mostly determined by the length of the spiral helix rotor. The main constraint on output power, is the inherent strength of the drive shaft components design, and material(s).

[0072] Another unique feature believed characteristic of the present invention, is the ability to operate with a single linear magnet array in operation, and with a single spiral helix magnet array on the rotor operating. It does not form an orbital magnetic path for each magnet node/slice/pole, but only a single magnetic pole reversal per revolution, per spiral helix rotor. It's operation is linear in nature. Depending on the design, a fully populated motor with linear electromagnet arrays covering the full 360 degrees available, creates a secondary virtual orbital pulse for each magnet node/slice/pole, as in the way a conventional orbital pulse motor functions.

[0073] The Spiral Helix Motor operates under full digital control. As a result there is complete control of a Spiral Helix Motors operating parameters. Rotational control includes the following 1. Will start in any rotational position, in any direction, at any power/torque level from maximum to minimum. 2. The ability to initiate full reverse at maximum torque at any rotational speed. 3. The ability to hold any position. 4. The ability to apply graduated levels of torque and rotational speed. 5. The ability to apply maximum torque at maximum designed rotation speed. 6. The ability to have infinite variable rotational speed from zero to designed maximum rotation speed. 7. When negative back torque exceeds available positive torque, motor maintains maximum available torque, and rotates backwards until negative back torque drops below available positive torque, and then it rotates in the desired direction. It acts like a shock absorber. 8. The ability to function with a high percentage of electromagnets on the linear arrays disabled because of faults and/or programmed disability. The operational parameters are under full digital control, and rotational performance characteristics are determined by the end users desired power delivery needs.

[0074] The particular embodiments disclosed above are illustrative only, as the embodiments may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the instructions herein. It is therefore evident that the particular embodiments disclosed above may be altered or modified, and all such variations are considered within the scope and spirit of the application. Accordingly, the protection sought herein is as set forth in the description. Although the present embodiments are shown above, they are not limited to just these embodiments, but are amenable to various changes and modifications without departing from the spirit thereof.