Electromagnetic machine with independent removable coils, modular parts and self-sustained passive magnetic bearing
A rotating electromagnetic machine has a tubular axle with mounting rings, a common ring, a coil input ring, and at least one bearing set mounted on it. A fitting is secured at a distal end of the tubular axle, and a commutator is secured at the proximal end. A housing is mounted on the bearing sets through adaptors. Connecting bars extend axially within the axle with lateral rods joined to the connecting bars at their distal ends, the bars commuting between segments of the commutator electromagnetic coils. A plurality of the electromagnetic coils are secured to the coil input ring. The coils are formed of spiral turns of a single flat strip electrically conductive material. A plurality of peripheral and sector magnets are mounted adjacent to the electromagnetic coils with electromagnetic interaction when relative motion occurs between the coils and the magnets.
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Notice: More than one reissue application has been filed for the reissue of U.S. Pat. No. 8,232,695. This is a continuation reissue of application Ser. No. 14/447,523, filed on Jul. 30, 2014, which is an application for reissue of U.S. Pat. No. 8,232,695, issued on Jul. 31, 2012. Application Ser. No. 14/447,523 issued as RE46,449 on Jun. 20, 2017. U.S. Pat. No. 8,232,695 granted from application Ser. No. 12/308,630, filed on Jul. 21, 2010, which is a National Stage of International Application No. PCT/US2008/008434, filed Jul. 9, 2008, each of which is hereby incorporated by reference herein in its entirety.
FIELD OF THE INVENTIONThis invention relates generally to electric motors and generators and more particularly to such an electromagnetic machine with novel structure and operation.
DESCRIPTION OF THE RELATED ARTTu et al, US 2004/0135452, discloses a flat rotary electric generator that includes at least one toroidal coil structure for cutting magnetic lines to induce a current and at least one disc-shaped magnetic pole structure oriented parallel to the helical coil structure. If multiple toroidal coil structures and disc-shaped magnetic coil structures are included, the toroidal coil structures and disc-shaped magnetic coil structures are arranged in alternating manner. The toroidal coil structure and disc-shaped magnetic pole structure are not provided with a permeable material. When either the toroidal coil structures or the at least one disc-shaped magnetic pole structure is rotated by an external force, the toroidal coil structure cuts the magnetic lines passing therethrough to generate an induced current.
Neal, US 2002/0135263, discloses a plurality of stator arc segments that form a toroidal core for a stator assembly used to make a motor. In a preferred embodiment, a plurality of magnetic fields is created when electrical current is conducted through wire wound around poles on the toroidal core. A monolithic body of phase change material substantially encapsulates the conductors and holds the stator arc segments in contact with each other in the toroidal core. Hard disc drives using the motor, and methods of constructing the motor and hard disc drives are also disclosed.
Rose, U.S. Pat. No. 6,803,691, discloses an electrical machine that comprises a magnetically permeable ring-shaped core centered on an axis of rotation and having two axially-opposite sides. Coils are wound toroidally about the core and disposed sequentially along the circumferential direction. Each coil includes two side legs extending radially alongside respectively sides of the core. Coil-free spaces exist between adjacent side legs. A bracket has first and second side flanges that are connected by a bridging structure and respectively abut the first and second sides of the coil.
Mohler, U.S. Pat. No. 6,507,257, discloses a bi-directional latching actuator that is comprised of an output shaft with one or more rotors fixedly mounted thereon. The shaft and rotor are mounted for rotation in a magnetically conductive housing having a cylindrical coil mounted therein and is closed by conductive end caps. The end caps have stator pole pieces mounted thereon. In one embodiment, the rotor has at least two oppositely magnetized permanent magnets which are asymmetrically mounted, i.e., they are adjacent at one side and separated by a non-magnetic void on the other side. The stator pole piece has asymmetric flux conductivity and in one embodiment is axially thicker than the remaining portion of the pole piece. An abutment prevents the rotor from swinging to the neutral position (where the rotor magnets are axially aligned with the higher conductivity portion of the pole piece). Thus, the rotor is magnetically latched in one of two positions being drawn towards the neutral position. Energization of the coil with an opposite polarity current causes the rotor to rotate towards its opposite latching position whereupon it is magnetically latched in that position.
Mohler, U.S. Pat. No. 5,337,030, discloses a permanent magnet brushless torque actuator that is comprised of an electromagnetic core capable of generating an elongated toroidally shaped magnet flux field when energized. Outside the generally cylindrical coil is an outer housing with upper and lower end plates at each end. Mounted to the end plates and extending towards each other are stator pole pieces separated from its opposing pole piece by an air gap. A permanent magnet rotor is disposed in the air gap and mounted on a shaft which in turn is rotatably mounted in each of the end plates. The permanent magnet rotor comprises at least two permanent magnets, each covering an arcuate portion of the rotor and having opposite polarities. Energization of the coil with current in one direction magnetizes the pole pieces such that each of the two pole pieces attracts one of the magnets of the rotor and repels the other magnet of the rotor resulting in a torque generated by the output shaft. Reversal of the current flow results in a reversal of the torque and rotation of the rotor in the opposite direction. Preferred embodiments are disclosed having multiple cells, i.e. a plurality of stator rotor stator combinations and/or cells in which there are a plurality of pole pieces at each stator pole plane.
Kloosterhouse et al, U.S. Pat. No. 5,191,255, discloses an electromagnetic motor that includes a rotor having a plurality of magnets mounted along a perimeter of the rotor. Preferably, adjacent magnets have opposite poles facing outward. One or more electromagnets are disposed adjacent to the perimeter of the rotor so that as the rotor rotates, the magnets mounted on the rotor are carried near the poles of the electromagnets. Current is supplied to the electromagnets by a drive circuit in a predetermined phase relationship with the rotation of the rotor such that, for substantially all angular positions of the rotor, magnetic attraction and repulsion between the poles of the electromagnets and the magnets mounted on the rotor urge the rotor to rotate in a desired direction. Reflective material is mounted on the rotor in predetermined angular positions. The drive circuit includes a photosensitive device which produces a signal whose value varies according to whether the device is receiving light reflected from the reflective material. The signal is amplified to produce drive current for the electromagnets.
Westley, U.S. Pat. No. 4,623,809, discloses a stepper motor housing a pole structure in which a pair of identical stator plates, each having a plurality of poles, are positioned back to back with the poles projecting in opposite directions, the stator plates being positioned between a pair of substantially identical stator cups, each stator cup having a plurality of poles projecting inwardly from a back wall with a peripheral side wall terminating in an outwardly extending flange. A major surface of each flange is in contact with a face on one of the stator plates so as to assure a low reluctance magnetic path.
Fawzy, U.S. Pat. No. 4,565,938, discloses an electromechanical device which can be used as a motor or as a generator. The device has a housing, including bearing means to support a rotatable shaft. Disc magnet means are provided, and poled to have alternating polarity and are mounted on the shaft to define a rotor. The device includes at least one first pole shoe in contact with the magnet means, having a portion extending radially therefrom to define a virtual pole chamber, of a first polarity. Also included is at least one second pole shoe in contact with the magnet and having a portion extending radially therefrom to define a virtual pole chamber of the other polarity. A toroid stator is mounted on the housing and has windings thereon. The stator is positioned annularly around the disc magnets such that the virtual pole chambers of the first and second pole shoes surround portions of said windings with circumferentially alternating fields of alternating polarity. Means are provided for electrical contact with the stator to draw off current when the device is operated as a generator, or provide current to operate the device as a motor.
Fawzy, U.S. Pat. No. 4,459,501, discloses an electromechanical device which can be used as a motor or as a generator that has a housing, including bearing means to support a rotatable shaft. A pair of disc magnets are poled to have opposite polarity on the two faces of each. The magnets are mounted face to face together on the shaft to define a rotor. The device includes at least one first pole shoe in contact with one face of each magnet, and having a portion extending radially therefrom to define, in its preferred form, a pair of virtual pole chambers, of the same polarity as said one face. Also included is at least one second pole shoe in contact with the other face of each magnet and having a portion extending radially therefrom to define in its preferred form a pair of virtual pole chambers of the same polarity as the other face. A toroid stator is mounted on the housing and has windings thereon. The stator is positioned annularly around the disc magnets such that the virtual pole chambers of the first and second pole shoes surround portions of said windings with circumferentially alternating fields of alternating polarity. Means for electrical contact with the stator draw off current when the device is operated as a generator, or provide current to operate the device as a motor.
SUMMARY OF THE INVENTIONThe present invention teaches certain benefits in construction and use which give rise to the objectives described below. In one embodiment, the present invention functions as an electric motor, in a second embodiment it functions as a rotating electric generator, and in a third embodiment it functions as a rotating transformer. In further embodiments, the present invention may operate as a linear machine rather than rotating. In each of these embodiments, the machine may be operated as an AC machine or a DC machine. The machine operates by coupling a moving electromagnetic field to magnets in attraction and also in repulsion. In each embodiment, primary electromagnets produce a field which couples to secondary magnets, which may be permanent magnets or electromagnets, with either the primary or the secondary magnets functioning as part of a stator structure of the machine, i.e., neither rotating nor translating. An important aspect of the present invention, in one structural embodiment, pertinent to the embodiments previously defined, is a novel electromagnetic coil structure wound or formed as spiral turns of a single flat strip of an either ferromagnetic or non-ferromagnetic material. A further important aspect of the present invention is the modularity of the entire construction by use of coil special shape housings of ferromagnetic material which is separated into a plurality of segments magnetically isolated from each other but in mutual electrical continuity and hence minimizing hysteresis effects. Another important aspect of the present invention is the incorporated self sustained passive magnetic bearing as a result of the permanent magnets sweeping a portion of the aluminum shaft ring beneath the permanent magnets and located between the guiding ball bearing and the electromagnets ferromagnetic core. Another important aspect of the present invention is the permanent magnets edges cut in a distinct angle, such as at 45 degrees, or triangular in shape which allows a continuous magnetic one pole face and avoids the alternating magnetic end effect at both ends of the permanent magnet. Another important aspect of the present invention is the useful capture of induced eddy currents of each ferromagnetic segment and sent back in the electrical circuit of the power supply.
A primary objective of the present invention is to provide an apparatus and method of use of such apparatus that yields advantages not taught by the prior art.
Another objective of the invention is to produce a machine as described herein having a high electromagnetic field density.
A further objective of the invention is the elimination of the need for a commutator.
A further objective of the invention is the establishment of low losses including losses derived from hysteresis, heat, radiation and eddy currents, which reduce the efficiency of typical machines of the present type.
A further objective of the invention is to produce a rotating machine with a compact, modular structure.
A further objective of the invention is to provide a rotating machine with open access to the interior of its central shaft on its axis of rotation.
A further objective of the invention is to provide rotating and translating machines with self sustained passive magnetic bearings as part of their integrated construction.
Other features and advantages of the embodiments of the present invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of at least one of the possible embodiments of the invention.
The accompanying drawings illustrate the embodiments of the present invention. In such drawings:
The above described drawing figures illustrate the present invention in at least one of its preferred embodiments, which is further defined in detail in the following description. Those having ordinary skill in the art may be able to make alterations and modifications in the present invention without departing from its spirit and scope. Therefore, it must be understood that the illustrated embodiments have been set forth only for the purposes of example and that they should not be taken as limiting the invention as defined in the following.
The present invention is a rotating electromagnetic machine which may be used in several ways as described above as is familiar to those of skill in the art. The physical construction especially that of the electromagnetic coils and the coil housings, the manner of interconnecting the coils to the commutator and most of the structural configurations of this machine are novel.
What is not depicted in
The enablements described in detail above are considered novel over the prior art of record and are considered critical to the operation of at least one aspect of one best mode embodiment of the instant invention and to the achievement of the above described objectives. The words used in this specification to describe the instant embodiments are to be understood not only in the sense of their commonly defined meanings, but to include by special definition in this specification: structure, material or acts beyond the scope of the commonly defined meanings. Thus if an element can be understood in the context of this specification as including more than one meaning, then its use must be understood as being generic to all possible meanings supported by the specification and by the word or words describing the element.
The definitions of the words or elements of the embodiments of the herein described invention and its related embodiments not described are, therefore, defined in this specification to include not only the combination of elements which are literally set forth, but all equivalent structure, material or acts for performing substantially the same function in substantially the same way to obtain substantially the same result. In this sense it is therefore contemplated that an equivalent substitution of two or more elements may be made for any one of the elements in the invention and its various embodiments or that a single element may be substituted for two or more elements.
Changes from the described subject matter as viewed by a person with ordinary skill in the art, now known or later devised, are expressly contemplated as being equivalents within the scope of the invention and its various embodiments. Therefore, obvious substitutions now or later known to one with ordinary skill in the art are defined to be within the scope of the defined elements. The invention and its various embodiments are thus to be understood to include what is specifically illustrated and described above, what is conceptually equivalent, what can be obviously substituted, and also what essentially incorporates the essential idea of the invention.
While the invention has been described with reference to at least one preferred embodiment, it is to be clearly understood by those skilled in the art that the invention is not limited thereto.
Claims
1. A rotating electromagnetic machine comprising:
- a tubular axle defining a distal and a proximal ends thereof, and mounted medially thereon, a pair of mounting rings, a common ring, a coil input ring, and at least one bearing set; a fitting is secured at the distal end of the tubular axle, and a commutator is secured at the proximal end of the tubular axle;
- a housing mounted on the bearing sets through adaptors; the common ring constructed in two pieces and independently removable from axle,
- connecting bars extending axially within axle; lateral rods joined to connecting bars at distal end thereof, the lateral rods commuting between bars and segments of commutator with distal ends joined with lateral plates;
- a plurality of electromagnetic coils secured to the mounting rings, the coils formed of spiral turns of a single flat strip electrically conductive material; and
- a plurality of peripheral and sector magnets mounted adjacent to the electromagnetic coils.
2. The rotating electromagnetic machine of claim 1 assembled with a modular construction with coil housings of a ferromagnetic material separated into a plurality of magnetically isolated segments in mutual electrical continuity, whereby hysteresis is minimized.
3. The rotating electromagnetic machine of claim 1 wherein each of the peripheral and sector magnets has edges cut in a shape that enables a continuous magnetic pole face and avoids an alternating magnetic end effect at opposing ends of the magnet, whereby, induced eddy currents of the ferromagnetic segments are returned to the electrical circuit thereof.
4. A rotating electromagnetic machine comprising:
- an axle;
- a plurality of coil housings spaced about and coupled to the axle, each of the plurality of coil housings including ferromagnetic material;
- a plurality of electromagnetic coils, each of the plurality of electromagnetic coils being disposed in a respective one of the plurality of coil housings; and
- a plurality of magnet sets, each of the plurality of magnet sets being disposed adjacent to a respective one of the plurality of electromagnetic coils, each of the plurality of magnet sets having a first sector magnet, a second sector magnet, and a peripheral magnet, each sector magnet of each of the plurality of magnet sets having a front surface facing toward the respective one of the plurality of electromagnetic coils, the peripheral magnet of each of the plurality of magnet sets having (i) a front surface facing toward the respective one of the plurality of electromagnetic coils and perpendicular to the front surface of each sector magnet, (ii) first and second end surfaces, each end surface facing parallel to and opposed to the front surface of one of the sector magnets, and (iii) first and second angled surfaces, each angled surface positioned between and at an angle relative to the front surface and one of the opposing end surfaces, the first sector magnet and the second sector magnet being disposed in mutually opposing and facing positions, the peripheral magnet being positioned orthogonal to both the first sector magnet and the second sector magnet,
- wherein each of the plurality of coil housings is disposed between a respective one of the plurality of electromagnetic coils and a respective one of the plurality of magnet sets, and
- wherein a first wedge-shaped portion of each of the plurality of coil housings extends between (i) the front surface of the first sector magnet of the respective one of the plurality of magnet sets, and (ii) the first angled surface of the peripheral magnet, and
- wherein a second wedge-shaped portion of each of the plurality of coil housings extends between (i) the front surface of the second sector magnet of the respective one of the plurality of magnet sets, and (ii) the first angled surface of the peripheral magnet.
5. The machine of claim 4, wherein the angle at which the first and second angled surfaces of each peripheral magnet are positioned is about 45 degrees.
6. The machine of claim 4, wherein each of the plurality of electromagnetic coils is formed of spiral turns of a single flat strip of electrically conductive material.
7. The machine of claim 4, wherein the plurality of coil housings is configured to capture eddy currents induced therein and to return the captured eddy currents to a power supply of the rotating electromagnetic machine.
8. The machine of claim 4, wherein each of the plurality of electromagnetic coils has a respective winding axis.
9. The machine of claim 8, wherein the respective winding axis of each of the plurality of electromagnetic coils is perpendicular to a central axis of the axle.
10. The machine of claim 8, wherein the respective winding axis of each of the plurality of electromagnetic coils is spaced apart from a central axis of the axle.
11. The machine of claim 4, further comprising:
- at least one bearing set rotationally disposed about the axle, and;
- a magnet housing having each of the plurality of magnet sets mounted therein, the magnet housing coupled to the at least one bearing set to allow relative rotation between the magnet housing and the axle.
12. The machine of claim 11, wherein the magnet housing acts as a stator of the rotating electromagnetic machine.
13. The machine of claim 4, wherein the axle acts as a stator of the rotating electromagnetic machine.
14. The machine of claim 4, wherein the plurality of electromagnetic coils are coupled together in an electrically parallel configuration.
15. The machine of claim 4, wherein the first sector magnet, the second sector magnet, and the peripheral magnet of each of the plurality of magnet sets are permanent magnets.
16. The machine of claim 4, wherein each of the plurality of coil housings is separated into a plurality of magnetically isolated segments in mutual electrical continuity, whereby hysteresis is minimized.
17. The machine of claim 4, further comprising a fitting being attached to a distal end of the axle and a commutator being attached to a proximal end of the axle.
18. The machine of claim 4, wherein each of the plurality of electromagnetic coils is mounted on a pair of mounting rings mounted to the axle.
19. The machine of claim 18, further comprising:
- the pair of mounting rings;
- a common ring mounted to the axle; and
- a coil input ring mounted to the axle.
20. The machine of claim 19, wherein the common ring is constructed in two pieces, each of the two pieces of the common ring being independently removable from the axle.
21. The machine of claim 18, further comprising a commutator attached to a first end of the axle, the commutator being electrically coupled to each of the plurality of electromagnetic coils.
22. The machine of claim 21, further comprising:
- a plurality of connecting bars extending generally axially within the axle, each of the plurality of connecting bars aiding in electrically coupling one of the plurality of electromagnetic coils to the commutator; and
- a plurality of lateral rods extending in a radial direction, a first end of each of the plurality of lateral rods being coupled to a first end of a respective one of the plurality of connecting bars.
23. The machine of claim 22, wherein a second end of each of the plurality of lateral rods is coupled to the commutator and wherein a second end of each of the plurality of connecting bars is coupled to the coil input ring.
24. The machine of claim 23, wherein a first end of each of the plurality of electromagnetic coils is coupled to the coil input ring to thereby electrically couple each of the plurality of electromagnetic coils to the commutator.
25. The machine of claim 24, wherein a second end of each of the plurality of electromagnetic coils is coupled to the common ring to electrically ground each of the plurality of electromagnetic coils.
26. The machine of claim 4, wherein each respective coil housing is disposed between a respective one of the plurality of electromagnetic coils and a respective one of the plurality of magnet sets.
27. A rotating electromagnetic machine comprising:
- an axle;
- a plurality of electromagnetic coils, each of the plurality of electromagnetic coils being mounted on separate coil housings of ferromagnetic material, each of the coil housings being mounted on the axle, each of the plurality of electromagnetic coils having a winding axis tangential to a direction of rotation of the machine;
- a plurality of sets of peripheral and sector magnets, the plurality of magnet sets positioned adjacent to the coils, each of the plurality of magnet sets having two of the sector magnets in mutually opposing and facing positions and at least one of the peripheral magnets positioned orthogonal to the sector magnets, each sector magnet of each of the plurality of magnet sets having a front surface facing toward the respective one of the plurality of electromagnetic coils, each peripheral magnet of each of the plurality of magnet sets having (i) a front surface facing toward the respective one of the plurality of electromagnetic coils and perpendicular to the front surface of each sector magnet, (ii) first and second end surfaces, each end surface facing parallel to and opposed to the front surface of one of the sector magnets, and (iii) first and second angled surfaces, each angled surface positioned between and at an angle relative to the front surface and one of the opposing end surfaces, and wherein the plurality of electromagnetic coils and the plurality of magnet sets are engaged for relative rotation between the electromagnetic coils and the magnet sets,
- wherein each of the plurality of coil housings is disposed between a respective one of the plurality of electromagnetic coils and a respective one of the plurality of magnet sets, and
- wherein a first wedge-shaped portion of each of the plurality of coil housings extends between (i) the front surface of the first sector magnet of the respective one of the plurality of magnet sets, and (ii) the first angled surface of the peripheral magnet, and
- wherein a second wedge-shaped portion of each of the plurality of coil housings extends between (i) the front surface of the second sector magnet of the respective one of the plurality of magnet sets, and (ii) the first angled surface of the peripheral magnet.
28. The machine of claim 27, wherein the angle at which the first and second angled surfaces of each peripheral magnet are positioned is about 45 degrees.
29. The machine of claim 27, wherein the plurality of coil housings is configured to capture eddy currents induced therein and to return the captured eddy currents to a power supply of the rotating electromagnetic machine.
30. The machine of claim 27, wherein each of the plurality of electromagnetic coils has a respective winding axis.
31. The machine of claim 30, wherein the respective winding axis of each of the plurality of electromagnetic coils is perpendicular to a central axis of the axle.
32. The machine of claim 30, wherein the respective winding axis of each of the plurality of electromagnetic coils is spaced apart from a central axis of the axle.
33. The machine of claim 27, further comprising:
- at least one bearing set rotationally disposed about the axle, and;
- a magnet housing having each of the plurality of magnet sets mounted therein, the magnet housing coupled to the at least one bearing set to allow relative rotation between the magnet housing and the axle.
34. The machine of claim 33, wherein the magnet housing acts as a stator of the rotating electromagnetic machine.
35. The machine of claim 27, wherein the axle acts as a stator of the rotating electromagnetic machine.
36. The machine of claim 27, wherein the plurality of electromagnetic coils is coupled together in an electrically parallel configuration.
37. The machine of claim 27, wherein the first sector magnet, the second sector magnet, and the peripheral magnet of each the plurality of magnet sets are permanent magnets.
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Type: Grant
Filed: Jun 16, 2017
Date of Patent: Sep 15, 2020
Assignee: CLEARWATER HOLDINGS, LTD. (Carson City, NV)
Inventor: Dumitru Bojiuc (Marina Del Rey, CA)
Primary Examiner: Kenneth Whittington
Application Number: 15/625,780
International Classification: H02K 11/00 (20160101); H02K 23/02 (20060101); H02K 7/00 (20060101); H02K 21/10 (20060101); H02K 41/02 (20060101); H02K 3/04 (20060101); H02K 1/22 (20060101);