U.S. patent application number 11/760704 was filed with the patent office on 2008-04-17 for poly-phasic multi-coil generator.
Invention is credited to Jonathan Ritchey.
Application Number | 20080088200 11/760704 |
Document ID | / |
Family ID | 38801028 |
Filed Date | 2008-04-17 |
United States Patent
Application |
20080088200 |
Kind Code |
A1 |
Ritchey; Jonathan |
April 17, 2008 |
POLY-PHASIC MULTI-COIL GENERATOR
Abstract
A polyphasic multi-coil generator includes a driveshaft, at
least first and second rotors rigidly mounted on the driveshaft so
as to simultaneously synchronously rotate with rotation of the
driveshaft, and at least one stator sandwiched between the first
and second rotors. The stator has an aperture through which the
driveshaft is rotatably journalled. A stator array on the stator
has an equally radially spaced-apart array of electrically
conductive coils mounted to the stator in a first angular
orientation about the driveshaft. The stator array is radially
spaced apart about the driveshaft. The rotors and the stator lie in
substantially parallel planes. The first and second rotors have,
respectively, first and second rotor arrays.
Inventors: |
Ritchey; Jonathan; (Vernon,
CA) |
Correspondence
Address: |
FURR LAW FIRM
2622 DEBOLT ROAD
UTICA
OH
43080
US
|
Family ID: |
38801028 |
Appl. No.: |
11/760704 |
Filed: |
June 8, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60804279 |
Jun 8, 2006 |
|
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11760704 |
Jun 8, 2007 |
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Current U.S.
Class: |
310/268 ;
310/112; 310/156.37; 310/266 |
Current CPC
Class: |
H02K 16/00 20130101;
H02K 3/28 20130101; H02K 21/24 20130101; H02P 9/48 20130101; H02K
21/12 20130101; H02P 9/02 20130101 |
Class at
Publication: |
310/268 ;
310/266; 310/112; 310/156.37 |
International
Class: |
H02K 47/00 20060101
H02K047/00; H02K 21/12 20060101 H02K021/12; H02K 1/22 20060101
H02K001/22 |
Claims
1-16. (canceled)
1. A polyphasic multi-coil generator apparatus comprising: a
driveshaft, first and second rotors rigidly mounted by mounting
means on said driveshaft so as to simultaneously synchronously
rotate with rotation of said driveshaft, first and second stators
interleaved with said first and second rotors wherein said stators
each have an aperture therethrough through which said driveshaft is
rotatably journalled and wherein said stators each have a stator
array; wherein a radially spaced-apart array of electrically
conductive coils are mounted to said stators in first and second
stator array angular orientations respectively about said
driveshaft, said stator arrays radially spaced apart about said
driveshaft, and wherein said rotors and said stators lie in
substantially parallel planes, wherein said first and second rotors
have, respectively, first and second rotor arrays, said first rotor
array having a first radially spaced apart array of magnets
radially spaced around said driveshaft at a first rotor array
angular orientation relative to said driveshaft, said second rotor
array having a second spaced apart array of magnets at a second
rotor array angular orientation relative to said driveshaft,
wherein said angular orientations are collectively offset by an
angular offset, wherein as said driveshaft and said rotors are
rotated in a direction of rotation of said rotors so as to rotate
relative to said stators, an attractive magnetic force of said
magnets of said first rotor array attracts said magnets of said
first rotor array towards corresponding next adjacent coils in said
first stator array which lie in said direction of rotation of said
rotors and substantially balances with and provides a withdrawing
force applied to said magnets of said second rotor array to draw
said magnets of said second rotor array away from corresponding
past adjacent coils in said second stator array as said magnets of
said second rotor array are withdrawn in said direction of rotation
of said rotors away from said past adjacent coils, and wherein as
said driveshaft and said rotors are rotated in said direction of
rotation of said rotors, an attractive magnetic force of said
magnets of said second rotor array attracts said magnets of said
second rotor array towards corresponding next adjacent coils in
said second stator array which lie in said direction of rotation of
said rotors and substantially balances with and provides a
withdrawing force applied to said magnets of said first rotor array
to draw said magnets of said first rotor array away from
corresponding post adjacent coils in said first stator array as
said magnets of said first rotor array are withdrawn in said
direction of rotation of said rotors away from said past adjacent
coils.
2. The apparatus of claim 1 wherein magnets in said rotor arrays
are pairs of magnets, each pair of said pairs of magnets arranged
with one magnet of said each pair radially inner relative to said
driveshaft and the other magnet of said each pair radially outer
relative to said driveshaft.
3-5. (canceled)
6. The apparatus of claim 1 wherein said first and second rotor
arrays are offset by said angular orientation relative to each
other, and further comprising: a further stator mounted on said
driveshaft, said driveshaft rotatably journalled through a
driveshaft aperture in said further stator, a further stator array
mounted on said further stator and having an angular orientation
about said driveshaft which is substantially the same angular
orientation as said first angular orientation of said stator array
of said at least one stator, a third rotor mounted on said
driveshaft so as to simultaneously synchronously rotate with
rotation of said at least first and second rotors, a third rotor
array mounted on said third rotor, said third rotor array having a
third radially spaced apart array of magnets radially spaced around
said driveshaft at a third angular orientation relative to said
driveshaft, said third angular orientation angularly offset by said
angular offset so that said third rotor array is offset relative to
said second rotor array by said angular offset, said further stator
and said third rotor lying in planes substantially parallel to said
substantially parallel planes.
7-19. (canceled)
20. The apparatus of claim 6 wherein said mounting means includes
clutches mounted between said third rotor, said each said at least
first and second rotors and said driveshaft, and wherein said
driveshaft includes means for selectively engaging each clutch of
said clutches in sequence along said driveshaft by selective
longitudinal translation of said driveshaft by selective
translation means.
21. The apparatus of claim 20 wherein said each clutch is a
centrifugal clutch adapted for mating engagement with said
driveshaft when said driveshaft is longitudinally translated by
said selective translation means into a first position for mating
engagement with, firstly, a first clutch of said clutches and,
secondly sequentially into a second position for mating engagement
with also a second clutch of said clutches, and, thirdly,
sequentially into a third position for mating engagement with also
a third clutch of said clutches.
22. The apparatus of claim 1 wherein said first rotor and said
first stator and said second rotor and a said second stator form
rotor/stator pairs wherein said first and second rotors are
angularly offset by said angular offset and mountable into a
generator with further rotor and stator pairs wherein rotors in
said further rotor and stator pairs are successively angularly
offset.
23. The apparatus of claim 1 wherein said rotor and stator arrays
are equally radially spaced apart.
24. The apparatus of claim 6 wherein said rotor and stator arrays
are equally radially spaced apart.
25. The apparatus of claim 6 wherein said mounting means is a rigid
mounting mounted between said third rotor, said each said at least
first and second rotors and said driveshaft, and wherein said
electrical windings on said rotor arrays in successive said stages
may be selectively electrically energized between an open circuit
for selective said windings and a closed circuit for said selective
said windings wherein rotational resistance for rotating said
driveshaft is reduced in the former and increased in the
latter.
26. The apparatus of claim 1 wherein said first and second rotor
arrays are angularly offset by said angular offset relative to one
another.
27. The apparatus of claim 1 wherein said first and second stator
arrays are angularly offset by said angular offset relative to one
another.
28. The apparatus of claim 1 wherein said first and second rotor
arrays are angularly offset relative to one another by a first
angular portion of said angular offset and wherein said first and
second stator arrays are angularly offset relative to one another
by a second angular portion of said angular offset.
29. The apparatus of claim 28 wherein said first and second angular
portions collectively add up to substantially said angular
offset.
30. The apparatus of claim 2 wherein said magnet is a permanent
magnet as well as an electromagnet.
31. The apparatus of claim 2 wherein said magnet comprises two
smaller magnets are situated at either pole with a ferromagnetic
material between and wherein the polarities of these magnets are
opposed.
32. The apparatus of claim 2 wherein said magnet is fitted with a
coil of magnet wire in the middle, between the poles, so as to
allow the magnet to function as well as an electromagnet when a
current is applied to the coil.
33. The apparatus of claim 2 wherein said magnet uses a bobbin to
bold a wire coil 83 in place.
34. The apparatus of claim 2 wherein said a single magnet is use
where this single magnet is encased in a housing material such as
to create a larger magnet with it's magnetic influence, and where a
coil of magnet wire is wrapped around the middle section such as
overtop of the magnet in the middle region of the ferromagnetic
housing material.
35. The apparatus of claim 1 which includes a circuit attached to
said apparatus designed to assess the relevant load
information.
36. The apparatus of claim 1 which includes a circuit designed to
assess the relevant prime-mover information.
37. The apparatus of claim 1 which includes a circuit designed to
assess the relevant prime-mover and load information.
38. The apparatus of claim 1 which includes a circuit wherein each
stage is monitored and when deemed appropriate, adds or removes
additional stages are added, by a control system, and where the
engagement or disengagement of these multiple stages is determined
by the availability of the energy source and the current operating
condition of existing generator stages.
39. The apparatus of claim 1 which includes an algorithmic
microprocessor connected to a high speed semiconductor switching
system designed to match source with load through the engaging, or
disengaging, electrical circuits.
40. The apparatus of claim 39 which includes conditioning
electronics between the semiconductor switching system and the grid
to ensure the signal is appropriate for grid integration.
41. The apparatus of claim 1 which includes a pulse wave
modulator.
42. The apparatus of claim 1 in which said generator will function
as its own gearbox.
43. The apparatus of claim 42 in which includes an integrated
electrical breaking system.
44. The apparatus of claim 42 in which includes a controlling means
that controls the rotational speed of the rotor in such a way as to
avoid shedding energy.
45. The apparatus of claim 44 in which wherein the generator uses a
process of increasing or decreasing the number of independent coils
engaged within the generator to allow the system to function as an
efficient gearbox system controlling the rotational speed of the
turbine.
46. The apparatus of claim 42 in which said generator adds
resistance to the rotation of the rotor through the process of
induction.
47. The apparatus of claim 42 in which said generator removes
resistance to the rotation of the rotor through the process of
electrically removing stages from the system.
48. The apparatus of claim 42 which has a direct-coupled connection
to a prime-mover rotor with multiple stator poles and the
resistance control system.
49. The apparatus of claim 42 in which a staged internal generator
is combined with pre-processing electronics.
50. The apparatus of claim 1 in which a stator and armature
assembly where a stage represents a single coil or a multitude of
coils as is determined by the desired output
51. The apparatus of claim 50 in which said coils are connected in
parallel.
52. The apparatus of claim 50 in which said coils are connected in
series.
53. The apparatus of claim 50 in which said coils are connected in
said stage is accomplished with the coils of a single disk being of
equidistant spacing in a radially spaced array.
54. The apparatus of claim 50 in which said stages are
unsymmetrical in spacing.
55. The apparatus of claim 50 where through the use of an
unsymmetrical array, more than one phase may be created from a
single stator and armature assembly.
56. The apparatus of claim 1 in which a various sizes of
salient-pole induction coils are used to create the desirable
system performance.
57. The apparatus of claim 1 with a configuration of three stator
arrays divided into numerous individual induction coils and where
each stator array is offset mechanically in such a way as to create
a three phase output signal.
58. The apparatus of claim 1 in which a plurality of coils from the
stator arrays is connected together either to create a multitude of
smaller independent induction stages each having a complete three
phase sine-wave as appropriate for grid integration, and, where
each of these stages creates the same output characteristics as all
other stages.
59. The apparatus of claim 1 in which a configuration magnets and
coils on a single disk offset in such as way as to create a
balanced multiphase output, and where said stator may have more
than one size of induction coil.
60. The apparatus of claim 1 in which said armature disks rotate
and serve to function as a flywheel.
61. The apparatus of claim 60 in which said flywheel will store
kinetic energy and will offer a mechanism for moderation of the
rotational speed of the turbine thus smoothing out sudden changes
in source energy and load.
62. The apparatus of claim 1 which has system electronics capable
of checking the integrity of individual coils or series of coils,
that represent a single stage, prior to engagement of the stage
being accomplished through the creation of a fault current by the
system that checks to ensure the integrity of each stage prior to
its engagement.
63. The apparatus of claim 1 which has processing circuitry where
as a fault occurs in a coil winding, it is treated as an isolated
fault by the processing circuitry.
64. The apparatus of claim 1 in which includes a fault detection
system which isolates detected faults.
65. The apparatus of claim 64 in which said system mechanically
manipulates the induction process and thus the output signal
created as the magnets pass by the induction coils
66. The apparatus of claim 1 in which said induction process
manipulates the field strength that passes through the coil cores
through changing the air gap between the magnetic influence and the
induction coil poles at specific regions of these poles.
67. The apparatus of claim 66 in which the relationship of magnet
poles and induction coil poles is manipulated to create the desired
output sine-wave shape, where the modification of poles may be to
the magnet's poles or the induction coil's pole's, or both and
where the shaping of the end of the poles is allowing a more
gradual, less abrupt approach of the magnetic field
68. The apparatus of claim 1 in which allows the outer and or inner
magnets to be adjusted so as to allow for and increased or
decreased air gap.
69. The apparatus of claim 1 in which allows the selecting various
combinations for coils to create various output voltages.
70. The apparatus of claim 1 in which pins or other electrical
contacts may be disposed around the casing in a manner that allows
the selection of various operating voltages for application
71. The apparatus of claim 70 which can orientation coil contacts
may be selected, such as to allow the operator to determine the
resultant voltage being created if it is acting as a generator, or
the appropriate input voltage, if it is acting as a motor.
72. The apparatus of claim 1 in which non metallic materials are
used for the housings.
73. The apparatus of claim 1 in which it functions as a high output
variable input motor.
74. The apparatus of claim 73 in which said motor is comprised of a
multitude of stages where some stages may function as a motor while
others are left disengaged and inactive.
75. The apparatus of claim 73 in which said motor has a flywheel
effect built in as all rotors may be turning at all times
regardless of how many stages are actually engaged with closed
circuits.
76. The apparatus of claim 73 wherein any number of stages may
function as a generator while any number of alternate stages may
function as a motor
77. The apparatus of claim 1 wherein said generator dynamically
controls the arrangement of the coils to achieve a targeted
voltage.
78. An apparatus comprising two magnets, and two field coils, in a
closed loop configuration thus allowing a completed path for
magnetic flux where said magnets are in the shape of horseshoes and
where the poles of both magnets are facing towards each other and
where there are induction cores that when aligned with the poles of
the magnets, will create a closed loop pathway for flux through
both magnets, and both coils where an armature disk having a
multitude of radially inner and outer magnetic influences that
along with the stator's induction coils create a multitude of
closed flux path induction.
79. The apparatus of claim 78, where said inner and outer magnets
are of similar size.
80. The apparatus of claim 78, where said inner and outer magnets
are not of similar size.
81. The apparatus of claim 78, where said inner or outer magnet is
a ferromagnetic material.
82. The apparatus of claim 78, where electromagnets are used for
magnets.
83. The apparatus of claim 78, where hybrid magnets are used for
magnets.
84. The apparatus of claim 78, where one or more of a set of
permanent magnets, electromagnets, or ferromagnetic materials are
used to complete the flux path.
85. The apparatus of claim 78, where stages within a single
armature and stator assembly where said armature will have an inner
and outer magnetic assembly in a non-symmetrical fashion so as to
allow for a multitude of phases to be created from a single
armature interacting with a single stator array and where the
desired force balancing effect is still accomplished as is done
with three armatures or stators offset to balance out forces.
Description
RELATED APPLICATIONS
[0001] This application claims the priority date of U.S.
Provisional Application No. 60/804,279 with a filing date of Jun.
8, 2006.
BACKGROUND OF INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to the field of generators,
and more particularly, it relates to a generator having polyphasic
multiple coils in staged staggered arrays.
[0004] 2. Background of the Invention
[0005] Conventional electric motors employ magnetic forces to
produce either rotational or linear motion. Electric motors operate
on the principle that when a conductor, which carries a current, is
located in the magnetic field, a magnetic force is exerted upon the
conductor resulting in movement. Conventional generators operate
through the movement of magnetic fields thereby producing a current
in a conductor situated within the magnetic fields. As a result of
the relationship between conventional motors and generators,
conventional generator technologies have focused mainly on
modifying electric motor designs, for example, by reversing the
operation of an electric motor.
[0006] In a conventional design for an electric motor, adding an
electrical current to the coils of an induction system creates a
force through the interaction of the magnetic fields and the
conducting wire. The force rotates a shaft. Conventional electric
generator design is the opposite. By rotating the shaft, an
electric current is created in the conductor coils. However the
electric current will continue to oppose the force rotating the
shaft. This resistance will continue to grow as the speed of the
shaft is increased, thus reducing the efficiency of the generator.
In a generator where a wire is coiled around a soft iron core
(ferromagnetic), a magnet may be drawn by the coil and a current
will be produced in the coil wire. However, the system would not
create an efficient generator due to the physical reality that it
takes more energy to pull the magnet away from the soft iron core
of the coil than would be created in the form of electricity by the
passing of the magnet.
[0007] As a result, there is a need for a generator wherein the
magnetic drag may be substantially reduced such that there is
little resistance while the magnets are being drawn away from the
coils. Furthermore, there is a need for a generator that minimizes
the impact of the magnetic drag produced on the generator. In the
prior art, Applicant is aware of U.S. Pat. No. 4,879,484 which
issued to Huss on Nov. 7, 1989 for an Alternating Current Generator
and Method of Angularly Adjusting the Relative Positions of Rotors
Thereof. Huss describes an actuator for angularly adjusting a pair
of rotors relative to each other about a common axis, the invention
being described as solving a problem with voltage control as
generator load varies where the output voltage of a dual permanent
magnet generator is described as being controlled by shifting the
two rotors in and out of phase.
[0008] Applicant also is aware of U.S. Pat. No. 4,535,263 which
issued Aug. 13, 1985 to Avery for Electric D.C. Motors with a
Plurality of Units, Each Including a Permanent Magnet Field Device
and a Wound Armature for Producing Poles. In that reference, Avery
discloses an electric motor having spaced stators enclosing
respective rotors on a common shaft wherein circumferential, spaced
permanent magnets are mounted on the rotors and the stator windings
are angularly offset with respect to adjacent stators slots so that
cogging that occurs as the magnets pass a stator slot are out of
phase and thus substantially cancelled out.
[0009] Applicant is also aware of U.S. Pat. No. 4,477,745 which
issued to Lux on Oct. 16, 1984 for a Disc Rotor Permanent Magnet
Generator. Lux discloses mounting an array of magnets on a rotor so
as to pass the magnets between inner and outer stator coils. The
inner and outer stators each have a plurality of coils so that for
each revolution of the rotor more magnets pass by more coils than
in what are described as standard prior art generators having only
an outer coil-carrying stator with fewer, more spaced apart
magnets.
[0010] Applicant is also aware of U.S. Pat. No. 4,305,031 which
issued Wharton on Dec. 8, 1981 for a Rotary Electrical Machine.
Wharton purports to address the problem wherein a generator's use
of permanent magnet rotors gives rise to difficulties in regulating
output voltage under varying external load and shaft speed and so
describes a servo control of the relative positions of the
permanent magnets by providing a rotor having a plurality of first
circumferentially spaced permanent magnet pole pieces and a
plurality of second circumferentially spaced permanent magnet pole
pieces, where the servo causes relative movement between the first
and second pole pieces, a stator winding surrounding the rotor.
[0011] Furthermore, while existing generator systems are relatively
efficient at converting mechanical to electrical energy, these
existing system have a narrow "efficient" operational range, and
lack the specific power density required to maximize usefulness for
many applications. Existing systems have only one "sweet spot" or
one mode of efficient operation. As a result, these technologies
are challenged to convert mechanical energy to electrical energy
efficiently when the prime-mover energy source is continuously
changing.
[0012] The "sweet spot" for many typical systems is about 1800 rpm.
At this speed the generator can efficiently process kinetic energy
into electricity, but at speeds outside this optimal range these
systems cannot adapt and therefore either the energy collection
system (i.e., turbine) or signal processing circuitry must
compensate. The methods for compensation are many, and may simply
be the turning of turbine blades away from the wind (furling or
pitching) to slow the rotor, or gearing mechanisms to compensate
when wind speeds are below the generators optimal operating range.
These methods all waist energy in an effort to match a constantly
changing energy source with a generator looking for a predictable
and constant prime-mover.
[0013] Therefore these conventional generators have an inability to
maintain a high coefficient of performance due to a limited
operating range. Extensive efforts have been made to expand the
turbines ability to cope with excessive energy (when wind energy
exceeds the threshold) through mechanical shedding of energy (i.e.,
wasted output). Conversely, in those cases where input energy is
below the threshold, current generators either fail to operate, or
they operate inefficiently (i.e., wasted input). Most of the
efforts to date have focused on either mechanical input buffers
(gear boxes) or electronic output buffers (controls), but the cost
has been high, both in terms of development costs &
complexities as well as inefficiencies and increased operations
costs.
[0014] As a result, there is a need for an adaptable generator
system with more than a single "sweet spot". This system would be
able to match prime-mover and load so as to increase the efficiency
of power generation in environments where either the source energy
is changing or the load requirement is changing.
[0015] The applicant is aware of industry's attempts to create a
generator with more than one "sweet spot". For example, the
WindMatic systems (http://www.solardyne.com/win15swinfar.html)
utilize two separate generators in an attempt to capture a broader
range of wind speeds. While this dual generator design does prove
to broaden the band of operation, the overall output for a given
weight would be lower than the disclosed Poly-Phasic Multi-Coil
Generator (PPMCG). The PPMCG essentially combines a multitude of
generators (18 for example) in a single unit rather than requiring
two separate generators to allow only two separate sweet spots. In
addition, for the WindMatic system these two generator systems are
combined and controlled through additional gearing and hardware.
Therefore, the design utilizing two separate generators would have
additional construction/material costs as well as additional
maintenance costs over the PPMCG design.
[0016] For many applications, the weight to output of the generator
is of utmost importance. Increasing the Specific Power Density of a
generator has been an ongoing and primary focus for generator
designers. The proposed generator addresses this issue through a
unique design characteristic called "Closed Flux Path
Induction".
[0017] Closed Flux Path Induction (CFPI) technology is possible in
the Poly-Phasic Multi-Coil Generator (PPMCG) design due to the
unique internal geometry with respect to the magnetic influences
and induction coils. The result is reduced flux leakage and a more
efficient induction process over conventional systems.
[0018] It is well known that the strength of the magnetic field
(flux density) in a generator system determines the magnitude of
the electrical output. Therefore the optimal system would ensure
the strongest field density at the induction coil poles while
minimizing straying magnetic fields (flux leakage) that creates
unwanted currents in various generator components wasting energy in
the form of heat and straying electrical currents. These issues are
addressed with the disclosed generator system as it maximizes flux
density where it is desired while at the same time reducing
unwanted flux leakage.
[0019] Closed Flux Path Induction provides a path of high magnetic
permeability for the flux lines to travel. A common example of a
closed flux path is a simple horseshoe magnet with a keeper. The
keeper acts to close the path for the magnetic field as it moves
from one magnetic pole to the other.
[0020] Magnets have a diffuse magnetic field that permeates their
immediate surroundings. The flux lines that leave one pole MUST
return to the opposite pole. The effective magnetic field induced
by a flux line depends on the path that it follows. If it must
cover a large distance through a medium of low magnetic
permeability (air) it will be a relatively weak field. If the flux
line can pass through a material of high magnetic permeability
(ferromagnetic materials) a stronger field is produced and less
leakage will occur.
[0021] As an example, a small button magnet can easily pick up a
paperclip if it is held close to it but, if held at a distance
equal to the paperclips length there will be little effect because
the permeability of air is very low. If a paperclip is placed
between the magnet and another paperclip, both paperclips may be
picked up. The first paper clip acts as a path of high permeability
for the magnet effectively increasing the strength of the magnetic
field at a distance.
[0022] The strength of a horseshoe magnet arises from this effect.
When you pick up a piece of metal with a horseshoe magnet it
completes the magnetic path by connecting the North and South poles
with a material of high magnetic permeability. A secondary effect
of providing a path of high permeability is that the flux leakage
is reduced.
[0023] Flux leakage is defined as the undesirable magnetic field.
That is, the magnetic field that is not focused on the desired
object (the induction coil in a generator). Flux leakage is
problematic for generators because it results in less magnetic
field strength where it is desired, at the induction coil poles,
and it generates unwanted effects such as eddy currents that reduce
the systems efficiency.
[0024] Conventional generators have attempted to deal with the
above issues by utilizing high permeability materials as cases or
end caps so that the large magnetic fields generated can be
utilized efficiently. Unfortunately, materials with high
permeability are also quite heavy and reduce the power to weight
ratio of the generator significantly. In addition, these systems
have not been successful in a completely isolated and controlled
induction process as is the case with the PPMCG.
[0025] Many conventional electromagnetic induction generator
systems utilize excitation systems as a current is required to
excite the electromagnets in order to create the necessary magnetic
field. This is often done with another smaller generator attached
to the same rotor as the primary system such that as the rotor
turns, a current is created in the primary system's electromagnets.
There are other systems that utilize electrical storage systems to
create the initial required charge. These systems are not as
efficient as a permanent magnet system as a certain amount of the
output power created by the generator is required to be fed back
into its own electromagnets in order to function, thus reducing
efficiency. In addition, a PM system offers more field strength per
weight than electromagnetic systems. Unfortunately, permanent
magnets get more difficult to work with as generators get larger,
and larger systems in the megawatt range are almost all
electromagnetic induction systems. The PPMCG system offers the
benefits of both a PM machine and an electromagnetic excitation
"induction" generator through the use of a hybrid magnetic
system.
[0026] Hybrid magnets can also be utilized in the PPMCG to further
increase the strength of the magnetic field beyond the strength of
just the permanent magnet. This hybrid magnet is an electromagnet
with a permanent magnet imbedded into it in such a way as to
maximize field strength and controllability over the field.
[0027] Because Voltage is dependent upon the length of a conductor
that passes through a magnetic field, selecting the total conductor
length of each phase selects the voltage. With the unique PPMCG
design the generator may be easily modified to act as various
systems with different voltage outputs. The pins or other
electrical contacts may be disposed around the casing in a manner
that allows the user or manufacture to select the operating voltage
of the motor or generator by connecting adjacent layers in a
selected angular orientation with respect to each other. An
orientation may be selected, such as to allow the operator to
determine the resultant voltage being created, if it is acting as a
generator, or the appropriate input voltage, if it is acting as a
motor. For example, the same machine may run at 120 volts, 240
volts or 480 volts.
[0028] Conventional generator systems utilize a post-processing
power electronics system that creates a sub-standard power signal
and then attempts to "fix" it through manipulating other system
parameters such as modifying the turbine blade pitch, or changing
gearing ratios that drive the rotor. This post-processing practice
that attempts to fix a signal after it is created lacks efficiency
and often leads to the need for asynchronous function where the
output is converted into DC and then back again to AC in order to
be synchronous with the grid. This is an inefficient process where
substantial losses are incurred in the inversion process.
[0029] As a result, there is a need for a more functional
processing system. The PPMCG "Pre-Processing" power electronics is
a key element to the PPMCG system. It allows the significant
advantage of creating the desired output signal in raw form rather
than creating an inadequate signal and then trying to fix it with
conventional "post-processing" electronics. The PPMCG generator
stages are monitored by the "Pre-Signal" Processing circuit, which
allows the device to harmonize output voltage and system resistance
with grid requirements, simultaneously through adding and removing
independent generator stages. While the staging system offers a
course control, the electronics system offers the fine control
required to ensure grid tolerances are met and seamless integration
is achieved. Various mechanisms can be employed to ensure smooth
fine control as stages are added or removed from the system. One
such mechanism would be a pulse wave modulator that pulses in and
out the stages while maintaining the desire generator
operation.
[0030] The current from each stage of the system is monitored by
the pre-signal processing circuit that determines what system
configuration is most beneficial based upon readily available
information. When the turbine (prime-mover) reaches adequate
momentum the pre-signal processing circuit will engage the first
stage. Each stage is monitored and additional stages are added, or
removed, by the control system depending on availability of the
energy source and the current operating condition of existing
engaged stages.
[0031] Another major challenge for electrical engineers is how to
remove the need for a conventional gearbox. Many existing
generators operate best at high speed and require step-up
gearboxes. These gearboxes are expensive, subject to vibration,
noise and fatigue, and require ongoing maintenance and lubrication.
The negative impact of gearboxes is considerable. Perhaps more
significantly, gearboxes allow the generator to function at low
wind speeds but when wind speeds are low the system can least
afford to waste precious wind energy.
[0032] The benefits of a direct-coupled gearbox are significant.
Many conventional systems have gearbox losses up to 5% of total
output. In addition the gearbox represents a costly and high
maintenance component often weighing as much as the generator
component. The gearbox is a weak link in the generator system that
adds unwanted weight, cost, and reduces overall efficiency of the
system.
[0033] In contrast to conventional designs, the PPMCG Technology is
well suited to a `direct-coupled` configuration that forgoes the
gearbox and the attendant losses that impede performance. The PPMCG
does not function through mechanical gearing but by applying
resistance to the rotor to maintain appropriate speeds, effectively
acting as its own gearbox. The required resistance at the rotor
will be determined by the system electronics and will be created by
engaging the appropriate number of complete generator stages. In
essence, the rotor speed is controlled (up to a predetermined
threshold) by the resistance created through the process of
creating electrical power, unlike a mechanical system that sheds
valuable energy to control the rotor rotation.
[0034] The PPMCG technology's multi-pole stator field will allow
slow speed operation such that the system could function
effectively without a conventional gearbox that impedes overall
system performance. With each rotation of the rotor each coil is
induced 18 times (assuming 18 coils per stator). Therefore
regardless of if there were I coil or 100 coils on the stator, each
coil would still produce electricity at the same frequency as all
other coils on the same stator. As each new coil is added then, a
consistent output signal is created for all coils on each stator.
As the three stator arrays are offset appropriately (i.e. by 120
degrees), the mechanical configuration determines that the output
signal is a synchronous 3 phase signal.
[0035] In recent years, a number of alternative concepts have been
proposed that remove the need for gearboxes and `direct-couple` the
turbine with the generator rotor. The challenge for these systems
is that the generator still requires a constant and predictable
prime mover to function efficiently. These direct-coupled
generators are thus compromised due to inadequate compensation
methods for controlling generator speeds. The output of an
induction generator can be controlled by varying the current flow
through the rotor coils. Induction generators produce power by
exciting the rotor coils with a portion of the output power. By
varying the current through the rotor coils the output of the
generator can be controlled. This control method is called `doubly
fed` and allows the operation of induction generators as
asynchronous variable speed machines. While offering some benefits
over constant speed systems, this type of generator is expensive
and incurs considerable losses in the process of conditioning the
output.
[0036] A major limitation of existing "variable speed" generators
is the additional cost and complication of power electronics. Power
electronics are required to condition the output so that it is
compatible with the grid and to ensure that the generator is
operating at its peak efficiency. These variable speed generators
work by rectifying the variable AC output of the generator to DC
and then inverting it back to grid synchronized AC. This method
requires the use of high power silicon (expensive) and losses are
incurred in the processes of transforming and inverting the output
current (i.e. AC to DC to AC).
[0037] The PPMCG technology shifts with the input source, capturing
more energy at a wider range and reducing the need for mechanical
interference and the wasted energy that results. Adding, or
dropping, stages as input energy and load varies, the self-adapting
unit reduces need for complex, expensive gearboxes and power
controls.
[0038] Yet another challenge with existing systems is the fault
control systems. For exiting systems the total output of the system
must be managed by the power electronics at all times and when a
fault occurs, the fault current is very problematic due to the
limited overloading capability of the power electronic converter.
For conventional systems, when a fault occurs, the system must be
shut down immediately or considerable damage can occur to the
generator.
[0039] A fault is defined here as a short circuit. When a short
circuit occurs, the output current of synchronous generators
increases substantially, because the impedance is reduced. The
large current can damage equipment and should therefore be reduced
as soon as possible by removing the faulted component from the
system, thus cancelling the low impedance current path. However,
the large current is also a clear indicator that a short circuit
exists. Thus, on the one hand, the fault current is undesirable
because it can lead to equipment damage while on the other hand it
is an essential indicator to distinguish between faulted and normal
situations.
[0040] PPMCG employs a unique and beneficial fault control
mechanism. When an internal failure occurs in a PM generator, the
failed winding will continue to draw energy until the generator is
stopped. For high-speed generators, this may represent a long
enough duration to incur further damage to electrical and
mechanical components. It could also mean a safety hazard for
individuals working in the vicinity. The induction generator, on
the other hand, is safely shut down by de-excitation within a few
milliseconds preventing hazardous situations and potential damage
to the unit. In either scynario, the system must be completely shut
down until it can be repaired causing unwanted downtime at
potentially very inopportune times when power is needed most.
[0041] With the PPMCG Technology, dividing the output current into
smaller manageable sections significantly reduces the negative
impact of faults in the stator windings. Since far less current is
created by the single three-coil sub-system or staged element,
system faults are localized. While they still must be managed,
damage can be avoided and safety issues reduced. One of the
advantages of the proposed "pre-processing" circuitry is the
ability to simply avoid utilizing the current from a faulty coil,
while allowing the remainder of the coils to continue functioning
(in fact, three coils will need to be shut down if there is a fault
in a three phase system).
[0042] Another challenge for many existing systems is that they are
not capable of creating a raw signal that doesn't require
significant manipulation to the sine-wave form in order to match
the required output frequency for grid integration. For many
conventional systems "shaping" of the field core poles is simply
not an available option and therefore there is no other choice but
to condition the power so it is in alignment with the desired
waveform.
[0043] In contrast, the PPMCG system will create the correct
sinusoidal sine wave as a raw signal directly from the field coils.
The sine wave created by the system can be manipulated through a
unique design attribute that allows, through internal geometry,
shaping of the waveform created by the generator. This is of
particular relevance as the sine wave for most conventional systems
required considerable conditioning in order for it to be adequately
synched with grid systems. These systems must typically function as
less desirable "asynchronous" machines.
[0044] Another unique and advantageous element of PPMCG is that the
mass of the balanced stages of the armature disks rotate and serve
to function as a flywheel. This stabilizes sudden and undesirable
changes in rotational speed and smoothes out the operation of the
system.
[0045] In addition to having a positive impact on renewable energy
systems that utilize variant energy sources to function, the
disclosed generator will also prove to offer significant value to
conventional non-renewable systems. For example, many conventional
systems having one state of efficient operation will utilize far
more fuel than is required to meet the power needs of the consumer.
With the disclosed generator system, the generator will
re-configure itself so as to be the right sized generator to meet
only the current needs of the consumer thus preserving fuel as
power requirements are lower than the rated speed for a
conventional system.
SUMMARY OF INVENTION
[0046] In summary, the polyphasic multi-coil generator includes a
driveshaft, at least first, second, and third rotors rigidly
mounted on the driveshaft so as to simultaneously synchronously
rotate with rotation of the driveshaft, and at least one stator
sandwiched between the first and second rotors. The stator has an
aperture through which the driveshaft is rotatably journalled. A
stator array on the stator has a radially spaced-apart array of
electrically conductive coils mounted to the stator in a first
angular orientation about the driveshaft. The stator array is
radially spaced apart about the driveshaft and may, without
intending to be limiting be equally radially spaced apart. The
rotors and the stator lie in substantially parallel planes. The
first, second, and third rotors have, respectively, first, second,
and third rotor arrays. The first rotor array has a first radially
spaced apart array of magnets radially spaced around the driveshaft
at a first angular orientation relative to the driveshaft. The
second rotor array has a second equally spaced apart array of
magnets at a second angular orientation relative to the driveshaft.
The third rotor array has a third equally spaced apart array of
magnets at a third angular orientation relative to the driveshaft.
Without intending to be limiting, the rotor arrays may be equally
radially spaced apart. The first and second angular orientations
are off-set by an angular offset so that the first and second rotor
arrays are offset relative to one another. The radially spaced
apart stator and rotor arrays may be constructed without the
symmetry of their being equally radially spaced apart and still
function.
[0047] The angular offset is such that, as the driveshaft and the
rotors are rotated in a direction of rotation of the rotors so as
to rotate relative to the stator, an attractive magnetic force of
the magnets of the first rotor array attracts the magnets of the
first rotor array towards corresponding next adjacent coils in the
stator array which lie in the direction of rotation of the rotors
so as to substantially balance with and provide a withdrawing force
applied to the magnets of the second rotor array to draw the
magnets of the second rotor array away from corresponding past
adjacent coils in the stator array as the magnets of the second
rotor array are withdrawn in the direction of rotation of the
rotors away from the past adjacent coils. Similarly, as the
driveshaft and the rotors are rotated in the direction of rotation
of the rotors, an attractive magnetic force of the magnets of the
second rotor array attracts the magnets of the second rotor array
towards corresponding next adjacent coils in the stator array which
lie in the direction of rotation of the rotors so as to
substantially balance with and provide a withdrawing force applied
to the magnets of the first rotor array to draw the magnets of the
first rotor array away from corresponding past adjacent coils in
the stator array as the magnets of the first rotor array are
withdrawn in the direction of rotation of the rotors away from the
past adjacent coils. The third rotor provides a further enhancement
of the above effects.
[0048] In one embodiment, a further stator is mounted on the
driveshaft, so that the driveshaft is rotatably journalled through
a driveshaft aperture in the further stator. A further stator array
is mounted on the further stator. The further stator array has an
angular orientation about the driveshaft which, while not intending
to be limiting, may be substantially the same angular orientation
as the first angular orientation of the stator array of the first
stator. A third rotor is mounted on the driveshaft so as to
simultaneously synchronously rotate with rotation of the first and
second rotors. A third rotor array is mounted on the third rotor.
The third rotor array has a third equally radially spaced apart
array of magnets radially spaced around the driveshaft at a third
angular orientation relative to the driveshaft. The third angular
orientation is angularly offset for example, by the angular offset
of the first and second rotor arrays so that the third rotor array
is offset relative to the second rotor array by the same angular
offset as between the first and second rotor arrays. The further
stator and the third rotor lay in planes substantially parallel to
the substantially parallel planes the first stator and the first
and second rotors. Advantageously the third rotor array is both
offset by the same angular offset as between the first and second
rotor arrays from the second rotor array and by twice the angular
offset as between the first and second rotor arrays, that is, their
angular offset multiplied by two, from the first rotor array. Thus
the first, second and third rotor arrays are sequentially angularly
staggered about the driveshaft.
[0049] The sequentially angularly staggered first, second and third
rotors, the first stator and the further stators may be referred to
as together forming a first generator stage. A plurality of such
stages, that is, substantially the same as the first generator
stage, may be mounted on the driveshaft. Further stages may or may
not be aligned with the first stage depending upon the desired
application.
[0050] The magnets in the rotor arrays may be pairs of magnets,
each pair of magnets may advantageously be arranged with one magnet
of the pair radially inner relative to the driveshaft and the other
magnet of the pair radially outer relative to the driveshaft. This
arrangement of the magnets, and depending on the relative position
of the corresponding coils on the corresponding stator, provides
either radial flux rotors or axial flux rotors. For example, each
pair of magnets may be aligned along a common radial axis, that is,
one common axis for each pair of magnets, where each radial axis
extends radially outwardly of the driveshaft, and each coil in the
stator array may be aligned so that the each coil is wrapped
substantially symmetrically around corresponding radial axes. Thus,
advantageously, the magnetic flux of the pair of magnets is
orthogonally end-coupled, that is, coupled at ninety degrees to the
corresponding coil as each pair of magnets are rotated past the
corresponding coil. The use of coupled inner and outer magnets on
the rotor array greatly increases the magnetic field density and
thus increases the power output from each coil.
[0051] In one embodiment not intended to be limiting, the first
rotor array is at least in part co-planar with the corresponding
stator array as the first rotor array is rotated past the stator
array, and the second rotor array is at least in part co-planar
with the corresponding stator array as the second rotor is rotated
past the stator array. The third rotor array is at least in part
co-planar with the corresponding stator array as the third rotor is
rotated past the stator array.
[0052] The rotors may include rotor plates wherein the rotor arrays
are mounted to the rotor plates, and wherein the rotor plates are
mounted orthogonally onto the driveshaft. The stators may include
stator plates and the stator arrays are mounted to the stator
plates, and wherein the stator plates are orthogonal to the
driveshaft.
[0053] The rotors may be mounted on the driveshaft by mounting
means which may include clutches mounted between each of the first
and second rotors and the driveshaft. In such an embodiment, the
driveshaft includes means for selectively engaging each clutch in
sequence along the driveshaft by selective longitudinal translation
of the driveshaft by selective translation means. The clutches may
be centrifugal clutches adapted for mating engagement with the
driveshaft when the driveshaft is longitudinally translated by the
selective translation means into a first position for mating
engagement with, firstly, a first clutch for example, although not
necessarily, on the first rotor and, secondly sequentially into a
second position for mating engagement with also a second clutch for
example on the second rotor and so on to sequentially add load to
the driveshaft, for example during start-up. Thus in a three rotor
stage, some or all of the rotors may have clutches between the
rotors and the driveshaft. As described above, the stages may be
repeated along the driveshaft.
[0054] In an alternative embodiment, the mounting means may be a
rigid mounting mounted between the third rotor, each of the first
and second rotors and the driveshaft. Instead of the use of
clutches, the electrical windings on the rotor arrays in successive
stages may be selectively electrically energized, that is, between
open and closed circuits for selective windings wherein rotational
resistance for rotating the driveshaft is reduced when the circuits
are open and increased when the circuits are closed. Staging of the
closing of the circuits for successive stator arrays, that is, in
successive stages, provides for the selective gradual loading of
the generator. By the use of control electronics, which activate
and deactivate individual coils, the output of the generator can be
varied from zero to the nominal power rating. Thus the generator
can produce a variable power output at a fixed frequency. The
control electronics could also be used to vary the voltage of the
generator output. By connecting coils in series or parallel the
voltage can be varied instantaneously.
[0055] There are numerous other unique and novel attributes to the
disclosed invention that offer desirable advantages over prior art.
Some of these include closed flux path magnetics, hybrid magnetics,
pre-processing electronics, mechanical sine wave control, and a
unique fault control system.
[0056] When additional stages are added electrically, increased
mechanical resistance will slow the rotation of the rotor as a
result of the effect of adding load and the additional resistance
it creates. This process will control current flow while creating
additional energy with available kinetic energy that might
otherwise be wasted. When either the input source or the demand for
energy is low, only one or two stages of the system stages may be
engaged. This allows the Variable Input system to operate when
conventional systems would be shut down due to insufficient
prime-mover energy or excessive resistance created by "oversized"
generator systems. Unlike conventional systems, the PPMCG output
can be modified to accommodate constantly changing source energy
"or" constantly changing energy consumption. For example, when
energy demand is low at night, the PPMCG system will simply
disengage un-necessary stages. This will be particularly
advantageous to Hydro systems that are challenged to adapt to
changing energy demands.
[0057] The PPMCG system varies stage engagement as required for
optimal output. The current PPMCG design divides the generator into
18 distinct 3 coil (three phase) stages bundled together in a
single generator. The three coils, one from each of the three
stators in a three stator system, may be connected to each other in
series or parallel depending upon the desired application. The
PPMCG's unique staged internal configuration and pre-processing
electronics will allow the system to serve as its own electronic
gearbox (with 18 stages for example) offering greater control over
the induction process and thus offering a better quality power
output. As part of the power electronics, a PWM (pulse wave
modulator) can be used to ensure a smooth transition from one
staging configuration to the next.
[0058] The generator sections are monitored by the "Pre-Signal"
Processing circuit, which allows the device to harmonize output
voltage and system resistance with grid requirements,
simultaneously through adding and removing independent generator
stages.
[0059] With the PPMCG, the current from each stage of the system is
monitored by a pre-signal processing circuit that determines what
system configuration is most beneficial based upon readily
available information. When the turbine (prime-mover) reaches
adequate momentum the pre-signal processing circuit will engage the
first stage. Each stage is monitored and additional stages are
added, or removed, by the control system depending on availability
of the energy source and the current operating condition of
existing engaged stages. The result of this process is greater
overall energy output due to capturing more of the potential energy
of the wind or other transient energy source.
[0060] The PPMCG utilizes a completely closed magnetic field path.
The disclosed generator system is divided into pairs of magnets
arranged in a shape that is similar to two opposing horseshoes with
two coil cores in the middle to complete the circuit thus directly
inducing magnetic flux into either end of an isolated electromagnet
with a North-Pole field orientation on one end, and a South-Pole
field orientation on the other. This salient-pole-to-salient-pole
configuration creates opportunities for increased electrical
current due to a more direct induction process where flux is
allowed to move freely though the coil cores and in a completed
magnetic field path. The geometry of this arrangement isolates the
induction process in such a way as to increase the field density at
the induction coil poles while at the same time greatly reducing
undesired flux leakage.
[0061] This configuration of induction coils and magnets will
increase the power to weight ratio as smaller magnets can be used
to create same output as larger magnets in less efficient systems.
This design will prove equally beneficial for induction style
generators increasing flux density where it is needed and reducing
unwanted leakage.
[0062] Another significant benefit of this isolated induction
process in that there is greater opportunity to utilize various
advantageous materials in the generator construction. With
conventional systems, there are many parts of the generator that
must be made of specific materials. An example of this is the
casing for many existing systems needing to be a conductive metal
(i.e. ground). With the PPMCG lighter and cheaper materials can be
used and in some instances it may not be desirable to have certain
components (such as a casing) at all, thus offering a reduction in
overall weight and manufacturing costs.
[0063] With the PPMCG a coil is wrapped around a backing plate for
two permanent magnets. When an appropriate electric current is
passed through the coil it acts as an amplifier of the magnetic
field. Research indicates that it is possible to increase the
strength of the magnetic field by twice the sum of the individual
magnetic fields (the permanent magnet and the electromagnet). Since
increasing the strength of the magnetic field increases the current
generated in the coils of a generator, this technology represents
an exciting opportunity to increase the power to output ratio for
generators and motors.
[0064] A coil would just have to be wrapped around the backing
plates for the permanent magnets creating a permanent magnet
augmented with an electromagnet. Such a design could provide an
even more powerful PPMCG also providing even more control over the
output of the PPMCG, since the hybrid coils could be used as a fine
control of the magnetic field and thus the output of the PPMCG.
[0065] The PPMCG pre-processing algorithmic microprocessor will use
a semiconductor switching system to match source with load to
engage, or disengage, electrical circuits for each of the induction
coils of a three armature/three stator system. Appropriate
conditioning electronics (i.e. filters) between the semiconductor
switching system and the grid will ensure seamless and trouble-free
grid integration.
[0066] The system will monitor relevant conditions such as load,
prime-mover status and the state of the current collective of
engaged stages to determine exactly when it is optimal to engage or
disengage the next generator stage.
[0067] With the PPMCG, the power electronics are not exposed to the
collective and significant implications of a fault current
representing the entire generator output due to the isolation of
independent coils throughout the system. Dividing the output
current into smaller manageable sections within the PPMCG System
significantly reduces the negative impact of faults in the stator
windings. Far less current is created by each three-coil
sub-system, or staged-element, and therefore negative system fault
impacts are localized and minimized. For example, if an 18 coil
stator is used in a three phase system with 9 complete stator
assemblies, the generator will have 18.times.3 or 54 independent 3
phase sub-stages (162 coils divided into 3 phase sub-stages). Each
of which will be managed with a simple semiconductor switching
mechanism to isolate faults. The microprocessor may be designed to
assess the status of each three-coil stage prior to engaging it,
and if in fact the stage is faulted, the system will automatically
skip this stage element allowing the generator to continue
operation where conventional systems would require shut down and
immediate repair. This segmenting of generator sections offers many
advantages in controlling the system as well as in reducing issues
with system damage and safety.
[0068] Control over the shape of the output sine wave created by
the generator is another unique opportunity that is offered by the
PPMCG design. Through shaping the field coils poles the induction
process can be manipulated in such as way as to form the desired
waveform as a raw output signal. As the magnets pass by the field
coil poles, the magnetic field strength that passes through the
coil cores will be relative to the air gap between the magnetic
influence and the induction coil poles. Therefore, by controlling
the shaping the poles, the desired sinusoidal waveform can be
produced as the raw unprocessed output. The result of this design
attribute is a better quality raw output signal with reduced
requirements for expensive power conditioning equipment.
BRIEF DESCRIPTION OF DRAWINGS
[0069] Without restricting the full scope of this invention, the
preferred form of this invention is illustrated in the following
drawings:
[0070] FIG. 1a is, in partially cut away perspective view, one
embodiment of the polyphasic multi-coil generator showing a single
stator sandwiched between opposed facing rotors;
[0071] FIG. 1 is, in front perspective view, a further embodiment
of the polyphasic multi-coil generator according to the present
invention illustrating by way of example nine rotor and stator
pairs wherein the nine pairs are grouped into three stages having
three rotor and stator pairs within each stage, the radially spaced
arrays of magnets on each successive rotor within a single stage
staggered so as to be angularly offset with respect to each
other;
[0072] FIG. 2 is, in front perspective exploded view, the generator
of FIG. 1;
[0073] FIG. 3 is the generator of FIG. 2 in rear perspective
exploded view;
[0074] FIG. 4 is a partially exploded view of the generator of FIG.
1 illustrating the grouping of the rotor and stator pairs into
three pairs per stage;
[0075] FIG. 4a is, in front elevation view, the generator of FIG. 1
with the front rotor plate removed so as to show the radially
spaced apart magnet and coil arrangement;
[0076] FIG. 5 is, in perspective view, the generator of FIG. 1
within a housing;
[0077] FIG. 6 is a sectional view along line 6-6 in FIG. 1;
[0078] FIG. 7 is, in front perspective exploded view a single rotor
and stator pair of the generator of FIG. 1;
[0079] FIG. 8 is the rotor and stator pair of FIG. 7 in rear
perspective exploded view;
[0080] FIG. 9 is, in cross sectional view, an alternative
embodiment of a single rotor and stator pair illustrating the use
of a centrifugal clutch between the rotor and the driveshaft;
[0081] FIG. 9a is a cross sectional view through an exploded front
perspective view of the rotor and stator pair of FIG. 9;
[0082] FIG. 10 is, in partially cut away front elevation view, an
alternative embodiment of the present invention illustrating an
alternative radially spaced apart arrangement of rotor and stator
arrays;
[0083] FIG. 11a is in side elevation a further alternative
embodiment of the generator according to the present invention
wherein the stator coils are parallel to the driveshaft on a single
stage;
[0084] FIG. 11b is in side elevation two stages according to the
design of FIG. 11a;
[0085] FIG. 11c is, in side elevation, three stages of a further
alternative embodiment wherein the stator coils are inclined
relative to the driveshaft;
[0086] FIG. 12 is, in front elevation view, an alternate embodiment
of the generator of FIG. 1 with the front rotor plate removed so as
to show a non-symmetrical arrangement of coil cores to magnets
where three or more phases can be accomplished with only one
stator;
[0087] FIG. 13 is, on front elevation view, one embodiment
representing a single stage comprised of two magnets and two field
coils;
[0088] FIG. 14 is, in front perspective view, a single rotor of the
generator of FIG. 16;
[0089] FIG. 15 is, in front perspective view, a single stator of
the generator of FIG. 16;
[0090] FIG. 16 is, a partial cross sectional view of a front
perspective of an alternate embodiment of the generator if FIG. 1
utilizing double sided rotors and stators; and
[0091] FIG. 17 is, a front perspective view of a one embodiment of
a single hybrid permanent magnet which will also act as an
electromagnet.
DETAILED DESCRIPTION
[0092] The following description is demonstrative in nature and is
not intended to limit the scope of the invention or its application
of uses.
[0093] There are a number of significant design features and
improvements incorporated within the invention.
[0094] The device is a generator polyphasic multiple coils in
staged staggered arrays.
[0095] Incorporated herein by reference in its entirety my U.S.
Provisional Patent Application No. 60/600,723 filed Aug. 12, 2004
entitled Polyphasic Stationary Multi-Coil Generator. Where any
inconsistency exists between these documents and this
specification, for example in the definition of terms, this
specification is to govern.
[0096] In FIG. 1a, wherein like reference numerals denote
corresponding parts in each view, a single stage 10 of the
polyphasic multi-coil generator according to the present invention
includes a pair of rotors 12 and 14 lying in parallel planes and
sandwiching there between so as to be interleaved in a plane
parallel and lying between the planes of the rotors, a stator 16.
Rotors 12 and 14 are rigidly mounted to a driveshaft 18 so that
when driveshaft 18 is rotated by a prime mover (not shown) for
example in direction A, rotors 12 and 14 rotate simultaneously at
the same rate about axis of rotation B. Feet 32 are provided to
mount stator 16 down onto a base or floor surface. Rotors 12 and 14
each have a central hub 19 and mounted thereon extending in an
equally radially spaced apart array around driveshaft 18 are pairs
of magnets 22a and 22b. Although only one pair of magnets, that is,
only two separate magnets are illustrated, with a keeper shown
between to increase flux, a single magnet with the polarities of
either end inducing the coils may be used with substantially equal
results. Each pair of magnets is mounted on a corresponding rigid
arm 24 extended cantilevered radially outwardly from hub 19. Each
pair of magnets 22a and 22b are spaced apart along the length of
their corresponding arm 24 so as to define a passage or channel 26
between the pair of magnets.
[0097] Electrically conductive wire coils 28 are wrapped around
iron-ferrite (or other favourable magnetically permeable material)
cores 30. Cores 30 and coils 28 are mounted so as to protrude from
both sides 16a and 16b of stator 16. Coils 28 are sized so as to
pass snugly between the distal ends 22a and 22b of magnets 22, that
is, through channel 26 so as to end couple the magnetic flux of the
magnets with the ends of the coils. In the embodiment illustrated
in FIG. 1a, again which is not intended to be limiting, eight coils
28 and corresponding cores 30 are mounted equally radially spaced
apart around stator 16, so that an equal number of coils and cores
extend from the opposite sides of stator 16 aligned so that each
coil and core portion on side 16a has a corresponding coil and core
immediately behind it on the opposite side of stator 16, that is,
on side 16b. It is to be understood that although this embodiment
employs an eight coil array, however, any number of coils with
corresponding magnet assemblies may by employed. For example, in
one embodiment, this design uses sixteen coils and two sets of
armatures (that is rotors) with twelve sets of magnets each. This
embodiment is not intended to suggest that a single stage may be
employed. Any number of stages may be utilized on the same
driveshaft.
[0098] Rotor 14 is a mirror image of rotor 12. Rotors 12 and 14 are
mounted in opposed facing relation on opposite sides of stator 16.
The angular orientation of rotors 12 and 14 about driveshaft 18
differs between the two rotors. That is, the magnets 22 on rotor 14
are angularly offset about axis of rotation B relative to the
magnets mounted on rotor 12. For example, each of the pairs of
magnets on rotor 14 may be angularly offset by, for example, and
offset angle .alpha. (better defined below) of five degrees or ten
degrees or fifteen degrees relative to the angular orientation of
the pairs of magnets on rotor 12. Thus, as rotors 12 and 14 are
simultaneously being driven by rotation of shaft 18, as a magnet 22
on rotor 12 is being magnetically attracted towards a next adjacent
core 30 portion on side 16a of the stator, the attractive force is
assisting in pushing or drawing the corresponding magnet on rotor
14 past and away from the corresponding core portion on side 16b of
stator 16. Thus the attractive force of incoming magnets (incoming
relative to the coil) on one rotor substantially balances the force
required to push the corresponding magnets on the other rotor away
from the coil/core. Consequently, any one magnet on either of the
rotors is not rotated past a core merely by the force of the
rotation applied to driveshaft 18, and the amount of force required
to rotate the rotors relative to the stator is reduced. The
efficiency of the generator is thus increased by the angular
offsetting of the magnet pairs on opposite sides of the stator
acting to balance or effectively cancel out the effects of the
drawing of the magnets past the cores.
[0099] Further stages may be mounted onto driveshaft 18 for example
further opposed facing pairs of rotors 12 and 14 having a stator 16
interleaved there between. In such an embodiment, further
efficiency of the generator may be obtained by progressive angular
offsetting of the magnets so as to angularly stagger each
successive rotors' array of magnets relative to the angular
orientation of the magnets on adjacent rotors. Thus, with
sufficient number of stages, the magnetic forces may be relatively
seamlessly balanced so that at any point during rotation of
driveshaft 18, the attractive force of the magnet approaching the
next adjacent cores in the direction of rotation balances the force
required to push or draw the magnet pairs on other rotors away from
that core thus reducing the force required to rotate driveshaft
18.
[0100] A further embodiment of the invention is illustrated in
FIGS. 1-9, again wherein similar characters of reference denote
corresponding parts in each view. In the illustrated embodiment
nine banks of rotors 34 each have radially spaced apart arrays of
magnet pairs 36a and 36b wherein the arrays are angularly displaced
or staggered relative to adjacent arrays on adjacent rotors. Thus
each magnet pair 36a and 36b in the equally radially spaced array
of magnet pairs 36a and 36b, radially spaced about axis of rotation
B are angularly offset by the same offset angle .alpha., for
example, five degrees, ten degrees or fifteen degrees, between
adjacent rotors. Thus the successive banks of rotors are
cumulatively staggered by the same angular displacement between
each successive rotor so as to achieve a more seamlessly
magnetically balanced rotation of the rotors relative to the
stators 38 and in particular relative to the coils 40 and cores 42
mounted on stators 38.
[0101] Magnets 36a and 36b are mounted onto a carrier plate 44. The
carrier plate 44 for each rotor 34 is rigidly mounted onto
driveshaft 18. Coils 40 and their corresponding cores 42 are
mounted onto a stator plate 48. Stator plate 48 is rigidly mounted
to housing 56, which itself may be mounted down onto a base or
floor by means of rigid supports (not shown).
[0102] In one alternative embodiment not intending to be limiting,
a small motor 54, which is in addition to the prime mover (not
shown), may be employed to engage additional stages or banks having
further progressively angularly displaced or staggered stages or
banks of magnet pairs in radially spaced array on successive
rotors. For example motor 54 may selectively drive a shifter rod so
as to sequentially engage centrifugal clutch mechanisms on each
rotor as described below.
[0103] A housing 56 may be provided to enclose stators 38 and the
armatures or rotors 34. Housing 56 may be mounted on a supporting
frame (not shown), and both may be made of non-magnetic and
non-conductive materials to eliminate eddy currents. In one
embodiment of the invention, not intended to be limiting, a single
stage 58 of the generator includes three stators 38 interleaved
with three rotors 34. The generator may include multiple stages 58
along the driveshaft to reduce the magnetic drag by offsetting any
resistances created within the generator.
[0104] Stators 38 may include a plurality of induction coils 40
made of electrically conducting materials, such as copper wire.
Each induction coil 40 may be wrapped around a highly ferromagnetic
core such as a soft iron core 42. Alternatively, induction coils 40
may be air coils (that is, not wrapped around any core) for
applications where less output current is required or where less
mechanical force is available to be applied to rotors 38. In the
illustrated embodiment of the invention, the stators are disk
shaped. The embodiment of FIG. 1a includes eight induction coils 28
mounted equidistant and equally radially spaced apart from each
other on a plate or disk made of non-magnetic and non-conductive
materials. In the embodiment of the remaining figures, stators 38
include sixteen induction coils 40 on each stator disk or plate 48.
The number of induction coils 40 may vary depending on the
application of the generator, and may be only limited by the
physical space available on the stator plate.
[0105] The induction coils 40 may be configured such that a first
set of induction coils 40 produce a first independent phase signal
and a second set of induction coils 40 produce a second independent
phase signal with opposing wave signals. The induction coils 40 are
alternately orientated such that an induction coil 40 producing the
first independent phase signal is positioned in between induction
coils 40 producing the second independent phase signal. In such
dual phase design, the two independent phases are exact reciprocals
of each other wherein one independent phase may be inverted to
combine the potential current of the two into one phase with a
synchronous wave pattern. Preferably, each of the first set and
second set of induction coils 40 have an equal number of induction
coils 40 wrapped around their cores 42 in a first direction and an
equal number of induction coils 40 wrapped around their cores 42 in
an opposite second direction to align the currents of the two
phases. For example, in the embodiment wherein the stators 38
include sixteen, that is, two sets of eight induction coils 40
(alternate phases), each of the first set of eight induction coils
40 will produce a first independent phase signal and the second set
of eight induction coils 40 will produce a second independent phase
signal.
[0106] Rotors 34 may have magnets 36 of any magnetic materials such
as neodymium magnets. Rotors 34 each include an array of equally
spaced apart pairs of magnets 36a and 36b which are mounted on
rotor plates made of non-magnetic and non-conductive materials so
as to discourage straying flux lines or eddy currents. In the
embodiment having sixteen induction coils 40 on each stator, the
rotor array of magnets (the "rotor array") includes eight
"U"-shaped opposed facing pairs of magnets 36 on each rotor 34.
Each end of each "U"-shaped magnet 36, sixteen ends in all on the
radially outer ring and sixteen on the inner ring, are paired to
the corresponding sixteen coils as the ends of the magnets are
rotated closely past the opposite ends of the coils.
[0107] In the illustrated embodiment of FIG. 1 the rotor arrays
between successive rotors 34 in stage 58 are angularly offset about
the axis of rotation B of the driveshaft by an offset angle .alpha.
of for example fifteen degrees. It is understood that an offset of
fifteen degrees is merely one preferred offset, but it may be any
number of degrees of offset. Offset angle .alpha. is seen best in
FIG. 4a as the angle between the radial axes 60 and 60' of magnets
36a and 36a' of successive rotors 34.
[0108] As the rotors are driven to rotate about the driveshaft by
an outside motive force, such as for example wind or water or other
prime movers, the magnets 36 travel towards induction coils 40 by
attraction of the magnets to the cores 42. AC pulse is created in
all the induction coils on the stators as the induction coils are
designed to draw the magnetic flux from the magnets 36. In the
embodiment of FIG. 1a, which is illustrative, the opposing polarity
of the magnets between each rotor and the angularly offset
alignment of the rotor array relative to each other permits the
magnets to be drawn away from one core and towards the next core.
For example, the north, south (N,S) polarity configuration of the
magnets on the first rotor 12 is drawn by the opposing south, north
(S,N) polarity configuration of the magnets on is the second rotor
14, where the first rotor array is offset by fifteen degrees
relative to the second rotor array such that the magnetic
attraction between the magnets on the first rotor and the magnets
on the second rotor draws the magnets away from the core. The
balancing of magnetic forces between magnets on the rotors reduces
the work required from the driveshaft to draw magnets off the
induction coils, thereby increasing the efficiency of the
generator.
[0109] The rotating magnetic fields created by the configuration of
the magnets with alternating magnetic orientation between rotors
and the alternating multi phase configuration of the induction
coils create multiple reciprocal AC phase signals. As the induction
coils are stationary, AC power may be harnessed directly from the
induction coils without brushes. The regulation and attenuation of
these currents may be achieved by methods known in the art. As the
magnets pass the induction coils, they induce a current that
alternates in direction. Magnets may be configured such that for
example an equal number of magnets influence the first set of
induction coils by a N,S magnetic polarity as the number of magnets
influencing the second set of induction coils by a S,N magnetic
polarity. The configuration of the rotors create an alternating
current in each of the two phases of the single stage embodiment of
FIG. 1a. The configuration of magnetic forces allow for a balancing
of the resistances within the generator.
[0110] In an alternative embodiment, such as seen in FIGS. 1-9,
there is a significant advantage to the addition of multiple stages
on the driveshaft. The work required to rotate the driveshaft may
be even further reduced through the addition of multiple stages 58.
The alignment of the multiple stages may be offset such that
additional stages further reduces resistance in the generator by
accomplishing even greater balancing of forces than can be done
with a single stage design. Alignment of stator arrays of coils
("stator arrays") may be offset or alternatively, the alignment of
the rotor arrays may be offset to reduce resistance. Consequently,
adding additional stages may increase electrical output without
proportionally increasing resistance within the generator. While
additional induction coils will increase magnetic drag, the greater
balancing of forces achieved by the orientation of the stator
arrays and rotor arrays of the additional stages offsets the
increase in drag and further increases the overall efficiency of
the generator. Additional stages may be engaged so as to rotate the
additional rotors by any number of mechanisms, such as current
driven sensors that use solenoids, or clutches such as the
centrifugal driven clutch mechanisms of FIGS. 7-9, 9a which may be
used to engage the next stage when the rotor of a subsequent stage
achieves a predetermined speed. An example of a clutch is
illustrated. Clutch 62 is mounted within the hub of each of rotors
34. Rotation of a clutch arm 64, once the clutch is engaged by the
splines on the splined portion 18b of driveshaft 18 engaging
matching splines within the arm hub 66, drives the arm against
stops 68. This drives the clutch shoes 70 radially outwardly so as
to engage the periphery of the shoes against the interior surface
of the rotor carrier plate hub 44a. A linear actuator, for example
such as motor 54, actuates shifter rod 72 in direction D so as to
engage splined portion 18b with firstly, the splines within the arm
hub 66. Then, once the clutch engages and the rotor comes up to
nearly match the rotational speed of the driveshaft, the splined
portion is further translated so as to engage the splines 74a
within the rotor hub 74. Subsequent rotor/stator pairs or
subsequent stages, such as stages 58, may be added, by further
translation of the shifter rod into the splines of subsequent
clutches and their corresponding rotor hubs. In a reversal of this
process, stages are removed by withdrawing the shifter rod. Rotor
hubs are supported by needle bearings 76 within stator hub 38a. In
the further alternative, linear motor driven mechanisms or spline
and spring mechanisms may be used. FIG. 10 is a further alternative
embodiment wherein the coils are offset in a concentric circle
around the driveshaft to achieve the magnetic balancing. The coils
are aligned end to end in a concentric circle around the driveshaft
in the further alternative embodiment seen in FIGS. 11a-11c. The
induction coils 40 are mounted parallel, or slightly inclined as in
FIG. 11c, relative to the driveshaft to reduce the draw of magnetic
flux from between the rotors due to the close proximity and the
strength of the magnets. A further advantage of positioning the
induction coils parallel to the driveshaft is that drawing magnets
directly past the end of each induction coil rather than from the
side may be more efficient in inducing current in the induction
coils. A horizontal orientation of the induction coils may also
permit doubling the number of induction coils in the generator,
resulting in greater output. In the embodiment of FIG. 11b, the two
stator arrays 80 and 80' have an angular offset relative to each
other that is one half of the desired total angular offset, that
is, the alignment that provides for optimum balance. The next
successive stator array may then have the same angular offset as
between stator arrays 80 and 80'. As in the other embodiments the
angular offset may be appropriately offset for any number of
stages. This embodiment shows that the coils may be offset while
leaving the magnet arrays in the armatures/rotors in alignment,
that is without an angular offset between successive rotor arrays,
and still accomplish the balancing effect.
[0111] As stated above, multiple stages reduce resistance as each
stage is added. For example, within a stage having three
rotor/stator pairs, rather than a single induction coil being
induced by the passing of two magnets with opposing magnetic poles,
such an embodiment allows two induction coils to effectively align
between the magnetic influences of the rotor arrays. In addition to
increasing the number of induction coils, the rotors arrays are
much further apart, thus significantly reducing the incidence of
straying magnetic flux across the space between the rotors.
[0112] To appropriately orientate additional stages for a staging
application, the rotor arrays may be appropriately angularly offset
as described above. Alternatively as seen in FIG. 11c, the
induction coils may be angled such that the rotor arrays are not
perfectly aligned in parallel to each other. As induction coils 40
and their corresponding cores 42 are on a slight angle, magnets
(not shown) on rotors 78 on either side of the stator arrays 80 are
preferably misaligned too as the magnetic influence from the
magnets should induce each of the induction coils from both ends
simultaneously for optimum function. In an embodiment of the
invention, the misalignment of rotor arrays is increasingly
smaller, becoming negligible as more stages are added. As
additional stages are added, the less of an angular offset exists
between the subsequent rotor arrays with the stages. Any number on
of stages may be added to the driveshaft and additional stages may
be aligned or misaligned with other stages within the generator,
depending on the desired function.
[0113] The optimum number of stages may be determined by the
degrees of offset of each stage relative to the previous stage. The
number of induction coils in the stator arrays need not depend on
the corresponding number of magnets in the rotor arrays. The stator
arrays may include any number of induction coils and they may or
may not be symmetrical in their placement about the stators.
[0114] There are many applications for a generator according to the
present invention. For example, rather than having a wind turbine
that requires significant energy to start rotating driveshaft 18
and which may be overloaded when too much wind is applied, the
generator may be reconfigured allow the maximum current to be
produced regardless of how much wind is driving the generator. This
may be accomplished by engaging a greater number of stages, such as
stages 58 for example as the wind increases and decreasing the
engagement of stages to reducing the number of engaged stages when
the wind decreases. Furthermore, the first stage of the generator
may include air coils such that very little wind energy is required
to start rotating the driveshaft, and subsequent stages may include
induction coils having iron cores such that greater currents may be
generated when there is greater wind energy. Further, additional
stages may increase is size and diameter so as to create greater
physical resistance when greater wind energy is present but as well
to create more electrical output from the system when input energy
is high. When wind energy is minimal, the generator may thus still
allow for rotor 30 to rotate as it will engage only one, that is
the first stage of the generator. As the wind energy increases, the
generator may engage additional stages, thus increasing the output
current. As wind energy continues to increase, more stages may be
added or engaged to allow for the maximum current to be drawn off
the generator. As wind energy decreases in intensity, the generator
may disengage the additional stages and thus reduce mechanical
resistance, allowing the blades of the wind turbine or other wind
driven mechanism to continue to turn regardless of how much wind is
present above a low threshold. This generator configuration allows
for maximized energy collection.
[0115] Applications for such a variable load generator are numerous
as the generator is not only able to adapt to variable source
energies, such as wind, but can be adapted to service specific
power needs when source energy can be controlled. One example would
be a hydro powered generator that rather than turning off at night,
and needing to warm up again to service greater power needs in the
day, may simply vary its output to suit the night cycle and thus
use less source energy to function during that time.
[0116] In an alternative design, all of the rotors in all of the
stages are rigidly mounted to the driveshaft, so that all of the
rotors are rotating simultaneously. Instead of clutches, the
windings circuits are left open on, at least initially, many or
most of the stages to reduce turning resistance, and only those
windings on the stages to be engaged are closed, that is
engergized. This allows for reduced resistance on the driveshaft
overall when a lesser number of stages are electrically engaged. As
additional circuits are closed and more windings thus added to the
system, this will result in increasing the load of the generator
and thus it will increase resistance on the driveshaft. By not
requiring clutching mechanisms, the generator may be less expensive
to construct and maintain as there are no maintenance issues
regarding any clutch mechanisms. This "electrical" staging system
may be applied to the magnetically balanced generator design
according to the present invention or any other conventional design
applicable for the staging application.
[0117] It should also be noted that the staging application,
mechanical with clutches, or electrical by engaging and disengaging
coil array circuitry may be applied to existing generator designs
that are appropriately constructed into short, stout sections so as
to accommodate the staging application.
[0118] One embodiment would have a circuit designed to assess the
relevant information about the device such as load information in
order to determine and employ the optimal number of stages of a
multi-sage generator apparatus. The device could have a circuit
designed to assess the relevant prime-mover information in order to
determine and employ the optimal number of stages of the generator
apparatus, or a circuit designed to assess the relevant prime-mover
and load information in order to determine and employ the optimal
number of stages of the generator or a circuit wherein each stage
is monitored and when deemed appropriate, additional stages are
added, or removed, by the control system, and where the engagement
or disengagement of these multiple stages is determined by the
availability of the energy source and/or the current operating
condition of existing generator stages or independent coils as part
of a stage.
[0119] The generator device can also have an apparatus comprising
an algorithmic microprocessor connected to a high speed
semiconductor switching system designed to match source with load
through the engaging, or disengaging, electrical circuits. It can
utilizing a pulse wave modulator or similar device in order to
offer fine control in smoothing out the transition of generator
stages as they are added or removed electrically from the system.
The above apparatus incorporating appropriate conditioning
electronics, such as filters, between the semiconductor switching
system and the grid to ensure the signal is appropriate for grid
integration.
[0120] The generator will have a system whereas the electronics of
the system are capable of checking the integrity of individual
coils or series of coils, that represent a single stage, prior to
engagement of the stage being accomplished through the creation of
a fault current by the system that checks to ensure the integrity
of each stage prior to its engagement. The system can have
processing circuitry that where as a fault occurs in a coil
winding, it is treated as an isolated fault by the processing
circuitry. The generator through various fault detection means and
whereas said fault occurrence is isolated by the system and avoided
by the system through leaving its circuit open and thus out of the
collective output signal.
[0121] FIG. 12 is, in front elevation view, an alternate embodiment
of the generator of FIG. 1 with the front rotor plate removed so as
to show a non-symmetrical arrangement of coil cores to magnets
where three or more phases can be accomplished with only one
stator. Unlike FIG. 4a that has a symmetrical spacing of magnets
and field coils, this illustration shows that a variety of
different sized coil cores 42 can be utilized and as well, the coil
winding can be modified to accomplish different results with the
induction process. It can be seen in this illustration that coil
windings 40 are larger than coil winding 40a. It may be desirable
to create less resistance to the rotation of the shaft in certain
circumstances, and with select stages, such as during the
generator's start up so as to reduce resistance. As well, the
illustration of FIG. 12 shows that a full three phase system, or
virtually any number of phases, can be accomplished with just one
stator and armature assembly. This can be seen as there are three
different mechanical positions with respect to magnets and
induction coils and that in this illustration, they are
appropriately offset from each other thus they will create the
desired three phase output appropriate for most grid systems.
[0122] In a stator and armature assembly a stage can represent a
single coil or a multitude of coils as is determined by the desired
output. The coils may be connected in parallel or series thus
creating as many phases in the output signal as is desired. The
staging may be accomplished with the coils of a single disk being
of equidistant spacing in a radially spaced array, or, an apparatus
where stages may be unsymmetrical in spacing as is seen in FIG.
12.
[0123] Through the use of an unsymmetrical array, more than one
phase may be created from a single stator and armature assembly. A
system where various sizes of salient-pole induction coils as seen
if FIG. 12 may be employed to create the desirable system
performance. The generator can have a configuration of three stator
arrays divided into numerous individual induction coils and where
each stator array is offset mechanically in such a way as to create
a three phase output signal. Also at least one coil from each of
the three stator arrays can be connected together either in series
or in parallel so as to create a multitude of smaller independent
induction stages each having a complete three phase sine-wave as
appropriate for grid integration, and, where each of these stages
creates the same output characteristics as all other stages as a
result of identical mechanical geometry with respect to the
relationship of magnetic influences to induction coils.
[0124] The generator can also have a configuration magnets and
coils on a single disk offset in such as way as to create a
balanced multiphase output, and where the stator may have more than
one size of induction coil, or induction coil cores, being employed
in one or more stages offering increased control over resistance
and output such as is seen in FIG. 12
[0125] FIG. 13 is, on front elevation view, one embodiment
representing a single stage comprised of two magnets and two
induction coils. This single induction element, or stage, serves
many unique purposes; most significantly it offers an isolated
induction process that increases flux density and reduces unwanted
flux leakage. The inner magnet 36a and the outer magnet 36b will
create a strong and focussed magnetic field that will induce in a
completed path from North magnetic poles to South magnetic poles
passing through both of the induction coils 40 and their cores 42
in such as way as to allow an isolated path for the flux.
[0126] Additionally, FIG. 13 illustrates how the relationship
between stator and armature is "salient-pole to salient-pole". This
characteristic of the design allows for manipulation of the
physical characteristics of either the magnet end poles or the
induction coil core end poles. Through manipulating the shape of
the ends of the poles, the sine-wave will take a different shape.
If the wave form created has sharp corners due to the abrupt
approach of the magnets to the induction coils, then the end of the
induction cores 42 may be shaved off as is shown in the
illustration by the line pointed to by number 82. Additionally, if
it is desirable to create a more gradual, smother induction
process, and thus a more rounded sine-wave, a more curved shaping
of the induction coil core 42 can be utilized as is shown by the
line 82a.
[0127] The generator can be set up to mechanically manipulate the
induction process and thus the output signal created as the magnets
pass by the induction coils and manipulate the field strength that
passes through the coil cores through changing the air gap between
the magnetic influence and the induction coil poles at specific
regions of these poles. This can be as illustrated in FIG. 13 where
the relationship of magnet poles and induction coil poles is
manipulated to create the desired output sine-wave shape and the
modification of poles may be to the magnet's poles or the induction
coil's pole's, or both, and where the shaping of the end of the
poles is allowing a more gradual, less abrupt approach of the
magnetic field thus smoothing out operation of the system whereby
further reducing cogging torque, and creating a more sinusoidal
wave-form shape as is desired for integration into most grid
systems. It can also allow the outer and or inner magnets to be
adjusted so as to allow for and increased or decreased air gap so
as to allow for greater control over the flux density impacting the
induction coil and the characteristics of the induction process;
particularly those that impact the shape of the resultant
sine-wave.
[0128] FIGS. 14 to 16 illustrate the parts of yet another alternate
design embodiment, focussed on reducing manufacturing costs by
utilizing both sides of the stator plate 38 and armature carrier
plate 44 to hold the induction coils and magnets in place. It can
be seen that with the exception of the armature assemblies at
either end of the generator, this design employs both sides of both
the stator and armature to house magnets and induction coils thus
reducing manufacturing costs. As well, this design will assist in
balancing out the bending force on the armature and stator plates
by offsetting the force on one side of the plate, with the force
being created on the other side of the plate.
[0129] The base feet 32 of the device will secure the system to a
footing and may be manufactured as a single plate that as well
holds the stator coils securely in place. FIG. 16 illustrates a
generator section with 4 stator arrays having removed a cross
section of the upper right quadrant. In this design the induction
coil cores 42 are mounted on the stator plates 38 and are tightly
packed between the armature plates 44. Wires from each coil will
pass through a hole in the stator plate 38 and may be housed in a
channel on the outer edge of the plate. Wires may come together at
the controller mounting brackets 85 that will direct the wiring
into the circuit box.
[0130] FIG. 17 illustrates a hybrid magnetic device that may be
employed in the generator. The magnet in this design may be simply
two magnets at either pole with an appropriate ferromagnetic
material serving as the housing between the two and thus allowing
the two magnets to act as one larger magnet. This permanent magnet
may be fitted with a coil in the middle so as to allow the magnet
to function as well as an electromagnet. The electromagnet may or
may not utilize a bobbin 84 to hold the wire coil 83 in place. An
alternate design for this hybrid magnet might be encasing only one
magnet in the housing material rather than two. This can be done by
simply encasing a permanent magnet in the middle of the housing
material, in this illustration, underneath the wire coil 83. This
hybrid magnet can act as a permanent magnet with the potential for
greater control in serving as an electromagnet as well. In
addition, this magnetic arrangement is particularly advantageous in
a closed flux path environment. Research shows that the collective
flux density of the combined magnet and electromagnet is beyond
simply adding up the two forces when applied in a closed path
arrangement.
[0131] Another embodiment is where the magnetic device, as in FIG.
17, comprises two smaller magnets that are situated at either pole
with a ferromagnetic material between and wherein the polarities of
these magnets are opposed; that is where one is facing outwardly
North, and the other outwardly South, and where there is an
appropriate ferromagnetic material serving as the housing between
the two magnets thus allowing the two magnets effectively act as
one larger magnet.
[0132] The magnetic apparatus above fitted with a coil of magnet
wire in the middle, between the poles, so as to allow the magnet to
function as well as an electromagnet when a current is applied to
the coil and where the electromagnet may or may not utilize a
bobbin 84 to hold the wire coil 83 in place.
[0133] An alternate design for this apparatus where only one magnet
is utilized rather than two, and where this single magnet is
encased in or about the housing material such as to create a larger
magnet with it's magnetic influence, and where a coil of magnet
wire is wrapped around the middle section such as overtop of the
magnet in the middle region of the ferromagnetic housing material,
as would be the case if a magnet where placed under wire coil 83 in
FIG. 17.
[0134] In an additional alternative embodiment, which is a Closed
Flux Path Induction, the generator has two magnets, and two field
coils, in a closed loop configuration thus allowing a completed
path for magnetic flux. There is a completed flux path where the
magnets are in the shape of horseshoes and where the poles of both
magnets are facing towards each other and where there are induction
cores that when aligned with the poles of the magnets, will create
a closed loop pathway for flux through both magnets, and both
coils. There is an armature disk having a multitude of radially
inner and outer magnetic influences that along with the stator's
induction coils create a multitude of closed flux path induction
stages within a single armature and stator assembly. The armature
having an inner and outer magnetic assembly in a non-symmetrical
fashion so as to allow for a multitude of phases to be created from
a single armature interacting with a single stator array and where
the desired force balancing effect is still accomplished as is done
with three armatures or stators offset to balance out forces. In
this embodiment, the generator will have an inner and outer magnets
that may, or may not be, of similar size and where either inner or
outer magnet may be replaced with a ferromagnetic material or an
electromagnet rather than utilizing a permanent magnet. The above
closed flux path apparatus utilizing electromagnets for inner or
outer magnets, or both and may utilize hybrid magnets for inner or
outer magnets, or both. Any combination of permanent magnets,
electromagnets, or ferromagnetic materials may be used to complete
the flux path in this embodiment.
[0135] The generator, one embodiment, will function as its own
gearbox where the generator that is of itself and electronic
gearbox and that as well offers a convenient and integrated
electrical breaking system. This configuration will have a method
of controlling the rotational speed of the rotor in such a way as
to avoid shedding energy wherein the generator itself through a
process of increasing or decreasing the number of independent coils
engaged within the system allows the system to function as an
efficient gearbox system controlling the rotational speed of the
turbine without conventional shedding techniques. The generator can
add resistance to the rotation of the rotor through the process of
induction thereby slowing the rotor speed as additional stages are
engaged as well as removing resistance to the rotation of the rotor
through the process of electrically removing stages from the
system. The generator can also allow for a direct-coupled (single
cog) connection to the prime-mover rotor as a result of multiple
stator poles and the resistance control system provided by the
engagement and disengagement of a multitude of generator stages.
The generator can also comprise of a unique staged internal
generator that is combined with pre-processing electronics so as to
allow the generator to function as its own electronic gearbox thus
offering a more efficient energy capture system.
[0136] The generator can use a flywheel effect where there are any
number of induction coils that are employed when at the same time
other induction coils (with open circuits) are not employed, and
where the rotor contains one or more armature plates rotating about
the stators regardless of how many stages, or coils in the system,
have closed circuits and are thus engaged, where the mass of the
balanced stages of the armature disks rotate and serve to function
as a flywheel that will stabilize the system from sudden and
undesirable changes in rotational speed thus smoothing out the
operation of the system and where said flywheel will store kinetic
energy and will offer a mechanism for moderation of the rotational
speed of the turbine thus smoothing out sudden changes in source
energy and load.
[0137] The generator can set up to be capable of selecting various
combinations for coils to create various output voltages where the
pins or other electrical contacts may be disposed around the casing
in a manner that allows the selection of various operating voltages
for application when the apparatus is operating as either a motor
or generator accomplished by connecting adjacent terminal layers in
a selected orientation with respect to each other and where the
orientation of coil contacts may be selected, such as to allow the
operator to determine the resultant voltage being created if it is
acting as a generator, or the appropriate input voltage, if it is
acting as a motor (for example, the machine may run at 120 volts,
240 volts or 480 volts or offer an output of 120 volts, 240 volts,
or 480 volts).
[0138] The generator can also have a Parallel-series coil
arrangement. In prior art, when using permanent magnets the output
voltage is directly proportional to generator rpm. Therefore a
generator designed to work at variable speeds must overcome the
varying voltage output that results. The generator dynamically
controls the arrangement of the coils so that at low speed (low
voltage output) the coils are in series, therefore their voltages
are summed to obtain the target voltage. As the speed increases the
coils are connected in two series banks, the banks are connected in
parallel. As speed increases again the coils are connected into
four series banks and the banks are connected in parallel. Etc.
Until at max operating speed (max voltage output from each coil)
all the coils are connected in parallel. At this point an
individual coil will be attaining a voltage equal to the low speed
voltage of all the coils in series.
[0139] For Example: The theoretical desired output is 1000V. The
theoretical generator has 10 coils. Each coil operates in a range
from 100V (100 rpm) to 1000V (1000 rpm) depending on generator rpm.
When the generator turns at 100 rpm all the coils are connected in
series to obtain the desired output of 1000V. As the generator rpm
increases the voltage will exceed 1000V. At 200 rpm the coils are
split in too two series banks (both producing 1000V), the banks are
connected in parallel. (Each coil produces 200V.times.5
coils=1000V). At 500 rpm the coils would be connected in parallel
banks of 2. (each coil produces 500V.times.2 coils=1000V). At 1000
rpm all coils would be connected in parallel since each coil will
be producing the desired output voltage.
[0140] The generator, in the preferred embodiment, is capable of
functioning as a high output variable input motor divided into
independent motor stages. This motor configuration is comprised of
a multitude of stages where some stages may function as a motor
while others are left disengaged and inactive. When functioning as
a motor with a flywheel effect built in as all rotors may be
turning at all times regardless of how many stages are actually
engaged with closed circuits and any number of stages may function
as a generator while any number of alternate stages may function as
a motor thus allowing the system to modify its state from a motor
to a generator quickly and with ease with certain applications it
may be advisable to have some stages acting as a motor while other
stages at the same time, act as a generator.
[0141] The generator has the benefit of the closed flux path
induction process apparatus that allows for greater flexibility and
choice in the selection of materials to be used in the construction
of the generator system. The generator can have a multitude of
isolated induction processes thereby allowing greater choice in the
materials that can be used to create the generator system allowing
lighter non metallic materials to be used for housings and other
parts thereby reducing the system weight.
[0142] The unique disclosed generator offers a multi-stage power
generation system designed to match generator resistance to source
energy through electronically adding, or dropping, generator stages
as input energy and load vary. In one embodiment, a single stage
can be just one coil or for three phase output, three coils; one
from each array in a three stator array arrangement for example.
Additional benefits for the proposed generator systems are numerous
and include reduced mechanical energy loss and a reduced
requirement for conventional signal processing electronics.
[0143] Although the present invention has been described in
considerable detail with reference to certain preferred versions
thereof, other versions are possible. Therefore, the point and
scope of the appended claims should not be limited to the
description of the preferred versions contained herein.
[0144] As to a further discussion of the manner of usage and
operation of the present invention, the same should be apparent
from the above description. Accordingly, no further discussion
relating to the manner of usage and operation will be provided.
[0145] With respect to the above description, it is to be realized
that the optimum dimensional relationships for the parts of the
invention, to include variations in size, materials, shape, form,
function and manner of operation, assembly and use, are deemed
readily apparent and obvious to one skilled in the art, and all
equivalent relationships to those illustrated in the drawings and
described in the specification are intended to be encompassed by
the present invention.
[0146] Therefore, the foregoing is considered as illustrative only
of the principles of the invention. Further, since numerous
modifications and changes will readily occur to those skilled in
the art, it is not desired to limit the invention to the exact
construction and operation shown and described, and accordingly,
all suitable modifications and equivalents may be resorted to,
falling within the scope of the invention.
* * * * *
References