Radial flux electric machine with kinematically synchronized counter-rotating rotors

Abstract

A radially flowing electric machine, comprising: a) a stationary cylindrical stator (10); b) a cylindrical inner rotor (9L) arranged concentrically within the stator (10); c) a cylindrical outer rotor (9R) arranged concentrically outside the stator (10); characterized by d) a kinematic synchronization system comprising: i) a central drive shaft (1); ii) a central bevel gear (2) which is operationally coupled to the central drive shaft (1); iii) a first left (4L) and a first right (4R) intermediate shaft, which are driven by the central gear (2) via bevel gears (3L, 3R); iv) a first (5L, 5R) and a second (7L, 7R) pair of cardan joints for redirecting the torque from the first intermediate shafts (4L, 4R) to the second intermediate shafts (6L, 6R), to the rotor shafts (8L, 8R); v) a left (8L) and a right (8R) rotor shaft driven by cardan joints (7L, 7R) for torque redirection; e) wherein the inner rotor (9L) is coupled to the left rotor shaft (8L) and the outer rotor (9R) is coupled to the right rotor shaft (8R) in an orientation offset by 180° to each other; f) whereby a rotation of the central drive shaft (1) induces a synchronized rotation of the first intermediate shafts (4L, 4R) and, via the means for torque redirection, a synchronized rotation with identical direction of rotation in the rotor shafts (8L, 8R), which, due to the 180° relative orientation, results in a counter-rotation of the inner rotor (9L) and the outer rotor (9R) relative to the stator (10).

Description

1. Title: Radial flux electric machine with kinematically synchronized counter-rotating rotors. 2. Technical field

[0001] The invention relates to the field of electromechanical machine engineering, in particular radially driven electrical machines that operate as generators or motors. Specifically, it relates to a novel drive system that enables passive, precise counter-rotation of two rotors from a single drive shaft. 3. State of the art

[0002] Conventional electric machines use a single rotor, which inevitably generates a cogging torque that reduces efficiency, especially at low speeds. Two-rotor designs can counteract this effect through magnetic force compensation, but this leads to considerable complexity. Existing solutions for achieving counter-rotation often rely on multiple independent motors or complex electronic control systems to synchronize the rotors. These approaches increase cost, complexity, weight, and the number of potential failure points. A robust, purely mechanical system for the precise and passive synchronization of counter-rotating rotors represents an unmet need in the prior art. 4. Summary of the invention

[0003] The invention provides a radially flowing electric machine comprising a stationary cylindrical stator arranged concentrically between an inner and an outer rotor. The core innovation is a kinematic synchronization system that drives both rotors in synchronized counter-rotation from a single central drive shaft. This is achieved via a central gear that transmits synchronized rotation to two intermediate shafts. The rotation of these shafts is then deflected by 90° via paired universal joints to drive the rotor shafts over greater distances. The outer rotor is mounted at a 180° angle to the inner rotor. This ensures that while both rotors physically rotate in the same direction, they exhibit counter-rotation relative to the stationary stator, enabling magnetic force compensation and improved performance in a cylindrical design. 5. Brief description of the drawings Fig. 1: Isometric exploded view of the radial flow design. Fig. 2: Sectional view showing the river paths. Fig. 3: Kinematic strand. Fig. 4: 180° perspective reversal mechanism for radial flow design 6. Detailed description 6.1 Core components (See Fig. 1 & 2) number component function 1 Central drive shaft Primary input for rotational power. 2 Central bevel gear Mounted on (1). 3L, 3R bevel gears Mounted on 4L, 4R and with (2) engaged 4L, 4R First intermediate waves Torque transmission. Driven by (2) via (3L, 3R). 5L, 5R Primary cardan joints Between (4L, 4R) and (6L, 6R). First 90° bend. 6L, 6R Second intermediate waves Transmit torque along the machine length. Are driven by (5L, 5R). 7L, 7R Secondary cardan joints Between (6L, 6R) and (8L, 8R). Second 90° bend. 8L, 8R Rotor shafts They drive the rotors. 9L, 9R Inner rotor (9L), outer rotor (9R) (9L), Cylindrical core with external magnets. (9R), Cylindrical sleeve with internal magnets, offset by 180° to (9L). 10 stator Fixed cylindrical core with windings. 11 Housing Supports all components. 6.2 Functionality

[0004] Rotation is applied to the central drive shaft (1) and the central bevel gear (2), which drives the bevel gears (3L, 3R) mounted on the first intermediate shafts (4L, 4R), causing the shafts to rotate at the same speed and direction.

[0005] The first intermediate shafts (4L, 4R) drive the primary cardan joints (5L, 5R), which transmit this rotation through a 90° angle to the second intermediate shafts (6L, 6R).

[0006] The second intermediate shafts (6L, 6R) drive the secondary cardan joints (7L, 7R), which transmit this rotation to the rotor shafts (8L, 8R), which drive the rotors (9L, 9R).

[0007] Since the outer rotor (9R) is mounted in a 180° orientation relative to the inner rotor (9L), their identical physical rotation (e.g., both counterclockwise) results in an apparent counter-rotation from the fixed reference frame of the stator (10). This is the fundamental principle that enables the advantages of the invention. 6.3 Technical Advantages 1. Passive cogging torque reduction: Magnetic force compensation between counter-rotating rotors significantly reduces the cogging torque. 2. Vibration damping: Gyroscopic and magnetic forces are balanced, resulting in smoother operation. 3. Increased power density: The effective magnetic flux velocity past the stator doubles for a given rotational speed, potentially increasing the output. 4. Simplified control: A single power input without the need for complex electronics. 5. Improved cooling: The cylindrical radial flow structure offers a large surface area for effective heat management. 6. Torque transmission over long distances and torsional tolerance: Ideal for cylindrical machine lengths. 7. High torque capacity: Suitable for large generators.

[0008] Legend for Fig. 1: • [1] = Central drive shaft • [2] = Central bevel gear • [3L, 3R] = bevel gears • [4L, 4R] = First intermediate waves • [5L, 5R] = First universal joints • [6L, 6R] = Second intermediate waves • [7L, 7R] = Second cardan joints • [8L, 8R] = Rotor shafts • [9L] = Inner rotor (with permanent magnets on its outer surface), • [9R] = Outer rotor (cylindrical sleeve with permanent magnets on its inner surface) •

[10] = Stator (fixed to housing, with windings) •

[11] = Housing

[0009] Legend for Fig. 2: • [Arrows] = Direction of radial magnetic flux between the rotors, through the stator teeth and the yoke. • [9L, 9R] = Rotors with 180° relative mounting, causing apparent counter-rotation. •

[10] = Stator

[0010] Legend for Fig. 3: • [1] = Central drive shaft (input, SUZ) • [2] = Central bevel gear (SUZ) • [3R] = Bevel gear on first intermediate shaft 4R • [4R] = First Intermediate Wave (UZS) • [5R] = Primary universal joint (90° deflection, maintains UZS rotation) • [6R] = Second intermediate wave (UZS) • [7R] = Secondary universal joint (90° deflection, maintains UZS rotation) • [8R] = Rotor shaft (UZS) • [9R] = Outer rotor (UZS) •

[10] = Stator

[0011] Legend for Fig. 4 • [8L] = Rotor L • [8R] = Rotor R • [9] = Stator

Claims

[1] A radially fluxed electric machine comprising: a) a stationary cylindrical stator (10); b) a cylindrical inner rotor (9L) arranged concentrically within the stator (10); c) a cylindrical outer rotor (9R) arranged concentrically outside the stator (10); characterized by d) a kinematic synchronization system comprising: i) a central drive shaft (1); ii) a central bevel gear (2) which is operationally coupled to the central drive shaft (1); iii) a first left (4L) and a first right (4R) intermediate shaft, which are driven by the central gear (2) via bevel gears (3L, 3R); iv) a first (5L, 5R) and a second (7L, 7R) pair of cardan joints for redirecting the torque from the first intermediate shafts (4L, 4R) to the second intermediate shafts (6L, 6R), to the rotor shafts (8L, 8R); v) a left (8L) and a right (8R) rotor shaft driven by cardan joints (7L, 7R) for torque redirection; e) wherein the inner rotor (9L) is coupled to the left rotor shaft (8L) and the outer rotor (9R) is coupled to the right rotor shaft (8R) in an orientation offset by 180° to each other; f) whereby a rotation of the central drive shaft (1) induces a synchronized rotation of the first intermediate shafts (4L, 4R) and, via the means for torque redirection, a synchronized rotation with identical direction of rotation in the rotor shafts (8L, 8R), which, due to the 180° relative orientation, results in a counter-rotation of the inner rotor (9L) and the outer rotor (9R) relative to the stator (10). [2] A kinematic synchronization system for driving the inner and outer rotor of a radial flux machine according to claim 1, wherein the system characterized byis that the mechanism is further configured to simultaneously provide an output for the left drive train and an output for the right drive train, with both rotors (9L, 9R) rotating in the same direction and exhibiting counter-rotation due to their 180° orientation to each other. [3] The machine according to claim 1, wherein the first cardan joints (5L, 5R) are set at a 90° angle. [4] The machine according to claim 1, wherein the second cardan joints (7L, 7R) are set at a 90° angle. [5] The machine according to claim 1, wherein the first and second cardan joints set at a 90° angle connect the intermediate shafts (4L, 4R), (6L, 6R) and the rotor shafts (8L, 8R) and form a total angle of 180°. [6] The machine according to claim 1, wherein the inner rotor (9L) and the outer rotor (9R) comprise permanent magnets arranged in Halbach arrays to focus the magnetic flux towards the stator (10). [7] The system according to claim 2, wherein the first and second drive train comprise cardan joints (5L, 5R) and (7L, 7R) to accommodate shaft misalignment.

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