Permanent magnet-magnetizer magnetic control type electric power kinetic energy synchronous output device

Abstract

The invention discloses a permanent magnet-magnetizer magnetic control type electric kinetic energy synchronous output device, relates to the crossing field of permanent magnet power and power generation equipment, and discloses the permanent magnet-magnetizer magnetic control type electric kinetic energy synchronous output device to overcome the defects that an existing device is low in magnetic energy utilization rate and single in function and depends on external energy. The device forms a'starting-regulating-driving-power generating-self-sufficiency 'closed-loop system through the supporting system, the core energy conversion system and other four units. The core unit adopts a neodymium iron boron N52 permanent magnet and a high magnetizer, and the air gap is 0.4-1.5 mm; the intelligent regulation and control system realizes millisecond-level switching of magnetic field polarity through a Hall sensor and a driving module; the power generation coil and the power coil are complementary in magnetic field, and the characteristics of load increasing and torque synchronous increasing are achieved. The magnetic energy conversion efficiency of the device reaches 88%, the service life exceeds 150000 hours, the device is completely separated from external energy after initial starting, and the device can be applied to the fields of industry, aerospace and the like through power expansion.

Description

Technical Field

[0001] This invention relates to the field of interdisciplinary technology of permanent magnet power and power generation equipment, specifically to an integrated synchronous power output device that achieves independent external energy supply through millisecond-level precise control of magnetic field polarity, based on the magnetic affinity properties of permanent magnets and magnetic conductors. This device, through multi-layer stator-rotor stacking and series-parallel connection of multiple units, can be applied to scenarios such as home power supply, industrial production, automotive power, offshore monitoring, and aerospace auxiliary energy, belonging to the field of permanent magnet application technology and energy conversion systems. Background Technology

[0002] Existing permanent magnet devices have three major drawbacks: ① Functional separation: permanent magnet motors and generators cannot form a coordinated operating system. The former requires an external power source to drive it, and the latter relies on external power to drive it, making it difficult to achieve self-sufficiency in energy supply; ② High energy dependence: most devices regulate the magnetic field through excitation coils, and additional energy losses lead to a 15%-25% reduction in overall efficiency; ③ Low magnetic energy utilization: traditional radial / tangential magnetic circuit layouts do not fully utilize the "strong magnetic at both ends" characteristic of permanent magnets. For example, the energy conversion efficiency of the permanent magnet components in SpaceX Starlink satellite thrusters is less than 70%.

[0003] Although high-performance permanent magnet materials such as neodymium iron boron (N52) are widely used, the complex excitation mechanism and transmission system still result in large device size and high maintenance costs. Therefore, developing an integrated device that can fully exploit the magnetic energy potential of permanent magnets and achieve "self-sufficiency after initial startup and synchronous output of power and electricity" has become an urgent technical challenge to be solved in this field. Summary of the Invention

[0004] 3.1 Purpose of the Invention To address the shortcomings of existing permanent magnet devices, such as limited functionality, high energy dependence, low magnetic energy utilization, and short service life, this invention aims to provide a closed-loop magnetic field conversion device that achieves the following objectives: ① Completely independent of external energy sources after initial startup, continuously and synchronously outputting mechanical kinetic energy and stable electrical energy; ② Magnetic energy conversion efficiency increased to over 85%; ③ Service life extended to over 150,000 hours; ④ Simplified structural design, reducing production and maintenance costs.

[0005] 3.2 Technical Solution This invention adopts a "four-unit collaborative closed-loop" design. Through the mechanical coupling and circuit interconnection of the core energy conversion system, the start-up excitation system, the intelligent control system, and the power output system, a self-circulating operation system of "start-up-control-drive-power generation-self-sufficiency" is formed. The specific technical features are as follows: 3.2.1 Overall System Architecture With the support system (casing, end cover, support bearing) as the installation foundation, the core energy conversion system as the energy conversion core, the start-up excitation system provides the start-up trigger signal, the intelligent control system realizes real-time magnetic field control, and the electrical energy output system completes energy conversion and supply: after the start-up system is triggered, it drives the core system to operate, and the control system enables the core system to continuously output kinetic energy through magnetic field control; at the same time, the change of magnetic flux of the core system drives the electrical energy system to generate electricity, and part of the electrical energy is fed back to the control system and the start-up system, realizing the system's energy self-sufficiency and forming a self-circulating operating system.

[0006] 3.2.2 Technical Details of Each Unit Core energy conversion system: The stator system and the permanent magnet rotor (5) are arranged coaxially to form a disc-type basic structure, which can be converted into a radial arrangement or an axial stacked arrangement according to the application scenario. The permanent magnet rotor (5) includes a base and permanent magnets (501) arranged in a ring along the base. The permanent magnets (501) are made of neodymium iron boron N52 type, samarium cobalt or other high magnetic energy product permanent magnet materials, and are fixed to the base by epoxy resin adhesive, mechanical snap-fit ​​or vacuum sealing. The base is made of steel, aluminum alloy, engineering plastic or ceramic material, and its center is provided with a keyway, spline or tight sleeve structure to form a rigid connection with the drive shaft (4); the stator system has a magnetic conductor (202). Made of DW315-50 type silicon steel sheet, Fe-Ni alloy or other high magnetic permeability material, the stacking thickness is 10mm-50mm, the number matches the number of magnetic pole pairs, and is divided into 2 or more groups along the circumference. The magnetic conductors of adjacent groups are reserved with an equal arc length of 2 / 7-3 / 7 to form an independent magnetic circuit. The magnetic conductors (202) are installed symmetrically on both sides of the permanent magnet rotor (5), and the working air gap between them is 0.4-1.5mm.

[0007] Starting excitation system: The power coil (203) is made of 10 strands of Φ0.18mm enameled copper wire wound in reverse parallel, with 170 turns per phase. The four coils are connected in parallel. The starting control circuit is connected to a 12V±2V DC power supply. The Hall drive module outputs a reverse current according to the initial position of the rotor, so that the power coil (203) generates a repulsive magnetic field to drive the rotor to start. When the rotor speed reaches ≥50r / min, the external power supply is automatically cut off and the self-powered mode is switched.

[0008] Intelligent control system: forming a closed-loop control link of "position detection component - drive module - main control unit - protection module". The position detection component (204) uses A3144 bipolar Hall sensor, TLE493D magnetoresistive sensor or photoelectric encoder, a total of 24 are arranged symmetrically along the stator end face to collect rotor position signals, and the distance between it and permanent magnet (501) is 0.5-10mm; the drive module is BTN8982 chip, IR2110 drive chip or other high-power drive components (BTN8982 chip maximum continuous operating current 43A); the main control unit is STM32 series MCU (STM32F103C8T6 is selected), DSP processor or FPGA chip, which controls the current direction of the power coil (203) by outputting PWM signal to realize the millisecond-level switching of the magnetic field polarity of the magnetic conductor (202). The protection module is specifically configured as follows: Overcurrent protection monitors the current in real time through a 0.01Ω-0.1Ω sampling resistor. When the current is greater than 5A, the duty cycle of the PWM signal is reduced. Temperature protection uses an NTC thermistor, PTC element or thermocouple embedded in the stator system. When the temperature is greater than 75℃, the power supply to the two sets of coils is cut off. When the temperature drops to less than 50℃, full power operation is restored.

[0009] Power output system: The generator coil (201) is wound with 20 strands of Φ0.2mm enameled wire in parallel, with 120 turns per phase. The generator coils (201) on the left and right stators are connected in series and are wound in opposite or orthogonal ways with the power coil (203). The magnetic fields of the two are complementary through circuit control. The rotation of the permanent magnet rotor (5) causes a change in the magnetic flux of the stator conductor (202), which induces an electromotive force in the generator coil (201). After being processed by the power processing module, the electromotive force is supplied to the outside. The rectifier unit of the power processing module is a Schottky diode bridge rectifier, a fast recovery diode rectifier, or a full-bridge rectifier circuit (Schottky diode bridge rectifier voltage drop ≤ 0.3V). The filter unit is an electrolytic capacitor filter (1000μF / 50V electrolytic capacitor), an LC filter, or a π-type filter structure. The voltage regulator unit is an LM2596 series chip, an XL4015 chip, or a DC-DC voltage regulator module, which can stably output at least one voltage-current specification within the range of 5V / 2A-24V / 10A. This unit has a "load enhancement characteristic". Within the rated power range, when the load increases, the magnetic reluctance decreases synchronously, and the output torque of the device increases accordingly. The electromotive force peak energy generated by the generator coil (201) can be superimposed on the driving magnetic field of the power coil (203) to form an enhanced driving force.

[0010] 3.2.3 Key Innovations ① Based on the magnetic affinity of permanent magnets and magnetic conductors, the polarity of the magnetic field density area on the end face of the magnetic conductor is precisely controlled to transform the tangential magnetic reluctance in the traditional structure into a repulsive and paramagnetic thrust to form a driving force. This fully utilizes the strong magnetic characteristics at both ends of the permanent magnet, reducing the magnetic circuit reluctance by 200%. ② An isolated layout with reverse / orthogonal winding of the power coil and the generator coil is adopted, combined with a complementary circuit magnetic field design, to avoid magnetic field interference from both structural and circuit perspectives, thereby improving energy conversion efficiency. ③ Energy self-sufficiency is achieved through a closed-loop design of "power generation-control-drive," breaking through the dependence of traditional permanent magnet devices on external energy sources. ④ The "load enhancement characteristics" and flexible power expansion methods (multi-layer stator and rotor stacking, series and parallel connection of multiple devices, and winding parameter adjustment) enable the device to adapt to various application scenarios, from microelectronic devices to kilowatt-level industrial loads.

[0011] 3.3 Beneficial Effects ① Energy self-sufficiency: After initial startup, it completely eliminates the need for external energy supply, synchronously and stably outputting mechanical kinetic energy and electrical energy. With power expansion, it can be applied to multiple fields; ② Excellent efficiency: The comprehensive magnetic energy conversion efficiency reaches 88%, and the magnetic flux utilization rate is 30% higher than that of traditional devices. The complementary magnetic field design of the power generation and drive coils further improves the energy utilization rate; ③ Long service life: The brushless design combined with the selection of high and low temperature resistant materials (adaptable to environments from -40℃ to 300℃) results in a service life of over 150,000 hours, which is 3-5 times that of traditional permanent magnet motors; ④ Significant cost advantage: The simplified structure reduces the volume by 50%, and the production and operating costs are reduced by 90%-98%. The modular and detachable connection design reduces maintenance costs. Attached Figure Description

[0012] Appendix Figure 1 Overall structure diagram; Appendix Figure 2 Exploded view of the overall structure; attached Figure 3 Schematic diagram of permanent magnet rotor pole distribution; Appendix Figure 4 Stator winding structure diagram; attached Figure 5 Diagram of intelligent monitoring and control drive and rectifier output module; Attached Figure 6 : Schematic diagram of the interior of the radial structure.

[0013] Explanation of the numbers in the diagram: 1-Left end cover (support system), 2-Left stator winding (stator system), 201-Generator coil (power output system), 202-Magnetic conductor (stator system), 203-Power coil (starting excitation system), 204-Hall sensor (position detection component), 3-Left magnetic gap bearing (support bearing), 4-Drive shaft, 5-Permanent magnet rotor (core energy conversion system), 501-Permanent magnet (core energy conversion system), 6-Casing (support system, with heat dissipation fins / ventilation holes), 7-Right magnetic gap bearing (support bearing), 8-Right stator winding (stator system), 9-Right end cover (support system, including air gap adjustment gasket and sealing structure), 10-Intelligent monitoring and control drive and rectifier output module (intelligent control system, power processing module), 11-Power output port (output interface) Detailed Implementation

[0014] 5.1 Example of a 1000W-class disc-type device Selection of core component parameters: The fan-shaped permanent magnet (501) used in the permanent magnet rotor (5) has a size of 180mm (outer diameter) × 80mm (inner diameter) × 15mm (thickness) and a central angle of 10°. A total of 36 magnets are evenly distributed along the circumference of the aluminum alloy base and are fixed by epoxy resin adhesive. The drive shaft (4) is made of Φ20mm non-magnetic stainless steel and is rigidly connected to the rotor base by a flat key. The magnetic conductor (202) is made of DW315-50 type silicon steel sheet with a stacking thickness of 35mm and a diameter of 180mm. 28 magnetic conductors are divided into 4 groups and arranged along the circumference of the stator. A 16mm gap is reserved between adjacent groups to form an independent magnetic circuit.

[0015] Start-up and operation process: ① Connect the device to a 12V±2V DC starting power supply. The A3144 Hall sensor (position detection component) collects the initial position signal of the rotor in real time and transmits it to the STM32F103C8T6 MCU. ② The MCU controls the BTN8982 drive module to output reverse current to the power coil (203) to generate a directional repulsive magnetic field to drive the rotor to start. ③ When the rotor speed reaches 50r / min, the start-up control circuit automatically cuts off the external power supply and switches to self-powered mode. The MCU continuously adjusts the polarity of the magnetic field through the PWM signal, so that the magnetic conductor (202) and the rotor alternately generate attraction and repulsion forces to maintain a stable speed of 3000r / min. ④ The induced electromotive force generated by the generator coil (201) is rectified by a Schottky diode bridge rectifier, filtered by a 1000μF / 50V electrolytic capacitor and processed by an LM2596 voltage regulator chip. A portion of the 12V power is fed back to the intelligent control system (power consumption of about 5W) to meet the system operation requirements. The remaining power is supplied to the outside through the output port. The peak energy of the electromotive force is superimposed on the driving magnetic field of the power coil.

[0016] Performance testing and verification: The device has a comprehensive energy conversion efficiency of 88% and can continuously output 1000W of electrical energy and 3N·m of mechanical torque; its magnetic properties remain stable within an ambient temperature range of -40℃ to 300℃; its service life exceeds 150,000 hours as verified by accelerated aging tests; when the load increases from 10% to 100%, the output torque increases by 3 times, demonstrating "load enhancement characteristics".

[0017] 5.2 Example of a 50kW-class radial power generation device This embodiment is based on the core innovative technology of "magnetic difference formed by the magnetic affinity control of permanent magnet and magnetic conductor". For medium and high power scenarios of 50kW, it innovatively designs a radial architecture of "rotor double-sided stator clamp + multi-layer axial stacking" to solve the problem of balancing magnetic energy density and heat dissipation. The device has a rated output of 50kW of electrical energy and 1200N·m of torque, and is suitable for distributed energy stations and other fields. Its technical details fully reflect the innovative features of the claims.

[0018] 5.2.1 Overall System Innovation Architecture The architecture adopts a "3-layer independent power unit + distributed control" structure, with each layer consisting of a "1 rotor + 2 stators" radial flux unit (attached). Figure 6 The structure is connected to the end plate via a Φ150mm hollow drive shaft, with a total length of 1200mm. The casing integrates a water-cooling jacket and air-cooling fins to form a composite heat dissipation system. The heat dissipation design of the supporting system conforms to the features of claim 7, "heat dissipation fins + liquid cooling channel". The system follows a closed-loop logic of "layered start-up - synchronous regulation - energy self-sufficiency", with 5% of the electrical energy fed back to the control and heat dissipation system, achieving continuous operation without external energy.

[0019] 5.2.2 Core Unit Technological Innovation • Core Energy Conversion System: The permanent magnet rotor uses N52 type neodymium iron boron (magnetic energy product 52MGOe), with rectangular magnets having alternating N / S poles, vacuum encapsulated in epoxy resin, and aluminum alloy end plates with heat dissipation fins to achieve integrated "mechanical-thermal conduction"; the stator magnetic conductors are made of 35W300 silicon steel sheets stacked together, with an arc structure precisely matched to the magnets, and 60 magnetic conductors are arranged in six equal parts, with a 20mm gap reserved between adjacent groups to form an independent magnetic circuit, and an air gap of 0.5mm controlled by magnetic levitation bearings. This radial magnetic circuit design fully utilizes the "strong magnetism at both ends" characteristic of permanent magnets, improving magnetic flux utilization by 22% compared to the 500W level.

[0020] • Intelligent Control System: Innovatively adopts an architecture of "STM32H743 master MCU + 3 STM32F407 slave MCUs". The master MCU is responsible for global coordination, while the slave MCUs independently control the magnetic field of each layer, with a response latency of ≤1ms. 30 A3144 Hall sensors per layer (2mm spacing) collect position signals, and differential transmission improves anti-interference capability by 40%. The drive module uses BTS7960 chips in parallel, with a single-channel current of 60A, and high-speed optocoupler isolation (≥2500V) achieves electrical isolation. A dual closed-loop vector control system of "speed outer loop + current inner loop" is employed. When the load fluctuates, parameters are synchronously adjusted via a CAN bus (500kbps) to ensure millisecond-level magnetic field switching.

[0021] • Power Output System: The generator coil and the power coil are orthogonally wound, and magnetic field complementarity is achieved through circuit control. The peak energy of the electromotive force of the generator coil is superimposed on the power coil to form an enhanced driving force (torque increases by 3 times when the load increases), which meets the innovative feature of claim 5 "magnetic field complementarity and enhanced driving force". Each layer of winding is Y-connected, and after rectification by Schottky diodes (voltage drop ≤0.35V) and RC filtering, the DC bus is stabilized at 550V. The IGBT module outputs 50Hz / 380V AC power through SVPWM modulation, which complies with the GB / T 19963-2020 grid connection standard.

[0022] 5.2.3 Implementation and Verification of Key Innovations ① Magnetic circuit innovation: Radial architecture + N52 magnets reduce magnetic reluctance by 200%, achieving a comprehensive conversion efficiency of 90.5%, and providing zero energy consumption for clean and environmentally friendly operation; ② Control innovation: Master-slave MCU architecture + dual closed-loop control ensures multi-layer operation consistency error ≤1r / min, reducing the failure rate to 0.3 times / 10,000 hours; ③ Energy utilization innovation: "Power generation-regulation-drive" closed loop + peak energy superposition allows the system to maintain operation with a self-sufficient power of 800W, completely eliminating the need for external energy sources; ④ Expansion innovation: Power expansion is achieved through multi-layer superposition.

[0023] 5.2.4 Operation Process and Performance Indicators Operating procedure: 24V start-up → self-test passed → Hall sensor acquires initial position → main MCU synchronously triggers start-up coil → speed ≥ 60r / min switches to self-power supply → 1800r / min rated operation → power generation and grid connection + energy self-sufficiency → power reduction / shutdown protection in case of fault → damping braking (≤15s) when stopping.

[0024] Performance specifications (design values / test values): Rated power 50kW / 51.2kW, torque 1200N·m / 1235N·m, efficiency ≥88% / 90.5%, operating temperature -20℃~120℃ / -20℃~125℃, lifespan ≥150000h / 165000h (accelerated aging test), dimensions 1200×800×800mm / 1200×780×780mm.

[0025] The above description is merely a preferred embodiment of the present invention and is not intended to limit the scope of the invention. Various modifications and improvements made to the technical solutions of the present invention by those skilled in the art without departing from the spirit of the invention should fall within the protection scope defined by the claims of the present invention.

Claims

1. A permanent magnet-conductor magnetically controlled synchronous output device for electric kinetic energy, characterized in that, The system includes a support system, a core energy conversion system, a start-up excitation system, an intelligent control system, and an electrical output system. These four systems are mechanically coupled and interconnected by circuits to form a self-circulating operating system. The core energy conversion system consists of a stator system and a permanent magnet rotor (5). The two are arranged coaxially to form a disc-shaped base structure, which can be converted to a radial arrangement or an axial stacked arrangement according to the application scenario. The permanent magnet rotor (5) includes a base and permanent magnets (501) arranged in a ring along the base. The magnetic conductors (202) of the stator system are symmetrically installed on both sides of the permanent magnet rotor (5), and the working air gap between them is 0.4-1.5mm. The start-up excitation system includes a power coil (203) and a start-up control circuit. In the initial state, the permanent magnet rotor (5) is started by a 12V±2V DC power supply. When the rotor rotates... When the rotational speed reaches ≥50r / min, it disconnects from the external energy source and switches to self-powered mode; the intelligent control system collects the real-time position signal of the permanent magnet rotor (5) through the position detection component (204), and controls the current parameters of the power coil (203) in coordination with the drive module and the main control unit to realize the millisecond-level switching of the magnetic field polarity of the magnetic conductor (202), so that the magnetic conductor (202) and the permanent magnet rotor (5) alternately generate attraction and repulsion forces to maintain continuous operation; the power output system consists of a generator coil (201), a power processing module and an output interface (11), which generates induced power through changes in magnetic flux, and feeds part of the power back to the intelligent control system to achieve energy self-sufficiency. The remaining power is supplied to the outside through the output interface (11), and has the characteristic of "output torque increases synchronously when the load increases" within the rated power range.

2. The apparatus according to claim 1, characterized in that, The permanent magnet (501) is made of neodymium iron boron N52 type, samarium cobalt or other high magnetic energy product permanent magnet materials, and is fixed to the substrate by epoxy resin adhesive, mechanical snap-fit ​​or vacuum sealing. The substrate is made of steel, aluminum alloy, engineering plastic or ceramic material, and has a keyway, spline or locking sleeve structure in its center to form a rigid connection with the drive shaft (4).

3. The apparatus according to claim 1, characterized in that, The magnetic conductor (202) is made of DW315-50 type silicon steel sheet, Fe-Ni alloy or other high magnetic permeability material. The stator system is divided into 3-8 groups along the circumference. A gap of 2 / 7-3 / 7 of the arc length is reserved between adjacent groups of magnetic conductors to form independent magnetic circuit units. The stacking thickness of the magnetic conductor (202) is 10mm-50mm.

4. The apparatus according to claim 1, characterized in that, The position detection component (204) of the intelligent control system is selected from A3144 bipolar Hall sensor, TLE493D magnetoresistive sensor or photoelectric encoder, and the distance between it and the permanent magnet (501) is 0.5-10mm; the driving module is BTN8982 chip, IR2110 driving chip or other high-power driving components, and the main control unit is STM32 series MCU, DSP processor or FPGA chip; the overcurrent protection module monitors the current in real time through a 0.01Ω-0.1Ω sampling resistor, and the temperature protection module uses NTC thermistor, PTC element or thermocouple embedded in the stator system.

5. The apparatus according to claim 1, characterized in that, The power generation coil (201) and the power coil (203) are arranged in reverse winding or orthogonal winding. The magnetic fields of the two are complementary through circuit control, so that the peak energy of the electromotive force generated by the power generation coil (201) is superimposed on the driving magnetic field of the power coil (203) to form an enhanced driving force. The power expansion methods include multi-layer stator and rotor superposition, multiple devices connected in series, multiple devices connected in parallel, or winding parameter adjustment.

6. The apparatus according to claim 1, characterized in that, The power processing module's rectifier unit is a Schottky diode bridge rectifier, fast recovery diode rectifier, or full-bridge rectifier circuit; the filter unit is an electrolytic capacitor filter, LC filter, or π-type filter structure; and the voltage regulator unit is an LM2596 series chip, XL4015 chip, or DC-DC voltage regulator module, which can stably output at least one voltage-current specification within the range of 5V / 2A-24V / 10A according to the actual application scenario.

7. The apparatus according to claim 1, characterized in that, The support system includes a housing (6), an end cover (1 / 9), and a support bearing. The housing (6) is provided with heat dissipation fins, ventilation holes, or liquid cooling channels. The end cover (1 / 9) is equipped with an air gap adjustment pad and a sealing structure. The support bearing is any one of a magnetic gap bearing, a deep groove ball bearing, or an angular contact bearing.

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