A coil coreless generator

Abstract

The application discloses a coil coreless generator, which comprises a rotating shaft, a support and a power generation unit. The power generation unit comprises a magnetic disc assembly rotating synchronously with the rotating shaft and a wire disc assembly fixedly arranged relative to the support. A preset axial air gap is formed between the magnetic disc assembly and the wire disc assembly. The magnetic disc assembly comprises a magnetic disc and a plurality of magnetic pieces arranged on the magnetic disc. The plurality of magnetic pieces are distributed along the circumference and the radius of the magnetic disc to form a multi-stage magnetic piece assembly. The wire disc assembly comprises a wire disc and a plurality of hollow coils arranged on the wire disc. The plurality of hollow coils are connected in series, in parallel or in series-parallel combination to form an output winding. The closed conductor part of the hollow coil is located in the outer peripheral edge sweeping track range of the magnetic piece, so that the induced electromotive force is generated in the hollow coil through the magnetic flux change at the outer peripheral edge of the magnetic piece. The application can improve the power generation efficiency and save materials.

Description

Technical Field

[0001] This invention relates to the field of power generation equipment technology, and more specifically, to a coreless generator with coils that improves material utilization and power generation efficiency by optimizing the utilization of magnet edges and the configuration of hollow coils. Background Technology

[0002] In existing permanent magnet generator designs, iron core structures are commonly used to increase magnetic flux density. However, the introduction of iron cores leads to a complex and bulky overall structure, while also causing eddy current losses and hysteresis losses during operation—the iron loss problem. Furthermore, the stator slots are designed to accommodate large permanent magnets and winding coils, further increasing material consumption and manufacturing costs. In low-speed operating conditions, such as in small-scale distributed power generation systems, low-speed wind power generation, and hydropower applications, the insufficient output power is particularly pronounced. Traditional solutions to compensate for power loss often involve increasing the volume of the permanent magnet or the number of turns in the winding coils. However, this not only results in a significant waste of magnetic materials but also increases winding resistance, leading to additional Joule heat loss and reducing overall system efficiency. In-depth research revealed that the magnetic field distribution of permanent magnets exhibits significant non-uniformity: the edge regions, due to their large magnetic field gradients and high flux change rates, are key areas for the generation of induced electromotive force; while the central region of traditionally used large-area monolithic permanent magnets has a relatively uniform magnetic field distribution and weak flux change, contributing very little to the power generation process, resulting in a severe underutilization of this part of the material. Summary of the Invention

[0003] The purpose of this application is to provide a coreless generator to improve the utilization rate of magnet and wire materials and optimize power generation output performance.

[0004] The present invention adopts the following solution:

[0005] A coreless generator includes a rotating shaft, a support, and at least one set of generator units. The generator unit includes a disk assembly that rotates synchronously with the rotating shaft and a coil assembly that is fixedly disposed relative to the support. A preset axial air gap is formed between the disk assembly and the coil assembly. The disk assembly includes a disk and a plurality of magnets disposed on the disk. The plurality of magnets are distributed along the circumferential and radial directions of the disk to form a multi-level magnet assembly. Each level of the magnet assembly includes a plurality of magnets arranged at intervals along the circumferential direction. From the center of the disk to the outer periphery, the area of ​​the magnets in each level of the magnet assembly increases progressively. The coil assembly includes a coil and a plurality of hollow coils disposed on the coil. The plurality of hollow coils are distributed along the circumference and radial direction of the coil to form a multi-level coil assembly. Each level of the coil assembly is disposed opposite to the magnet assembly of the corresponding level. The plurality of hollow coils form an output winding by means of series connection, parallel connection or series-parallel combination. From the center of the coil to the outer periphery, the area of ​​the hollow coils in each level of the coil assembly increases progressively. The hollow coil has a closed conductor portion, at least a portion of which is located within the sweep trajectory of the outer peripheral edge of the corresponding magnet, so that when the magnet moves relative to the hollow coil, an induced electromotive force is generated in the hollow coil through the change in magnetic flux at the outer peripheral edge of the magnet.

[0006] Furthermore, in the coil assembly and magnet assembly of the same level, the ratio of the number of magnets to the number of hollow coils is 4:3.

[0007] Furthermore, the number of hollow coils in the multi-stage coil assembly is the same; the number of magnets in the multi-stage magnet assembly is the same.

[0008] Furthermore, in the same level of the coil assembly and the corresponding magnet assembly, the area of ​​the hollow coil is 2 to 4 times the area of ​​the corresponding magnet.

[0009] Furthermore, the coil is cast from insulating resin, the hollow coil is embedded in the coil, and the coil is provided with mounting holes, grooves, or casting cavities for positioning the hollow coil.

[0010] Furthermore, the disk assembly and the coil assembly are alternately stacked along the axis of the rotating shaft to form two or more sets of the power generation units, with a preset axial gap maintained between adjacent power generation units.

[0011] Furthermore, the axially adjacent disk assemblies or coil assemblies have a preset circumferential misalignment angle, so that a predetermined phase difference is formed between the inductive outputs of adjacent power generation units, which helps to reduce output pulsation.

[0012] Beneficial effects: 1. Magnets are placed on the disk. The magnetic field gradient and magnetic flux change rate are relatively high at the edge of the magnet. By increasing the contact length between the edge of the magnet and the coil, the amount of magnet used is reduced, resulting in an increase in the overall contact length and improved power generation efficiency.

[0013] 2. The coil is an air-core coil, with the coils of different sizes distributed axially around each other to form a single coil that coincides with the edge of the magnet. The air-core coil does not have an iron core, which reduces iron loss and magnetic reluctance torque. Furthermore, by reducing the length of ineffective conductors, the winding resistance and heat loss are reduced, thus improving efficiency.

[0014] 3. Multiple disks and coils can be stacked together, which makes it easy to increase the frequency (the smaller the diameter of the coil magnet, the higher the frequency) and improve the overall power generation efficiency.

[0015] 4. It significantly saves raw materials, improves material utilization, increases power generation efficiency, reduces weight and volume, and saves energy. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of a coreless generator according to an embodiment of the present invention; Figure 2 This is a front view schematic diagram of a coreless generator according to an embodiment of the present invention; Figure 3 This is a cross-sectional structural schematic diagram of a coreless generator according to an embodiment of the present invention; Figure 4 This is a schematic diagram of the disk assembly of a coreless generator according to an embodiment of the present invention; Figure 5 This is a schematic diagram of the coil assembly of a coreless generator according to an embodiment of the present invention; Figure 6 This is a schematic diagram comparing the dimensions of a circular magnet assembly and a trapezoidal action area in a coreless coil generator according to an embodiment of the present invention. Figure label: 1. Shaft; 2. Bearing; 3. Fixing ring; 4. Support plate; 5. Disk assembly; 51. Disk; 52. Magnet; 6. Coil assembly; 61. Coil; 62. Hollow coil. Detailed Implementation

[0017] Traditional permanent magnet generator designs, in pursuit of high magnetic flux density, generally rely on iron core structures, large stator slots, and bulky permanent magnets. This results in cumbersome equipment, high material costs, and significant copper and iron losses. Especially under low-speed operating conditions, to increase output power, the size of the permanent magnet or the number of winding turns is often increased, leading to waste of magnetic materials, increased winding resistance, increased heat loss, and increased overall size and weight. The magnetic flux change in the central region of the permanent magnet is weak, resulting in low material utilization. Furthermore, the internal regions and corners of existing trapezoidal or sector magnets contribute limitedly to the induction output, requiring longer straight sections or end connections in the coil, increasing copper wire usage, resistance, and heat loss.

[0018] Combination Figures 1 to 6As shown, this application proposes a three-phase generator with a coil without an iron core, including a rotating shaft 1, a bracket, and at least one set of generating units. The generating unit includes a disk assembly 5 that rotates synchronously with the rotating shaft 1 and a coil assembly 6 that is fixedly disposed relative to the bracket. The bracket includes bracket plates 4 disposed at the front and rear ends and at least one fixing ring 3 located between two bracket plates 4. The fixing ring 3 is used to fix the coil assembly 6, and the fixing ring 3 and the bracket plate 4 can be connected by bolts. A preset axial air gap is formed between the disk assembly 5 and the coil assembly 6. The disk assembly 5 includes a disk 51 and a plurality of magnets 52 disposed on the disk 51. The plurality of magnets 52 are distributed along the circumference and radial direction of the disk 51 to form a multi-level magnet assembly. Each level of the magnet assembly includes a plurality of magnets 52 arranged at intervals along the circumference. From the center of the disk 51 to the outer periphery, the area of ​​the magnets 52 in each level of the magnet assembly increases progressively. The support plate 4 can be connected to the rotating shaft 1 by a bearing 2. The coil assembly 6 can also be connected to the rotating shaft 1 by a bearing 2. This is used to support or avoid the rotating shaft 1 when it passes through the coil 61, so that the coil 61 cannot rotate with the rotating shaft 1. The coil assembly 6 includes a coil 61 and a plurality of hollow coils 62 disposed on the coil 61. The plurality of hollow coils 62 are distributed along the circumference and radial direction of the coil 61 to form a multi-level coil assembly. Each level of the coil assembly is disposed opposite to the corresponding level of the magnet assembly. The plurality of hollow coils 62 are connected in series, in parallel, or in a series-parallel combination to form an output winding. From the center of the coil 61 to the outer periphery, the area of ​​the hollow coils 62 in each level of the coil assembly increases progressively. The hollow coil 62 has a closed conductor portion, at least a portion of which is located within the sweeping trajectory of the outer peripheral edge of the corresponding magnet 52, so that when the magnet 52 moves relative to the hollow coil 62, an induced electromotive force is generated in the hollow coil 62 through the change in magnetic flux at the outer peripheral edge of the magnet 52.

[0019] For ease of understanding, the following explains some key terms in this embodiment: The hollow coil 62 refers to a coil without an iron core, with a hollow center to save material and reduce wire resistance. This coil generates an induced electromotive force by cutting the magnetic lines of force generated by the edge of the magnet 52 through its closed conductor portion. The closed conductor portion refers to the part of the hollow coil 62 that can form a closed loop and effectively cut magnetic lines of force, and is the hollow coil body formed by winding wires around it.

[0020] A multi-level magnet assembly refers to a series of different levels formed by the radial distribution of magnet elements 52 along the disk 51. Each level of the magnet assembly has a specific circumferential arrangement and area characteristics for the magnet elements 52.

[0021] A multi-level coil assembly refers to different levels formed by the radial distribution of hollow coils 62 along the coil spool 61. The hollow coils 62 in each level of the coil assembly are arranged opposite to the magnet assembly of the corresponding level.

[0022] The preset axial air gap refers to the specific distance maintained between the disk assembly 5 and the coil assembly 6 along the axis 1. This air gap ensures no mechanical contact between the components and affects the magnetic field coupling efficiency.

[0023] The range of the outer peripheral edge sweep trajectory refers to the area swept by the outer peripheral edge of the magnet 52 in space during its rotation.

[0024] In this embodiment, the disk assembly 5 includes a disk 51 and a plurality of magnets 52 disposed on the disk 51. The disk 51 may be made of a non-magnetic material to avoid eddy current losses. The magnets 52 may be permanent magnets in the shapes of rectangles, squares, circles, ellipses, trapezoids, etc., including but not limited to these; trapezoidal or rectangular shapes are preferred, as trapezoids and rectangles have a longer edge perimeter in the same area, thereby making full use of the advantage of stronger magnetism at the edges of the magnets 52 to obtain higher magnetism in the same area. The magnets 52 may be mounted on the disk 51 by means of bonding, embedding, or mechanical fixing. The plurality of magnets 52 are distributed along the circumference and radial direction of the disk 51 to form a multi-level magnet assembly. For example, the magnets 52 may be distributed radially to form three, four, or more levels. Each level of magnet assembly includes a plurality of magnets 52 arranged at intervals along the circumference. From the center of the disk 51 to the outer periphery, the area of ​​the magnets 52 in each level of magnet assembly increases progressively. For example, the area of ​​the first-stage magnet 52 can be A, the second-stage magnet can be 1.5A, and the third-stage magnet can be 2A.

[0025] The coil assembly 6 includes a coil 61 and a plurality of hollow coils 62 disposed on the coil 61. The coil 61 may be made of insulating material. The hollow coils 62 may be wound with enameled wire, and their shape may be circular, rectangular, elliptical, etc., including but not limited to these, and may correspond to the same or similar shape as the magnet 52. Of course, a structure with a different shape than the hollow coil 62 may be used. For example, a circular hollow coil 62 may be used in conjunction with a trapezoidal or rectangular magnet 52 to obtain a stronger induced electromotive force with fewer wires and fewer magnets of the same area. The coils may be disposed on the coil 61 by prefabrication and subsequent embedding. The plurality of hollow coils 62 are distributed circumferentially and radially along the coil 61 to form a multi-stage coil assembly. The hollow coils 62 may be radially distributed to form a number of stages corresponding to the magnet assembly. Each stage of the coil assembly is disposed opposite to the corresponding stage of the magnet assembly. The plurality of hollow coils 62 are connected in series, in parallel, or in a series-parallel combination to form an output winding. For example, all coils can be connected in series to obtain a high voltage output, or all coils can be connected in parallel to obtain a high current output, or a combination of series and parallel connections can be used to balance voltage and current requirements. From the center of the coil spool 61 outwards, the area of ​​the hollow coils 62 in each stage of the coil assembly increases progressively. For example, the area of ​​the hollow coils 62 in each stage of the coil assembly can be increased in a similar proportion to the increase in the area of ​​the magnet 52.

[0026] The hollow coil 62 has the closed conductor portion. At least a portion of the conductor segment of the hollow coil 62 intersects with the sweeping trajectory of the outer peripheral edge of the corresponding magnet 52. At least a portion of the closed conductor portion is located within the sweeping trajectory of the outer peripheral edge of the corresponding magnet 52. When the magnet 52 rotates, its outer peripheral edge forms an annular region. The effective conductor segment of the hollow coil 62 is placed within this annular region to increase the rate of change of magnetic flux. Thus, when the magnet 52 moves relative to the hollow coil 62, an induced electromotive force is generated in the hollow coil 62 through the change of magnetic flux at the outer peripheral edge of the magnet 52. When the magnet 52 rotates with the disk assembly 5, the magnetic field at its outer peripheral edge rapidly sweeps across the closed conductor portion of the hollow coil 62. Due to the large magnetic field gradient at the edge of the magnet, this sweeping motion causes a change in the magnetic flux inside the hollow coil 62, thereby generating a stronger induced electromotive force in the coil according to Faraday's law of electromagnetic induction.

[0027] The coreless generator proposed in this application effectively reduces the overall weight of the device and lowers material consumption by employing a coreless hollow coil 62. The magnets 52 and the hollow coil 62 are radially distributed to form a multi-stage assembly, with the area gradually increasing from the center to the outer periphery. This improves the utilization rate of magnetic and coil materials, especially under low-speed operating conditions. It can more effectively utilize the high magnetic field gradient region at the edge of the magnet to enhance the generation of induced electromotive force. In particular, it is adapted to the different linear velocities of magnets at different radii. The design of the hollow coil 62 further reduces winding resistance and lowers heat loss. Therefore, this generator can achieve lightweight and compact design and improve power generation efficiency in applications such as small-scale distributed power generation, low-speed wind power generation, and hydropower generation.

[0028] Combination Figures 4 to 5 As shown, in this embodiment, in the coil assembly and magnet assembly of the same level, the three-phase ratio is 4:3, and the ratio of the number of magnets 52 to hollow coils 62 is 4:3. That is, during generator operation, whenever the magnetic field of four magnets 52 sweeps across, three hollow coils 62 will inductively couple with it. This ratio optimizes the interaction between the magnetic field and the coil. This ratio allows the magnetic field of the magnets 52 to link with the closed conductor of the hollow coils 62 in a predetermined and efficient manner during rotation, thereby improving the effective capture of magnetic flux changes. Furthermore, this ratio helps to balance the magnetic force, reduce potential radial or axial unbalanced forces, and thus reduce vibration and noise during operation, improving generator performance. This specific quantitative relationship also allows the magnetic field of the magnets 52 to form a more coordinated and efficient magnetic coupling with the hollow coils 62 during rotation. This not only helps improve energy conversion efficiency and reduce magnetic energy loss, but also effectively reduces the pulsation of output current or voltage, thereby obtaining smoother and higher quality electrical energy output, improving the dynamic interaction between the magnetic field and the coil, and further enhancing the overall performance and operational stability of the generator. For example, in a preferred embodiment, each stage of the coil assembly has 24 hollow coils 62, and each stage of the magnet assembly has 32 magnets 52. In other embodiments, each stage of the coil assembly may have 12 hollow coils 62, and each stage of the magnet assembly may have 16 magnets 52.

[0029] In this embodiment, the number of hollow coils 62 within the multi-level coil assemblies is the same; the number of magnets 52 within the multi-level magnet assemblies is also the same. The same number of hollow coils 62 within the multi-level coil assemblies means that regardless of the radial position of the coil assembly 6, each level of the coil assembly will contain the same number of hollow coils 62. For example, if the innermost coil assembly contains N hollow coils 62, then all outwardly extending coil assemblies will also contain N hollow coils 62. This design helps standardize the manufacturing process of the coil assembly 6 and ensures consistency in the electromagnetic induction potential of each radial level. Similarly, the same number of magnets 52 within the multi-level magnet assemblies means that each radial level of the disk assembly 5 will be configured with the same number of magnets 52. For example, if the innermost magnet assembly contains M magnets 52, then all outwardly extending magnet assemblies will also contain M magnets 52. This simplifies the manufacturing of the disk assembly 5 and the arrangement of the magnets 52, and ensures predictable consistency in the magnetic field distribution of each radial level. This standardized design ensures that the electromagnetic coupling characteristics of different radial levels remain highly consistent, even as the area of ​​each level of hollow coil 62 and magnet 52 increases progressively. This effectively reduces output ripple and the need for complex control mechanisms.

[0030] In one embodiment, the hollow coil 62 is preferably circular. When the hollow coil 62 is circular, the overall outline formed by its winding wires is annular. Using a circular hollow coil 62 allows for a relatively short coil circumference within the same area, thus helping to reduce the amount of wire used and consequently lowering the coil's resistance loss. Simultaneously, the circular structure exhibits good symmetry in a rotating magnetic field, which contributes to a smooth output of the induced electromotive force and reduces output fluctuations.

[0031] For a circular hollow coil 62, given the same area, the circumference of a circular coil is relatively short, which helps to reduce the length of the wire and the winding resistance. For example, as Figure 6 As shown in the diagram, in a set of comparative dimensions, if the same radial sector area is equivalent to a trapezoidal functional area, the perimeter of the trapezoidal outline can be calculated as approximately 17.77 + 49.76 based on the lengths of the upper base, lower base, and two side sides. 2 + 4.78 = 122.07 mm; When five circular magnets 52 are arranged within the trapezoidal area of ​​action, the total circumference of the five circular magnets 52 can be calculated as approximately (15.59 + 11.99 + 9.22 + 7.09 + 5.45). 3.14 = 154.9276 mm, meaning the total edge length provided by the circular magnet 52 is approximately 1.269 times the perimeter of the corresponding trapezoidal outline. Simultaneously, the area of ​​the trapezoidal functional region is approximately (2.74 + 10.95). 45.32 / 2 = 310.2154 The total area of ​​the five circular magnets is approximately 167.8466. The area of ​​the five circular magnets is approximately 54.1% of the area of ​​the corresponding trapezoid. In other words, while achieving a greater total edge length, the required magnetic material area can be reduced by about 45.9%. Measured by the ratio of boundary length to magnet area, this enhances the coupling between the magnet edge sweep region and the effective sensing area of ​​the hollow coil 62 with less magnetic material.

[0032] Therefore, by setting a circular hollow coil 62, the relative motion trajectory between its edge and the edge of the circular magnet 52 is smoother during the relative rotation of the magnet, which helps to generate a continuous and less fluctuating induced electromotive force, while simplifying the manufacturing process. By optimizing the interaction between the coil shape and the edge of the magnet 52, changes in magnetic flux can be captured more effectively, thereby improving the generation efficiency and stability of the induced electromotive force and ensuring the reliability of the generator output performance.

[0033] In another embodiment, when the hollow coil 62 is rectangular, the overall outline formed by its wires is rectangular. Using a rectangular hollow coil 62 allows for more effective matching with the edges of rectangular or square magnets 52, resulting in a longer overlap time or tighter coupling between the flux change region and the effective conductor segment of the coil when the magnet 52 sweeps across it. The rectangular coil can also be manufactured using a winding die. By setting the hollow coil 62 to a rectangular shape, longer straight edges can be provided, allowing for a longer effective flux cut when the edge of the magnet 52 sweeps across these edges. This increases the peak value of the induced electromotive force per cut in a specific design and facilitates close arrangement on a plane, improving the space utilization of the coil assembly 6.

[0034] In a preferred embodiment, in the coil assembly and the corresponding magnet assembly of the same level, the area of ​​the hollow coil 62 is 2 to 4 times the area of ​​the corresponding magnet 52.

[0035] The area of ​​the hollow coil 62 refers to the maximum area enclosed by the wires constituting the coil. During generator operation, when the magnet 52 moves relative to the hollow coil 62, the magnetic flux passing through the area of ​​the hollow coil 62 changes, thereby generating an induced electromotive force (EMF) in the coil. This area ratio effectively covers the magnetic field variation area of ​​the magnet 52, capturing more magnetic flux and increasing the amplitude of the induced EMF. The area of ​​the magnet 52 refers to the effective magnetic pole surface area of ​​the magnet 52. Setting the area of ​​the hollow coil 62 to 2 to 4 times the area of ​​the corresponding magnet 52 optimizes the magnetic coupling efficiency between the magnet 52 and the hollow coil 62. When the area of ​​the hollow coil 62 is within this ratio range, it can fully cover the magnetic field variation area generated by the magnet 52 during its movement, especially the strong magnetic field area at the outer periphery of the magnet 52. This allows the magnetic flux generated by the magnet 52 to be fully captured by the hollow coil 62, reducing magnetic flux leakage and thus increasing the amplitude of the induced EMF. Meanwhile, compared to an excessively large coil area, this ratio range avoids unnecessary increases in coil length, effectively controls the coil's internal resistance, and reduces energy loss. Combined with the 4:3 ratio of magnets 52 to air coils 62 in the generator, this optimized area ratio further improves the overall energy conversion efficiency and output power of the power generation unit, while also helping to reduce output pulsation and enabling the generator to maintain high performance at different speeds.

[0036] In one embodiment, the coil 61 can be cast from insulating resin, with the hollow coil 62 pre-embedded within it. The coil 61 is provided with mounting holes, grooves, or casting cavities for positioning the hollow coil 62. Casting the coil 61 involves injecting liquid insulating resin (e.g., epoxy resin, unsaturated polyester resin, or polyurethane resin) into a mold and allowing it to solidify, thereby forming a coil 61 with a specific shape and size. This molding method enables the coil 61 to possess excellent mechanical strength and rigidity, while providing good electrical insulation performance, effectively isolating the hollow coil 62 from the external environment and preventing short circuits and leakage. Simultaneously, this casting process simplifies the coil installation and fixing process, reducing production costs and assembly difficulty.

[0037] In a preferred embodiment, the disk assembly 5 and the coil assembly 6 are alternately stacked along the axial direction of the shaft 1 to form two or more sets of power generation units, with a preset axial gap maintained between adjacent power generation units. Specifically, the alternating stacking of the disk assembly 5 and the coil assembly 6 along the axial direction of the shaft 1 means that multiple disk assemblies 5 and coil assemblies 6 are stacked along the direction of the shaft 1. This stacking method allows more power generation units to be integrated within a limited axial space, thereby effectively improving the overall power output of the generator. For example, this can be achieved by sequentially installing the disk assembly 5 and the coil assembly 6 on the shaft 1, each assembly having a central hole for fitting onto the shaft 1, and ensuring appropriate axial spacing and positioning through shims, spacer rings, or structural design. Multiple sets of structures can improve the overall power output of the generator and meet applications with higher power requirements. At the same time, maintaining a preset axial gap between adjacent power generation units ensures that there is no physical interference between the components and maintains the effectiveness of the magnetic field distribution. Furthermore, stacking multiple generator units along the axial direction allows for a significant increase in the effective interaction area and frequency of the magnetic field and coils without increasing the generator's radial dimensions, thereby improving the generator's overall power output and energy conversion efficiency. This multi-unit stacked structure effectively solves the problem of insufficient power density in a single generator unit, enabling the generator to adapt to application scenarios with higher power output requirements.

[0038] In another preferred embodiment, axially adjacent disk assemblies 5 or coil assemblies 6 have a preset circumferential misalignment angle, creating a predetermined phase difference between the induced outputs of adjacent power generation units to reduce output pulsation. This preset circumferential misalignment angle refers to rotating the axially adjacent disk assemblies 5 or coil assemblies 6 relative to each other circumferentially by a specific angle during generator assembly. For example, when installing the second disk assembly 5 onto the shaft 1, it can be rotated circumferentially by a preset angle relative to the first disk assembly 5; or when fixing the second coil assembly 6 to the bracket, it can be rotated circumferentially by a preset angle relative to the first coil assembly 6. This misalignment angle setting can change the relative positional relationship between the magnet 52 and the hollow coil 62 in adjacent power generation units, thereby affecting the timing of the magnetic flux linkage changes between them. It should be noted that this misalignment angle can be fixed or precisely calculated and adjusted according to the generator design requirements. By setting a preset circumferential misalignment angle between axially adjacent disk assemblies 5 or coil assemblies 6, the relative motion between the magnets 52 and hollow coils 62 in different power generation units is no longer completely synchronized when the shaft 1 rotates. Specifically, the moment when the outer periphery of the magnet 52 in one power generation unit sweeps across the hollow coil 62 will have a time offset from the moment when the outer periphery of the magnet 52 in the adjacent power generation unit sweeps across the hollow coil 62. This time offset is directly reflected in the phase of the induced electromotive force of each power generation unit, thus forming a predetermined phase difference between the outputs of adjacent power generation units. Output pulsation refers to the periodic fluctuation of the generator output voltage or current over time. In multiphase or multi-unit generators, if the output phases of each unit are inappropriate, these fluctuations may be superimposed and amplified, leading to a decrease in overall output quality. Through the above technical solution, setting a preset circumferential misalignment angle between axially adjacent disk assemblies 5 or coil assemblies 6 can effectively control the formation of a predetermined phase difference between the induced outputs of adjacent power generation units. When these induced outputs with specific phase differences are superimposed, they can compensate for or smooth each other. For example, a momentary trough in the output of one generator unit can be compensated for by a momentary peak in the output of another generator unit. This phase control mechanism reduces the ripple amplitude of the overall generator output voltage or current, making the output waveform smoother, thereby improving the stability, quality, and efficiency of power generation. It avoids the ripple enhancement problem that may result from the synchronous superposition of outputs from multiple generator units, thus optimizing the generator's operating performance.

[0039] Through the above embodiments, the generator of this application can accurately utilize the magnetic field with a high flux change rate at the outer periphery of the magnet 52, and ensure that the closed conductor portion of the hollow coil 62 is in full contact with this area, effectively increasing the effective contact length between the edge of the magnet 52 and the hollow coil 62, and improving the generation efficiency of the induced electromotive force. The use of the hollow coil 62 avoids iron loss and reluctance torque introduced by the iron core, and can reduce the length of ineffective conductors by optimizing the winding method, thereby reducing coil resistance and heat loss. Furthermore, through the superimposed configuration of multiple sets of disk assemblies 5 and coil assemblies 6, the generator can improve output power and frequency, further optimizing the overall power generation performance. These measures work together to achieve significant savings and improved utilization of raw materials, while reducing the weight and size of the generator, ultimately improving power generation efficiency and saving energy.

[0040] It should be understood that the above are merely preferred embodiments of the present invention, and the scope of protection of the present invention is not limited to the above embodiments. All technical solutions that fall within the scope of the present invention are within the scope of protection of the present invention.

[0041] The accompanying drawings used in the above description of the embodiments only illustrate certain embodiments of the present invention and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained from these drawings without creative effort.

Claims

1. A coreless generator, characterized in that, It includes a rotating shaft, a support frame, and at least one set of power generation units. The power generation unit includes a disk assembly that rotates synchronously with the rotating shaft and a coil assembly that is fixedly disposed relative to the support frame. A preset axial air gap is formed between the disk assembly and the coil assembly. The disk assembly includes a disk and a plurality of magnets disposed on the disk. The plurality of magnets are distributed along the circumferential and radial directions of the disk to form a multi-level magnet assembly. Each level of the magnet assembly includes a plurality of magnets arranged at intervals along the circumferential direction. From the center of the disk to the outer periphery, the area of ​​the magnets in each level of the magnet assembly increases progressively. The coil assembly includes a coil and a plurality of hollow coils disposed on the coil. The plurality of hollow coils are distributed along the circumference and radial direction of the coil to form a multi-level coil assembly. Each level of the coil assembly is disposed opposite to the magnet assembly of the corresponding level. The plurality of hollow coils form an output winding by means of series connection, parallel connection or series-parallel combination. From the center of the coil to the outer periphery, the area of ​​the hollow coils in each level of the coil assembly increases progressively. The hollow coil has a closed conductor portion, at least a portion of which is located within the sweep trajectory of the outer peripheral edge of the corresponding magnet, so that when the magnet moves relative to the hollow coil, an induced electromotive force is generated in the hollow coil through the change in magnetic flux at the outer peripheral edge of the magnet.

2. The coreless generator according to claim 1, characterized in that, In the coil assembly and magnet assembly of the same level, the ratio of the number of magnets to the number of hollow coils is 4:

3.

3. The coreless generator according to claim 2, characterized in that, The number of hollow coils in the multi-stage coil assembly is the same; the number of magnets in the multi-stage magnet assembly is the same.

4. The coreless generator according to claim 1, characterized in that, In the same level of the coil assembly and the corresponding magnet assembly, the area enclosed by the hollow coil is 2 to 4 times the area of ​​the corresponding magnet.

5. The coreless generator according to claim 1, characterized in that, The coil is cast from insulating resin, the hollow coil is embedded in the coil, and the coil is provided with mounting holes, grooves, or casting cavities for positioning the hollow coil.

6. The coreless generator according to claim 1, characterized in that, The disk assembly and the coil assembly are alternately stacked along the axis of the rotating shaft to form two or more sets of the power generation units, and a preset axial gap is maintained between adjacent power generation units.

7. The coreless generator according to claim 6, characterized in that, The axially adjacent disk assemblies or coil assemblies have a preset circumferential misalignment angle, so that a predetermined phase difference is formed between the inductive outputs of adjacent power generation units, which helps to reduce output pulsation.

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