Improved internally adaptive variable generator and motor

Abstract

A dynamoelectric machine includes an inner cylindrical stator, an outer cylindrical stator, and a cylindrical rotor radially disposed between the inner and outer cylindrical stators. The cylindrical rotor is rotatable relative to the inner and outer cylindrical stators. The cylindrical rotor includes at least one rotating conductor including a mixture of electrically conductive and ferromagnetic materials. The inner and outer cylindrical stators include at least one of: (i) gradient magnetic field strength regions with varying magnetic flux density longitudinally downward along the axial direction of the dynamoelectric machine; (ii) different radial diameters of overlapping rotor and stator portions at different axial locations of the dynamoelectric machine; and (iii) electromagnets configured to be selectively energized based on a changing variable.

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims priority to U.S. Patent Application No. 18 / 232,959, filed August 11, 2023, and U.S. Provisional Patent Application No. 63 / 467,850, filed May 19, 2023, U.S. Provisional Patent Application No. 63 / 467,843, filed May 19, 2023, and U.S. Provisional Patent Application No. 63 / 373,582, filed August 26, 2022, the entire contents of which are incorporated herein by reference.

[0002] (1. Technical Field) The present invention relates to novel structures and systems for improving generators and motors. More specifically, the present invention relates to generators and motors that are smaller, more powerful, more efficient, and capable of performing better under variable inputs and operating conditions (e.g., gusty winds and widely varying wind speeds, or vehicle load and rpm operating conditions). These improvements will have a significant impact on the power generation (particularly wind power) and electric vehicle industries. For power generation, preferred embodiments of the present invention are smaller, lighter, and more robust, while being able to harvest more power from variable inputs such as wind. For the electric vehicle industry, generators and motors of preferred embodiments of the present invention achieve higher efficiency, range, power density, and improved regenerative braking capacity. Background Field

[0003] (2. Description of Related Art) With the advent of wind power, engineers took the traditional constant input / constant RPM devices, mounted them on a tower, and added one of several different types of turbines to the input shaft. This was considered a success because the wind spun the turbine and some electricity was generated. However, the input from the wind was highly variable, the opposite of the constant, stable input required in earlier designs, and therefore little of the available energy could be harvested.

[0004] Generally, generators facing the above inputs produce little or no power for a significant portion of the time when the wind is slower, wasting most of the available energy when the wind speed is faster than required for ideal RPM. Modifications have been made to improve the functionality of wind turbines and other generators with variable inputs. Most focus on finding ways to match grid frequency, wasting energy and sacrificing collection efficiency to prevent the generator from overspinning. A reasonable estimate is that wind turbines can waste up to 60% of the energy they can collect. Therefore, currently available generators can only be installed in costly and remote locations with the best winds, such as offshore or mountaintops. This results in more power loss due to line losses and limits feasible installation options.

[0005] Efforts have been made to increase the RPM range and tolerance of variable inputs for generators, and to improve the range of RPMs and loads over which motors can function at maximum efficiency, but the improvements have been minimal. In the field of wind power, the claimed improvements have primarily consisted of wasting excess wind energy at speeds greater than the generator's ideal speed, allowing the generator to continue operating at a lower output.

[0006] Active airfoils and responsive braking increase capability at variable wind speeds by wasting excess energy in high-speed winds. This makes the system significantly less efficient, but keeps the generator running during high-speed winds. Similarly, decoupling the rotor RPM from the rotor field RPM in a doubly-fed induction generator (DFIG) system primarily serves to reduce mechanical stress on the generator, again by wasting excess profit energy in high-speed winds. In fact, most generator improvements called "variable capability" do so by wasting harvestable energy. Summary of the Invention

[0007] To overcome the above-mentioned problems, preferred embodiments of the present invention provide a new generator system and architecture that instantly and continuously adapts to wind fluctuations. Potentially, preferred embodiments of the present invention can generate up to approximately 2.5 times more power than conventional designs, depending on wind patterns. More importantly for the wind energy industry, because generators according to preferred embodiments of the present invention are so efficient, they can be deployed in many more locations, including closer to where power is needed.

[0008] According to a preferred embodiment of the present invention, a dynamoelectric machine includes an inner cylindrical stator, an outer cylindrical stator, and a cylindrical rotor radially disposed between the inner and outer cylindrical stators. There are no salient poles, and the magnetic field strength is uniform along the circumferential axis. The inner and outer cylindrical stators include gradient magnetic field strength regions in which the magnetic flux density varies longitudinally downward along the axial direction. Each of the inner and outer cylindrical stators may include hybrid electromagnetic / permanent magnets. The inner cylindrical stator may include permanent magnets and electromagnets that are stronger than the permanent magnets and electromagnets of the outer cylindrical stator, respectively, in proportion to the size difference between the inner and outer cylindrical stators. The magnetic field difference caused by the size difference between the inner and outer cylindrical stators can be balanced by the difference in strength between the permanent magnets and electromagnets of the inner and outer cylindrical stators and the difference in rotor thickness.

[0009] According to another preferred embodiment of the present invention, a dynamoelectric machine includes an inner stator, an outer stator, and a rotor concentrically disposed between the inner and outer stators. The inner and outer stators include gradient magnetic field strength regions in which magnetic flux density varies longitudinally downward along the axial direction. Each of the inner and outer stators may include hybrid electromagnetic / permanent magnets. The inner stator may include permanent magnets and electromagnets that are stronger than the permanent magnets and electromagnets of the outer stator, respectively, in proportion to the size difference between the inner and outer stators. The magnetic field difference caused by the size difference between the inner and outer stators can be balanced by the strength difference between the permanent magnets and electromagnets of the inner and outer stators and the wall thickness of the rotor. Both the inner and outer stators have the shape of, for example, a truncated cone, a Gabriel horn, or a series of cylindrical segments with successively larger radii.

[0010] In a preferred embodiment of the present invention, the rotor cylinder wall is defined by a plurality of bars. These bars taper toward their narrow axial ends, but not so much that the reduction in capacity causes undo heating. Toward their wide axial ends, the rotor bars can be wide enough to accommodate eddy currents. The bars can be split longitudinally (e.g., like a tuning fork) to maintain the desired thinness.

[0011] The above and other features, elements, characteristics, steps, and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the present invention, taken in conjunction with the accompanying drawings. [Brief explanation of the drawings]

[0012] [Figure 1] FIG. 1 shows a stator magnet arrangement according to a preferred embodiment of the present invention. [Figure 2] FIG. 2 shows an end view of FIG. [Figure 3] FIG. 3 shows a multi-layer stator according to a preferred embodiment of the present invention. [Figure 4] FIG. 4 shows various stator magnetic fields including (A) radial field and near magnet according to a preferred embodiment of the present invention, (B) permanent magnet and long longitudinal field of a conventional machine, (C) induction / squirrel-cage, DFIG, arcing long field of a conventional machine, and (D) four arcing fields of a conventional DC machine. [Figure 5] FIG. 5 illustrates a radial magnetic field of alternating polarity according to a preferred embodiment of the present invention. [Figure 6] 6A-6F show a hybrid permanent magnet / electromagnet configuration according to a preferred embodiment of the present invention. [Figure 6G] FIG. 6G illustrates another exemplary embodiment of a stator according to a preferred embodiment of the present invention. [Figure 7] FIG. 7 shows a cross-sectional side view of a dynamoelectric machine in accordance with a preferred embodiment of the present invention. [Figure 8] FIG. 8 shows a side cross-sectional view of a dual rotor / three layer stator configuration in accordance with a preferred embodiment of the present invention. [Figure 9] FIG. 9 illustrates various possible rotor configurations according to preferred embodiments of the present invention, including (A) a solid / monolithic rotor core, (B) a segmented rotor core, (C) bar segments defining a rotor core, (D) a multi-layered rotor core, (E) a radially curved or skewed bar rotor core with or without longitudinally stacked bar segments of dispersed iron, and (F) an embedded wire rotor core with or without iron material dispersed in or comprising a binder. [Figure 10]FIG. 10 shows additional possible rotor configurations, including: (G) a thin-walled bar segmented rotor core with no iron content to minimize inter-iron distance; (H) a rotor core having a material such as copper interspersed with longitudinally electrically insulated iron segmented laminations; (J) interspersed electrically insulated iron laminations in a rotor core defined by circumferentially adjacent laminations connected to the inside of the rotor; (K) interspersed iron laminations in a rotor core defined by circumferentially adjacent electrically insulated laminations connected to the outer surface of the rotor; (L) interspersed iron laminations in a rotor core defined by circumferentially adjacent electrically insulated laminations connected on the inner and outer surfaces of the rotor; (M) an iron material rotor core within insulated, generally radial perforations of the rotor; (N) a rotor core film having a thinly deposited iron material, a longitudinally separated segmented coating on one or more surfaces; and (O) an iron material rotor core defined by circumferentially adjacent electrically insulating rings traversing back and forth from the inner and outer walls of the rotor. [Figure 11] FIG. 11 illustrates additional possible rotor configurations in accordance with preferred embodiments of the present invention, including (P) ferrous material, inclusions, particles, fillers, strips, etc. embedded in uniform or substantially uniform, generally radially oriented or aligned rectangular or filamentary particles, and (Q) ferrous material and a conductive material, e.g., copper or silver thin film, arranged in concentric layers interspersed with layers of iron or other suitably highly magnetically permeable material. [Figure 12] FIG. 12 shows a stator cylinder having different strength segments to generate different strength magnetic portions of the inter-magnet stator magnetic field according to a preferred embodiment of the present invention. [Figure 13] FIG. 13 shows various inter-magnet distances achieved in three different ways according to a preferred embodiment of the present invention. [Figure 14] FIG. 14 shows a frustum stator according to a preferred embodiment of the present invention in (A) a side perspective view and (B) a side cross-sectional perspective view. [Figure 15] FIG. 15 shows a stator frustum according to a preferred embodiment of the present invention, including assembled longitudinal wedge pieces. [Figure 16] FIG. 16 shows a stator including spacer-free transverse wedge sections in accordance with a preferred embodiment of the present invention, where the longitudinal seams are preferably diagonal and staggered to prevent longitudinal areas of weakness within the field. [Figure 17] FIG. 17 shows a stator according to a preferred embodiment of the present invention having alternating adjacent longitudinal wedge segments magnetized with opposite polarities. [Figure 18] FIG. 18 shows a step gradient stator according to a preferred embodiment of the present invention. [Figure 19] Figure 19 shows the cross-sectional spaces between magnets with different thicknesses but the same amount of cross-sectional area in each short region, see the longitudinal cross-section lines. [Figure 20] Figure 20 shows an end view of the preferred embodiment of Figure 19 with the inter-magnet cross-sectional spaces having the same cross-sectional area in each short region, see cross-sectional view lines. [Figure 21] FIG. 21 shows a rotor with non-embedded straight rod bars according to a preferred embodiment of the present invention. [Figure 22] FIG. 22 shows some examples of rotor configurations according to preferred embodiments of the present invention, including (A) solid walls, (B) longitudinal bars, (C) straight, spiral, or angled walls, and (D) embedded wires. [Figure 23] Figure 23 is an example of a Gabriel trumpet / Torricelli horn. [Figure 24] FIG. 24A is a side view of a preferred embodiment of the outer stator electromagnet of the present invention, which includes FIG. 24B. [Figure 25] FIG. 25 shows longitudinally arranged stator electromagnets in a preferred embodiment of the present invention. [Figure 26] FIG. 26 shows a cross section of a dynamoelectric machine according to a preferred embodiment of the present invention. [Figure 27] FIG. 27 is an exploded perspective view of the dynamoelectric machine shown in FIG. [Figure 28]FIG. 28 shows a cross section of a dynamoelectric machine according to another preferred embodiment of the present invention. [Figure 29] FIG. 29 shows another cross section of a dynamoelectric machine according to another preferred embodiment of the present invention. [Figure 30] Figure 30 is a cross-sectional view of a preferred embodiment of the present invention, including a dual rotor and tri-stator configuration with hybrid electromagnet / permanent magnets on the inner and outer stators and only permanent magnets on the center stator. The permanent magnets in the illustration are preferably adjacent frusto-conical segments on the rotor side of the permanent magnets, with inner and outer stator electromagnets on the yoke side of the stator. [Figure 31] FIG. 31 shows an example of a rotor configuration according to a preferred embodiment of the present invention. [Figure 32] FIG. 32 shows a cross section of a dynamoelectric machine according to another preferred embodiment of the present invention. [Figure 33] FIG. 33 shows another cross section of a dynamoelectric machine according to another preferred embodiment of the present invention. [Figure 34] FIG. 34 shows another cross section of a dynamoelectric machine according to another preferred embodiment of the present invention. [Figure 35] FIG. 35 shows another cross section of a dynamoelectric machine according to another preferred embodiment of the present invention. [Figure 36] FIG. 36 shows another cross section of a dynamoelectric machine according to another preferred embodiment of the present invention. [Figure 37] FIG. 37 shows another cross section of a dynamoelectric machine according to another preferred embodiment of the present invention. BEST MODE FOR CARRYING OUT THE INVENTION

[0013] Hereinafter, embodiments of the present invention will be described with reference to the drawings.

[0014] Preferred embodiments of the present invention can be used in electric motor applications as well as generator applications. In the electric motor field, motors function at their peak efficiency at a constant RPM and load value specific to each design. This is ideal when the motor is part of a system, such as running a conveyor belt at a specific speed with a steady load. The design engineer simply selects the appropriate type and size motor for the application, and it will always operate efficiently. However, if either the motor's load or RPM changes, the motor will move outside of its highest efficiency range, thus reducing range and power.

[0015] For example, propelling an automobile is one of the most variable operating environments an electric motor can face. Vehicles stop, start, reverse, accelerate, decelerate, go up and down hills, and carry variable amounts of passengers and load. Because load demands and RPMs are constantly changing, electric motors often find themselves operating outside of their ideal efficiency zone.

[0016] Similarly, in the field of generators, generators are typically configured to output peak power at a predetermined rotational frequency. This rotational frequency is typically selected based on the desired AC power frequency, such as 60 Hz. If the input rotational speed to the generator exceeds the rotational speed required to output peak power at the predetermined rotational frequency, the generator's rotational speed is reduced via braking or other mechanisms. This braking action results in a significant loss of efficiency because the generator cannot use all of the energy provided by the input rotational speed.

[0017] An electric motor that can instantly adjust itself to constantly changing operating conditions can add significant leeway to a vehicle with increased propulsion and regenerative braking efficiency. Similarly, an electric machine that can constantly and dynamically change its power parameters can efficiently provide power over a continuous operating band that includes different environmental parameters.

[0018] A more advanced understanding of generators and motors is that they are not devices, nor are they a combination of their physical parts. An actual generator / motor is only the interaction of electric and magnetic fields. Therefore, the only part of the device that does the work is invisible and intangible. All physical parts and systems contain only magnetic fields. It is a mistake to think of a motor / generator as a physical device made of assembled parts. It is not a machine, but an interface between two energies: magnetic and electrical. The physical parts are merely the structure to generate and transmit the two energies.

[0019] By starting with a conceptualization of the complete field interactions and working backward to understand the parts necessary to facilitate and nurture those complete interactions, it becomes possible to discover and create an entire new family of motors and generators in accordance with preferred embodiments of the present disclosure.

[0020] (First Preferred Embodiment) A first preferred embodiment of the present disclosure provides novel improvements directed to increasing magnetic field strength, efficiency, and effectiveness, and includes a family of generally cylindrical embodiments, expanded upon in the next section with a conical embodiment. The completed device includes a series of innovations that build upon previous ones, and is described beginning with the simplest and most basic variants and then with variants that build upon the previous variants. The improvements generally fall into at least one of two categories: the first is to improve the function and strength of the magnetic field, and the second is to improve the adaptability of the generator / motor so that it performs well over a wide range of variable input power.

[0021] In the family of novel preferred embodiments described herein, the novel stator preferably includes a minimum of two concentrically nested stator magnet layers of different diameters (see Figures 1, 2, 7, 8, 12, 13, 18, 19, 21-25, and 30-32). In some other preferred embodiments, additional stator layers exist between levels of the multi-layer rotor (see, for example, Figures 8 and 35).

[0022] 1, a stator assembly 1 according to one preferred embodiment of the present disclosure includes at least an inner yoke 11 having inner permanent magnets 12 and an outer yoke 15 having outer permanent magnets 14 arranged concentrically to define a hollow cylindrical or frustum-shaped air gap 13 (or magnetic flux region) between them in which the rotor assembly rotates. The inner and outer permanent magnets 12 and 14 are generally radially magnetized and typically have opposite poles facing each other across the space between the concentric layers of the inter-magnet air gap 13; i.e., they may be north pole-outside / south pole-inside on the inside, or both south pole-outside and north pole-inside.

[0023] Generally, the air gap 13 contains a strong inter-magnet radial magnetic field throughout its entire length and annular volume, as represented by Figure 4A. This contrasts with prior art stators, which generally either traverse the diameter of the stator, or return from the stator ring to a different spot on the outer ring that does not directly intersect, as shown in Figures 4B, 4C, and 4D.

[0024] Arranging the magnets (e.g., inner permanent magnet 12 and outer permanent magnet 14) in accordance with preferred embodiments of the present disclosure increases magnetic field strength due to magnet proximity, prevents magnetic field bulging as described below, and avoids cross-sectional magnetic fields.

[0025] The inter-magnet air gap 13 in most preferred embodiments of the present disclosure is structured to be just wide enough to hold the body of the rotor 2 (discussed elsewhere herein) with minimal air gap at the sides to prevent friction. However, as described below, there are some preferred embodiments in which the stator (e.g., 11 and 15) and rotor 2 have regions with increased or gradient gap widths (see, e.g., FIG. 13).

[0026] Figures 1, 2, and 7 illustrate the general components of a first preferred embodiment of a dynamoelectric machine of this invention. The dynamoelectric machine includes a rotor 2 opposed to a stator assembly 1, preferably including two opposing stator yokes 11 and 15, on which radially magnetized inner and outer stator magnets 12 and 14, respectively, are mounted through an air gap 13. The rotor 2, stator magnets 12 and 14, and yokes 11 and 15 are preferably all conical or cylindrical. The rotor 2 may have conductors 21 (preferably linear conductors) configured to rotate relative to the stator yokes 11 and 15. The stator yokes 11 and 15 contain magnets (preferably permanent magnets 12 and 14 and / or electromagnets 16 and 220) that generate a magnetic field within the air gap 13 around which the conductors 21 of the rotor 2 rotate.

[0027] The dynamoelectric machine of Figure 26 further includes a fan 26 preferably disposed within the central tube 111 of the inner yoke 11. The fan 26 is spirally shaped and includes a fan shaft 27 that is fixed to the rotor 2 via the rotor fixing point 24 and rotates with the rotor 2. The fan 26 generates airflow for cooling the components of the dynamoelectric machine.

[0028] The rotor 2 preferably includes an upper rotor ring 23 and a rotor support frame 22 provided at both axial ends of the rotor conductor 21. An upper rotor bearing 31 is preferably provided between the upper rotor ring 23 and the outer stator 4. The rotor support frame 22 preferably includes an integral drive shaft 25 that receives a rotational input for rotating the rotor 2 in the case of a generator, or outputs a rotational force for driving an attached member in the case of a motor.

[0029] As shown in FIG. 26 , the inner yoke 11 has a housing upper end 18 provided at both axial ends of the inner yoke 11 and a lower support plate 113. The inner yoke 11 is configured to support the inner radial surfaces of the inner permanent magnets 12 (which may be permanent magnets, electromagnets, or hybrid permanent / electromagnets). Both the housing upper end 18 and the lower support plate 113 preferably include connecting tabs 38 configured to support the axial portion of the inner electromagnet stator 16. The housing upper end 18 preferably includes a recess 39 that accommodates the upper shaft bearing 32 that rotatably supports the upper end of the fan shaft 27. The lower support plate 113 preferably includes an opening 40 through which the lower end of the fan shaft 27 extends. The lower end of the fan shaft 27 is preferably fixed to a rotor fixing point 24 defined within the rotor support frame 22. The rotor fixation point 24 may include a recessed structure that extends into the rotor support frame 22, and the lower end of the fan shaft 27 may be attached within the rotor fixation point 24 using, for example, fasteners, adhesive, welding, or the like.

[0030] The outer stator yoke 15 preferably includes a lower housing end 19. The lower housing end 19 preferably includes a recess 192 that accommodates the lower bearing 33 and an opening 193 that allows the drive shaft 25 to extend outwardly through the lower housing end 19. The lower bearing 33 is configured to rotatably support the drive shaft 25. The outer yoke 15 defines an outer shell 151 of the stator assembly 1. The outer yoke 15 is configured to support the radially outer surfaces of the outer permanent magnets 14 and to provide a magnetic flux path and cooling fins.

[0031] The inner electromagnet stator 16 preferably includes a plurality of bobbins 162 wound with the wire of the electromagnetic coil 17, and a plurality of connecting plates 163 interconnecting adjacent bobbins 162. In other preferred embodiments of the present invention, the bobbins 162 may be replaced / exchanged with teeth. Furthermore, if the coils wound on the plurality of bobbins 162 are too large to provide clearance for the connecting plates 163, which may be coils, the plurality of connecting plates 163 may be omitted.

[0032] In preferred embodiments of the present disclosure, the magnetic field is much stronger because it is defined by magnets (e.g., permanent magnets 12, 14 and / or electromagnets 16, 220) that are closer to each other. The magnet layout of preferred embodiments of the present invention prevents the magnetic fields from expanding the way they do in conventional structures, making them even stronger, and the magnetic field is 100% ordered without cross-fielding or incorrectly oriented sections. Traditional, large, heavy, and expensive laminated central rotor cores and laminated stator cases are not required, thus reducing weight by half. These advantages, and others described in the benefits section, allow motors and generators to be smaller, lighter, and more powerful. Better magnetic utilization means that cheaper, non-rare earth magnets can be used.

[0033] The generally cylindrical configuration requires a novel rotor. Starting with the theoretically simplest preferred embodiment of the invention, the rotor can be one or more generally cylindrical tubes of conductive material suspended so that they can rotate within the inter-magnet air gap 13.

[0034] This rotor positioning and rotation can be achieved through a variety of structures, including bearings 31, 31', 32, and 33 associated with the ends and / or end caps of stator assembly 1 and rotor 2. This configuration creates a significantly more efficient / powerful rotor. In its most basic variant, as rotor 2 rotates, the entire magnetic inter-rotor wall (i.e., rotor conductors 21) across its entire length, circumference, and thickness intersects the radial magnetic field at right angles to the radial magnetic field lines. Rotor 2 does this for 100% of its rotational duty cycle. No other conventional rotor design achieves this. All other conventional designs have dead zones within the rotor, field-relative dead zones in the rotor's path of travel, where parts and areas of the rotor do not contribute to torque or power generation.

[0035] In a preferred embodiment of the present invention, increasing the rotor length increases the voltage generated. Increasing the cross-sectional thickness of the rotor wall increases the amperage, assuming the stator field is tuned to a constant flux density, as long as neither the field nor the metal reaches saturation. Increasing the diameter of the stator and rotor increases the number of magnetic field lines crossed per second for a given RPM, which reduces speed cut and increases the power generated, while also increasing amperage in a second way. A larger rotor has a larger circumference, so there is more volume of metal. This increases the amount of metal simultaneously crossing the field lines, so the current increases.

[0036] The rotor thickness and inter-magnet air gap width for each of these variations is best optimized by balancing multiple factors, including the stator magnetic field strength range, how to promote rotor flux conductance, material susceptibility to current induction, permeability / saturation, amperage vs. voltage, expected RPM range, current and voltage loads, cooling requirements, type and amount of iron or magnetically permeable material used in the rotor, and the need for longitudinal gradient strength in the magnetic field.

[0037] Such a simple, elegant, and relatively monolithic type of rotor has several advantages. It can spin very fast with minimal impact from vibrations and centrifugal forces that would destroy other structures. Virtually its entire mass can be a current source. There are no gaps, such as the space between wires in a coil, allowing full use of the EMF-active inter-magnet zone. It can be cast, machined, 3D printed, or extruded as a single piece, reducing manufacturing time, cost, and complexity. It does not require the expense, weight, or complexity of a laminated metal core.

[0038] In addition to incorporating any combination of the above-mentioned attributes, the first preferred embodiment of the present invention is further adapted to be a tapered generally conical frustum that is similar in overall shape but now includes layers of generally conical frustum segments. Each of these variations can be combined with others to adapt the technology to a particular application.

[0039] As will be described, shaping the stator assembly 1 and rotor 2 into a generally frusto-conical shape gives the generator a powerful ability to instantly adapt to a wider range of variable input power to precisely match the generator strength required for maximum energy harvesting of that input. This adaptation of gain and loss of generator strength to match the input power is seamless, instantaneous, and occurs without the need for additional equipment, gearing, clutches, brakes, active vanes, computers, sophisticated controllers, etc. Much of that adaptability and control derives from the inherent advantages of the conical or stepped cylindrical shape.

[0040] A properly oriented wire or conductor moving in the correct direction and speed to cross enough correctly oriented magnetic field lines will experience both (1) an electromagnetic force (EMF) that moves electrons down the length of the wire and (2) a resistance to motion that is proportional to the amount of current being produced. It is important to understand that a certain number of magnetic field lines must be crossed per second to generate enough EMF to initiate current flow. If the wire is moving too slowly or the magnetic field is too weak to supply the required number of magnetic field lines per second, no current will flow.

[0041] As a frustum rotates around its central axis (height), all longitudinal points rotate at the same RPM. Because points toward the wide end must travel further around their larger circumference with each rotation, they move proportionally faster and farther than points closer to the narrow end. For example, if the wide end has twice the diameter of the narrow end, points at the wide end must travel twice the distance and therefore twice as fast as points at the narrow end. As used herein, the terms conical, near-conical, and frustum include, but are not limited to, shapes resembling a Gabriel's horn / Torricelli trumpet and shapes resembling a convex surface. These terms also encompass shapes that function similarly but have portions arranged with graduated diameters and / or that do not have a radial gradient. Examples are shown in Figures 27, 33, 35, and 40. Reference to shapes such as cones, conical, near-conical, frustum, etc., describes all substantially similar thick-walled, open-ended hollow structures.

[0042] In this series of variations, the stator preferably includes two or more concentrically nested, radially magnetized, generally frustoconical sections, as shown in FIG. 14. The generally conical inner yoke 11, inner permanent magnet 12, outer yoke 15, and outer permanent magnet 14 are arranged with opposite poles facing each other across the gap between the two cones. For example, the outer cone may include the outer permanent magnet 14 with a north pole facing inward, and the inner frustum may include the inner permanent magnet 12 with a south pole facing outward, or vice versa. This produces a circumferentially uniform inter-magnet radial magnetic field with lines oriented like bicycle spokes, generally perpendicular to the surfaces of the outer permanent magnet 14 and inner permanent magnet 12. The cones of the outer permanent magnet 14 and inner permanent magnet 12 can be made from a single piece of magnetic material, or they can be formed from several magnets machined or molded to fit together to create such a generally conical structure. Examples of these preferred embodiments can be seen in FIGS. 19-22.

[0043] 15 shows that the outer permanent magnet 14 can be defined by longitudinally extending permanent magnet wedge pieces 141 that oppose the permanent magnet wedge pieces 122 of the inner permanent magnet 12. FIG. 16 shows an example of a stator assembly 333 that includes latitudinal wedge segments 3331. The latitudinal wedge segments 3331 include diagonal ends that act to prevent longitudinal areas of weakness in the stator magnet 333.

[0044] 17 shows that the outer permanent, electromagnet, or hybrid magnet 14 may be defined by longitudinally extending permanent, electromagnet, or hybrid magnet wedge pieces 141 that oppose the permanent, electromagnet, or hybrid magnet wedge pieces of the outer permanent, electromagnet, or hybrid magnet 14, and the inner permanent magnet 12 is reversed.

[0045] Another feature according to preferred embodiments of the present invention is that the magnetic field also has a longitudinal gradient strength. For example, the magnetic material at the wide end of the stator cone is stronger, thus generating a stronger, denser magnetic flux field compared to the weaker narrow end, or vice versa, or any other organization of circumferentially uniform but longitudinally varying sections of magnetic field strength. Furthermore, the magnetic flux field can be adjusted via electromagnets or the electromagnet portion of a hybrid magnet.

[0046] The stator of a preferred embodiment of the present invention includes a hybrid electric / permanent magnet. The permanent magnet allows the generator to start without requiring an excitation current, and the electromagnet can be used to selectively increase the magnetic field strength as a way to adapt the generator's generating capacity, allowing it to operate as a more powerful or weaker generator on demand. In fact, the electricity entering the electromagnet can come from the generator itself, thus creating an opportunity for the generator to not only be an adaptive generator, but also a self-regulating generator that adjusts automatically. Wind speed changes RPM, increasing the amount of available electricity. A small portion of that electricity is diverted through the electromagnet, making the generator stronger so that it can handle the higher energy input of increasing wind speeds. This also increases the counter-torque resistance to further acceleration, referred to herein as "dynamic braking."

[0047] In a preferred embodiment of the rotor of the present invention, the conical stator / rotor may be configured as a stepped cylinder or frustum. The stepped configuration offsets the voltage difference generated at each radius. The voltage is a function of rotational speed, field strength, and the length of the metal within the field. That is, the more magnetic flux lines traversed per second by the rotor's metal bars, the higher the voltage generated.

[0048] The additional area provided by a conical stator / rotor (i.e., an area not present in a conventional cylindrical stator / rotor) preferably generates similar voltages. In one example, this can be achieved by having a shape that is the same as or substantially similar to the overall shape of Gabriel's trumpet, thereby making subsequent traversals of longer areas so that subsequent traversals of the area generate voltages equal to the shorter but wider area traversed initially. Another way to equalize voltages is to make the narrow diameter segments proportionally longer than the narrow diameter segments, as shown in Figure 40. Yet another method is to control the stator field strength of each segment.

[0049] Further variations of the concentric and cylindrical designs can be made in accordance with further preferred embodiments of the present invention. Some of the preferred embodiments of the present disclosure include the following non-limiting examples.

[0050] (alternate stator polarity) The stator magnetization polarities may be arranged in other ways, such as with different longitudinal, generally wedge-shaped, oppositely magnetized regions, as in stepper motors, three-phase machines, and AC generators and motors described in later discussion.

[0051] (Differential strength of stator magnets) The two magnetic stator layers can have similar or different magnetic strengths. One example is to make the inner, smaller layer out of a stronger or thicker magnet composition to balance the larger magnetic field coming from the larger outer magnet.

[0052] (Alternative stator / rotor configurations) The generally cylindrical magnet and yoke can rotate individually or together as a rotor, and the rotor can be a stator. Or, both can rotate relative to the other. In the most commonly used preferred embodiment, the magnet is fixed, forming an air gap between the stator and the magnet. There may be a non-magnetized buffer zone between adjacent regions of opposite polarity.

[0053] (permanent magnets and electromagnets) The stator can be a permanent magnet, an electromagnet, or any combination of either. As shown in Figures 6A-6F, the following configurations are possible: Figure 6A shows an outer yoke 15 including an electromagnetic coil 17 wound around a stator protrusion 161; Figure 6B shows an outer yoke 15 including multiple bobbins 162 wound with individual electromagnetic coils 17; Figure 6C shows an outer yoke 15 including outer permanent magnet bobbins 142 wound with individual electromagnetic coils 17; Figure 6E shows an outer yoke 15 including outer electromagnet bobbins 142 wound with individual electromagnetic coils 17, which have spaced-apart ferromagnetic bobbins 142 with permanent magnets 14 between them; and Figure 6F shows an outer yoke 15 with outer magnet bobbins 142 wound with individual electromagnetic coils 17 and covered by ferromagnetic levelers 20, which have permanent magnets 14 between them.

[0054] 6C-6F, if the magnet is structured with an unsaturated domain, a specially fabricated permanent magnet extension can define and function as the electromagnet core. If the electromagnet components are on the rotor side of the outer yoke 15, their iron core and coils will be of sufficient size and composition that they will not saturate unless the electromagnet is at full strength.

[0055] (single solid magnet or composite magnetic segment) In a preferred embodiment, starting with a generally cylindrical structure, the stator permanent magnets each comprise a single solid continuous magnet. They may alternatively be constructed from magnetic segments structured to fit together to create stator magnets of the same overall shape.

[0056] (ferromagnetic layer, strong magnetization, or staggered seam) Typically, when a cylindrical magnet stator is formed from a subset of segments, a thin, field-leveling layer of iron or other magnetically active / conductive material can help even out the non-uniformity of the magnetic field that forms around the magnet center, since weak spots in the magnetic field can potentially limit generation capacity by allowing electrical backflow or eddy currents. Another method of preventing electrical eddy currents and backflow is to utilize strong magnetization in all or circumferential segments of the rotor, as described below, to offset the seams and create laminated or segmented rotors.

[0057] (permanent magnets and / or electromagnets) Preferred embodiments of these generally cylindrical forms utilize a hybrid combination of electromagnetic and permanent magnets. In one such example, due to area differences, an inner magnetic cylinder made of the same material and thickness with the same magnetization as the outer ring will support a smaller magnetic field than the outer ring. This can be balanced by making the inner ring a stronger magnet through increased magnetization, changes in composition, and thickness, or even by adding electromagnetic components. Utilizing electromagnetic components can allow for active control of the inter-magnet magnetic field strength.

[0058] FIG. 6G shows another example of a preferred embodiment of a stator assembly of the present disclosure. The stator assembly 1 of FIG. 6G includes an inner yoke 11 and an outer yoke 15 connected via end portions 18. The inner yoke 11, the outer yoke 15, and the end portions 18 may be made of a ferromagnetic material (preferably iron for AC applications and a permanent magnet material for DC applications). A lower electromagnetic coil 250 is preferably provided on the inner surface of the end portions 18 between the inner yoke 11 and the outer yoke 15. A coil holding barrier or a portion of a bobbin 251 is preferably provided on the upper surface of the lower electromagnetic coil 250 to firmly hold the lower electromagnetic coil 250 on the inner surface of the end portions 18 between the inner yoke 11 and the outer yoke 15. The lower electromagnetic coil 250 is configured to be driven with a current to adjust the magnetic field between the inner yoke 11 and the outer yoke 15. An inner rotor and an outer rotor (not shown) can be inserted between the inner yoke 11 and the outer yoke 15 and within the central tube 111 of the inner yoke 11, respectively. The outer yoke 15 preferably corresponds to a south pole and the inner yoke 11 preferably corresponds to a north pole, although these polarities can be reversed if desired.

[0059] Next, a comparison will be made between the generator stator structure of the preferred embodiment of the present disclosure and a conventional wind power generator stator structure.

[0060] Preferred embodiments of the present invention provide generally conical or functionally conical machines with multiple stators that produce magnetic fields with characteristics different from those of the prior art, resulting in machines that are structurally and functionally unique. First, as noted above and further described herein, unlike prior art stators, preferred embodiments of the present invention include stators defined by circumferentially uniform cylindrical or conical circumferential annular segments, rings, cylindrical and / or conical truncated segments, without strongly defined salient poles, and with a circumferentially uniform radial magnetic field. Unlike prior art, at the circumferential cross-section, the magnetic field is completely radial and uniform, with no gaps, weak spots, bulges, side magnetic fields, or broken cross-sections. This helps create their novel functionality. Furthermore, unlike prior art, some preferred embodiments of the present invention include hybrid electromagnet / permanent magnets that can be circumferentially oriented and maintain the circumferential uniformity of the magnetic field.

[0061] The majority of generators used for wind power have a single stator around the rotor. Induction, squirrel-cage, DFIG, Type 2, reluctance, synRM, synRM IPM, and all others use nearly identical stators. These stators contain a series of adjacent, often partially overlapping, electromagnet winding coils. When this type of stator is operating as a motor, a certain number of grouped adjacent coils are energized momentarily (for a small fraction of a second), creating electromagnetic fields that combine to create a series of simply mixed magnetic fields.

[0062] Different configurations energize the coils in different patterns, producing mixed magnetic fields of different shapes and numbers. In some motors or generators, the mixed magnetic field is oriented directly across the center and on opposite sides. In other motors or generators, the stator field arcs in a more diagonal course to adjacent side regions. When this form of stator is used in an induction generator, current loops are induced in the rotating rotor bars as they rotate past the energized stator coils. The current loops create their own electromagnetic fields. These induced magnetic fields are moved by the rotating rotor through the stator windings, which then induce a back EMF that becomes strong enough to overcome and reverse the flow of the excitation current. This current is the generator output. In a grid-tied system, the rotor must rotate approximately 3% faster than the 1500-3600 RPM of the stator field, adjusted for the number of poles.

[0063] When this form of stator is used in a wound rotor or D-shaped generator, instead of a bar, the rotor has electromagnets that are selectively energized to generate their own setting of magnetic field RPM. These magnetic fields still rotate past the stator core, where they propagate through the stator windings, which induce current flow, into the core. Again, in a direct grid-tied system, the rotor must rotate faster than the stator field, which typically rotates at 1500-3600 RPM (depending on the number of poles) relative to the American power grid.

[0064] In a preferred embodiment of the rotor of the present invention, the entire rotor is solid. This maximizes the amount of rotor metal in the magnetic field, but the lack of longitudinal laminations increases the tendency for eddy and reverse currents in weak spots. This is partially suppressed by making the magnetic field stronger and as completely uniform as possible. However, another preferred embodiment of the present invention, shown in Figure 31, has a rotor 2 that is divided into longitudinal sections, hereafter referred to as bars or longitudinal segments 211. In a tapered preferred embodiment, the wider ends of the rotor have wider laminations than the narrow ends and / or branch laminations. The wider ends still have some tendency for eddy and reverse currents under heavy loads. One solution is to partially split the wide ends of the bars longitudinally one or more times, as shown in Figure 31.

[0065] In Figure 31, the tapered rotor 2 is shown with the narrow end facing outward. The tapered rotor is divided into four sections to illustrate different methods for forming the laminations. Note that Figure 31 is for informational purposes only. An actual device would preferably have a structure in only one of the quadrants of Figure 27. In quadrant A of Figure 31, the rotor 2 is solid and unlaminated. In quadrant B, the rotor 2 is formed from simple laminated tapered bars 211. In quadrant C, the individual bars 211 are further split longitudinally (212) at points where width may cause problems. In quadrant D, each bar is split three times, with the center split 212 proceeding further down the bar 211 than the lateral splits 213.

[0066] The thinnest areas of the bars 211 can heat up if they are too small due to the reduced current carrying capacity of the smaller cross section of the metal. This can be partially addressed by radially thickening the narrow ends to provide a larger cross section. It can also be addressed by providing a more robust cooling mechanism in that area. Because the inner air chamber is narrower at the end prone to heating, it naturally experiences a larger Venturi wind flow, which increases cooling. There is a variation where cooling air enters from the sides, which also experience the coldest air.

[0067] The number of bars 211 into which the rotor 2 is divided is limited by the current carrying capacity of the narrowest section and the maximum developed current. Interestingly, the amount of amperage generated depends on the radial thickness of the bars 211, such that additional thickness of the bars 211 increases the amount of amperage generated.

[0068] The preferred radial thickness of the rotor 2 is derived from a balance of several factors. The more metal in the magnetic field (up to a saturation point), the more power is generated. However, as the amount of metal increases and the distance (i.e., air gap) between the stator magnets must also be increased to accommodate the rotor 2, it reduces the magnetic field by a factor of 1 / 3 of the increased distance. Therefore, a balance must be struck between as much metal as possible without weakening the field strength beyond the point of diminishing returns.

[0069] From the perspective of the magnet, the copper space is essentially the same as an air gap (i.e., a magnetic air gap). The prior art partially avoids this problem with laminated cores that conduct magnetic flux. Alternatively, preferred embodiments of the present invention include a specifically structured construction of one or more mixtures of highly permeable materials, such as iron, silicon steel, mu metal, permalloy, and the like, in the form of particles, filaments, etc., embedded within the rotor's copper. This is not possible in the prior art, because the electrically and magnetically conductive components must remain separated to prevent induced magnetic fields that generate back EMFs in response to counter eddy currents. Such problems are much less likely with the construction of preferred embodiments of the present invention.

[0070] As shown in Figure 36, there are variations on the preferred embodiment of the present invention that include structure and / or circuitry for feeding back current occurring at the negative end of the rotor to its positive end, reminiscent of a power bus system that can cycle the flow of current through the magnetic field, increasing the voltage each time. When the voltage exceeds a certain threshold, the voltage powers an electrical collection circuit, including, for example, a step-up transformer device, a power conditioner, a converter circuit, or an inverter circuit, so that a desired higher voltage and regulated current can be selectively derived from the generator.

[0071] There are various preferred embodiments of rotors adapted for specific applications, having the same overall shape but assembled from different subcomponents for various applications (see Figures 9 and 10). Rather than being a purely monolithic tube, the rotor can be divided into a series of longitudinal segments called bars, or other segments. Segmented coils can have seams designed not to align with the length of the rotor, called diagonal bar segments. The rotor body may be formed from coated and embedded wire. The segments can have an electrically insulating coating that helps prevent electrical backflow.

[0072] Many of these parallel wound rotors require a diode function at the distal bar level and / or between the current collector and the load to prevent harmful backflow of current within the rotor parts.

[0073] As shown in Figure 22, the longitudinal segments 211 of the rotor 2 can be straight, diagonal, or spiral, which is useful if the stator assembly 1 has a seam to avoid being parallel to the magnetic seam of the stator assembly 1. The layers can have different internal configurations, including thickness, material, and segment shape, depending on the needs of the application. AC rotors are described in their respective sections.

[0074] If a thicker rotor is desired, iron or other magnetically permeable material must be incorporated into the permanent magnet portion of the rotor to allow magnetic flux to conduct through the rotor wall to reduce distance-based field losses. This material can be incorporated in several ways, with exemplary representative styles shown in Figures 10(H)-(O) and 11(P) and (Q).

[0075] Specifically, Figures 9 and 10 illustrate various possible rotor configurations. Sections A-F are directed to possible rotor bar configurations, while sections G-Q are directed to demonstrating various ways in which iron material can be incorporated to increase the net magnetic permeability of the rotor, allowing for thicker rotors. Specifically, we show (A) solid / monolithic, (B) bar segments, (D) multilayered, (E) radially curved or diagonal bar segments with or without longitudinally stacked bar segments, (F) with or without interspersed iron material within a binder, (G) iron segments to minimize intermagnet spacing, (H) with materials such as copper, and (I) interspersed, electrically insulated iron laminations defined by circumferentially adjacent laminations connected on the inner surface of a material such as copper. The figure shows a rotor, (K) circumferentially adjacent electrically insulated laminations connected to the rotor's outer surface, (L) circumferentially adjacent electrically insulated laminations connected to the rotor's inner and outer surfaces, (M) ferrous material in the rotor's insulated, generally radial, material perforations, (N) thin rotor bars having ferrous material deposited in thin films, longitudinally separated segmented coatings on one or more surfaces, (O) ferrous material defined by circumferentially adjacent electrically insulated rings traversing back and forth from the rotor's inner and outer walls, (P) ferrous material embedded in uniform, generally radially oriented, oval or filamentary grains or inclusions, and (Q) ferrous material and conductive material, such as copper or thin film silver, arranged in concentric layers. Additionally, a thin film silver layer can be deposited over the entire rotor's outer surface to enhance electrical conductivity.

[0076] Among other things, a rotor should have high electrical conductivity, high magnetic permeability, reasonable cost, acceptable Young's modulus, corrosion resistance, and thermal expansion. The first three parameters listed are the most important. Copper is one of the best choices when considering conductivity per dollar. Unfortunately, copper's very low permeability limits rotor power output by significantly weakening the magnetic flux field per unit of rotor thickness.

[0077] Increasing rotor thickness increases the mass of the metal generating current, but to accommodate the additional thickness, the stator magnets must be spaced farther apart. The distance between magnets reduces the magnetic flux density by the cube of the distance. This highly detrimental effect can be reduced by using rotor materials with greater magnetic permeability. For example, materials such as pure annealed iron, Mu metal, Metglas, silicon steel, Permalloy, and Supermalloy have excellent permeability, thus significantly reducing distance-related magnetic field losses. However, these materials have insufficient conductivity / susceptibility to current induction and are expensive. Silicon steel has acceptable permeability and cost, but poor electrical conductivity. Pure iron has good permeability but suboptimal conductivity.

[0078] Since no material has all the good properties and all the drawbacks, preferred embodiments of the present invention combine selected materials and combine them in specific ways to combine benefits while limiting problems.

[0079] The rotor material according to a preferred embodiment of the present invention can be fabricated by mixing iron powder and the high-permeability materials mentioned above with molten copper and casting the rotor. The smelting temperature is maintained so that the copper is liquid and the high-permeability granules do not melt, but rather are mixed together as a whole particle. 3D printing also allows for the easy construction of precise structural mixtures.

[0080] Copper has sufficient density to be perfectly electrically adjacent to avoid impedance losses from currents being forced through the junction of dissimilar metals. In conventional generators, eddy currents inherent in their design make these types of materials unsuitable for use in rotors.

[0081] Another concern is the need to avoid the stretching / distortion of magnetic flux lines that typically occurs in conventional spinning rotors. The magnetic flux lines are dragged and stretched halfway through the rotor's path or more. This distortion weakens their effectiveness. A rotor with good, generally homogeneous magnetic permeability will have less distortion, a stronger flux field, and can incorporate more current-producing mass.

[0082] The above novel generator structures of preferred embodiments of the present invention allow generators to be smaller, lighter, simpler, more efficient, and more powerful. The next set of described novel structures allows the generator to operate over a much wider range of power inputs than conventional generators by instantly / automatically adapting via internal synergies to become exactly the right generator for the input. This makes it particularly suitable for variable input applications such as wind generators or vehicle generators / alternators.

[0083] The stators can be formed with roughly the same shape but with gradients or varying circumferential ring segment field strengths arranged along their longitudinal lengths. For example, the first cylindrical ring segments of the inner and outer stators can be fabricated with stronger magnets than the next segment, etc. In Figure 12, these field variations are shown as gradient field strength regions 2A'-2C' arranged from left to right, from weaker to stronger.

[0084] Depending on the desired adaptive parameters, there may be more or fewer of the different gradient magnetic field strength regions 2A'-2C' shown in Figure 12. The gradient magnetic field strength regions 2A'-2C' may be in any order, and may be a gradual gradient of magnetic field strength rather than a stepwise progression. Different magnetic strengths can be achieved by varying the magnetization steps or composition materials used. The segments may differ in magnetic field strength in several ways, including being made from different magnetic materials such as alnico, ceramic, and neodymium, or they may be made from magnetic materials of different grades or dilutions, or they may be magnetized to different strengths. They may be made as described in the next section paired with electromagnets to strengthen or weaken the magnetic field, or they may consist of electromagnets powered to different strengths.

[0085] In Figure 12, as the rotor rotates, different sections pass through progressively stronger magnetic fields. While the entire rotor has the same RPM and all electrically active rotor segments move at the same speed, different longitudinal rotor regions pass through magnetic fields of different strengths. This can be conceptualized by realizing that each electrically active rotor segment traverses a different number of magnetic field lines per second. The segment with the strongest magnetic field has the most lines per area, and the coil speed increases from an RPM that is too slow to generate power; only the section of the coil with the segment with the highest magnetic field strength initially experiences enough magnetic field lines per second to induce current. Thus, the generator acts like a much smaller unit than a conventional generator. It produces a small amount of power, but is relatively easy to spin because it generates less backward force to resist rotation.

[0086] Continuing with reference to FIG. 12, as the RPM increases, at a certain RPM, section 2B' encounters and traverses enough magnetic field lines per second to also contribute current, even as section 2A' has a similarly increasing power output. Thus, as the rotor rotates faster, the current output and EMF resistance to spin also rise more than directly proportional to the change in RPM. As the RPM increases further, the power output and required input torque increase more proportionally until section 2C' also encounters enough magnetic field lines per second to become productively electrically active. At this point, both the electrical output and the force required to rotate the generator rise again.

[0087] The various field strength segments allow different parts of the generator to function as different additional generators that can be employed or disengaged depending on rpm input conditions such as wind speed. In conventional technology, this differentiation is analogous to having multiple generators of different sizes: a small generator that is easy to spin but produces little power to harvest slow wind speeds, a medium-sized generator to produce moderate power from moderate wind speeds, and a large generator that requires more energy to spin but produces a lot of power from high-speed winds, all combined into one self-adaptive machine.

[0088] By having sections of different magnetic field strength, the generator can automatically increase or release power generation capability based on wind drive RPM.

[0089] Another way to more seamlessly match the generated power / electrical output to the input force, thereby allowing the generator to handle a wider range of input forces, is to create regions of varying magnetic space. The magnets can be varied to create different magnetic gaps, creating regions of different magnetic field strengths, as shown in Figure 13.

[0090] Another, more generally cylindrical, way to further expand the generator's ability to accommodate a wider input range is to make it a multi-rotor device, as shown in Figures 3, 33, and 34-37. The outer rotors move faster and over a larger area, so they traverse more lines per second and at a lower RPM than the inner rotor layers. The magnet layers can have different field strengths and / or gradient fields to further tailor this advantage.

[0091] Brushes serve as part of the current collection for many types of generators. They have the disadvantage of being a wear item that requires intermittent replacement. They wear into conductive dust that can arc and spark and contaminate the equipment. While various brushes and commutators can be used in the preferred embodiment described later in this disclosure, in the preferred embodiment, the bearings are specially adapted with a conductive lubricant to act as current collectors, eliminating the need for brushes. Part of this novel adaptation is an insulating layer in the areas needed to prevent current flow in the yoke, etc.

[0092] Rotor segments may be collectively bussed by current collectors at the ends to create a high amperage, low voltage system. Bar segments may be bussed together in a more series circuit to create a higher voltage / lower amperage output. Different segments may be bussed together for three-phase and AC preferred embodiments described in later applications. They may be bussed or rectified so that current from one segment is returned to the far end of a different segment, creating a series circuit to increase voltage.

[0093] In some preferred embodiments, individual segments are enabled, grouped, or excluded by a controller and a series of brushes / commutators, which is advantageous in AC, three-phase, and direct grid interconnected systems.

[0094] The stator can be an electromagnet with electronically controlled polarity, variable power, and reversibility. The rotor can be a longitudinal electromagnet with a variable polarity control. In motor applications, the stator can be a permanent magnet offset with alternating polarity. The rotor can embody electromagnets that can be activated in a pattern and polarity to rotate the rotor. Conversely, the longitudinal electromagnets can be in the stator and the longitudinal alternating polarity permanent magnets can be in the rotor. The stator magnets can be flash-charged in a pattern and polarity to impose torque on the rotor. The electromagnet pattern and speed can be varied for various torque, load, and RPM operating conditions to generate different torques or speeds or to maximize efficiency. These variations are discussed further below.

[0095] A series of ring, cylindrical, or frustum segment magnets of different radii can be used to approximate the general truncated cone shape (see Figure 18).

[0096] There are variations in which the generally conical stator magnet layers have different wall angles to create tapered inter-magnet spaces. An example of this is having inner walls that are slightly steeper than the outer stator walls, so that the inter-cone spaces for the rotor are wider at the narrow end of the machine than at the wide end. This can be stepped and / or gradient, or other configurations.

[0097] These can be manufactured so that the cross-sectional area of ​​the inter-magnet spaces is maintained along the length of the device. Doing so not only maintains the same cross-sectional volume of the rotor across all segments, but also adds another way to provide variable power adaptability by providing wider sections 132 in the inter-magnet spaces 13 as one approaches the narrow end of the device and narrower sections 131 at the wide end of the inter-magnet spaces 13 (see Figures 19 and 20). This has the added benefit of relatively increasing the field strength as one approaches the wide end.

[0098] At the narrow end, the circumference of this inter-magnet space is smaller, but the radial thickness is proportionately greater, resulting in the area of ​​the space being the same as at the wide end, which has a larger circumference but a smaller radial thickness. This uniformity of area is maintained across every cross section along the longitudinal length of the inter-magnet space. This variation allows for equal mass of rotor metal in all equal-length cross-sectional areas of the rotor annular segment, regardless of the overall diameter of that segment.

[0099] The space between the stator magnet layers contains a rotor that rotates within this space. According to a preferred embodiment of the present invention, many rotor variations are possible. The first possibility is a solid metal frustum, the body of which is configured to fit within the inter-stator space. While the uniformity of the magnetic field reduces the potential for eddy currents compared to conventional designs, this rotor still has some potential for harmful eddy current formation. In a second variation, the rotor body is divided into longitudinal, diagonal, spiral, or other shaped electrically insulating strips called bars. These are similar to those described in the cylindrical section, but modified to a more conical, hollow, frustum shape. Examples of rotors according to a preferred embodiment of the present invention can be seen, for example, in Figures 26 and 27. As shown in Figure 21, the rotor assembly 2 can include a conductor array 21 disposed between a rotor support frame 22 and an upper rotor ring 23. Furthermore, as shown in Figure 22, other examples of rotor configurations according to a preferred embodiment of the present invention include (A) solid walls, (B) longitudinal bars, (C) straight, spiral, or diagonal walls, and (D) embedded wires.

[0100] In the above variations, the bars are arranged electrically in parallel. A series of buses, brushes, and / or commutators may be used to form a functionally serially wound rotor. The wires or strips may have straight, diagonal, spiral, or other skew orientations within the cone shape.

[0101] In a variant, the rotor is defined by a series of wires arranged longitudinally throughout the body of the cone, which may be embedded in a ferrometallic, or possibly ferrometallic-infused (or non-infused) plastic, resin, or epoxy substance, etc.

[0102] Sub-variants of wire or bar-based rotor bodies include wires / bars that are close together on the small end of the cone and spread apart on the larger end, or they can be tapered to fit or converge with fewer wires / bars. Rotor variations exist where the wires / bars themselves are longitudinally tapered, such that the small end of the cone has the small or narrow ends of the wires and the large end of the cone has the large ends of the wires.

[0103] If the rotor is constructed from wire, at the narrow end the wire is stacked more radially to fill the thicker area, while at the narrow width end the wire is stacked more circumferentially to fill the area.

[0104] If the rotor is defined by strip segments, these segments can vary in width, being larger in the radial axis on the narrow end with a narrow circumferential width, and larger in the circumferential axis and shorter in the radial axis on the wide end. This prevents narrow spots that could limit current or generate heat.

[0105] Alternatively, additional response range for RPM or input torque adaptation can be obtained by tapering the generally conical section of the stator to greater or less than the equivalent volume ratio, creating a thickened rotor gradient gap, or as an air gap on one or both sides of the rotor. This is an additional method of producing a gradient by additionally creating a more or less gradient in magnetic field strength via a change in intermagnetic distance.

[0106] The above variations can be used with a Gabriel's trumpet (see Figure 23) shape or a gradient cylinder of a particular length, chosen so that the extra voltage expected in the wider section is proportionately offset by making the narrower section longer to increase that voltage. This offsets the wider rotor section creating a higher voltage than the narrower section unless the narrower section is proportionately longer to balance the voltage.

[0107] If the unit area strength of the stator magnet is held constant, increasing the rotor / stator diameter increases the maximum amperage that can be produced, and also increases the number of stator field lines crossed per second for a given RPM. This can increase power generation capacity in low wind speeds, but there is some increased resistance to spin caused by back pressure on the longer lever arm.

[0108] Using a combination of electromagnets that work synergistically with permanent stator magnets provides an even wider range of instantaneous and automatic adaptability. There are many possible ways to achieve this. For this conceptualization, neodymium material is used with an excess of iron content to create a powerful magnet that is not magnetized to its strongest potential. The dilution effect of the excess iron prevents it from becoming fully magnetically saturated. If this material is used for the inner frustum, for example, the outer surface is smooth to reduce or minimize the air gap between the stator wall and the outer rotor surface, while the inner stator surface is fabricated with studs, ridges, or rings as protrusions to accommodate the surrounding electromagnet coils, as in Figures 6 and 30, part (C). Alternatively, the coils can be spooled around the magnetic segments, as in Figure 30. Another embodiment for delivering a uniform, radial electromagnetic flux is seen in Figure 6G, where the multiple coils of the previous design are augmented or replaced by a single large coil 250. When energized, the electromagnetic field combines with the permanent magnet field, increasing or decreasing the magnetic field strength. In the outer stator magnets, the electromagnetic core projections may be on the outside as seen in FIG. 25, or may be part of the permanent magnet as seen in FIGS. 6D-6F, or they may be separate adjacent structures as seen in FIG. 25, showing an array of stator projections 161 on the electromagnetic stator 16 wrapped with electromagnetic coils 17.

[0109] Alternatively, the electromagnets and permanent magnets can be individual structures, with the electromagnet core separate from the permanent magnet. Like cylindrical magnet sections, they can be configured in multiple ways to function as hybrid electromagnetic / permanent magnet stator walls, and can be on one stator, on part of one stator, or on two or more stators. Alternatively, the stator can be primarily made up of electromagnets.

[0110] If the electromagnets are charged with the same magnetic orientation as the underlying radially magnetized cone, the electromagnetic fields are additive to the permanent magnetic field, creating a stronger inter-radial field with more magnetic field lines per volume. They therefore add speed-opposing power output and counterforces to accommodate higher wind speeds, allowing the generator to increase its power as wind speeds increase, while relatively restricting increases in rotor and turbine RPM.

[0111] Alternatively, the electromagnets may be energized in opposite directions so that the net result of the interaction between the electromagnets and the permanent magnetic field is an attenuation or reduction of the radial electromagnetic field between the magnets.

[0112] These coils can be charged together or to individual levels, or the charging can be controlled unevenly. When they are energized together through a series or parallel connection, the overall magnetic field is boosted or reduced. As wind speed increases, the generator automatically boosts the magnetic field, so output is proportional to input, while the increase in RPM is relatively smaller than in conventional designs. The range of applicability is increased when the coils are energized with segments near the wide end receiving progressively more power.

[0113] The electromagnet may include stator protrusions 161 positioned or arranged longitudinally on the outer periphery of the electromagnet stator 16, as shown in Figures 29A-30. This is particularly useful for stepper motors, EV motors, and three-phase and AC generator applications, which are described in more detail in subsequent applications.

[0114] Charging of the electromagnet components can be performed by a controller or simply by diverting small amounts of increased power generated from faster winds from the load to the magnets, for example, by overcoming resistance. In this way, the added flexibility is automatic and solid-state, and less dependent on the parasitic additional control systems required by conventional generators.

[0115] The wide-end diameter of a conical rotor determines the rotor's effect on rotational speed cutoff. The stator's magnetic field strength is also a factor. The stronger the magnetic field, the lower the transverse speed, and vice versa. The greater the ratio of increasing diameter from narrow end to wide end, the greater the range of RPM adaptability over which the conical function mobilizes additional electroactive rotor length, and therefore the power generation or torque generation function. The longer the rotor, the higher the voltage. While variations in magnetization strength, the space between stator sides, and the narrow-end rotor diameter, among other factors, determine the limits of adaptability for increasing RPM transmitted by the rotor's conical shape, the generator or motor is designed so that the hybrid-electromagnetic function takes over to transmit the additional range tolerance. If desired, the stator cone may be fully electromagnetic without permanent magnets.

[0116] The electromagnet may have a control system that independently modulates each region, including the longitudinal segments, such as those used to generate stepper motors or rotating magnetic field analogs. These controls can be used, for example, in the DFIG generator analogs described in more detail in later applications.

[0117] In certain preferred embodiments, the electromagnets may be part of the transformer to step up the voltage and, in addition, strengthen the stator field with an internal synergy of the variable transformer field. Additional Preferred Embodiments

[0118] 33-35 and 37-42 provide drawings and illustrations of the structure of several additional preferred embodiments of the present invention. For the sake of brevity, only those elements of the additional preferred embodiments that differ from the preferred embodiments and variations described above will be described in detail.

[0119] 28 shows a preferred embodiment in which the stator assembly 1 preferably includes an inner stator yoke 11 and an outer stator yoke 15 each including an inner electromagnet stator 16 wound with an electromagnetic coil 17 and an outer electromagnet stator 220 wound with an electromagnetic coil 17. The inner stator yoke 11 and the outer stator yoke 15 further include inner permanent magnets 12 and outer permanent magnets 14, respectively. By using both permanent magnets and electromagnets, the stator assembly 1 can have a strong magnetic field generated by the permanent magnets, which can also be adjusted by changing the current flowing through the electromagnetic coils 17 of the inner electromagnet stator 16 and the outer electromagnet stator 220.

[0120] 28 also illustrates that the surfaces of the inner stator yoke 11 and the outer stator yoke 15 may include cooling fins. Additionally, the housing upper end preferably includes upper ventilation openings 181, the housing lower end 19 preferably includes lower ventilation openings 191, and the rotor support frame 22 preferably includes rotor ventilation holes 222. The upper ventilation openings 181, lower ventilation openings 191, and rotor ventilation holes 222 allow the fan 26 to direct airflow through the central tube 111 to further assist in cooling.

[0121] 29 shows a preferred embodiment in which the stator assembly 1 includes an inner stator yoke 11 including an inner electromagnet stator 16 preferably wound with an electromagnetic coil 17 and an inner permanent magnet 12 defined by a plurality of laterally stacked permanent magnet ring frustum elements. An outer stator yoke 15 includes an outer permanent magnet 14 preferably defined by a plurality of stacked permanent magnet elements.

[0122] FIG. 30 shows a preferred embodiment in which the stator assembly 1 preferably includes an inner electromagnetic stator 16 wound with an electromagnetic coil 17 (the inner electromagnetic stator 16 may be defined by a permanent magnet having protrusions 161), an inner permanent magnet 12 defined by a plurality of stacked permanent magnet elements, an intermediate stator 221 including a permanent magnet 2211, an outer permanent magnet 14 defined by a plurality of stacked permanent magnet elements, and an outer electromagnetic magnet stator 220 wound with an electromagnetic coil 17.

[0123] Figure 32 shows a preferred embodiment in which the rotor conductor array 21 is rotated between the outer permanent magnet 14 and the inner permanent magnet 12, which contain different gradient field strength regions 2A' and 2B' separated by a dividing line J'. In this configuration, the left side of the rotor conductor array 21 cuts a larger magnetic flux density than the right side, cutting and ramping up power production at lower rpm than the right side. This makes its output and the power required for acceleration more sensitive to rpm changes. There can be multiple gradient field strength regions, not just two. Furthermore, the field strength can also be varied longitudinally in an analog gradient fashion.

[0124] 33 shows a preferred embodiment in which a rotor 2 including an inner conductor array 21 and an outer conductor array 21' is rotated between an outer permanent magnet 14, an intermediate permanent magnet 221, and an air gap 13 defined between the inner permanent magnet 12, each including different gradient magnetic field strength regions 2A' and 2B' separated by a dividing line J'. In this polyrotor iteration, while each rotor conductor array 21 and 21' has the same rpm, each rotor conductor array moves a different distance and at a different speed as it rotates. Thus, material in the outer rotor array 21 travels farther and faster around each revolution than material in the inner rotor array 21.

[0125] If both the inner and outer stator air-gap fields 13 have the same magnetic flux density, the outer rotor 21' will kick in sooner, and the ramp-up power at lower RPM will vary with rpm; for example, at one speed the outer rotor 21' will kick in but the inner rotor 21 will not yet be producing significant power. At higher rpm, both air-gap fields will now be producing significant power, thus adding further flexibility; each of these separate rotor fields can be of different strengths, and each can vary longitudinally as long as they are circumferentially homogeneous.

[0126] In Figure 33, the longitudinal difference is divided into gradient field strength regions 2A' and 2B'. Here, there are four distinct regions, including outer rotors 2A' and 2B' and inner rotors 2A' and 2B'. Each distinct region activates at a specific rpm and increases power production. This further widens the range of response changes in power generation as the speed at which the rotors rotate changes.

[0127] FIG. 34 shows a preferred embodiment in which a rotor 2 including the conductor array 21 and the outer conductor array 21′ is rotated between two air gaps 13 defined between the outer electromagnet stator 220, the middle electromagnet stator 221, and the inner electromagnet stator 16, which can generate different gradient magnetic field strength regions 2A′ and 2B′, respectively, separated by a dividing line J′. The two air gaps 13 define four magnetic flux regions, two for each of the opposing stator arrays (e.g., four separate regions, i.e., the outer rotors 2A′ and 2B′, and the inner rotors 2A′ and 2B′). Furthermore, 2A′ and 2B′ can be further divided into different strength field sections by differentially feeding the stator electromagnets. The stator electromagnets may be hybrid magnets that combine permanent magnets and electromagnets.

[0128] Here, the stator field strength of each segment can be increased or decreased individually via electromagnets. This allows for multiple modifications when the machine is used as both a generator and a motor. Focusing on generators used for wind power generation, as wind speeds increase, more power is collected, and conventional generators must waste revenue power to prevent excessive spin of the generator or blade tips. Before any excessive spin phenomenon can occur in this generator, and as power output increases (in addition to the increased resistance to acceleration provided by different radial regions of the rotor, different regions of baseline field strength, different rotor thicknesses and air gaps, etc.), the final protection against excessive spin is to increase the stator field strength in all segments to its maximum, allowing some of the large excess power output to be diverted to the electromagnet coils. This increases the magnetic flux traversed by the rotor, not only increasing power but also increasing the amount of force required to rotate and accelerate the generator / turbine. This prevents or inhibits excessive spin.

[0129] In gusts of wind, the control algorithm preferentially energizes certain electromagnets over others, creating a wider range of magnetic field strengths and making the machine more sensitive to sudden changes in wind speed. In low wind conditions, charging of the electromagnets is minimized, making it equivalent to a small, spin-prone, low-power generator.

[0130] FIG. 35 shows a preferred embodiment in which a rotor 2 including an inner conductor array 21 and an outer conductor array 21′ is rotated between an air gap 13 defined between an outer hybrid-electric / permanent stator 220, a middle hybrid-electric / permanent stator 221, and an inner hybrid-electric / permanent stator 16, capable of generating different gradient magnetic field strength regions 2A′-2C′ separated by dividing lines J′ and J′, respectively.

[0131] The above structure and configuration increases the voltage from a smaller diameter rotor by changing the magnetic flux density, and also by a longer inner assembly, so that it can more closely match the voltage generated by a larger diameter rotor. Arranging the rotors concentrically also saves magnet cost and weight. It also increases the power density of the device by making it more compact. It also gives the device a conical shape, which has a small aerodynamic advantage.

[0132] In Figure 35, there are three zones of different baseline magnetic strengths (A, B, C) surrounding two different diameter / length rotor conductor arrays (inner 21 and outer 21'). In this configuration, there are five zones with different cut-in / ramp-up characteristics (A / inner rotor, A / outer rotor, B / inner rotor, B / outer rotor, C / inner rotor). Each of these five zones contributes to adaptability, as each has a different power / rpm curve based on its individual rotor diameter and magnetic field strength.

[0133] A control system for selectively energizing the windings of the electromagnetic components of stators 16, 221, and 220 will now be described. The ability to power each circumferential band of the electromagnetic components of stators 16, 221, and 220 increases the number of adaptive zones; i.e., as shown in the figure, section A has two electromagnet circumferential bands. If only one is energized, or if they are energized unevenly, section A becomes two distinct sections (A and A prime). Thus, for example, there are a total of 10 distinct zones. Each of these zones has a unique radius-to-field-strength ratio; therefore, together, they impart a cone-shaped variability, referred to as functional conicity.

[0134] Each circumferential section can be magnetized anywhere within a range of multiple field strengths, not just one different fixed level of field strength, so you're not limited to 10 single fixed options for adaptability / generation / damping characteristics.

[0135] Additionally, algorithmic variation of specific circumferential magnetic field strengths allows a generator corresponding to Figure 35 to adapt to conditions in different ways. For example, on a high-wind day, all electromagnets can be energized maximally and uniformly to maximize power capture while providing maximum protection against excessive spin. Also, on a gusty wind day, magnets can be energized with some at their maximum range, others at their minimum range, and the remaining magnets gradient-stratified to generate a wide spectrum of different operating parameters, thus maximizing the generator's adaptability and preparing for highly variable gusty wind inputs. On a mild wind day, if the stator contains both permanent magnets and electromagnets, the electromagnetic input can be blocked, resulting in the magnetic field within the generator's air gap 13 at its weakest, facilitating spin estimation and continuing to capture its range. Under more constant, moderate wind conditions, various segments can be adapted to have magnetic flux field strengths that improve or optimize output relative to that input. That is, each segment can be controlled to have an optimized magnetic flux density-to-diameter ratio for maximum power output and proper damping. For example, an inner rotor, which moves less per revolution than an outer rotor, will have its magnetic field strengthened relative to the outer rotor's field. Another way to explain this is that the two are made to have the same rotor circumference to flux crossing ratio, so that they contribute in a balanced way.

[0136] However, this electromagnetic control is also applicable to motors, especially EV motors, which encounter a highly variable set of operating conditions as the vehicle accelerates and decelerates, climbs and descends hills, and carries various loads of passengers and cargo.

[0137] Prior to these novel designs according to preferred embodiments of the present invention, recall that every type of motor has a small range of load / rpm over which it can operate at greater than 90% efficiency (sweet spot). Outside of that particular type of motor's sweet spot, efficiency can drop to, for example, 55%. In constant load and RPM operating applications, such as running a conveyor belt, a design engineer maximizes efficiency by simply selecting a motor type that has the same sweet spot as the operating requirements of the machine or system.

[0138] "But in an automobile, RPMs and loads are constantly changing rapidly. (1) By having a motor that starts with zones that have different sweet spots, but (2) can change the magnetization of those zones, we can change the motor's entire sweet spot in real time to match the instantaneous operating conditions of the EV motor, even as they change. The end result is a motor that operates at its sweet spot for a wider range of operation, and therefore requires fewer rechargeable batteries for that wider range."

[0139] In one preferred AC embodiment, all electromagnets can be AC ​​powered. The same generator can power the US 60 Hz grid, as well as the European 50 Hz grid, the Japanese 60 Hz and 50 Hz grids, and all other remaining standard 50 Hz and 60 Hz grids.

[0140] FIG. 36 shows a preferred embodiment in which a transverse double rotor assembly 6 acts on a transverse double stator assembly 7. The double rotor assembly 6 includes an upper rotor disk 61 interconnected to one lower part of a common connecting shaft 62 and a lower rotor disk 61′ interconnected to another lower part of the common connecting shaft 62. The double stator assembly 7 has upper stator magnets 71 and lower stator magnets 71′ facing the upper rotor disk 61 and the lower rotor disk 61′. It should be noted that these disks can be replaced with drums similar to those shown in FIG. 37.

[0141] An insulating shaft insert (preferably made of a non-conductive resin or metal) is preferably provided between one side of the common connecting shaft 62 and the other side of the common connecting shaft 62, and a transformer or similar component 9 is provided, for example, such that input leads 91 connected to opposite ends of the transverse double rotor assemblies 6 can provide output current through output leads 92. The input leads 91 are connected to opposite ends of the common connecting shaft 62, preferably via brushes or some other rotary connector. Although not shown in this figure, the periphery of the left disc is preferably electrically coupled to the periphery of the right disc. The directly generated low-voltage / high-ampere electrical energy enters a circular orbit where the load is the transformer or similar component 9.

[0142] It is important to note that the magnetic field polarity has been reversed from left to right in Figure 36; in this side view, the six rotating rotor disks (61 and 61') are fixed to and electrically coupled to the same single axle / spindle rod 62. However, due to a novel method for addressing brush losses, described below, the entire set of six disks 61 and 61' and the axle rod can be cast as a single piece from a suitable conductive material, and the transformer or similar component 9 moves to connecting wires on the disk periphery. It is also the only moving part. In this iteration, the disks 61 and 61' are made with different diameters to provide additional flexibility. All but the end disk magnets 71, 71' include a hole in the center that allows the axle rod to pass through. They are all positioned opposite each other across the inter-magnet space occupied by the rotating rotor disks 61 and 61'. Note that the group of magnets on the left are preferably positioned with their south poles to the left and their north poles to the right, while the group of magnets 71' on the right are preferably positioned with their north poles to the left and their south poles to the right. Thus, as the axel 62 and rotor 6 spin, on the left group, electrons are induced to flow from the periphery of the disk to the center and out into the rod. On the right, the disks rotate in the same direction as those on the left, but the magnetic field polarity is reversed, resulting in electrons being induced to flow from the central rod to the periphery of the disk. The magnets can be electromagnets or hybrid or permanent magnets in DC versions, and electromagnets in AC versions. The groups on each side of the disks can be thought of as arranged in parallel so that their individual amperages are additive, but the two groups are connected in series so that the voltages are additive.

[0143] Current collecting brushes (not shown) preferably contact the outer periphery of discs 61 and 61'. This layout has several advantages. The first is reduced brush losses. Sliding brushes collect current, but at the penalty of voltage losses.

[0144] A more important concept here comes from considering the non-conductive insulated shaft insert 8 and the transformer 9. If the system is an AC generator, the current in the rod 62 must pass through the primary winding 91 of the transformer 9 (preferably a step-up transformer). For simplicity and lack of vibration, the transformer 9 should be understood to be a cylindrical transformer constructed uniformly circumferentially around the rod axis 62, rotating together with the rod 62. High voltage power is extracted from the secondary transformer coil 92 via, for example, slip rings or the like.

[0145] With this transformer system, the low voltage direct rotor "output" does not even need to exit the generator. It only needs to travel a short circular distance inside the generator. The path is effectively a short circuit, and therefore the percentage of voltage loss is minimal. The output from the transformer secondary winding 92 exits the generator casing and has a high voltage that can be efficiently transferred.

[0146] It is possible to construct a similar system for a generator using permanent magnets. The internal circuitry can be low-voltage DC, and power can pass through an internal inverter / converter. Alternatively, a pair of rotor disks / drums 61 and 61' can have intermittent non-conductive areas built into their outer rims, which intermittently interrupt the flow of DC current. During the off-time, excess charge is stored on disks 61 and 61' and delivered during the on-time, as is known to occur in homopolar designs. The on- and off-switching of DC current can operate a suitably constructed step-up transformer or similarly functioning inverter.

[0147] 37 shows a preferred embodiment in which a longitudinal double rotor assembly 4 acts on a longitudinal double stator assembly 5. The double rotor assembly 4 includes an upper rotor cup 41 interconnected to an upper base 411 and a lower rotor cup 41' interconnected to a lower base 411'. The lower base 411' is connected to the upper base 411 via a common connecting shaft 8. The longitudinal double stator assembly 5 includes an upper stator magnet 51 and a lower stator magnet 51' facing the upper rotor cup 41 and the lower rotor cup 41'.

[0148] Again, similar to Figure 36, although not shown, there may be an internal step-up transformer whose low voltage, high amperage primary output primary circuit travels only a very short circular path from rotor drums 41 and 41' through the primary transformer windings and back to rotor drums 41 and 41'. Power induced in the secondary transformer coils leaves the generator. Again, in a DC preferred embodiment, an inverter can replace the transformer.

[0149] Advantages of Preferred Embodiments of the Present Invention Preferred embodiments of the present invention provide a true internally adaptive variable-speed generator or motor. That is, the generator or motor can instantly adapt and modify its operating parameters in response to the current environment in which it is operating. That is, a primary advantage of the generally conical shape or function is its adaptability to varying force inputs, which, unlike conventional designs, makes the novel structure of the preferred embodiments of the present disclosure a true internally adaptive variable-input speed device capable of efficiently operating over a large, continuous range of operating conditions. This occurs because, at any RPM, while any point longitudinally along the rotor has the same RPM, they have different speeds and progressively intercept different numbers of magnetic field lines. The closer the point is to the wide end, the faster it moves, intercepting more magnetic field lines per second. Thus, as the RPM increases from zero, the wide end moves the fastest, intersecting the greatest number of magnetic field lines per second, and is the first to be traversed and only the initial portion to begin generating electricity and resistance to rotation. At this slow traversal, it functions as a very small generator in that it produces a small amount of power and is easy to spin.

[0150] As the RPMs increase progressively, more of the rotor's longitudinal length crosses the threshold, traversing enough lines of force per second to become productive. In this way, the rotor automatically activates additional generating capacity without additional equipment, acting progressively as a larger generator, producing more power and spinning with more force as the input power increases. Adaptation to changes in wind speed is automatic and requires no extra equipment. The generator automatically adapts to function as the correct size machine over a wide range of wind speeds.

[0151] Preferred embodiments of the present disclosure can also provide intrinsic regenerative braking. In addition to producing more power when the wind blows faster, supplementing with more generated power also creates more resistance to rotating faster. The increased force required to rotate a faster-moving rotor reduces the relative increase in rpm. Therefore, the generator can be thought of as automatically using regenerative braking to produce more power while preventing a sudden increase in system rotational speed. The stronger the wind blows, the more power the generator produces and the harder it rotates, resulting in more regenerative braking. Turbine RPM does not increase as quickly as with conventional designs because output power and rotational resistance increase in proportion to the power in the wind, not the wind speed itself. The net result is that input power is matched by output power, but turbine speed is relatively restrained by the increased force required to rotate a progressively more powerful generator. In this way, the generator largely eliminates the need for active wing equipment, gearing, and braking systems. Providing more power is a primary aspect of its braking system.

[0152] The automatic seamless instantaneous adaptability to variable inputs can be enhanced or tempered by including gradient strength to the magnets as described above, as well as by the option of additional gradient enlargement of the inter-magnet spacing as described above, increasing the narrow end to large end diameter ratio, adding additional rotor and stator levels, and using hybrid electromagnetic / permanent magnets in the stator. This can be done with or without a conical shape.

[0153] For example, when winds blow slowly and frequently, even if only a small amount of power is available, the wind occurs more frequently, increasing the significance of power output. At gentle to moderate wind speeds (e.g., approximately 5-10 m / s), the increase in power in conventional designs is essentially due solely to, proportional to, and limited by, the increase in rotor RPM. In the novel structure of the preferred embodiment of the present disclosure, this increase in RPM, in addition to supplementing additional electroactive armatures or rotor length, results from the ability to automatically supplement or engage electromagnets to further increase the field strength of the stator magnets and boost power output. The net result is more power production across this entire range than is available from conventional designs.

[0154] At medium to high wind speeds (e.g., approximately 10 m / s to 25 m / s), conventional generators must utilize power waste, and expensive additional equipment such as friction brakes, active blades, and DFIG rotation stabilizes output despite a significant asymptotic increase in available energy. These new structures continue to employ additional generating capacity to recapture that additional power. In doing so, as the generator becomes more powerful to match its output to the available energy of its input, it also becomes more difficult to spin, resulting in a relatively reduced RPM increase compared to conventional technologies. This is similar to regenerative braking in that the generation of excess power reduces the RPM increase, allowing the generator to generate more power at higher wind speeds. The net benefit is the production of significantly more power.

[0155] In very high wind speed regimes (e.g., above about 25 m / s), the regenerative braking analogues inherent in these novel designs allow the generators to not only produce more power per wind speed, but also continue to function at relatively low RPMs at higher wind speeds than conventional generators. Thus, the generators can function at wind speeds that force cutouts of other generators, allowing for greater energy capture as the design of preferred embodiments of the present disclosure can quickly adapt to operating conditions where it performs well.

[0156] The novel features described herein are advantageous for improving most generators and motors in that they are stronger, lighter, longer lasting, and smaller. They are particularly advantageous for applications with variable load and input conditions, such as wind turbines, alternators / generators, and electric vehicles.

[0157] First, let's discuss generators, with a focus on wind power rather than motors in later sections. Traditional generators are based on designs developed to function within a specific, very small range of RPM. They are so slow that they miss much or all of that energy. Traditional generators are so fast that they must use various methods to waste all the excess energy they can harvest. Thus, they capture a surprisingly small amount of available power. For the wind energy industry, engineering efforts have been made to address this problem, which can loosely be explained as something like a variable input generator. A closer assessment shows that generators don't actually function by adapting to that variability to always harvest the maximum available power. These improvements, referred to as "variable generators," merely help find ways to discard, rather than capture, the range of harvestable power that allows the generator to function.

[0158] (No wind speed for low wind speed) The construction of the preferred embodiment allows for a lower cut-in speed.

[0159] (Increase to moderate wind speed) The power increase in conventional designs is essentially due to, proportional to, and limited only by the increase in rotor RPM. In the preferred embodiment design, as the RPM PLUS increases, additional electroactive armatures or rotor lengths and layers are added, and PLUS can automatically add electromagnets to further increase the field strength of the stator magnets, increasing power output.

[0160] (medium to fast) Conventional generators have a significant amount of excess harvestable energy, yet must utilize additional, power-wasting and expensive equipment such as throttling and stabilizing power output, friction brakes, active blades, and DFIG rotation. The preferred embodiment design continues to replenish and engage additional generating capacity to harvest that additional power. In doing so, as the generator becomes more powerful to match its output to the available energy in its input, it also becomes more difficult to spin, resulting in a relatively reduced RPM increase compared to conventional technology. This is similar to regenerative braking in that the generation of excess power reduces the RPM increase, allowing the generator to generate more power in higher winds.

[0161] (very high wind speeds) The regenerative braking analogue inherent in the design of the preferred embodiment not only allows the generator to produce more power per wind speed, but also allows the generator to continue to function at a relatively low RPM in stronger winds than conventional generators, thus allowing the generator to function at wind speeds that would cut out other generators.

[0162] The innovations of the preferred embodiments of the present disclosure allow for stronger and more effective magnetic fields. Specific advantages are described.

[0163] Advantages of magnetic proximity. The strength of the magnetic field decreases with increasing distance between magnets, depending on the size of that distance. Therefore, even a small increase in the distance between magnets causes a very large decrease. If the distance between two magnets is doubled, the magnetic force between them will decrease to one-fourth to one-eighth of its initial value. Conversely, if the distance between two magnets is halved, the magnetic force between them will increase to four to eight times its initial value.

[0164] In many generators, magnets are spaced as far apart as the diameter of the generator allows. In the novel design of the preferred embodiment of the present disclosure, the magnets are concentric and as close together as possible. For example, in the novel generator design of the preferred embodiment of the present disclosure, the distance between magnets is closer to, say, about 1 / 2 inch. Even if the magnets are the same strength, placing them so close together increases the magnetic field strength by about 10,000 times. To partially compensate for this, inventors of conventional generators have added heavy and expensive laminated steel cores to the rotor and stator to conduct the magnetic field. As such, they only lose about an order of magnitude in field strength compared to the design of the preferred embodiment of the present disclosure.

[0165] In most wind turbines, such as those with squirrel-cage, winding, and DFIG rotors, the magnetic field arcs approximately one-sixth of the way around the inside diameter of the stator. The stator of a 9-inch diameter unit is approximately 1 inch thick, so the inside circumference is approximately 23 inches. Thus, each subfield averages approximately 3.66 inches between poles, but the field does not traverse this distance in a straight line. Instead, it arcs over a long distance, averaging 5.75 inches, losing approximately 75% of its field strength, but not in the expensive and heavy laminated steel core. This arcing flux path increases the functional distance between the magnets. Furthermore, the resulting arcing field is not uniform. It is stronger when the two poles are closer and weaker, and weaker when they are farther apart, causing less functional area and dead zones. Furthermore, at the center of that arc, the magnetic field lines run parallel to the rotor rotation, so they do not contribute but act as dead space.

[0166] In the preferred embodiment power structure, the rotor travels through a series of perfectly aligned, uniform lines of force, positioned to achieve the straightest, strongest radial line between two points. Power is induced in the simplest, most complete manner. Furthermore, in the preferred embodiment, the rotor's novel internal material architecture is designed to reduce flux distortions caused by the architecture of conventional designs.

[0167] This contrasts sharply with the convolutional method by which power is generated in the most commonly used types of wind turbines. Starting with a squirrel-cage induction design, the stator coils require excitation energy input to begin functioning, a distinct efficiency loss at first. While the stator magnetic field may not be optimally shaped or oriented as described above, this is not so significant that the stator magnetic field will not generate output power. This induces a series of looped short-circuit currents in the rotor. This creates a series of electromagnetic fields around the cage bars. As the rotor rotates, the magnetic fields are entrained through the stator core and expand through the stator coils, inducing opposing currents and generating generator output. This is a phenomenologically indirect method of generating power, with each energy transition having its own efficiency cost.

[0168] In a Type 2 wound rotor generator, the rotor relies on parasitic shedding of the stator magnetic field to create its rotating field. This requires parasitic currents to flow through a series of rotor electromagnets to generate the magnetic field. Again, these fields are continuously entrained by the rotating rotor, extending into the coil core and out onto the stator wires to generate power. While this works reasonably well, it is less direct, more complex, and less efficient than power generation according to the preferred embodiment of the present disclosure.

[0169] In a Type 3, DFIG system, the wound rotor has a separate charge from the stator coils, which allows a computer-generated phi replica of the rotating magnetic field to be superimposed on the rotation caused by the spinning rotor. This functionally decouples the net rotor field RPM from the rotor's physical RPM, reducing mechanical stress by allowing the rotor to rotate at different speeds, but it also acts as a way to electronically dissipate all the excess generating power in faster winds. This requires a surprising amount of parasitic control equipment and parasitic energy on the rotor and stator, generating power in the same complex way.

[0170] In preferred embodiments of the present invention, all inter-magnet stator field lines are straight, linear, regular, and aligned at precise angles for maximum effectiveness. The field lines are oriented perfectly perpendicular to the rotor segments and direction of motion. Unlike conventional generators, these generators maintain this orientation over the full 360-degree rotor duty cycle. Essentially, all conventional generators have complex magnetic fields that are highly suboptimal in comparison. Unlike conventional generators, in the new design, well-placed incident magnets compress the magnetic fields against each other, increasing the magnetic flux density and therefore further increasing the motor's power and range.

[0171] Related to the aforementioned advantages, magnetic field losses are essentially zero because the magnetic field does not arc, bulge, have subtractive interactions, or have weak areas or regions where the lines are not perfectly aligned. All field lines are equidistant apart and packed much closer together. This perfect magnetic field alignment gives even more power with much less input energy.

[0172] In a preferred embodiment of the present disclosure, the inter-magnet magnetic field is almost exactly the same size as the rotor thickness.

[0173] The field in preferred embodiments of the present disclosure is time-stable and circumferentially uniform, avoiding efficiency losses. Unlike many conventional generators, the field is not made up of dozens of intermittent, pulsating, and reversing subunits, so there are no losses from misoriented forward expanding subfields and no losses from negative cross-field interactions.

[0174] Many generators are said to have rotating magnetic fields. While this is partially true, in that the polarity of the net magnetic field rotates, the field itself does not actually rotate. This dichotomy is achieved in an energetically expensive and inefficient manner. The net field is created by sequentially energizing and de-energizing dozens of fixed, adjacent electromagnet coils, similar to how a Las Vegas marquee flashes its fixed lights to create the illusion of movement. This creates dozens of small, immobile, transient subfields that constantly grow, contract, dissipate, and grow and dissipate in a counter-stroboscopic fashion.

[0175] The pattern mimics rotation, rotating the net polarity. However, compared to the stronger, constant, perfectly aligned base theta field of the preferred embodiment, the stroboscopically generated field is a rolling, organized mass of constantly changing, interacting sub-fields. This gets the job done, but at the cost of multiple inefficiencies; the sub-fields lose potential efficiency as they interact with each other.

[0176] Another efficiency loss seen in strobe fields comes from how the line of sight in a particular area changes orientation as the field of view grows and shrinks beyond that area. As the electromagnets are energized and de-energized (many times per second), the magnetic fields do not suddenly appear and disappear at their full size. Rather, when the electromagnets are turned on, they start small at the edges of the electromagnet and rapidly expand outward to their full size. They then collapse inward and disappear as the electromagnets are de-energized.

[0177] When a magnetic field expands and contacts a fixed point in a metal where current or torque is desired, the EMF generated at that point is directed in an unwanted direction at a different time. The same thing happens as a magnetic field contracts. Only a uniform alignment of the magnetic field lines at the center contains a force in the direction needed to generate current flow. As the magnetic field grows and contracts, it momentarily exerts a counterproductive force in the wrong direction. Although this is a tiny phenomenon, it occurs up to thousands of times per second, adding to the Loeb efficiency.

[0178] Preferred embodiments of the present invention do not have these power losses because the magnetic field takes much less power to generate yet is much stronger and more effective. The magnets are physically and functionally closer together compared to the prior art, so magnets of equal strength can create magnetic fields that are orders of magnitude stronger. Every part of the magnetic field of preferred embodiments of the present invention helps to increase the power of every adjacent part, and every part is perfectly oriented for maximum effectiveness, compared to the prior art, where a surprisingly large percentage of the field does not contribute to power or torque production.

[0179] The best result is that conventional generators generally use more energy and more powerful, more expensive magnets to obtain a weaker and more disorganized magnetic field than the preferred embodiment of the present invention, which has the effect of significantly limiting the functionality of conventional generators.

[0180] Preferred embodiments of the present invention can significantly improve permeability or field orientation losses. Unlike the losses mentioned above, at full field size, the net field of a reluctance, DFIG, or DC machine rotor passes through the rotor and returns to the stator.

[0181] At the periphery of the rotor, the arcs of magnetic field lines are aligned in the correct vertical direction to generate force on the rotor, but at the center of the arcs the lines point in the wrong direction to do any work. These misalignments and non-linearities result in a weaker magnetic field. Preferred embodiments of the present disclosure do not suffer from field losses due to this problem. The inter-magnet magnetic field of the novel structure is always exactly in a straight line, and it is always perfectly oriented in the perfect direction along its entire length. This contributes to greater range and power.

[0182] Preferred embodiments of the present disclosure can provide significantly reduced stator energy requirements. The basic stator field according to preferred embodiments of the present disclosure utilizes primarily permanent magnets, without reducing efficiency. Many generator stator fields are created by passing electricity through dozens of coils, which is very expensive. Electromagnet coils according to preferred embodiments of the present disclosure are typically only energized during high wind conditions when the amount of available energy is enormous.

[0183] The generators and motors of the preferred embodiments of the present invention have few non-electroactive generating components. All other conventional designs require components that do not directly contribute to current generation. While necessary, they require maintenance and add weight and cost. In the rotor coils of a standard permanent magnet machine, up to about one-third of the wire must be oriented so that it does not contribute to torque generation. However, this adds weight, size, cost, and complexity. The new design simply does not have that problem or anything similar. As mentioned above, conventional rotors also require an iron-filled central core to conduct the magnetic field.

[0184] Preferred embodiments of the present disclosure can provide generators and motors that require fewer parts yet are much more powerful. To reduce eddy currents, both the rotor and stator of conventional designs require a steel core. The core is constructed from tens to thousands of laminations, which are formed, assembled, and bonded together. This process adds significant cost, energy, and time to manufacturing. The extra cost and complexity of using laminations reduces, but does not eliminate, the problem. Conversely, machines according to preferred embodiments of the present disclosure do not require as many laminations of metal. DFIGs require sophisticated control systems that allow the turbine to rotate freely. However, preferred embodiments of the present disclosure do not require such control systems, gearboxes, or active blade release systems.

[0185] Preferred embodiments of the present invention can provide a larger electroactive area percentage. The electrically active area of ​​a generator is the area where electrical current is actually generated. The increased production-to-volume ratio allows for further size reduction, reducing costs.

[0186] Compared to the most common large wind turbines or DFIGs, preferred embodiments of the present invention avoid common efficiency losses because: they do not need to spin above 1000 RPM before power is generated; they do not need as much or any efficient sapping gear; they do not need expensive controllers; both cut off at lower wind speeds and do not waste power in high speed winds; they utilize permanent magnets for their base stator field, saving efficiency; they only use electromagnets when generating excess power; and they follow the wind speed so that they automatically adjust to collect maximum power at all wind speeds rather than wasting it.

[0187] Preferred embodiments of the present invention can provide a positive feedback loop: the above benefits automatically lead to a cascade of further benefits. For example, because of such advantages, motors and generators according to preferred embodiments of the present disclosure are stronger in size and can be built smaller, which again eliminates cost and weight. In the case of wind, such advantages in turn improve aerodynamics, reduce forces on towers, and reduce the cost of building towers. In the case of electric vehicles, increasing the power output and reducing the weight of the motor can increase the range over which the vehicle can travel.

[0188] Preferred embodiments of the present invention can provide additional benefits to the wind power industry. Additional advantages of preferred embodiments of the present disclosure specific to the wind power industry include: up to 2.5 times more power per turbine; the ability to install in more locations; the ability to install closer to where the power is used, reducing both cost and ground line losses; They are smaller, lighter and more powerful, reducing tower costs, reducing road and power line costs, magnets are used in much more powerful configurations, and generators can avoid the use of rare earth elements.

[0189] Additionally, preferred embodiments of the present invention are useful for electric vehicle applications. The smaller, simpler, lighter, and more efficient motor structure according to preferred embodiments of the present disclosure offers multiple benefits, improving both power and regenerative braking while adding breakthrough range extension. Electric vehicle motors according to preferred embodiments of the present disclosure utilize extensive field and rotor improvements that are more powerful, more robust, and more efficient, enabling greater range at a lower cost. This will extend EV range while providing more torque (EV equivalent horsepower), allowing both companies to adopt this new technology. This is a crucial advantage for achieving leadership in an explosive market.

[0190] In the burgeoning electric vehicle industry, the market-driving design premiums are efficiency, lightweight, full-spectrum torque, and regenerative braking. These are the holy grails of the next generation of EVs, and are exactly what the preferred embodiments provide. The most important development driver is range extension. Preferred embodiments of the present invention provide, for example, an overall range increase on the order of about 10% or more.

[0191] Preferred embodiments of the present invention can provide improved propulsion efficiency. Propulsion is divided into torque, which accelerates the vehicle, and range, which is the distance the vehicle can be charged. Compared to other EV motors, the variations in preferred embodiments of the present disclosure generate a baseline magnetic field that is phenomenologically more efficient and powerful, yet requires less energy.

[0192] This field is not only much more powerful, but also precisely and perfectly organized. Every part of the rotor moves simultaneously and continuously immersed in a stable, powerful magnetic field that is always perfectly aligned, shaped, sized, and powered throughout 100% of its duty cycle. The IPM Syn RM, for all its impressive attributes, cannot come close. The following describes how a motor according to a preferred embodiment of the present disclosure achieves this gain.

[0193] All electric motors have a specific set of RPM and load operating conditions under which they can operate at peak efficiency. IPM motors are efficient when generating high torque at low RPM. In this respect, they can be thought of as similar to a bulldozer: slow and powerful. When forced to operate outside their optimal sweet spot, efficiency drops rapidly. In contrast, new computer-driven synchronous reluctance motors perform better in higher RPM ranges, lower torque conditions, and become less efficient when operated outside this "sweet spot." New computer controls expand the range of their maximum efficiency sweet spot, but benefits still need to be realized. The problem is that propelling an EV presents one of the most variable operating conditions a motor can face. The vehicle moves slowly or fast. It accelerates, decelerates, stops, starts, and reverses. The number of people and cargo is constantly changing. The transmission is constantly shifting through multiple gears. Even with the control pedal bolted to one place, the vehicle will still climb and descend hills and even mountains.

[0194] Ultimately, the operating conditions of load, torque, and RPM are constantly changing. Only when the motor's sweet spot RPM and load are perfectly aligned will the motor operate at maximum efficiency. However, the car is rarely in that spot; it simply passes through, spending most of its time in an inefficient operating region of the torque / load / RPM axis. This translates to a greatly reduced range.

[0195] The preferred embodiment design has adjustable field strength and multiple available rotor diameters, allowing the motor to instantly reconfigure itself and hit its sweet spot regardless of operating demands. Essentially, the motor can move its sweet spot to where the current operating conditions are. This results in better range and better power output.

[0196] The basic stator field of the preferred embodiment utilizes permanent magnets, so it does not drain the battery bank. Essentially, instead of using battery power or electromagnets, permanent magnets are used to harness free energy from nature. Traditional stator fields are created by running electricity through dozens of giant coils. That takes a lot of electricity. This means additional weight and cost for batteries. The preferred embodiment can utilize the energy savings advantage of more than 10 times the amount of permanent magnets. This results in more power at less energy cost, thus significantly improving range and acceleration.

[0197] In preferred embodiments of the present invention, all field lines are aligned linearly, linearly, and regularly at precise angles for maximum effectiveness. Conventional motors have complex magnetic fields that are significantly less optimal by comparison. All field lines in preferred embodiments of the present invention are equidistantly spaced and packed much closer together. Unlike conventional motors, the magnetic field has no arcs, bulges, or weak areas. Well-placed auxiliary magnets compress the magnetic field against each other, increasing the magnetic flux density and thus further increasing the motor's power and range. There are zero field losses. This perfect magnetic field orientation provides even more power with much less input energy. All field lines are perfectly perpendicular to the rotor. If they deviate from perpendicular, the force is reduced by the sine of the skew angle. Perpendicularity is maintained throughout the entire rotor rotation cycle. The field in preferred embodiments of the present invention is the exact same size, or substantially the same size, as the rotor. Preferred embodiments of the present invention include a field that is both time-stable and uniform. Unlike conventional motors, the magnetic field is not made up of dozens of pulsating and reversing subunits, so there are no losses from subfields expanding with the wrong direction forward, and no losses from negative cross-field field interactions.

[0198] Another efficiency loss seen in rolling magnetic fields comes from how the magnetic field lines in a particular region change orientation as the field grows and contracts beyond that region. A simple strong force in the correct direction is all that's needed, but as the field expands beyond a fixed point, it pushes that point in different directions at different times. As the field grows and contracts, it momentarily exerts a counterproductive force in the wrong direction, like one rower in a long boat intermittently growing backward. For lack of a better name, this is called a "push-me, pull-you efficiency loss." It's minute, but it happens hundreds of times per second, robbing the field of potential power and range. Preferred embodiments of the present invention do not have these power losses. In fact, the magnetic field in preferred embodiments of the present invention requires much less power to produce, yet is much stronger and more effective. Every bit of field helps increase the power of all neighboring parts. The best result is that conventional systems use much more electricity to obtain a much weaker, more chaotic magnetic field than the preferred embodiments of the present invention. This has a significantly limiting effect on their range. This requires more battery pack and motor mass to compensate.

[0199] The magnetic field of the preferred embodiment of the present invention is always perfectly oriented in the perfect direction for torque generation, so every part of the magnetic field is pushing against the rotor. This contributes to greater range and power. Furthermore, the entire rotor of the preferred embodiment of the present invention is immersed in a uniform magnetic field, oriented with the proper field strength / rotor volume ratio for maximum torque and efficiency.

[0200] Conventional motor designs require components that do not directly contribute to force generation. While necessary in conventional systems, these create problems and increase weight and cost. In conventional motor rotor coils, approximately one-third of the wire must be oriented so that it does not contribute to torque generation. However, this adds weight, size, cost, and complexity. The structure of the preferred embodiment of the present invention simply does not have that problem or anything similar. The coils in the motor also need to have an iron-filled central core to conduct the magnetic field. This increases weight and cost.

[0201] In traditional designs, motors are sized to be efficient at the most common operating torque and rpm demands, with larger motors being more efficient at higher conditions and smaller motors being more efficient at lower ranges. These new designs utilize a variety of rotor diameters, differential field strength sections, and field adjustment capabilities to configure themselves to function as the motor size and power required to operate at maximum efficiency under all drive conditions, not just the most commonly encountered.

[0202] Therefore, considering the above advantages, the motor structure of the preferred embodiment of the present invention requires much less energy to generate more torque, which further reduces the need for expensive batteries, thus reducing weight and cost and resulting in fewer batteries. Also, high regenerative braking capability is provided by the same design enhancements, resulting in more energy being charged into rechargeable batteries, requiring fewer rechargeable batteries, reducing cost and weight and further reducing the need for rechargeable batteries. All of the above combine to create a smaller, lighter, yet more powerful motor, requiring less electrical and balance plant equipment, which can enable a greater range from a smaller battery pack. The motor structure according to the preferred embodiment of the present invention can provide an EV with a very long range while reducing cost and weight from the battery.

[0203] This also discloses the following items:

[0204] (Item 1) A dynamoelectric machine includes an inner cylindrical stator, an outer cylindrical stator, and a cylindrical rotor radially disposed between the inner and outer cylindrical stators. The cylindrical rotor is rotatable relative to the inner and outer cylindrical stators. The cylindrical rotor includes at least one rotating conductor including a mixture of electrically conductive and ferromagnetic materials. The inner and outer cylindrical stators include at least one of: (i) gradient magnetic field strength regions with varying magnetic flux density longitudinally downward along the axial direction of the dynamoelectric machine; (ii) different radial diameters of overlapping rotor and stator portions at different axial locations of the dynamoelectric machine; and (iii) electromagnets configured to be selectively energized based on a changing variable.

[0205] (Item 2) Item 1. The dynamoelectric machine of item 1, wherein one or both of the inner and outer cylindrical stators include hybrid magnets that include electromagnetic and permanent magnet components.

[0206] (Item 3) Item 3. The dynamoelectric machine of item 2, wherein the magnitude of the gradient magnetic field strength region of varying magnetic flux density is adjustable by varying the amount of current flowing through at least one electromagnetic component of the hybrid magnets of the inner and / or outer cylindrical stator.

[0207] (Item 4) 4. The dynamoelectric machine of claim 1, 2, or 3, wherein the gradient magnetic field strength regions of varying magnetic flux density are generated by varying the radial distance between opposing portions of the inner and outer cylindrical stators.

[0208] (Item 5) different diameters of the overlapping rotor and stator portions at different axial positions of the dynamoelectric machine; a first diameter corresponding to the inner and outer stators at an axially lower portion of the dynamoelectric machine, and a second diameter corresponding to the inner and outer stators at an axially upper portion of the dynamoelectric machine, 4. The dynamoelectric machine of claim 1, 2, or 3, wherein the first diameter is greater than the second diameter.

[0209] (Item 6) 4. The dynamoelectric machine of claim 1, 2, or 3, wherein the cylindrical rotor includes a main copper component having magnetically permeable particles, fillers, strips, inclusions, or filaments embedded therein.

[0210] (Item 7) 4. The dynamoelectric machine according to claim 1, 2 or 3, wherein the gradient magnetic field strength region with varying magnetic flux density is generated by arranging uniform magnets so that their strength varies circumferentially along the axial direction of the rotating electric machine.

[0211] (Item 8) 4. The dynamoelectric machine of claim 1, 2, or 3, including a central cylindrical stator radially disposed between the inner and outer cylindrical stators, and including first and second concentrically disposed rotor conductor portions between the inner and central cylindrical stators and between the central and outer cylindrical stators.

[0212] (Item 9) Item 9. The dynamoelectric machine of item 8, wherein the central cylindrical stator, the inner cylindrical stator, and the second rotor conductor portion have a greater longitudinal length along the axial direction of the dynamoelectric machine than the outer cylindrical stator and the first rotor conductor portion.

[0213] (Item 10) Item 1. The dynamoelectric machine of item 1, wherein the cylindrical rotor includes longitudinally extending conductor bars comprising copper.

[0214] (Item 11) 4. The dynamoelectric machine of claim 1, 2, or 3, wherein the cylindrical rotor comprises laminated copper and magnetically permeable layers interleaved with one another in the radial direction of the dynamoelectric machine.

[0215] (Item 12) Item 12. The dynamoelectric machine of item 11, wherein the radially innermost layer and the radially outermost layer of the cylindrical rotor are defined by copper layers.

[0216] (Item 13) Item 7. The dynamoelectric machine of item 6, wherein the magnetically permeable particles, fillers, strips, inclusions, or filaments are uniformly or substantially uniformly spaced and radially aligned throughout the copper structure.

[0217] (Item 14) 7. The dynamoelectric machine of claim 6, wherein the magnetically permeable particles, fillers, strips, inclusions, or filaments comprise at least one of mu metal, iron, permalloy, silicon steel, or supermalloy.

[0218] (Item 15) 13. The dynamoelectric machine of items 1, 2, 3, 6, 11, or 12, wherein a thin film silver layer is provided on the outer surface of the rotor.

[0219] (Item 16) 4. The dynamoelectric machine of claim 1, 2, or 3, wherein the gradient magnetic field strength region has a uniform level of magnetic flux in both radial and circumferential directions without salient poles.

[0220] (Item 17) the inner stators include one or more pairs of inner stators facing each other in the axial direction, the outer stator includes one or more pairs of outer stators facing each other in the axial direction, 13. The dynamoelectric machine of claim 1, wherein the rotor includes one or more pairs of rotors opposed to each other in the axial direction.

[0221] (Item 18) Item 18. The dynamoelectric machine according to item 17, wherein the one or more pairs of rotors are rotatably connected to one another via a common rotor shaft axially between the one or more pairs of rotors.

[0222] (Item 19) further comprising an electrical collection circuit including an input lead and an output lead; the common rotor shaft includes a non-conductive insulated shaft insert; Item 19. The dynamoelectric machine of item 18, wherein at least some of the input leads are connected to portions of the common rotor shaft on either side of the non-conductive insulated shaft insert.

[0223] (Item 20) 13. The dynamoelectric machine of items 1, 2, 3, 6, 11, or 12, wherein at least one of the cylindrical rotor, inner cylindrical stator, or outer cylindrical stator includes a plurality of frustum segments extending axially along the central axis of the dynamoelectric machine and having radially inner or radially outer surfaces that gradually vary in distance from the central axis of the dynamoelectric machine.

[0224] It should be understood that the foregoing description is merely illustrative of preferred embodiments of the invention. Various alternatives and modifications may be devised by those skilled in the art without departing from the invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications, and variations that fall within the scope of the appended claims.

Claims

1. an inner cylindrical stator, an outer cylindrical stator, and a cylindrical rotor radially disposed between the inner and outer cylindrical stators; the cylindrical rotor is rotatable relative to the inner and outer cylindrical stators; the cylindrical rotor includes at least one rotating conductor including a mixture of conductive and ferromagnetic materials; The dynamoelectric machine includes inner and outer cylindrical stators that include at least one of: (i) gradient magnetic field strength regions that vary in magnetic flux density longitudinally downward along the axial direction of the dynamoelectric machine; (ii) different radial diameters of overlapping rotor and stator portions at different axial locations of the dynamoelectric machine; and (iii) electromagnets configured to be selectively energized based on a changing variable.

2. The dynamoelectric machine of claim 1 , wherein one or both of the inner and outer cylindrical stators include hybrid magnets that include electromagnetic and permanent magnet components.

3. 3. The dynamoelectric machine of claim 2, wherein the magnitude of the gradient field strength region of varying magnetic flux density is adjustable by varying the amount of current flowing through at least one electromagnetic component of the hybrid magnets of the inner and / or outer cylindrical stator.

4. 4. A dynamoelectric machine as claimed in claim 1, 2 or 3, wherein the gradient magnetic field strength regions of varying magnetic flux density are produced by varying the radial distance between opposing portions of the inner and outer cylindrical stators.

5. different diameters of the overlapping rotor and stator portions at different axial positions of the dynamoelectric machine; a first diameter corresponding to the inner and outer stators at an axially lower portion of the dynamoelectric machine, and a second diameter corresponding to the inner and outer stators at an axially upper portion of the dynamoelectric machine, The dynamoelectric machine of claim 1 , 2 or 3 wherein the first diameter is greater than the second diameter.

6. 4. The dynamoelectric machine of claim 1, 2 or 3, wherein the cylindrical rotor includes a main copper section having magnetically permeable particles, fillers, strips, inclusions or filaments embedded therein.

7. 4. The dynamoelectric machine according to claim 1, 2, or 3, wherein the gradient magnetic field strength region with varying magnetic flux density is generated by arranging magnets whose strength varies circumferentially and uniformly along the axial direction of the rotating electric machine.

8. 4. The dynamoelectric machine of claim 1, 2, or 3, including a central cylindrical stator radially disposed between the inner and outer cylindrical stators, and including first and second concentrically disposed rotor conductor portions between the inner and central cylindrical stator and between the central and outer cylindrical stator.

9. 9. The dynamoelectric machine of claim 8, wherein the central cylindrical stator, the inner cylindrical stator, and the second rotor conductor portion have a greater longitudinal length along the axial direction of the dynamoelectric machine than the outer cylindrical stator and the first rotor conductor portion.

10. The dynamoelectric machine of claim 1 , wherein the cylindrical rotor includes longitudinally extending conductor bars comprising copper.

11. 4. The dynamoelectric machine of claim 1, 2 or 3, wherein the cylindrical rotor comprises laminated copper and magnetically permeable layers interleaved with one another in a radial direction of the dynamoelectric machine.

12. The dynamoelectric machine of claim 11 , wherein the radially innermost and radially outermost layers of the cylindrical rotor are defined by copper layers.

13. The dynamoelectric machine of claim 6 , wherein the magnetically permeable particles, fillers, strips, inclusions, or filaments are uniformly or substantially uniformly spaced and radially aligned throughout the copper structure.

14. The dynamoelectric machine of claim 6 , wherein the magnetically permeable particles, fillers, strips, inclusions, or filaments comprise at least one of mu metal, iron, permalloy, silicon steel, or supermalloy.

15. The dynamoelectric machine of claim 12 wherein the thin film silver layer is disposed on an outer surface of the rotor.

16. 4. The dynamoelectric machine of claim 1, 2 or 3, wherein the gradient magnetic field strength region has a uniform level of magnetic flux in both radial and circumferential directions without salient poles.

17. the inner stators include one or more pairs of inner stators facing each other in the axial direction, the outer stator includes one or more pairs of outer stators facing each other in the axial direction, The dynamoelectric machine according to claim 1 , 2 or 3 , wherein the rotor includes one or more pairs of rotors opposed to each other in the axial direction.

18. The dynamoelectric machine of claim 17 , wherein the one or more pairs of rotors are rotatably connected to one another via a common rotor shaft axially between the one or more pairs of rotors.

19. further comprising an electrical collection circuit including an input lead and an output lead; the common rotor shaft includes a non-conductive insulated shaft insert; The dynamoelectric machine of claim 18 , wherein at least some of the input leads are connected to portions of the common rotor shaft on either side of the non-conductive insulated shaft insert.

20. 4. The dynamoelectric machine of claim 1, 2, or 3, wherein at least one of the cylindrical rotor, inner cylindrical stator, or outer cylindrical stator includes a plurality of frustum segments extending axially along the central axis of the dynamoelectric machine and having radially inner or outer surfaces that gradually vary in distance from the central axis of the dynamoelectric machine.

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