Electric motor and control method thereof

Abstract

An electric motor and a method for controlling the electric motor are described herein. The electric motor includes a moving component having at least one permanent magnet coupled thereto and a stator spaced apart from the moving component. The stator includes at least one stator pole having a ferromagnetic core and a coil wound around the ferromagnetic core. The ferromagnetic core is naturally attracted to the at least one permanent magnet. The motor also includes a magnetic position control system configured to monitor the position of the at least one permanent magnet relative to the stator and controllably supply electric pulses to the coil of each stator pole to generate a repulsive magnetic flux in the ferromagnetic core, counteracting the attractive force between the ferromagnetic core and the at least one permanent magnet, thereby controlling movement of the moving component.

Description

[Technical Field]

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 015,566, entitled "Electric Motors and Methods of Controlling Thereof," filed April 25, 2020, the contents of which are incorporated herein by reference in their entirety. [Background technology]

[0002] FIELD OF THE INVENTION The embodiments disclosed herein relate to motors and methods of controlling motors, and more particularly to electric motors and methods of controlling electric motors.

[0003] Various types of electric machines include electric motors that include permanent magnets. Electric motors are traditionally used in applications including, but not limited to, heating, ventilation, and air conditioning (HVAC) systems, pumps, and household appliances. Such permanent magnet motors traditionally include a stator and a rotor. The rotor traditionally includes a generally toroidal rotor core and a plurality of surface magnets attached to the periphery of the rotor core.

[0004] The implementation of conventional electric motors featuring permanent magnets is limited by our current understanding of magnetism. Expanding our theoretical understanding of magnetism may provide new and improved implementations of electric motors with permanent magnets. Global efforts to reduce humans' environmental footprint and increase autonomy and flexibility are driving a growing need for higher-performance, more efficient, and more versatile electric motors. Examples of this include the electrification of various modes of transportation and the digitalization of various businesses.

[0005] Therefore, there is a need for new types of electric motors and methods of controlling electric motors. Summary of the Invention

[0006] According to broad aspects, an electric motor is described herein. The electric motor includes a movable component coupled to at least one permanent magnet, each permanent magnet having an outer surface with a surface area; and a stator spaced from the movable component, the stator having at least one stator pole positioned to face the at least one permanent magnet. Each stator pole includes a ferromagnetic core and a coil wound around the ferromagnetic core, the ferromagnetic core being naturally attracted to the at least one permanent magnet. The electric motor also includes a magnetic position control system configured to monitor the position of the at least one permanent magnet on the movable component relative to the stator and, in response to the position of the at least one permanent magnet, controllably supply electric pulses to the coil of each of the at least one stator pole to generate a repulsive magnetic flux in the ferromagnetic core to counteract the attractive force between the ferromagnetic core and the at least one permanent magnet and control the movement of the movable component. The difference between the surface areas of the outer surfaces of each of the permanent magnets is less than 10%. The maximum distance between the centerlines of two adjacent stator poles is twice the width of one of the permanent magnets. The outer surface of each permanent magnet of the moving component has the same polarity.

[0007] According to broad aspects, an electric motor is described herein. The electric motor includes a rotor having at least one permanent magnet coupled thereto, each permanent magnet having an outer surface with a surface area; a shaft fixedly coupled to the rotor such that rotation of the rotor rotates the shaft; and a stator surrounding the rotor, the stator having at least one stator pole positioned opposite the at least one permanent magnet, each stator pole including a ferromagnetic core and a coil wound around the ferromagnetic core, the ferromagnetic core being naturally attracted to the at least one permanent magnet. The electric motor also includes a magnetic position control system configured to monitor the position of the at least one permanent magnet on the rotor relative to the stator and, in response to the position of the at least one permanent magnet, controllably supply electric pulses to the coil of each of the at least one stator pole to generate a repulsive magnetic flux on the ferromagnetic core to counteract the attractive force between the ferromagnetic core and the at least one permanent magnet and control movement of the moving component. The difference between the surface areas of the outer surfaces of each of the permanent magnets is less than 10%. The maximum distance between the centerlines of two adjacent stator poles is twice the width of one of the permanent magnets. The outer surface of each permanent magnet of the moving component has the same polarity.

[0008] In at least one embodiment, the difference between the surface areas of the outer faces of each of the permanent magnets is less than 5%.

[0009] In at least one embodiment, the difference between the surface areas of the outer faces of each of the permanent magnets is less than 3%.

[0010] In at least one embodiment, the difference between the surface area of ​​the outer surface of any one of the permanent magnets and the surface area of ​​the outer surface of any one of the stator poles is less than 10%.

[0011] In at least one embodiment, the difference between the surface area of ​​the outer surface of any one of the permanent magnets and the surface area of ​​the outer surface of any one of the stator poles is less than 5%.

[0012] In at least one embodiment, the difference between the surface area of ​​the outer surface of any one of the permanent magnets and the surface area of ​​the outer surface of any one of the stator poles is less than 3%.

[0013] In at least one embodiment, each of the permanent magnets has a cylindrical shape.

[0014] In at least one embodiment, each of the permanent magnets has a prismatic shape.

[0015] In at least one embodiment, a magnetic position control system monitors and manages the relative position of at least one permanent magnet based on the magnetic flux of the at least one permanent magnet by providing modulated electrical pulses to at least one stator pole to control the motor and provide for the motor to operate in various modes of operation.

[0016] In at least one embodiment, each ferromagnetic core of the stator is radially and / or axially spaced from each permanent magnet of the rotor by a gap.

[0017] In at least one embodiment, the motor includes one stator pole and one permanent magnet.

[0018] In at least one embodiment, the motor includes two or more permanent magnets.

[0019] In at least one embodiment, the motor includes two or more stator poles.

[0020] In at least one embodiment, the motor includes a number of stator poles in the range of 1-100.

[0021] In at least one embodiment, the motor includes a number of stator poles in the range of 10-75.

[0022] In at least one embodiment, the motor includes a number of stator poles in the range of 15-50.

[0023] In at least one embodiment, the motor includes a number of stator poles in the range of 15-30.

[0024] In at least one embodiment, the motor includes a number of stator poles in the range of 16-20.

[0025] In at least one embodiment, the motor includes a number of stator poles in the range of 1 to 100 per rotor stack.

[0026] In at least one embodiment, the motor includes a number of stator poles in the range of 10 to 75 per rotor stack.

[0027] In at least one embodiment, the motor includes a number of stator poles in the range of 15 to 50 per rotor stack.

[0028] In at least one embodiment, the motor includes a number of stator poles in the range of 15 to 30 per rotor stack.

[0029] In at least one embodiment, the motor includes a number of stator poles in the range of 16 to 20 per rotor stack.

[0030] In at least one embodiment, the stator poles are generally equally spaced around the circumference of the stator.

[0031] In at least one embodiment, the stator poles are generally equally spaced axially and parallel to the moving component.

[0032] In at least one embodiment, the motor includes two or more stator poles interconnected in parallel, or in series, or a mixture of parallel and series, in one or more circuits arranged around the rotor in one or more groups that have the same polarity when energized together.

[0033] In at least one embodiment, the stator poles are generally equally spaced from one another around the periphery of the stator.

[0034] In at least one embodiment, the movable component has a diameter or length in the range of 1 inch to 200 inches.

[0035] In at least one embodiment, the movable component has a diameter or length in the range of 1 inch to 60 inches.

[0036] In at least one embodiment, the movable component has a diameter or length in the range of 6 inches to 36 inches.

[0037] In at least one embodiment, the rotor has a diameter in the range of 1 inch to 200 inches.

[0038] In at least one embodiment, the rotor has a diameter in the range of 1 inch to 60 inches.

[0039] In at least one embodiment, the rotor has a diameter ranging from 6 inches to 36 inches.

[0040] In at least one embodiment, the motor has a maximum rotational speed in the range of about 1 to 100,000 revolutions per minute (RPM).

[0041] In at least one embodiment, the motor has a maximum rotational speed in the range of about 1 to 50,000 revolutions per minute (RPM).

[0042] In at least one embodiment, the motor has a maximum rotational speed in the range of about 1 to 30,000 revolutions per minute (RPM).

[0043] In at least one embodiment, the permanent magnets are made from neodymium or any other magnetic alloy.

[0044] In at least one embodiment, the ferromagnetic core is made from a ferromagnetic metal such as laminated silicon iron, soft iron, or the like.

[0045] In at least one embodiment, one or more electrical pulses are applied for a fraction of the time of a full rotor revolution.

[0046] In at least one embodiment, the electrical pulse has a power input in a range that is equal to or less than the FMD energy for a fraction of the time of one rotation.

[0047] In at least one embodiment, a magnetic position control system is configured to controllably supply electrical pulses to a coil of at least one stator pole to generate a repulsive magnetic flux on the ferromagnetic core to counteract and / or repel an attractive force between the ferromagnetic core and the permanent magnet when the at least one stator pole is aligned with the permanent magnet to rotate the rotor.

[0048] In at least one embodiment, the magnetic position control system is configured to stop controllably supplying modulated electrical pulses to the coil of at least one stator pole to generate a repulsive magnetic flux on the ferromagnetic core to counteract and / or repel an attractive force between the ferromagnetic core and the permanent magnet to rotate the rotor when the at least one stator pole is positioned between about 3 and about 20 degrees from the rotor pair pole alignment point.

[0049] In at least one embodiment, a magnetic position control system is configured, in response to a position of the at least one permanent magnet, to controllably supply electrical pulses to a coil of each of the at least one stator pole to generate a repulsive magnetic flux in the ferromagnetic core, generating a repulsive force between the ferromagnetic core and one of the permanent magnets.

[0050] In at least one embodiment, the magnetic position control system is further configured, in response to the position of the at least one permanent magnet, to controllably supply electrical pulses to the coil of each of the at least one stator pole to generate a repulsive magnetic flux on the ferromagnetic core to reduce an attractive force between the ferromagnetic core and one of the permanent magnets and slow motion of the movable component.

[0051] According to a broad aspect, a method of controlling an electric motor is described herein, the electric motor having a stator with at least one independent pole or pole circuit generally equally spaced along the stator, the independent poles or pole circuits alternating around a circumference of the stator. The method includes initiating movement of a moving component of the electric motor by controllably supplying a first modulated electric pulse to an electric coil surrounding a ferromagnetic core of a first stator pole of the stator when the ferromagnetic core faces and is magnetically attracted to a permanent magnet coupled to the moving component of the electric motor. The method also includes controllably supplying a second modulated electric pulse to the ferromagnetic core of the second stator pole when the permanent magnet reaches the second stator pole as the permanent magnet rotates away from the first stator pole and toward a second stator pole of the electric motor, while the permanent magnet is attracted by the ferromagnetic pole of the second stator pole, to generate a repulsive magnetic flux in the ferromagnetic core of the second stator pole and counteract the attractive force between the permanent magnet and the ferromagnetic core of the second stator pole.

[0052] In at least one embodiment, after initiating movement of the movable component by controllably supplying a first modulated electric pulse to an electric coil surrounding a ferromagnetic core of a first stator pole, the method includes controllably supplying one or more subsequent modulated electric pulses to the electric coil surrounding the ferromagnetic core of the first stator pole to generate a repulsive magnetic flux in the ferromagnetic core of the first stator pole to promote movement of the permanent magnet away from the first stator pole.

[0053] According to a broad aspect, a method of controlling an electric motor having a stator with at least one independent pole or pole circuit generally equally spaced along the stator, the independent poles or pole circuits alternating around a circumference of the stator, is described herein. The method includes initiating rotation of the electric motor by applying an external torque or force to a rotor and / or shaft, and, as a permanent magnet of the rotor rotates from a first stator pole toward a second stator pole of the electric motor while the permanent magnet is attracted by the ferromagnetic pole of the second stator pole, controllably supplying a second modulated electric pulse to a ferromagnetic core of the second stator pole to generate a repulsive magnetic flux in the ferromagnetic core of the second stator pole, thereby counteracting an attractive force between the permanent magnet and the ferromagnetic core of the second stator pole.

[0054] In at least one embodiment, when the permanent magnet rotates away from the second stator pole toward the third stator pole, the method includes controllably supplying modulated electrical pulses to a ferromagnetic core of the second stator pole to generate a repulsive magnetic flux in the ferromagnetic core of the second stator pole, generating a repulsive force between the permanent magnet and the second stator pole to push the permanent magnet toward the third stator pole.

[0055] In at least one embodiment, with the permanent magnet being attracted by the ferromagnetic core of the third stator pole as it rotates away from the second stator pole toward the third stator pole, the method includes controllably supplying a third modulated electrical pulse to a ferromagnetic core of the third stator pole when the permanent magnet reaches the third stator pole, generating a repulsive magnetic flux in the ferromagnetic core of the third stator pole and counteracting the attractive force between the permanent magnet and the ferromagnetic core of the third stator pole.

[0056] According to a broad aspect, a method of controlling an electric motor having a stator with at least one independent pole or pole circuit of stator poles generally equally spaced along the stator, the at least one independent pole or pole circuit being alternately arranged around the circumference of the stator, is described herein. The method includes initiating rotation of the rotor by controllably supplying a first modulated electric pulse to the electric coil of each stator pole when each permanent magnet of the rotor is aligned with the ferromagnetic core of a respective stator pole of the stator, with each stator pole having an electric coil surrounding the ferromagnetic core. The method also includes de-energizing each of the electric coils of each stator pole when each permanent magnet of the rotor is positioned between that respective stator pole and a respective adjacent stator pole, and controllably supplying a second modulated electric pulse to the electric coil of each adjacent stator pole when each permanent magnet of the rotor reaches the adjacent stator pole to generate a repulsive magnetic flux in the ferromagnetic core and counteract an attractive force between the respective permanent magnet and the ferromagnetic core of that respective adjacent stator pole.

[0057] According to broad aspects, an electric motor is described herein. The electric motor includes a movable component having at least one permanent magnet coupled thereto, each permanent magnet having an outer surface with a surface area; and a stator spaced from the movable component, the stator having at least one stator pole positioned opposite the at least one permanent magnet. Each stator pole includes a ferromagnetic core and a coil wound around the ferromagnetic core, the ferromagnetic core being naturally attracted to the at least one permanent magnet. The electric motor also includes a magnetic position control system configured to monitor the position of the at least one permanent magnet on the movable component relative to the stator and, in response to the position of the at least one permanent magnet, controllably supply electric pulses to the coil of each of the at least one stator pole to generate a repulsive magnetic flux on the ferromagnetic core to counteract an attractive force between the ferromagnetic core and the at least one permanent magnet, thereby controlling movement of the movable component.

[0058] According to broad aspects, an electric motor is described herein. The electric motor includes a rotor having at least one permanent magnet coupled thereto, each permanent magnet having an outer surface with a surface area; a shaft fixedly coupled to the rotor such that rotation of the rotor rotates the shaft; and a stator surrounding the rotor, the stator having at least one stator pole positioned opposite the at least one permanent magnet, each stator pole including a ferromagnetic core and a coil wound around the ferromagnetic core, the ferromagnetic core being naturally attracted to the at least one permanent magnet. The electric motor also includes a magnetic position control system configured to monitor a position of the at least one permanent magnet on the rotor relative to the stator and, in response to the position of the at least one permanent magnet, controllably supply electric pulses to the coil of each of the at least one stator pole to generate a repulsive magnetic flux on the ferromagnetic core and counteract an attractive force between the ferromagnetic core and the at least one permanent magnet to control movement of the movable component.

[0059] These and other features and advantages of the present application will become apparent from the following detailed description read in conjunction with the accompanying drawings. It should be understood, however, that the detailed description and specific examples, while indicating preferred embodiments of the present application, are given by way of illustration only, since various changes and modifications within the spirit and scope of the present application will become apparent to those skilled in the art from this detailed description.

[0060] For a better understanding of the various embodiments described herein, and to show more clearly how these may be put into practice, reference is made to the accompanying drawings, which show, by way of example, at least one illustrative embodiment and which will now be described. The drawings are not intended to limit the scope of the teachings described herein. [Brief explanation of the drawings]

[0061] [Figure 1A] FIG. 1 illustrates a top view of the rotor, permanent magnets, and electromagnets of an electric motor in a first angular position (aligned (0 degrees) or at rest), according to one embodiment. [Figure 1B]1B is a graph showing the change in torque with changing angular position of the rotor of the electric motor shown in FIG. 1A, illustrating force-magnetostatic (FMS) as described herein. [Figure 2A] 1B is a top view of the rotor, permanent magnets, and stator poles of the electric motor of FIG. 1A in a second angular position, in which the magnets are attracted to adjacent ferromagnetic poles, according to one embodiment. [Figure 2B] 2B is a graph showing the change in torque with changing angular position of the rotor of the electric motor shown in FIG. 2A, illustrating force-magnetodynamic (FMD) as described herein. In the position shown, a magnet is attracted to an adjacent ferromagnetic pole. [Figure 3A] 1B is a top view of the rotor, permanent magnets, and stator poles of FIG. 1A in a first angular position (aligned (0 degrees) or at rest), according to one embodiment. [Figure 3B] 3B is a graph showing the change in torque with changing angular position of the rotor of the electric motor shown in FIG. 3A, illustrating force-reaction dynamics (FRD) as described herein. [Figure 4A] 1B is a top view of the rotor, permanent magnets, and stator poles of FIG. 1A in a first angular position (aligned (0 degrees) or rest state), according to one embodiment. [Figure 4B] 4B is a graph showing the change in torque with changing angular position of the rotor of the electric motor shown in FIG. 4A, illustrating a braking mode as described herein. [Figure 5A] 1B is a top view of the rotor, permanent magnets, and stator poles of FIG. 1A in a first angular position, according to one embodiment. [Figure 5B] 4B is a graph showing the change in torque with changing angular position of the rotor of the electric motor shown in FIG. 4A, illustrating a phantom moment as described herein. [Figure 6] FIG. 1 illustrates a top view of an electric motor, according to one embodiment. [Figure 7] FIG. 7 is a top view of the electric motor of FIG. 6 showing the synchronizing disc and the sensor. [Figure 8]FIG. 7 is a circuit diagram of the electric motor of FIG. 6 according to another embodiment. [Figure 9] FIG. 7 is a circuit diagram of the electric motor of FIG. 6 showing the motor at step 0 when the rotor begins to rotate. [Figure 10] 7 is a circuit diagram of the electric motor of FIG. 6, showing the motor at step 1. [Figure 11] 7 is a circuit diagram of the electric motor of FIG. 6, showing the motor at step 2. [Figure 12] 7 is a circuit diagram of the electric motor of FIG. 6, showing the motor at step 3. [Figure 13A] 1 shows a top view of an electric motor with each of its stator poles connected to each of the other stator poles on the same magnetic circuit, each of the stator poles being in a first polarity. [Figure 13B] 1 shows a top view of an electric motor with each of its stator poles connected to each of the other stator poles on the same magnetic circuit, each of the stator poles being of a second polarity. [Figure 14A] FIG. 7 is a top view of the rotor, permanent magnets, and stator poles of FIG. 6 during dynamic braking mode, according to one embodiment. [Figure 14B] 14B is a graph showing the change in torque with respect to the angular position of the rotor shown in FIG. 14A in dynamic braking mode. [Figure 15A] FIG. 7 is a top view of the rotor, permanent magnets, and stator poles of FIG. 6 in the vibration zone, according to one embodiment. [Figure 15B] 15B is a graph showing the change in torque with respect to the angular position of the rotor shown in FIG. 15A in the vibration zone at start-up. [Figure 16A] FIG. 7 is a top view of the rotor, permanent magnets, and stator poles of FIG. 6 during startup, according to one embodiment. [Figure 16B] 16B is a graph showing the change in torque versus angular position of the rotor shown in FIG. 16A upon start-up in a desired direction. [Figure 17A] FIG. 7 is a top view of the rotor, permanent magnets, and stator poles of FIG. 6 during startup, according to another embodiment. [Figure 17B]17B is a graph showing the variation of torque with angular position of the rotor shown in FIG. 17A during start-up in the opposite direction. DETAILED DESCRIPTION OF THE INVENTION

[0062] Further aspects and features of the exemplary embodiments described herein will become apparent from the following description read in conjunction with the accompanying drawings.

[0063] Various devices and methods are described below to provide an example of at least one embodiment of the claimed subject matter. The embodiments described below do not limit any claimed subject matter, and any claimed subject matter may be directed to devices and methods other than those described below. The claimed subject matter is not limited to devices and methods having all of the features of any one device or method described below, or to features common to several or all of the devices and methods described below. It is possible that a device or method described below is not an embodiment of the claimed subject matter. Subject matter disclosed in the devices or methods described herein but not claimed herein may be the subject of other means of protection, e.g., a continuing patent application, and the applicant, inventor, and / or owner do not intend to abandon, abdicate, or dedicate such invention(s) to the public by its disclosure herein.

[0064] Furthermore, it will be understood that for simplicity and clarity of illustration, where considered appropriate, reference numerals may be repeated among the figures to indicate corresponding or analogous elements. Additionally, numerous specific details have been described in order to provide a thorough understanding of the exemplary embodiments described herein. However, those skilled in the art will understand that the exemplary embodiments described herein may be practiced without these specific details. In other instances, well-known methods, procedures, and components have not been described in detail so as not to obscure the exemplary embodiments described herein. Additionally, this description should not be considered to limit the scope of the exemplary embodiments described herein.

[0065] It should be noted that terms of degree, such as "substantially," "about," and "approximately," as used herein, refer to a reasonable amount of deviation from the modified term that does not significantly alter the end result. These terms of degree should be interpreted as including a deviation from the modified term, such as a deviation of at least ±5% or at least ±10%, if this deviation does not negate the meaning of the term it modifies.

[0066] Additionally, the recitation herein of any numerical range by endpoints includes all numbers and fractions subsumed within that range (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.90, 4, and 5). It is also understood that all numbers and fractions are presumed to be modified by the term "about," which refers to a variation of the stated number by a certain amount, such as, for example, 1%, 2%, 5%, or 10%, where the end result would not be significantly altered.

[0067] Also, it should be noted that, as used herein, the term "and / or" is intended to mean an inclusive or. That is, "X and / or Y" is intended to mean, for example, X or Y or both. As a further example, "X, Y, and / or Z" is intended to mean X or Y or Z or any combination thereof.

[0068] The following description is not intended to limit or define the claimed or unclaimed subject matter. Claimable subject matter may reside in any combination or subcombination of elements or process steps disclosed in any part of this document, including the claims and figures. Thus, it will be understood by those skilled in the art that an apparatus, system, or method disclosed in accordance with the teachings herein may embody any one or more of the features contained herein, and that the features can be used in any particular combination or subcombination that is physically feasible and achievable for its intended purpose.

[0069] In recent years, there has been growing interest in developing electric motors using permanent magnets. The electric motors described herein may be electrodynamic motors that include one or more permanent magnets and a rotor that interacts with prominent stator poles. In a conventional electric motor, the rotor (i.e., rotating part) rotates inside the stator (i.e., stationary part). In a linear motor, the stator is unwound and flat, and the rotor moves linearly past it. Thus, as used herein, the term "rotor" is not limited to linearly moving parts and can include or refer to any moving or rotating part. Both conventional electric motors and linear motors are described herein.

[0070] In some embodiments, rotor movement (e.g., rotation) may be initiated and maintained primarily by attraction of one or more permanent magnets coupled to the rotor to the solid iron cores of electromagnets disposed on or around the stator poles. In some embodiments, current pulses applied to the stator electromagnets are sufficient to counteract any rearward drag of the rotor permanent magnets as soon as they pass the stator electromagnet cores, thereby enabling continued motion (e.g., rotation) of the rotor.

[0071] In some embodiments, the electric motors described herein generally relate to forms of electric motors that can produce mechanical drive torque, or linear force, depending on the selected configuration, with high efficiency (potential for positive gain) relative to the power input to the electric motor.

[0072] Other key characteristics of some embodiments of the electric motors described herein may include, but are not limited to, self-starting, speed control, on-demand CW or CCW operation, overload protection, minimal heat generation, modular construction, constant high torque / force, and dynamic braking.

[0073] In some embodiments, electric motors as described herein include switched flux pulse motors and their controls, which generally refer to machines that operate by virtue and properties of mutual magnetic attraction and / or repulsion, such as between magnetized poles.

[0074] It should be understood that the following description and examples include some fundamental principles by which the electric motors described herein operate, as well as various principles that have been discovered and quantified while the electric motors described herein are operating. In some embodiments, the electric motors described herein may include one or more of the following states or functions: - Force-Magnetostatic (FMS) - Force-Magnetic Dynamic (FMD) - Force-rebound dynamic (FRD) - Brake mode - MPF operation mode - Dynamic Operation Mode - Magnetic Position Control System (MPCS)

[0075] Each of these states or functions is described in more detail below.

[0076] In the following description, it should be understood that reference numeral 100 refers to an electric motor including a permanent magnet (sometimes referred to as element "A"), an electromagnet (sometimes referred to as element "B"), and a rotor (sometimes referred to as element "C"). In the following description, an electric motor in one or more rotary motor variants is described, but it should be understood that the same principles described herein can be applied to other embodiments, not limited to linear motor or wheel hub motor variants.

[0077] As used herein, the term "force-magnetostatic" (FMS) refers to a force that does not result in any angular motion of the rotor 106 of the electric motor 100. More specifically, as shown in FIG. 1A, FMS refers to the attractive force (indicated by arrow 110 in FIG. 1A) between the permanent magnet 102 and the ferromagnetic pole 104, directed toward the ferromagnetic pole 104, perpendicular to the axis of rotation of the rotor 106, and intersecting the axis of rotation of the rotor 106. Note that the axis of rotation of the rotor 106 passes directly through the center 107 of the rotor 106. Because the FMS intersects the axis of rotation of the rotor 106, no torque is generated. FMS can be compared to the electromotive force found in a typical induction motor. However, in this case, the FMS does not originate from the inductor, but rather from the magnetic field of the permanent magnet 102. FMS can be quantified as a function of the strength of the permanent magnet 102, the distance of the gap 112 between the permanent magnet 102 and the ferromagnetic pole 104, and the ferromagnetic alloy itself.

[0078] FIG. 1B is a graph of torque versus angular position for motor 100 of FIG. 1A, showing that the FMS does not generate any torque.

[0079] As used herein, the term "force-magnetodynamic" (FMD) refers to a force that causes angular motion of the rotor 106 in the electric motor 100. More specifically, as shown in FIG. 2A, FMD refers to the attractive force that results in rotation between the permanent magnets 102 and the ferromagnetic poles 104, as indicated by arrows 110 in FIG. 2A. The FMD is directed toward the ferromagnetic poles 104, perpendicular to the axis of rotation of the rotor 106, but offset therefrom (e.g., laterally spaced), thus generating a resultant torque. The generated torque can be useful free energy from the relative motion of the magnetic fields and the natural magnetic attraction / repulsion effects of the permanent magnets. FMD is available with the use of permanent magnets (such as the permanent magnets 102) and does not require any external energy input. FMD can be quantified as a function of, or in relation to, the strength of the permanent magnet 102, the lateral distance 114 between the permanent magnet 102 and the ferromagnetic pole 104, the shape of the magnet (i.e., one or both of the permanent magnet 102 and the ferromagnetic pole 104), and the ferromagnetic alloy itself.

[0080] FIG. 2B shows a graph of torque versus angular position for motor 100 of FIG. 2A, illustrating that the FMD generates torque.

[0081] As used herein, the term "force-repulsion dynamic" (FRD) refers to a separate force that causes angular motion of the rotor 106 in the electric motor 100 (FIG. 3A). More specifically, the FRD requires an additional external energy input. As shown in FIG. 3A, the FRD can be referred to as the result of a repulsive magnetic field generated by the permanent magnets 102 on the ferromagnetic poles 104 as they pass through the FMD zone after the braking point 116. This magnetic field can be modulated to have a more or less pronounced effect on the rotor 106. The energy demand of the electric motor 100 during operation can be considered proportional to the selected FRD strength. The time course over which this force is applied is relatively short in the electric motors described herein during a rotation cycle. By way of example, in some embodiments, pulses are applied within approximately 3 to 20 degrees of rotation; therefore, the faster the rotor rotates, the shorter the pulses. While operating in the MPF operating mode, the FRD strength is low to nonexistent. However, while operating in the dynamic operating mode, it is used more vigorously. The FRD can be quantified as a function of the strength of the permanent magnet 102, the strength of the magnetic field generated by the electromagnet 104, the time lapse over which the FRD is applied, the distance of the gap 112 between the permanent magnet 102 and the ferromagnetic pole 104, and the ferromagnetic alloy itself.

[0082] FIG. 3B shows a graph of torque versus angular position for motor 100 of FIG. 3A, illustrating the FRD generating torque.

[0083] As used herein, the term braking mode refers to an operating mode of electric motor 100 in which there is no external electrical energy input (i.e., no current or voltage) applied to electric motor 100. In this mode, permanent magnet 102 self-aligns with the ferromagnetic core of electromagnet 104, as shown in FIG. 4A . Because the distance of gap 112 between permanent magnet 102 and electromagnet 104 is at its smallest point (e.g., permanent magnet 102 and electromagnet 104 are directly facing each other), FMS is maximum, preventing rotation of rotor 106. Any angular misalignment on either side between permanent magnet 102, electromagnet ferromagnetic core 104, and the axis of rotation of rotor 106 is arrested by FMD, which generates a reaction torque to naturally center permanent magnet 102, electromagnet ferromagnetic core 104, and rotor 106 about the maximum FMS.

[0084] In the MPF operating mode, when no external electrical energy input is applied to the electric motor 100 (i.e., no current or voltage) and the permanent magnets 102 are not aligned with the electromagnet ferromagnetic core 104, the FMD generates a torque on the rotor 106 (as shown in FIG. 2A ) to rotate and realign the rotor 106 toward the maximum FMS (also called the “braking point”).

[0085] At this stage, after reaching the braking point, the rotor 106 is about to face a sufficient counteracting FMD torque strong enough to brake the rotor 106. At this point, the magnetic position control system (MPCS; described below) injects an electromagnetic pulse through the ferromagnetic core of the stator pole 104 using minimal external electrical energy input. The electromagnetic pulse has a repulsive effect on the permanent magnet 102 equivalent to the attractive force between the permanent magnet 102 and the ferromagnetic core of the stator pole 104. The electromagnetic pulse is applied long enough to move the permanent magnet 102 out of the FMD influence zone where it may decelerate (see FIGS. 5A and 5B). As a result, the opposing FMD torque is momentarily annealed, which makes the stator pole 104 invisible to the magnetic flux of the permanent magnet 102, allowing the rotor 106 to rotate freely beyond the "braking point" until it reaches the next attractive zone of the ferromagnetic pole of the adjacent (or neighboring) stator pole 104. The moment when the stator poles 104 are no longer subject to the magnetic flux of the permanent magnets 102 can be called a "phantom moment."

[0086] In a dynamic operating mode, similar to the MPF operating mode described above, when no external electrical energy input is applied to the electric motor described herein (i.e., no current or voltage), if the permanent magnets 102 are misaligned with the electromagnet ferromagnetic cores of the stator poles 104, the FMD will generate a torque on the rotor 106 in accordance with FIGS. 2A and 2B, causing the rotor 106 to naturally rotate and realign toward the maximum FMS, also known as the "braking point" (FIGS. 4A and 4B).

[0087] At this stage, after reaching the "braking point," the rotor 106 is about to face a sufficient counteracting FMD torque strong enough to brake the rotor 106. At this point, the MPCS, using minimal external electrical energy input, injects an electromagnetic pulse through the ferromagnetic core of the stator pole 104 that has a repulsive effect on the permanent magnet 102 that is greater than the attractive force between the permanent magnet 102 and the ferromagnetic core of the stator pole 104. The electromagnetic pulse is applied long enough to move the permanent magnet 102 out of the FMD influence zone, but now applies an additional repulsive torque (due to the FRD) that favors rotation (see Figures 3A and 3B). As a result, not only is the opposing FMD momentarily annealed, but the rotor 106 is also pushed by the FRD with increased torque toward the next ferromagnetic pole's attractive zone in addition to the magnet's natural attraction by the next adjacent ferromagnetic pole.

[0088] The MPCS is a system that monitors and controls the various magnetic fluxes in the electric motors described herein. The MPCS continuously interacts with the ferromagnetic cores of the stator poles 104 to modulate magnetic pulse functions for various operating modes, such as, but not limited to, the operating modes described above and / or the power demands for the motors described herein. This system can provide various control options and control the execution of each step of the components that interact together in the electric motors described herein. The MPCS includes mechanical, electronic, and software components. The electric motors described herein can include one or more MPCSs to operate.

[0089] Components The following sections describe the various components found in the electric motors described herein. As described below, the various components can be used in several different configurations. Regardless of the combination of components selected for each electric motor, each of the electric motors described herein adheres to the principles described herein.

[0090] Referring to Figure 6, shown therein is an electric motor 600 according to at least one embodiment. The electric motor 600 includes a rotor 606. The rotor 606 includes all of the moving components of the electric motor 600. In general, the rotor 606 translates rotational dynamic magnetostatic forces into mechanical torque via the shaft 601 (see Figure 7) of the motor 600.

[0091] The rotor 606 includes one or more permanent magnets 602 that provide for the rotor 606 to rotate about the axis of the shaft 601. The number of permanent magnets 602 in the motor 600 can be odd or even. Furthermore, the permanent magnets 602 can be made of various forms, shapes, or alloys. For example, in the electric motor 600 shown in FIG. 6, a set of four permanent magnets 602 are evenly spaced around the shaft 601 and fixedly coupled to the rotor 606.

[0092] Stator 605 includes all of the stationary components of electric motor 600. For example, in some embodiments, stator 605 includes all of the parts that form a completely self-contained motor unit that can be fixed and installed for any application for which electric motor 600 is intended.

[0093] The stator 605 includes a frame 607 for containing the components of the stator 605. The stator 605 serves as a support for each of the stator poles 604 and their respective windings 609, which, in combination with the permanent magnets 602 of the rotor 606, generate rotational motion for the electric motor 600. The number of stator poles 604 in the stator 605 can range from about 1 to about 100, or from about 10 to about 75, or from about 15 to about 50, or from about 15 to about 30, or from about 16 to about 20, or from about 1 to about 25, or from about 10 to about 25, or from about 15 to about 20, or from about 16 to about 18. In at least one embodiment, the rotor 606 can have more than one rotor stack. For example, the motor 600 can include 1 to 20 stacks, 1 to 12 stacks, 1 to 10, 1 to 8, 1 to 6, 1 to 5, 1 to 4, 1 to 3, or 1 to 2 stacks. In at least one embodiment, the number of stator poles 604 of stator 605 can range from about 1 to about 100 per rotor stack, or from about 10 to about 75 per rotor stack, or from about 15 to about 50 per rotor stack, or from about 15 to about 30 per rotor stack, or from about 16 to about 20 per rotor stack.

[0094] It should be noted that in embodiments having more than one stator pole 604, the stator poles need not be evenly paired with each permanent magnet 602 of the rotor 606. Furthermore, the stator poles 604 are generally equally spaced from one another around the shaft 601. The stator poles 604 may be made from a variety of forms, shapes, coil wires, or core alloys. By way of example, in some embodiments, the electric motor 600 may include a set of eight stator poles 604 evenly distributed (i.e., spaced) around the shaft 601 and secured to the stator 605 via the back iron 607.

[0095] Selection of various characteristics of the rotor 606 and stator 605 components, such as, but not limited to, the positions of the stator poles 604 relative to each other and relative to the positions of the permanent magnets 602, and the positions of the permanent magnets 602 relative to each other and relative to the positions of the stator poles 604, may emphasize particular performance characteristics and functionality of the electric motor 600.

[0096] Rotor 606 is generally made from a material strong enough to maintain the structural integrity of all rotating components of electric motor 600, which are subject to magnetic, centrifugal, gravitational, vibrational, and thermal expansion forces. Rotor 606 may be made from a ferromagnetic or non-ferromagnetic material, provided that if rotor 606 is made from a ferromagnetic material, the ferromagnetic material does not interfere with the magnetic field of permanent magnets 602. In some embodiments, rotor 606 may be made from a material that magnifies the magnetic field of permanent magnets 602. For example, in some embodiments, rotor 606 may be made from an alloy of copper and zinc (e.g., brass). In some embodiments, rotor 606 may have a conventional cylindrical shape.

[0097] Shaft 601 can be made from any material typically used to make shafts found in conventional electric motors. Shaft 601 passes through the center of rotor 606 and is fixedly coupled to rotor 606 such that rotation of rotor 606 provides rotation of shaft 601.

[0098] The permanent magnets 602 may be made from different alloys and may have various shapes and / or thicknesses, provided that each of the permanent magnets 602 has the same shape and thickness. As mentioned above, the electric motors described herein may include one or more permanent magnets 602, in odd or even numbers.

[0099] In some embodiments, the shape of the outer surface 611 of each of the permanent magnets 602 (as shown in FIG. 8 ) corresponds to (e.g., closely mirrors or provides equal spacing with) the outer surface 613 of each of the stator poles 604. The stator poles 604 or stator 602 are generally spaced from the permanent magnets 602 by generally equal distances around the circumference of the stator poles 604 or stator 602.

[0100] In some embodiments, the maximum angular distance between two adjacent centerlines of the stator poles 604 (i.e., the axis extending through their centers transverse to or perpendicular to the axis of the rotor 601) is approximately twice, or twice the width or diameter, of each of the permanent magnets 602.

[0101] In some embodiments, the polarity of each of the permanent magnets 602 in the portion of the magnet facing the stator poles 604 is the same for each of the permanent magnets 602 in the rotor 606 .

[0102] Each permanent magnet 602 has an outer surface 611 with a surface area corresponding to the surface area of ​​the magnet exposed to (i.e., facing) one or more stator poles. Stated another way, the surface area of ​​the outer surface 611 is the area of ​​the portion of the permanent magnet that exerts a magnetic influence on the stator poles. In some embodiments, the difference in surface area of ​​each outer surface 611 of the permanent magnets 602 is less than about 10%, or less than about 5%, or less than about 3%.

[0103] Similarly, each of the stator poles 604 has an outer surface 613 having a surface area. The surface area of ​​the outer surface 613 of each stator pole 604 is the area of ​​the portion of the stator pole where the stator pole is magnetically influenced by the permanent magnet 602. In at least one embodiment, the difference between the surface area of ​​the outer surface 613 of each of the stator poles 604 and the surface area of ​​the outer surface 611 of each of the permanent magnets 302 is less than about 10%, or less than about 5%, or less than about 3%.

[0104] Each of the permanent magnets 602 has a width. The size and shape of the magnets 602 can be varied from one motor configuration to another to achieve particular attributes. In at least one embodiment, the permanent magnets 602 have a cylindrical shape. In this case, in at least one embodiment, the width of the magnet 602 is equal to its diameter. The size and shape of the permanent magnets 602 (e.g., their width) and / or the spacing of the permanent magnets 602 and / or the spacing of the stator poles 604 can affect the torque capability of the motor 600. In at least one embodiment, the maximum distance between the centerlines of two adjacent stator poles 604 is twice the width of one of the permanent magnets 602.

[0105] In some embodiments, each permanent magnet 602 has the same polarity facing each stator pole 604 .

[0106] 7, electric motor 600 may include a synchronization or indexing disk 620. Disk 620 is a component that operates in parallel with a sensor 622. Both disk 620 and sensor 622 are part of a magnetic position control system (MPCS) 624 of electric motor 600.

[0107] It should be noted that disk 620 is an optional feature of the electric motors described herein. Although electric motor 600 includes disk 620, it is not required.

[0108] Electric motor 600 includes a disk 620 with a series of eight small disk permanent magnets 626 evenly distributed around disk 620. Disk permanent magnets 626 have the following polarity: NSNSNSNS. The function of disk 620 is to constantly index the position of rotor 606 relative to stator 605 to MPCS 624.

[0109] While MPCS 624 is represented in the drawings by disk 620 and sensor 622, it should be noted that MPCS 624 is a complete system that provides for positioning different magnetic fluxes in electric motor 600. MPCS 624 modulates its operation and the signals sent to stator poles 604 according to the selected operating mode (discussed above) and the load of electric motor 600. In this manner, MPCS 624 can be thought of as functioning as the "brain" of electric motor 600 by controlling the execution of each step of all active components in electric motor 600 to perform its intended function based on the selected options. MPCS 624 includes mechanical, electronic, and software components. MPCS 624 can be unique (e.g., singular), or there can be multiple MPCSs 624 in motor 600. Furthermore, MPCS 624 can be located internal or external to electric motor 600.

[0110] Each stator pole 604 includes a coil 609 wound around a ferromagnetic metal core 608 .

[0111] The coil 609 may be copper or aluminum wire (or any other conductive material) sized to withstand the amperage of the circuit. Additionally, in some embodiments, the coil 609 includes enough windings to withstand the received voltage while achieving sufficient magnetic flux to repel the permanent magnet 602 at a particular time and for a given duration.

[0112] The core 608 is made of a ferromagnetic material and generally has the same shape as the permanent magnets 602 (i.e., the outer surface 613 of the core 608 generally has a shape that corresponds to the shape of the outer surface 611 of each permanent magnet 602). The outer surface 611 of each permanent magnet 602 generally faces the outer surface 613 of the core 608 when the rotor 606 rotates. Each permanent magnet 602 is positioned on the rotor 606 such that the outer surface 611 of each permanent magnet 602 has the same polarity.

[0113] Each stator pole 604 directly affects the attributes and performance of the electric motor 600. For example, the stator poles 604 may be interconnected in parallel, in series, in a single circuit, and / or in multiple circuits (also referred to as asymmetric and symmetric design configurations). In some embodiments, the electric motor 600 can be configured around a single stator pole 604 or can include an infinite number of stator poles 604 (i.e., the number of stator poles is limited only by physical constraints). As mentioned above, the number of stator poles 604 in each electric motor embodiment described herein need not be the same as the number of permanent magnets 602 found on the rotor 606.

[0114] When the stator poles 604 are not energized, the permanent magnets 602 are naturally attracted to the ferromagnetic material of each core 608. When the stator poles 604 are energized, the stator poles 604 have a natural repulsion to the permanent magnets 602, the degree of which is controllable based on the selected operating mode (e.g., MPF or dynamic).

[0115] 6 and 7, the stator poles 604 are organized into two groups, Group A and Group B, connected in series, which may also be referred to as an asymmetric design configuration. In one embodiment, each stator pole 604 is controlled by an MPCS and is made of laminated silicon iron.

[0116] The back iron, or frame 607, is an optional component of the stator 605. The back iron 607 may, for example, form part of the laminations surrounding the stator poles 604 of the stator 605. Mechanically, the back iron 607 holds the stator poles 604 in place while providing connection of the stator 605 to, for example, the motor frame. Magnetically, the back iron 607 creates a magnetic circuit between the stator poles 604. This provides that de-energized stator poles 604 have a positive effect on the operation of the electric motor 600. Additionally, the back iron 607 can group stator poles 604 together (e.g., A and B) or mix them together (e.g., A1 and B1 and A2 and B2). This provides for stacking circuit groups on top of each other, thus increasing the overall power output of the electric motor 600.

[0117] Depending on the features and configuration selected, back iron 607 is an optional feature. Note that the ability to stack stator poles 604 and rotor sets is a primary feature of electric motor 600, regardless of the presence of back iron 607. In at least one embodiment, motors with 1, 2, 4, 8, and 18 poles can be formed with a single rotor stack. In at least one embodiment, motors with up to approximately 100 poles can be formed with a single rotor stack. In at least one embodiment, motors with up to 100 poles can be formed with a single rotor stack. In at least one embodiment, motors with two or more motor stacks (i.e., multiple disks and magnets axially connected to a shaft) can be formed. In these embodiments, each rotor stack can include up to approximately 100 poles.

[0118] Gap 610 is the distance between the outer surface 611 of each of the penetrating magnets 602 (as shown in FIG. 6) and the outer surface 613 of each of the stator poles 604 (eg, core 608).

[0119] Step-by-step operation The electric motors described herein are versatile and can have a variety of configurations, as discussed above. Regardless of the configuration, the electric motors described herein generally adhere to the principles set forth below.

[0120] The electric motors described herein are essentially DC-powered motors. That is, the electric motors described herein can be coupled, for example, with a rectifier, which allows the electric motor to operate with an AC power source (e.g., single-phase or three-phase) or even with a polarity-free DC input. This is a fully variable linear speed motor function of its input voltage. Due to its construction, the electric motors described herein can generate high, nearly constant torque from 0 RPM up to its maximum speed, such as, but not limited to, 30,000 RPM, or 50,000 RPM, or 100,000 RPM.

[0121] The following description illustrates principles that should be applied to the operation of an electric motor having an asymmetric configuration according to at least one embodiment described herein. One exemplary embodiment is described below, but the claims should not be construed as being limited to the exemplary embodiment described below.

[0122] FIG. 8 presents a basic schematic diagram of one example of the operation of an electric motor according to at least one embodiment described herein. Specifically, FIG. 8 illustrates the electric motor 600 of FIGS. 6 and 7 with eight stator poles 604 connected in two groups (A-series and B-series, which alternate around the rotor 602 as shown) on the stator 605, four permanent magnets 602 on the rotor 606, a synchronous disk 620 on the rotor shaft 601 that is read by a sensor 622 connected to the MPCS 624, and switches S1 and S2 that provide power to an electrical circuit that is itself managed by the MPCS 624. Input power, here represented by "B+," is received from a rectifier module (not shown). The input power is ready to provide the necessary power to the various stator poles 604, while ground return is achieved via switches S1 and S2 controlled by the MPCS 624.

[0123] In this embodiment, each of the four permanent magnets 602 is shown initially aligned with a respective A-series stator pole 604. Referring to the above description, this illustrates an FMS, where the MPCS 624 knows the position of the rotor 606 via sensors 622 and synchronous disk 620.

[0124] In the MPF operating mode, the MPCS 624 activates switch S2 (or an equivalent switch), supplying current to the electric motor 600 (i.e., coil 609) to induce the same polarity as the magnet in the ferromagnetic core 608, canceling the attractive effect between the permanent magnet 602 and the stator pole 604 when overcoming the braking point. In general, the coil 609 can control the shape and strength of the magnetic field of each ferromagnetic pole 604. At this moment, the permanent magnet 602 is slightly misaligned and repelled by the FMD from the A series of stator poles 604, and is naturally attracted to the next unenergized adjacent ferromagnetic pole. Figure 9 shows a circuit diagram of this operation. Cancellation of the attractive effect is achieved by applying an equivalent external energy ranging from 0 to approximately 75% of the FMD energy for a duration corresponding to approximately 120 degrees of full rotation. This changes the phantom effect function expected for a given design.

[0125] In the dynamic mode of operation, the same scenario is repeated except that the current induced in the coil 609 is stronger, thus generating an additional repulsive force on the permanent magnets 602 that favors further rotation of the rotor 606. At this stage (step 0), the rotor 606 begins to rotate.

[0126] The rotor 606 and permanent magnet 602 continue to rotate until the permanent magnet 602 is rotationally positioned between the A-series stator poles 604 and the B-series stator poles 604 (see FIG. 10) and crosses the FMD zone (shown in FIGS. 2A and 2B). At all times, the MPCS 624 is aware of its position via the sensor 622 and the synchronization disk 620. Regardless of the selected operating mode, the MPCS 624 is configured to disable switch S2, thus removing power to the A-series stator poles 604. This is typically set to occur when the permanent magnet 602 moves to a position between 3 and 20 degrees of rotation relative to the magnet-pole alignment position (e.g., the alignment shown in FIG. 8). In one example herein, 15 degrees was used.

[0127] The permanent magnet 602 may then be attracted by the A-series stator poles 604 that it just moved away from, or by the B-series stator poles 604 that it is approaching. The stored kinetic energy and inertia of the rotor 606 mass naturally continue its forward rotation toward the B-series stator poles 604. When the centerline between the A-series stator poles 604 and the B-series stator poles 604 is crossed by a permanent magnet (e.g., if the permanent magnet is positioned closer to the B-series stator poles 604 than to the A-series stator poles), the magnetic attraction to the closest pole takes over, adding the stator pole 604 and its energy to the motion. That is, in this example, the rotor 601 continues its motion without requiring external energy for approximately 30 degrees of rotation. This is shown in the drawings as the FMD of the B-series stator poles 604 (FIGS. 2A and 2B). A circuit diagram of this step is shown in FIG. 10.

[0128] As rotor 606 continues to rotate, permanent magnets 602 become aligned with B-series stator poles 604, which is represented by the FMS moment as described above. At this point, MPCS 624 again knows the position of rotor 606 via rotor 606 sensor 622 and synchronous disk 620.

[0129] In the MPF mode of operation, the MPCS 624 activates switch S1 (or equivalent), modulating the polarity of the ferromagnetic core 608 and supplying sufficient current to the stator poles 604 (i.e., coils 609) to counteract the natural attractive effect between the permanent magnets 602 and the ferromagnetic core 608. This effect is referred to herein as "phantom moment," in which the stator poles 604 are "invisible" to the magnetic flux of the permanent magnets 602, allowing the rotor 606 to rotate freely beyond the "braking point." A circuit diagram illustrating the phantom moment is shown in FIG. 11.

[0130] In the dynamic operating mode, the same scenario is repeated except that the current induced in coil 609 is stronger than the current induced in the MPF operating mode, resulting in an additional repulsive force on magnet 602 that favors further rotation of rotor 606.

[0131] The rotor 606 and permanent magnet 602 continue their rotational motion, moving to a position between the FMD zones of the A-series stator poles 604 and the B-series stator poles 604, thus crossing the FMS zone (shown in FIGS. 1A and 1B), as shown in FIG. 12. It should be understood that at all times, the MPCS 624 is aware of the position of the rotor 606 via the sensor 622 on the rotor 606 and the synchronous disk 620. Regardless of the selected operating mode, the MPCS 624 disables switch S1, thus removing power to the B-series stator poles 604.

[0132] The permanent magnets 602 may then be attracted by the B-series stator poles 604 that they just moved away from, or by the A-series stator poles 604 that they are approaching. This is shown in FIG. 12. The stored kinetic energy and inertia of the rotor 606 mass will, by default, cause it to continue rotating forward toward the A-series stator poles 604. As the permanent magnets 602 cross the centerline between the A-series stator poles 604 and the B-series stator poles 604, the magnetic attraction between each permanent magnet 602 and its respective ferromagnetic core 609 takes over, adding its energy to the rotation of the rotor 606 and naturally attracting it to the next unenergized adjacent ferromagnetic pole. This is referred to as FMD of the A-series stator poles 604 (see FIGS. 2A and 2B).

[0133] The permanent magnet 602 then returns to step 0 (shown in FIG. 8). The cycle described above may be repeated, with the MPCS 624 continuing to control the supply of current to the stator 605. In the illustrated example, four cycles (as described above) correspond to one complete rotation of the rotor.

[0134] Posterior iron effect In some embodiments, another phenomenon may be encountered in step 0 (see FIG. 9 ) and step 2 (see FIG. 11 ). For example, for the electric motor 600 shown in the figure, when each of the stator poles 604 is interconnected through the back iron 607, energizing one of sets A or B of stator poles 604 has a similar but opposite effect on the adjacent set of stator poles 604, even though no external power is applied to the further back set of stator poles 604. This can occur when each of the stator poles 604 is connected to each of the other stator poles 604 on the same magnetic circuit (see FIGS. 13A and 13B ). In effect, the magnetic field lines inside the core 608 simply find and take the path of least resistance to circulate through the back iron 607. For the electric motor 600, this represents an advantage because the magnetic field of any one stator pole 604 can repel nearby permanent magnets 602 in the rotor 606 while the magnetic field of an adjacent stator pole 604 attracts permanent magnets 602. The stronger the magnetic field of a stator pole 604, the stronger it attracts adjacent poles. Thus, the energy used to energize the poles results in the natural attraction of the magnets toward the iron core.

[0135] eddy current effect By definition, "Eddy currents (also called Foucault currents) are loops of electric current induced in a conductor by a changing magnetic field within the conductor according to Faraday's law of induction. Eddy currents flow in closed loops within the conductor in a plane perpendicular to the magnetic field. They can be induced in a nearby stationary conductor, for example, by a time-varying magnetic field produced by an AC electromagnet or transformer, or by relative motion between a magnet and a nearby conductor. The magnitude of the current in each given loop is proportional to the magnetic field strength, the area of ​​the loop, and the rate of change of magnetic flux, and inversely proportional to the resistivity of the material. When graphed, these circular currents in a piece of metal appear vaguely like eddies or whirlpools in a liquid."

[0136] In the electric motors described herein, heat can be generated by eddy current effects when the stator poles are energized and when the ferromagnetic core switches polarity. Eddy current effects can be minimized in the electric motors described herein by limiting the duration for which a polarization pulse is applied to the stator poles compared to the duration between two pulses, which may be referred to as the de-energization duration. Limiting the duration for which a polarization pulse is applied to the stator poles can provide for iron molecules in the ferromagnetic core to naturally regain their natural polarization without crowding together. This thermal efficiency can improve the performance of the electric motors described herein.

[0137] Forced and natural movements It should be understood that in the electric motor described herein, unlike other conventional electric motors in which the rotor is forced to follow a rotating magnetic field, the described steps can be sequenced to follow the natural attraction of the rotor's permanent magnets from one stator pole to another. External power to the stator poles can be applied precisely (e.g., only when the permanent magnets are a few degrees away from the midline of the ferromagnetic core of the stator poles (e.g., 3 to 20 degrees for a total of 120 degrees during a full rotation)). In conventional electric motors, if the rotor becomes blocked or overloaded, the motor typically overheats and burns. In the electric motor described herein, if the rotor becomes blocked or overloaded, the motor can enter dynamic braking mode by default, requiring no energy input and thus self-protecting the motor's electrical components.

[0138] Thus, in the example shown herein, rotor 606 can only rotate if it is induced to rotate in step 0 (see FIG. 9 ). Otherwise, rotor 606 will, of course, remain in braking mode. Therefore, starting an electric motor as described herein requires, for example, either an external rotational force or electronic circuitry capable of executing a starting sequence to initiate a small rotational motion in the rotor.

[0139] Operating Mode Characteristics As previously mentioned, several operating modes are possible in the electric motors described herein. Each operating mode has characteristics that may be better suited to a given application, depending on the needs of the motor. The flexibility of the electric motors described herein provides very sharp, application-centric adjustments. For example, it may be possible to switch from one mode to another during operation in the same motor.

[0140] In MPF ​​operation mode The MPF operating mode is designed to achieve high efficiency while generating high torque. The examples presented herein demonstrate this high efficiency, potentially generating positive gains under certain operating conditions. It also tolerates very low to very high rotational speeds. The examples presented herein were tested at speeds ranging from 300 RPM to 23,000 RPM (limited only by the materials used in the prototype components). It should be understood that the rotational speed of the electric motor described herein operating in the MPF operating mode is generally a linear function of the input voltage. In this mode, kinetic energy regeneration and back-EMF energy recovery are possible using commonly known laws and principles of electromagnetism. More precisely, kinetic energy regeneration is achieved by utilizing the movement of magnetic flux across the stator poles during rotation. In this way, a portion of the electromotive force is reconverted into electrical energy according to Lenz's law. Back-EMF energy recovery is achieved by utilizing the decrease in magnetic flux when a given pole is deactivated. Both are sources of energy temporarily stored in the MPF motor during operation.

[0141] In dynamic operating mode The dynamic operating mode, sometimes referred to as "boost" mode, operates similarly to the MPF operating mode described above. An electric motor operating in the dynamic operating mode described herein may contain the same components as an electric motor operating in the MPF operating mode described above and may not have any usage limitations. The dynamic operating mode may require an increased amount of external power input to operate compared to the MPF operating mode. In some embodiments described herein, up to three times the initial voltage may be required to demonstrate the functionality and performance of the dynamic operating mode. The maximum applied voltage may be limited by the prototype design, components, and material selection. Once activated, the dynamic operating mode can quickly improve the mechanical performance of the electric motor described herein. The electric motor described herein can operate in the dynamic operating mode for very long periods of time, if necessary. This mode also allows for kinetic energy regeneration and back-EMF energy regeneration, similar to the MPF mode. Furthermore, this operating mode may be even more important because the increased amperage circulating through the coils 609 results in a larger magnetic flux circulating within the stator poles.

[0142] In dynamic braking mode Dynamic braking mode is also a natural operating mode for the electric motor described herein. Dynamic braking mode is applied when the rotor's permanent magnets are aligned with the stator poles, also known as the FMS zone (see Figures 14A and 14B). Dynamic braking mode rapidly decelerates the rotor when power is removed. Dynamic braking mode can also lock the rotor in the stator with maximum torque while the rotor is stationary, without requiring external input power. Dynamic braking mode can be modulated and controlled as needed. For example, it can achieve gentle, gradual braking or a more aggressive, nearly instantaneous, complete emergency stop. Again, dynamic braking mode can accommodate a variety of potential applications requiring both static and dynamic braking. Dynamic braking mode can be activated at any time and can even be used to regenerate electrical energy and reconvert electromotive force into electrical energy according to Lenz's law.

[0143] In starting mode Starting mode is an optional operating mode for the electric motors described herein that is managed entirely by the MPCS. Starting mode is an alternate mode used only during starting of the electric motors described herein to initiate rotation without the need for external torque.

[0144] At the beginning of the starting operation, the electric motors described herein are generally in dynamic braking mode (see FIG. 14A). From this point on, when the stator pole coils are energized, the force balance is temporarily broken, thus allowing the rotor to rotate. This is the beginning of the starting phase (see FIGS. 15A and 15B). At this stage, the direction of rotation is undefined and occurs in the direction of least resistance.

[0145] The MPCS detects the direction of rotation and continues to send power to a given set of stator poles as long as it detects movement in the intended direction, long enough to move past the FMD zone and until the permanent magnet reaches the centerline window between the two stator poles (see Figures 16A and 16B).

[0146] If the MPCS detects motion in the opposite direction to the desired rotation, it will de-energize the coil. The permanent magnet will then be attracted by the stator pole core and move back in the other direction. This reverse motion is large enough to clear the FMD zone and large enough for the MPCS to detect motion in the correct direction. Power is then reapplied to the same coil long enough to clear the FMD zone and until the permanent magnet reaches the centerline window between the two stator poles (see Figures 16A and 16B).

[0147] These start-up steps can be repeated until the rotor gains sufficient speed to cause the electric motor described herein to rotate fast enough for the other operating modes described herein to take over control.

[0148] Note that at the beginning of startup, the rotor motion is more oscillatory around the FMS zone. This motion then rapidly gains amplitude and power under the pendulum effect caused by the continuous cycle of attraction and repulsion between the permanent magnets and stator poles at their strongest points. This allows the electric motor described herein to start with maximum torque. Furthermore, the direction of rotation is controlled and fully managed by the MPCS. The MPCS can enable a single MPF motor to rotate in either direction, and can even change direction during operation if desired. Furthermore, the motor's ascent or descent can also be fully controlled via the MPCS.

[0149] Other features The permanent magnets of the rotor of the electric motor described herein can always be in an attractive mode, while the active pole can always be in a repulsive mode. The electric motor described herein can be rotary or linear. The electric motor described herein can efficiently convert electrical power into mechanical torque / force, and vice versa. In the example described herein, the injection of external power represents, for example, approximately 108 degrees of a 360-degree rotation. In the example described herein, a prototype operated without problems at 20,000 RPM. However, above 23,000 RPM, the same prototype began to show signs of mechanical weakening. Thus, in the motor described herein, the motor's rotational speed can theoretically approach the attraction speed (i.e., the speed at which the two magnets approach each other) of two adjacent permanent magnets, which varies based on the strength, shape, and relative distance between the permanent magnets and the ferromagnetic cores of the poles. In practice, the maximum speed is physically limited by the nature of the magnetic flux, the design, component selection, and materials used.

[0150] The following is a non-exhaustive list of some potential advantages and attributes of the embodiments described herein. In some embodiments, the rotation speed can be adjusted linearly by the MPCS or by an external power supply voltage. In some embodiments, the electric motor can operate under AC or DC power, one or more phases, depending on its configuration. In some embodiments, the electric motor may or may not have a constant torque. In some embodiments, the electric motor may necessarily have a dynamic brake. In some embodiments, the electric motor can recover energy from back EMF and / or dynamic braking and / or EMF. In some embodiments, the electric motor is capable of recovering induced electromotive force (Faraday's law). In some embodiments, the electric motor can regulate its rotational speed regardless of its load or its power source. In some embodiments, the electric motor may have a fast or slow acceleration or deceleration curve, whether modulated or not. In some embodiments, the electric motor can double its dynamic braking power with an external energy supply. In some embodiments, the electric motor can achieve constant torque without drop-off zones (slip). In some embodiments, the electric motor is capable of achieving constant torque throughout its speed range. In some embodiments, the electric motor can articulate a very low speed range (eg, less than 10 RPM) to very high speeds (eg, greater than 30,000 RPM). In some embodiments, the electric motor may or may not have a locked rotor while not rotating and can turn to dynamic braking if its power is exceeded. In some embodiments, the electric motor may or may not have a free-spinning, no-load, rotor operating mode (no acceleration, no braking, just inertial rotation). In some embodiments, electric motors may be constructed using different form factors such as, but not limited to, rotary, linear, or wheel hub motor variants. In some embodiments, the electric motor can be fully autonomous, with all of its control embedded within the motor. In some embodiments, the electric motor can be controlled by manual control, remote control, wireless control, or other system. In some embodiments, the electric motor may or may not be self-starting. In some embodiments, the electric motor can be operated and controlled as required to rotate clockwise (CW) or counterclockwise (CCW). In some embodiments, MPF motors generate little or no heat compared to conventional AC or DC motors. In some embodiments, the MPCS automatically selects and modulates operating modes during operation for best efficiency and performance.

[0151] Methods for controlling an electric motor are also described herein. In a broad aspect, a motor having a stator with at least one independent pole or pole circuit generally equally spaced along the stator, the independent poles or pole circuits alternating around the periphery of the stator, can be controlled by initiating movement of a moving component of the electric motor by controllably supplying a first modulated electrical pulse to an electric coil surrounding a ferromagnetic core of a first stator pole of the stator when the ferromagnetic core opposes and is magnetically attracted to a permanent magnet coupled to the moving component of the electric motor. A MPCS that detects the direction of rotation continues to send power to a given set of stator poles as long as it detects movement in the intended direction, thereby continuing to send power to the same coil long enough to traverse the FMD zone and until the permanent magnet reaches the centerline window between the two stator poles. When the MPCS detects movement in the opposite direction to the desired rotation, it discontinues powering the coil. The permanent magnet then returns in the opposite direction due to the attractive effect of the stator poles. This reverse movement is large enough to traverse the FMS and is large enough for the MPCS to detect movement in the correct direction. Power would then be reapplied to the same coil for a time sufficient to move past the FMD zone and until the permanent magnet reached the centerline window between the two stator poles.

[0152] These starting steps may be repeated until the moving components attain a sufficient speed that the electric motor described herein rotates fast enough for other operating modes described herein to take over control. As the permanent magnet rotates away from the first stator pole of the electric motor and toward the second stator pole, a second modulated electric pulse is controllably supplied to the ferromagnetic core of the second stator pole as it approaches the second stator pole, generating a repulsive magnetic flux in the ferromagnetic core of the second stator pole to counteract the attractive force between the permanent magnet and the ferromagnetic core of the second stator pole.

[0153] In a broad aspect, a method of controlling an electric motor having a stator with at least one independent pole or pole circuit generally equally spaced along the stator, the independent poles or pole circuits alternating around the circumference of the stator, is described herein. The method includes initiating rotation of the electric motor by applying an external torque to the rotor and / or shaft. An MPCS that detects rotation continues to send power to a given set of stator poles, thereby continuing to power the same coil long enough to move past the FMD zone and until the permanent magnet reaches the centerline window between two stator poles while the magnet is naturally attracted by the next adjacent ferromagnetic pole.

[0154] In at least one embodiment, when the permanent magnet is approaching the second stator pole as it rotates away from the first stator pole toward the second stator pole of the electric motor, the method includes controllably supplying a second modulated electric pulse to the ferromagnetic core of the second stator pole to generate a repulsive magnetic flux in the ferromagnetic core of the second stator pole to counteract the attractive force between the permanent magnet and the ferromagnetic core of the second stator pole while the magnet is naturally attracted by the next adjacent ferromagnetic pole.

[0155] In at least one embodiment, as the permanent magnet rotates away from the second stator pole and is approaching a third stator pole, the method includes controllably supplying a third modulated electrical pulse to a ferromagnetic core of the third stator pole to generate a repulsive magnetic flux in the ferromagnetic core of the third stator pole to counteract and / or repel an attractive force between the permanent magnet and the ferromagnetic core of the third stator pole while the magnet is naturally attracted by the next adjacent ferromagnetic pole.

[0156] In another broad aspect, a method of controlling an electric motor having a stator with at least one independent stator pole or pole circuit generally equally spaced along the stator, the independent poles or pole circuits alternately arranged around the circumference of the stator, is described herein. The method includes initiating rotation of the rotor by controllably supplying a first modulated electric pulse to the electric coil of each stator pole when each permanent magnet of the rotor is aligned with a ferromagnetic core of a respective stator pole of the stator, each stator pole having an electric coil surrounding the ferromagnetic core. When each permanent magnet of the rotor is positioned between its respective stator pole and a respective adjacent stator pole, the method also includes de-energizing each of the coils. When each permanent magnet of the rotor reaches its respective adjacent stator pole, the method includes controllably supplying a second modulated electric pulse to the electric coil of each stator pole to generate a repulsive magnetic flux in the ferromagnetic core to counteract and / or repel an attractive force between the respective permanent magnet and the ferromagnetic core of its respective adjacent stator pole. [Example]

[0157] Table 1 below provides five non-limiting examples of prototype devices fabricated in accordance with at least one of the above-described embodiments. Each of the fabricated prototypes had different characteristics, as shown in Table 1. [Table 1]

[0158] Table 2 shows the various outputs measured during experiments performed with each of the prototypes listed in Table 1. [Table 2]

[0159] Table 3 provides a summary of the properties demonstrated by each of the prototypes listed in Table 1. [Table 3]

[0160] While applicants' teachings described herein are associated with various embodiments for illustrative purposes, it is not intended to limit applicants' teachings to such embodiments, as the embodiments described herein are intended to be exemplary. On the contrary, applicants' teachings as described and illustrated herein encompass various alternatives, modifications, and equivalents without departing from the embodiments described herein, the general scope of which is defined in the appended claims.

Claims

1. 1. An electric motor, comprising: a movable component having at least two permanent magnets coupled thereto, the at least two permanent magnets comprising a first permanent magnet, each permanent magnet having an outer surface with a surface area; a stator spaced from the movable component, the stator having a first set of stator poles, each stator pole of the first set positioned to simultaneously face a respective permanent magnet of the movable component, each stator pole comprising a ferromagnetic core and a coil wound around the ferromagnetic core, the ferromagnetic core being naturally attracted to each respective permanent magnet; 1. A magnetic position control system, comprising: monitoring a position of the first permanent magnet on the movable component relative to the stator; when the first permanent magnet is aligned with a first stator pole, controllably supplying an electric pulse to a coil of the first stator pole to generate a repulsive magnetic flux on a ferromagnetic core of the first stator pole to overcome an attractive force between the ferromagnetic core of the first stator pole and the first permanent magnet, causing the first permanent magnet to move freely away from the first stator pole and towards a subsequent, un-energized stator pole of the stator, wherein the first permanent magnet is attracted to the subsequent, un-energized stator pole positioned in the direction of movement of the movable component; a magnetic position control system configured to: the difference between the surface areas of the outer surfaces of the permanent magnets is less than 10%; the maximum distance between the centerlines of two adjacent stator poles is twice the width of one of the permanent magnets; the outer surface of each permanent magnet of said movable component has the same polarity; a magnetic position control system; An electric motor comprising:

2. 2. The electric motor of claim 1, wherein the difference between the surface areas of the outer faces of each of the permanent magnets is less than 5%.

3. 3. An electric motor according to claim 1, wherein the difference between the surface area of ​​the outer surface of any one of the permanent magnets and the surface area of ​​the outer surface of any one of the stator poles is less than 10%.

4. 4. The electric motor of claim 3, wherein the difference between the surface area of ​​the outer surface of any one of the permanent magnets and the surface area of ​​the outer surface of any one of the stator poles is less than 5%.

5. 5. The electric motor of claim 1, wherein the magnetic position control system monitors and manages the relative position of at least the first permanent magnet based on the magnetic flux of at least the first permanent magnet by supplying modulated electric pulses to at least one stator pole to control the electric motor and provide for the electric motor to operate in various operating modes.

6. An electric motor according to any one of claims 1 to 5, wherein each ferromagnetic core of the stator is radially and / or axially spaced from each permanent magnet of the rotor by a gap.

7. An electric motor according to any one of claims 1 to 6, wherein the electric motor comprises two stator poles and two permanent magnets.

8. An electric motor according to any one of claims 1 to 6, wherein the electric motor comprises two or more permanent magnets.

9. An electric motor according to any preceding claim, wherein the electric motor comprises more than two stator poles.

10. An electric motor as claimed in any preceding claim, wherein one or more electrical pulses are applied for a fraction of the time of a full rotor revolution.

11. 11. An electric motor according to any preceding claim, wherein the electrical pulses have a power input in the range of less than or equal to the force-magnetodynamic (FMD) energy over a fraction of the time of one revolution.

12. 12. The electric motor of claim 1, wherein the magnetic position control system is configured to controllably supply electrical pulses to the coil of each stator pole of the set of stator poles when the respective stator pole is aligned with the respective permanent magnet to simultaneously generate a repulsive magnetic flux on the ferromagnetic core of each stator pole to overcome the attractive force between the ferromagnetic core and each permanent magnet to rotate the rotor.

13. 13. The electric motor of claim 1, wherein the magnetic position control system is configured to stop controllably supplying modulated electrical pulses to the coil of each stator pole of the set of stator poles to generate a repulsive magnetic flux on the ferromagnetic core of each stator pole to overcome an attractive force between the ferromagnetic core of each stator pole and each permanent magnet to rotate the rotor when the first stator pole is positioned between about 3 and about 20 degrees from a rotor pair pole alignment point.

14. 14. The electric motor of claim 1, wherein the magnetic position control system is further configured to controllably supply electric pulses to a coil of the first stator pole when the first permanent magnet is aligned with the first stator pole to generate a repulsive magnetic flux in the ferromagnetic core, thereby generating a repulsive force between the ferromagnetic core and the first permanent magnet.

15. 2. The electric motor of claim 1, wherein the magnetic position control system is further configured to controllably supply electrical pulses to a coil of the first stator pole when the first permanent magnet is aligned with the first stator pole to generate a repulsive magnetic flux on the ferromagnetic core to reduce an attractive force between the ferromagnetic core and the first permanent magnet and slow motion of the movable component.

16. 1. A method of controlling an electric motor, the electric motor having a stator with a first set of stator poles, the first set of stator poles being generally equally spaced along the stator, the stator poles of the first set being alternately positioned around a periphery of the stator, the method comprising: initiating movement of a movable component of the electric motor by controllably supplying a first modulated electric pulse to an electric coil surrounding a ferromagnetic core of a first stator pole of the first set of stator poles when the ferromagnetic core faces and is magnetically attracted to a permanent magnet coupled to the movable component of the electric motor, wherein each stator pole of the first set of stator poles includes a respective ferromagnetic core and a respective coil wound on the ferromagnetic core, each ferromagnetic core being naturally attracted to a respective permanent magnet; controllably supplying a second modulated electric pulse to a ferromagnetic core of the second stator pole when a first permanent magnet is aligned with the second stator pole to generate a repulsive magnetic flux in the ferromagnetic core of the second stator pole, overcoming an attractive force between the first permanent magnet and the ferromagnetic core of the second stator pole, and causing the first permanent magnet to move freely away from the second stator pole and towards a subsequent, un-energized stator pole of the stator, wherein the first permanent magnet is attracted to the subsequent, un-energized stator pole of the stator, and the subsequent, un-energized stator pole is positioned in the direction of movement of the movable component; A method comprising:

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