Hybrid contra-rotating multi size and power engine for all propeller-based vehicles or instruments

Abstract

One of the most important reasons to use hybrid engines specially in cars is to reduce fuel consumption by adding and taking the help of an electric engine able to reduce fuel consumption in these cars by 30 to 50 percent and as a result, there will be less environmental pollution. But in the case of airplanes and other types of vehicles, perhaps due to the lower circulation, this category has not been given much attention and we see the increasing use of fuel engines in them. The idea and effort for this invention is making a hybrid engine with tandem airscrew technology for vehicles with propellers or airscrews. Like hybrid car engines, by adding two-electric motors and reducing the power and fuel consumption of the fuel engine, this engine has tried to achieve an engine with the same or even higher power with a 40-60% reduction in fuel consumption.

Description

Hybrid contra-rotating multi size and power engine for all propeller-based vehicles or instruments

[0001] Contra-rotating, sometimes referred to as coaxial contra-rotating, is a technique in which components of a mechanism rotate in opposite directions around a shared axis, typically aimed at minimizing torque effects. This approach is exemplified in certain aircraft propellers, where a single piston or turboprop engine powers two propellers that rotate in opposing directions. Contra-rotating propellers are also frequently utilized in certain marine propulsion systems, particularly in high-speed boats with planning hulls. In this setup, two propellers are arranged one behind the other, and power is transmitted from the engine via a planetary gear transmission. A similar concept is employed in the design of helicopters with coaxial rotors, which encounter similar torque-related issues.

[0002] B64D, B60K

[0003] CN111817463 - SINGLE-STATOR DOUBLE-ROTOR AXIAL FLUX HYBRID PERMANENT MAGNET CONTRA-ROTATING MOTOR

[0004] The invention provides a single-stator double-rotor axial flux hybrid permanent magnet contra-rotating motor and relates to the technical field of motors. The contra-rotating motor comprises a disc-type stator, a first disc-type rotor and a second disc-type rotor, wherein the first disc type rotor and the second disc type rotor are located on two sides of the disc type stator respectively, a stator winding is wound on the disc type stator, a high-coercivity permanent magnet set is arranged on the inner side of the first disc type rotor, a mixed permanent magnet set is arranged on the inner side of the second disc type rotor, and the mixed permanent magnet set comprises a second high-coercivity permanent magnet and a low-coercivity permanent magnet. The contra-rotating motor is advantaged in that the structure that the high-coercivity permanent magnet rotor is matched with the hybrid permanent magnet rotor is adopted, asymmetric adjustment of air-gap magnetic fields on the two sides of the stator is achieved, direct current vector pulses with controllable amplitude and direction are applied to a stator winding, magnetization intensity of the low-coercivity permanent magnet is changed, and therefore the single-side air-gap magnetic field of the second disc type rotor is adjusted to adapt to asymmetric load operation.

[0005] The differences:

[0006] It is a contra-rotating system with a fully electric motor. However, my invention is a hybrid motor with one fuel engine that can also function as a fully electric motor in emergency or other situations. The mechanism of both engines is contra-rotating, but in this invention, the electric motors are joined directly and mixed with each other. In my invention, one of them (the fuel engine) is linked indirectly and has a tooth clutch that can work independently. These electric motors have a hollow shaft and are specialized. However, in my invention, I can use any motor that is available and not necessary to specialize for these uses. This invention basically consists of two electric motors, but my invention has three motors (two electric and one fuel engine).

[0007] The propellers of this invention work independently, but in my invention, they work dependently. However, it can also work independently for special usages with slight changes. This invention is a compact system consisting of electric motors attached to the main shaft. In my invention, each motor is separate from each other and not directly attached to the main shafts. My invention also has a clutch and generator system, which this invention does not have.

[0008] CN107521647 - HYBRID CONTRA-ROTATING PROPULSION SYSTEM FOR SHIP

[0009] The invention discloses a hybrid contra-rotating propulsion system for a ship. The system comprises a rudder, a rudder horn, a main engine, a propeller shaft, a front propeller, a back propeller and a pod propulsor, the main engine is connected with the propeller shaft in a transmitted mode, the end, away from the main engine, of the propeller shaft is fixedly connected with the front propeller axially in a sleeved mode, the back propeller and the pod propulsor are arranged in the axial direction of the propeller shaft, the center lines of the back propeller and the pod propulsor and the center line of the propeller shaft are in the same axis, the pod propulsor is connected with the back propeller in a driving mode, the pod propulsor is fixed to the rudder horn, and the rudder horn is fixedly connected with the rudder. The system is composed of a front propeller system and a back propeller system which are independent propulsion systems, the propulsion efficiency of the whole propulsion system is improved through a method that rotational energy loss of front propeller wakes is recycled by the back propeller through contra-rotation, and the system has the advantages of simple structure, compact installation, and wide application.

[0010] Differences:

[0011] This invention is not classified as a hybrid motor; instead, it is categorized as a mixed or contra-rotating propeller system. Therefore, there is a significant distinction between this invention and mine.

[0012] US20200017228A1

[0013] United States

[0014] Parallel Hybrid Aircraft

[0015] A parallel hybrid aircraft comprising an electric propulsion system and a combustion propulsion system. The electric propulsion system may include a motor, one or more batteries, and a first propeller. The combustion propulsion system may include a combustion engine and a second propeller. The combustion propulsion system may be decoupled and independently operable from the electric propulsion system. A flight control system may control which of the electric propulsion system and / or the combustion propulsion system provides propulsion and / or thrust for ground movement, takeoff, forward flight at cruising altitude, and / or landing. The flight control system may control the electric propulsion system to provide propulsion and / or thrust to propel the parallel hybrid aircraft on the ground; control both the electric propulsion system and the combustion propulsion system to provide propulsion and / or thrust during takeoff; and / or control the combustion propulsion system to provide propulsion and / or thrust during forward flight at the cruising altitude.

[0016] Differences: there are some significant and obvious differences between these two engines, but the import differences are these:

[0017] In this invention, there are two separate motors in two different places, but in my invention, all three motors are in one place as a complete system.

[0018] This invention basically has two engines: one electric and one fuel engine, but my invention comprises three motors (two electric and one fuel engine).

[0019] This invention was designed for a special aircraft, whereas my invention consists of a large group of vehicles and facilities.

[0020] This invention's propellers work independently, but in my invention, they work dependently. However, it can also work independently for special usages with slight changes.

[0021] This invention is a two-separate system consisting of electric and fuel motors, two far away. In my system, propellers are configured in a contra-rotating system.

[0022] My invention is contra- rotating propeller technology, that needs two motor works in the same power, RPM and works as a master and slave but in this invention, it is not needed.

[0023] The engines in this invention work as a puller and pusher engine but in my invention all motors work as a puller or pusher engine.

[0024] In this invention motors and propellers do not have the same thrust line but in my invention, they are in the same thrust line.

[0025] As the theoretical and experimental fact my invention with contra-rotating system has better efficiently and it is related to contra-rotating system.

[0026] US20180022461A1

[0027] United States

[0028] Hybrid airship

[0029] A hybrid airship (drone, UAV) capable of significantly extended flight times can use one of two technologies, or both together. The first technology uses a combination of a lifting gas (such as hydrogen or helium) in a central volume or balloon and multirotor technology for lift and maneuvering. The second technology equips the airship with an on-board generator to charge the batteries during flight for extended flight operations, with an internal combustion engine (such as a high power to weight ratio gas turbine engine) driving the generator. A quadcopter or other multirotor configuration is desirable.

[0030] This invention is completely different from my invention and the only thing that is the same is the hybrid word.

[0031] WO2023084297 - HYBRID ENGINE CONSTRUCTION IN THE FORM OF CONSECUTIVE (CONTRA-ROTATING) PROPELLERS FOR USE IN PROPELLER LIGHT AIRCRAFT

[0032] As a hybrid system with a combination of fuel and electric motors, this system could be an alternative to traditional fuel engines. The system works by connecting the fuel motor to the front propeller via a series of shafts and bearings that pass through the electric motor. It revolves in the same direction as the engine (possibly counterclockwise).

[0033] The differences are as follow:

[0034] The electric motor in the previous system was custom designed with a hollow shaft. In the invention of this system, it has replaced the standard motors available in the market in various types.

[0035] The independent operation system of propellers has been replaced by the dependent and more conventional system. This change aims to maintain optimal operation and take advantage of the benefits of this type of propeller in all conditions.

[0036] In the previous system, if the fuel engine was turned off, an electric motor could only rotate one propeller and generate power with less than half the power of the propulsion system. With the addition of a backup electric motor in the new system, in case of a failure causing the fuel engine to stop, two electric motors can still provide access to the full power of the engine.

[0037] In the previous system, the fuel engine rotated the front propeller, and the electric motor rotated the rear propeller. This arrangement is reversed in the new system.

[0038] In the previous system, a CVT transmission system served as the interface between the generator and the fuel engine, always engaged. It generated electricity based on the change in the rotation speed ratio of the generator by the CVT transmission, dependent on the pressure applied to the fuel engine.

[0039] In the new system, an electromagnetic clutch has been added. The generator is larger and stronger, and its location has changed. This system releases the clutch of the generator when the fuel engine is operating with high power. It engages only when the engine is in a fuel-wasting state at low speed, preventing the fuel engine from wasting energy. This mechanism is simpler and more efficient than the previous system, adhering to the law of conservation of energy.

[0040] In simpler words: In the previous system, the CVT gearbox was always involved, creating different ratios for the generator according to needs. It naturally used some of the power of the fuel engine to produce electricity. In the new electromagnetic clutch system, it engages the large generator only when the fuel engine is idle or at low revs, generating electricity only from the wasted power and free movement of the fuel engine.

[0041] Due to the new design, the connection method, and the engine's location, this type of engine can be easily optimized for a wide range of aircraft, marine applications, etc., with different powers, needs, and dimensions. This feature was limited to the previous engine. The system is designed to have better damping than the previous design due to the use of belts, resulting in fewer vibrations.

[0042] The dependence of this engine on the fuel engine has been significantly reduced compared to the previous engine. It can travel a considerable distance even without using the fuel engine and with full power, which was not possible with the previous engine, only operating at half power under special conditions.

[0043] Due to the ability to use various gear ratios and components, this system can create different fuel and electric engines from different brands. This allows the consumer to change, strengthen, and apply personal preferences.

[0044] Considering the mentioned aspects, this engine has transformed from a two-engine design in the previous invention to a three-engine design. It is more environmentally friendly due to the presence of two electric engines and more reliable, as the system can still function in the event of failure of one or two engines.

[0045] Due to the synchronization of two propellers and the addition of an electric backup motor, the power and weight of the motor have increased compared to the previous model. However, in comparison, the weight-to-power ratio has more advantages.

[0046] This invention is a hybrid engine that combines both fuel and electric components, suitable for a variety of vehicles equipped with propellers or airscrews, spanning air, land, and sea. The adaptability of this engine across different power levels and applications suggests versatility in its design. Additionally, the incorporation of contra-rotating propeller technology, a proven concept used in various vehicles, indicates an effort to optimize propulsion force. If you have more details or specific aspects, you'd like to discuss about this hybrid engine, feel free to provide additional information, that combines both fuel and electric components, suitable for a variety of vehicles equipped with propellers or airscrews, spanning air, land, and sea. The adaptability of this engine across different power levels and applications suggests versatility in its design

[0047] In the previous systems, the electric motor was custom designed with a hollow shaft, which in the invention of this system replaced the usual motors that exist in the market in different types.

[0048] We are also seeking one hybrid engine that can be more suitable for placing a wide range of electric and fuel engines without significant design changes.

[0049] If we can make an engine for lots of vehicles and instruments, we can have a perfect engine and make more profit from that.

[0050] We also thinking about a system that two engines can works dependently and independently toSolution of problem

[0051] The fuel engine in new design transferred in behind of engine and attached indirectly with timing belt and pulley. Besides the main electric motor transfer to the end of inner shaft to get rid of making a hollow shaft electric engine.

[0052] In this design the behind motor is separated from the total system. Besides, the electric motor at the end of the inner shaft can easily be replaced with another motor. As a result, both motors can easily change and replace with other kinds of motors without significant changing the system.

[0053] Due to the separation system for all motors for the chassis and total system design. This engine will permit the customer to change the motor and chassis easily based on their own need. For example, this design is also usable for air-conditioning systems that need fans and are applicable to produce in any sizes and powers.

[0054] The system is designed with convectional bevel gears that can synchronize two engines. On the other hand, it also can work separately with a simple clutch that attached to upper free bevel gear.Advantage effects of invention

[0055] With the addition of the backup fuel engine in the new system, in case of failure of the fuel engine, we have access to all the power of the engine with two fuel engines.

[0056] The independent operation system of propellers has been replaced by the dependent and usual system and more usual propellers to maintain the optimal operation and advantage of this type of propellers in all conditions.

[0057] In the previous system, the fuel engine rotates the front propeller, and the electric motor rotates the rear propeller, which is the opposite in the new system.

[0058] In the previous system, a CVT transmission system was the interface between the generator and the fuel engine, while in the new system, an electromagnetic clutch was added, the generator became bigger and stronger, and its location was also changed.

[0059] In the previous system, the CVT gearbox was always involved, according to the need, it created different ratios for the generator, which naturally always consumed some of the power of the fuel engine. While in the new electromagnetic clutch system, it engages the large generator only when the fuel engine is idle (IDLE) or at low revs, so that it can generate electricity from the wasted power and free movement of the fuel engine.

[0060] Due to the new design of the chassis, the way of connecting and the location of the engines, this type of engine can be easily optimized for a wide range of aircraft, marine, etc. with different powers, needs and dimensions, while in the previous engine this feature was limited.

[0061] The system is designed to have better damping than the previous design due to the use of belts and less vibrations.

[0062] The dependence of this engine on the fuel engine has been significantly reduced compared to the previous engine, so that it can travel a considerable distance even without using the fuel engine and with full power, which was not the case with the previous engine and only for special conditions were at half power.

[0063] Due to the ability to use a variety of pulley ratios, gears, etc., this system also could create different fuel and electric engines from different brands, which allows the consumer to change, strengthen and apply personal taste that this item brings.

[0064] According to the mentioned cases, this engine has been changed from a double engine in the previous invention to the triple engine which is more compatible with the environment due to the presence of two electric engines and more reliable due to the possibility of the system failing in case of failure of one or two numbers of engines in this product.

[0065] Due to the synchronization of two propellers and the addition of an electric back-up motor, the power of the motor as well as its weight have increased compared to the previous motor.

[0066] : In this figure we have element as below

[0067] 1.Front (electric motor) propeller.

[0068] 2.Rear (fuel engine) propeller

[0069] 3.Front propeller to inner shaft connector

[0070] 4.Inner shaft

[0071] 5.Inner and outer shaft bearing connector.

[0072] 6.Outer shaft

[0073] 7.Free (idle) pulley

[0074] 8.Inner and outer shaft bearing connector.

[0075] 9.Outer shaft pillow bearing

[0076] 10.Larger timing belt pulley for outer shaft

[0077] 11.Smaller timing belt pulley for fuel engine.

[0078] 12.Timing belt

[0079] 13.Alternator timing belt pulley

[0080] 14.Bearing for outer shaft and large timing belt pulley.

[0081] 15.Electromagnetic clutch for alternator.

[0082] 16.The male part of tooth clutch system for outer shaft and backup electric motor

[0083] 17.Alternator

[0084] 18.Bearing of tooth clutch system

[0085] 19.Main gear of backup electric motor

[0086] 20.First and second gears of backup electric motor

[0087] 21.Backup electric motor

[0088] 22.Pillow bearing for outer shaft.

[0089] 23.Straight bevel gears for synchronous inner and outer shafts

[0090] 24.Free (idle) pulley holder

[0091] 25.Main electric motor coupling to inner shaft

[0092] 26.Main electric motor

[0093] 27.Esc and controller board for main and backup electric motor (2x)

[0094] 28.Internal combustion engine (fuel engine)

[0095] 29.Main chassis.

[0096] 30.Aluminum case for battery pack

[0097] 31.Li-ion battery pack.

[0098] : In the there are parts as below:

[0099] 1.First gear of backup electric motor

[0100] 2.Relative gear of backup electric motor

[0101] 3.Backup electric motor

[0102] 4.Main gear of backup electric motor

[0103] 5.Outer shaft

[0104] 6.Straight bevel gears for synchronous inner and outer shafts

[0105] 7.Main electric motor coupling to inner shaft

[0106] 8.Main electric motor

[0107] 9.Tooth clutch actuator

[0108] 10.The male part of tooth clutch system for outer shaft and backup electric motor

[0109] 11.Alternator

[0110] 12.Internal combustion engine (fuel engine)

[0111] 13.Timing belt

[0112] 14.Smaller timing belt pulley for fuel engine.

[0113] 15.Electromagnetic clutch for alternator

[0114] 16.Alternator timing belt pulley

[0115] 17.Free (idle) pulley

[0116] 18.Free (idle) pulley holder

[0117] 19.Larger timing belt pulley for outer shaft

[0118] 20.Front propeller to inner shaft connector

[0119] 21.Rear propeller and inner shaft bearing connector.

[0120] 22.Inner shaft

[0121] 23.rear propeller to outer shaft connector

[0122] 24.Outer shaft

[0123] 25.Inner and outer shaft bearing connector.

[0124] All the bearings have the standard sizes and materials that are related to the SKF company and have the special serial number that is in order on the SKF website.

[0125] All the fuel motor and electric motor are applicable due to this design. For example, the below figures related to a light Aircraft engine that the fuel engine is Rotax 912 IS, and the electric engines are MGM 70KW from MGM company with actual size and dimension. Besides the chassis design gave the best places to put lots of different motors with different powers and torques, because in this system the fuel engine is not directly connected to the shafts.

[0126] All the material and designs in this patent have consideration about having simplicity as much as possible, use commercial parts that already exist.

[0127] The applicant has more than ten years’ experience as an expert person who has worked with lots of industrial machines such as CNC, laser cut, 3D printer, etc. Also, knows about tolerances and limitations of each machine.

[0128] All the belts and pulleys are existed and produced before(commercialized), and the other material such as the shafts, chassis, clutch, etc. are applicable easily with industrial machines or even can replaced or fitted with another commercialized product.

Claims

This device is a hybrid electric engine with contra-rotating propellers, which is suitable for any engine with propellers like airplanes, helicopters, floating objects, boats or even fans and turbines in different sizes.According to claim No.1, the system is designed in a size that can be placed in regular old engine spaces without requiring any specific modifications.According to claim No.2, the chassis and the whole system is designed in a way that is compatible with any kind of existing electric / petrol engines, with no need to redesigning or customizing the device.According to claim No.3, the system is designed in a way that can be used generally in various devices in different sizes and types of engines, including aerial, marine and terrestrial.According to claim No.4, the engine is designed in a way that two electric engines (one of them as the main one), spin directly the front propeller and a petrol engine at the bottom, spins the back propeller, using the timing belt system.According to claim No.5, in case the petrol engine breaks down or it is not economically wise to use.According to claim No.6, both front and back propellers are synchronized in a way that simulate the contra-rotating engine system, meaning the rotation of one of them with a specific speed, makes the other one spin as well in the opposite direction.According to claim No.7, for the system to work properly, both petrol and electric engins need to spin with similar speed which in this case, the petrol engine operates as the main one and the electric engine as the function and spins as many times as petrol engine does.According to claim No.8, the simultaneous operation of both engines makes their power add up and the engine rated power is the result of both petrol and electric engines power.According to claim No.9, both electric and petrol engines must have simillar rated power and torque so that they have the best operation for the whole system when working together.According to claim No.10, the connection of the outer shaft and the petrol engine by the timing belt makes it possible to change the pulley, the compression ratio, and the torque difference, to equalize and synchronize the petrol and electric engine.According to claim No.11, the user that uses the engine can only control the speed and the power of the petrol engine and the electric engine is its function.According to claim No.12, in case of intentional or accidental break down of the petrol engine, and when the clutch automatically replaces the backup electric engine by the installed gear, the backup engine will be recognized as the main engine and the other electric engine will follow it.According to claim No.13, this system benefits from all the advantages of consecutive propeller engines so it can have better performance than similar engines.According to claim No.14, given that one of the petrol engines operates with only half of the system's capacity, the use of petrol can be reduced to 40-60 percent.According to claim No.15, one aim of this device is to decrease pollution, and using a weaker petrol engine in this case, serves perfectly this aim and has a significant effect on reducing the pollution.According to claim No.16, as a propulsion propeller engine, using three engines instead of one, reduces significantly the probable sudden engine failures. This is particularly a great advantage for the airplanes.According to claim No.17, operating two engines with similar powers in opposite directions reduces the reaction force caused by engine torque to zero.According to claim No.18, in case of working as propulsion force in relevant machines, this system changes the function of that machine, from a single engine to triple engine.According to claim No.19, it has been attempted to use the existing equipment and tools in the market to design and construct the whole pieces of the system, so to decrease as much possible, the inquiry to design new pieces and prevent unpredicted problems regarding construction, repair and preserving the device.According to claim No. 20, this engine can also function as an independent system if we incorporate a simple clutch with the free bevel gear that synchronizes the two engines. This option is beneficial in various applications; such as fan systems.

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