An electrodynamically synchronized DC to ac inverter / converter system

Abstract

The present invention relates to an electrodynamically synchronized DC-to-AC inverter / converter system (100) that generates a near-sinusoidal output with minimal reliance on high-frequency power electronic switching. A motor-driven cyclic connector (114) sequentially connects multiple voltage stages from a battery or capacitor bank (104), forming a stepped waveform that is smoothed by a reactor (140). In standalone mode, a DC shunt motor (112DM) provides the necessary rotation; for grid-tied operations, a synchronous motor (112SM) automatically locks the output to the grid frequency. The high- current flow bypasses the motor windings, reducing switching losses, electromagnetic interference, and complex gating circuits. Protective devices (116) isolate fault conditions, while optional transformers (130) enable voltage stepping or galvanic isolation. By avoiding high-frequency gating, the invention offers robust, efficient performance for renewable energy systems and other power electronics applications. Simplicity and scalability make it ideal for industrial applications.

Description

[0001] FORM 2

[0002] PATENTS ACT, 1970 (39 of 1970) &

[0003] The Patents Rules, 2003 COMPLETE SPECIFICATION (See section 10 and rule 13)

[0004] 1. TITLE OF THE INVENTION

[0005] “AN ELECTRODYNAMICALLY SYNCHRONIZED DC TO AC INVERTER / CONVERTER SYSTEM”

[0006] 2. APPLICANT(S) a) Name : VEERABHADRA ELITE ELECTRODYNAMIC

[0007] SOLUTIONS LLP b) Nationality : INDIAN c) Address : Plot No 149, Door No 202, Venkat Classic

[0008] Apartments, Road No 4, KTR colony, Nizampet, Medchal-Malkajgiri, Telangana- 500090.

[0009] 3. PREAMBLE TO THE DESCRIPTION

[0010] COMPLETE

[0011] The following specification particularly describes the invention and the manner in which it is to be performed. 4. DESCRIPTION

[0012] Technical Field of the Invention

[0013] The present invention generally relates to the field of power electronics. More particularly, relates to DC to AC Inverter / Converter system designed to offer enhanced efficiency, reduced harmonics, and cost -effectiveness for various power system applications.

[0014] Background of the Invention

[0015] The evolution of power electronics has led to a variety of methods for converting direct current (DC) to alternating current (AC). Among these, multi-level inverter topologies have become popular thanks to their ability to produce stepped waveforms with lower total harmonic distortion (THD) compared to single -level converters. However, as illustrated by the prior art in Figures 1 and 2, these multi-level inverters usually depend on numerous semiconductor switches, each operating at relatively high switching frequencies. This arrangement significantly increases switching losses and electromagnetic interference (EMI), while demanding complex driver circuits, snubber components, and advanced digital controls.

[0016] In Figure 1 (prior art), a single -phase multi-level inverter relies on carefully timed gating signals applied to multiple power devices, such as IGBTs or MOSFETs. The DC source is segmented into several voltage levels, and each level is connected in rapid on-off sequences to approximate a sine wave. Although such an approach can reduce harmonic distortion compared to a basic two-level design, it dramatically expands component counts and requires an intricate gating strategy. Power electronics engineers must manage gate drivers for each transistor, incorporate robust cooling systems, and include EMI filters to mitigate noise caused by the high-frequency switching transients.

[0017] Turning to Figure 2 (prior art), a three-phase version of a multi-level inverter demonstrates even greater complexity. Here, each phase leg replicates a similar network of switches and clamping diodes or capacitors. As the number of levels increases — thereby improving the waveform’s fidelity — the quantity of active components rises exponentially. The overall control scheme also becomes more demanding. Precise synchronization among all phases must be upheld to maintain balanced line voltages and mitigate circulating currents. This typically necessitates sophisticated real-time control algorithms deployed on digital signal processors (DSPs) or microcontrollers. The system’s firmware must generate pulse -width modulation patterns at high speed, while detecting and responding to transient events in a matter of microseconds or less.

[0018] Despite these refinements, traditional multi-level inverters face a series of persistent drawbacks. The extensive use of high-frequency switching devices translates into appreciable conduction and switching losses, often necessitating large heatsinks or forced- air cooling. Electromagnetic interference grows with the switching frequency, forcing designers to add shielding or filtering components that further raise costs and complicate installation. Meanwhile, the reliability and maintainability of systems with many power semiconductors can become problematic, as each active component poses a potential failure point and can create a cascading effect if it malfunctions.

[0019] Outside the realm of multi-level semiconductor-based inverters, motor-generator sets represent an older category of DC to AC conversion. They use a mechanical linkage to convert DC to rotary motion and then from rotary motion to AC output. While these systems can offer robust isolation and do not produce high-frequency EMI, they often rely on large rotating masses sized for the full load current. Wear and tear on brushes and commutators are commonplace, and synchronization with an external grid typically requires extra control hardware or manual operator skill. Consequently, motor-generator sets see limited adoption in most modern, high-performance contexts.

[0020] The prior art thus reveals two polarized solutions: complex multi-level inverters that are efficient in principle but require numerous high-frequency switches and advanced controls, or mechanical sets that avoid semiconductor switching but at the cost of higher mass, reduced efficiency, and cumbersome operation. In many industrial and renewable energy scenarios, neither of these extremes offers a comprehensive solution. Large-scale installations especially feel the impact of high component counts, where each switch demands its own protective circuitry and gating driver, thereby escalating the total cost and complexity. Meanwhile, motor-generator sets appear too bulky and inefficient for widespread modern use. Designers are left to choose between intricately controlled, high- switch-count inverters or heavy, slow-to-respond mechanical generators with suboptimal efficiency. These observations highlight a gap in the art for an approach that combines the multi-level principle’s harmonic benefits with simpler, lower-loss commutation. Figures 1 and 2 exemplify how multi-level topologies inherently provide improved waveform quality over single -level inverters, yet they also intensify issues related to power device count and control requirements. Given this backdrop, the inventors recognized a vital need for a system that yields comparable or superior waveform fidelity while drastically curtailing the complexity and drawbacks of high-frequency switching electronics.

[0021] Specifically, a major problem arises when one attempts to synchronize a multi-level inverter to a grid, as typically required in renewable energy projects. Conventional inverters rely on precise digital monitoring of grid phase angle, generating gating signals that remain in close alignment with the utility supply. Any disturbances or measurement errors can lead to instability or delayed responses, especially in large power systems. This underscores why simpler automatic synchronization — one that does not demand tight high-frequency control loops — would be enormously valuable. Moreover, the ability to produce multi-level output without recourse to switching many transistors in microsecond intervals could greatly cut down on conduction losses, reduce or eliminate high-frequency EMI, and reduce hardware overhead.

[0022] In addition, remote or standalone sites often have to contend with the reliability challenges of high-frequency electronics in harsh conditions. Dust, humidity, temperature swings, and limited cooling options can all degrade the performance of semiconductor -intensive solutions. Traditional motor-generator sets might be mechanically reliable in such settings, but they demand extensive maintenance and are rarely designed to deliver stepped waveforms that produce low THD. As the power demands of off-grid or microgrid systems climb, developers seek a solution that merges the mechanical robustness of a generator with the stepped AC outputs typical of a multi-level inverter — yet without the cost and inefficiency of carrying full load currents through the motor’s windings.

[0023] Hence, the inventors identified an opportunity for a new design that harnesses the basic notion of dividing the DC supply into multiple stages but uses a motor-driven, electromechanical connector to step through these stages in sequence. The timing of the “switching” is governed by the rotational speed of the motor shaft rather than by high- frequency pulses. By choosing a synchronous motor when grid connection is desired, the system inherently matches the grid frequency, avoiding the complexities of phase -locked loops. Meanwhile, the load current does not pass through the motor windings; it flows instead through a network of brushes, slip rings, and diodes, so the motor sees minimal torque. This approach not only cuts down on switching losses — there is no large bank of transistors switching at tens of kilohertz — but also substantially reduces EMI.

[0024] Brief Summary of the Invention

[0025] One principal object of the present invention is to provide a DC to AC inverter or converter system that reduces the complexity and limitations of existing multi-level inverters by minimizing the use of high-frequency semiconductor switches. Traditional multi-level inverters often employ numerous power electronic devices, leading to substantial switching losses, increased electromagnetic interference, and high costs. The present invention specifically addresses these challenges by leveraging an electromechanically driven approach for generating multi-level stepped AC waveforms, thereby eliminating much of the switching circuitry required in conventional systems.

[0026] A second object of the invention is to facilitate automatic synchronization with an external AC grid without resorting to sophisticated digital phase-locked loops or similar control strategies. Conventional grid-tied inverters rely on high-speed sensing of the grid’s voltage and frequency, followed by precise gating signals to semiconductor switches. By contrast, the invention herein described relies on a synchronous motor whose rotation is inherently locked to the grid frequency. This approach naturally synchronizes the output without the need for elaborate modulation or real-time computational algorithms.

[0027] A third object is to provide a scalable system that can operate effectively in both standalone (off-grid) and grid-tied modes. In some situations, a user may wish to deploy the inverter solely for isolated loads, for example in remote settings where no utility connection is available. In other cases, the ability to export surplus power into a utility grid is paramount. The invention contemplates both situations by offering a DC shunt motor for standalone applications and a synchronous motor for grid-synchronized deployment, each driven by the same underlying concept of a cyclic-connector mechanism.

[0028] A fourth object is to increase reliability and lower maintenance overhead through a design that subjects the driving motor to minimal mechanical load. In the proposed system, the main current that powers the AC load or the grid does not pass through the motor windings themselves. Instead, it flows through a carefully arranged network of brushes, slip rings, and diodes, thus allowing the motor to draw only the small torque needed to overcome brush friction and windage losses. By decoupling large load currents from the motor circuit, the system avoids the common thermal stresses seen in motor-generator sets.

[0029] A fifth object of the present invention is to reduce overall harmonic distortion in the AC output by creating a relatively high number of discrete voltage levels without necessitating large numbers of semiconductor switches. Each additional battery or capacitor tap in the DC source can be seen as an incremental voltage step, thereby enabling the formation of a more finely stepped waveform. A reactor (inductor) is then used to smooth these discrete steps, resulting in a near-sinusoidal output with lower total harmonic distortion than prior multi-level designs that rely on fewer steps or high-frequency pulse-width modulation.

[0030] Having set forth these objectives, the invention in its broader aspects can be summarized as follows. The system comprises a battery bank or capacitor bank capable of providing multiple DC voltage levels, arranged so that each level can be tapped independently through diodes that prevent reverse current flow. A motor — either a DC shunt motor or a synchronous motor — drives a shaft connected to a cyclic -connector assembly. This cyclic- connector includes a circular special segmented connector or stationary special commutator-like structure subdivided into multiple conductive segments, each segment corresponding to a voltage tap from the battery or capacitor bank. The rotating brush assembly physically and sequentially connects these stationary segments to form a stepped AC waveform, which is subsequently filtered through an inductor or reactor to produce a smoother sinusoidal output. Protective devices such as breakers or fuses are installed to safeguard against faults, and optional transformers are employed either to provide galvanic isolation or to step up the voltage for utility grid interfacing.

[0031] A primary aspect of the present invention, involves the motor being a synchronous motor powered by a three-phase grid when the system is to be grid-connected. In such a scenario, the synchronous motor’s stator is energized by the utility supply, thus creating a rotating magnetic field. Its rotor, which receives DC excitation from the same battery or capacitor bank that forms part of the inverter, establishes a magnetic field that locks to the stator’s field. Because the rotor must rotate at synchronous speed (for instance, 3000 rpm at 50 Hz or 3600 rpm at 60 Hz in many designs), the cyclic -connector likewise rotates in perfect synchronism with the grid frequency. This ensures the stepped AC output is inherently matched to the grid’s frequency and phase, greatly simplifying the task of synchronizing power flows and maintaining stable operation. Traditional inverters would attempt to measure line frequency electronically and then produce gating signals at precisely the right moments to remain in phase, but here the mechanical coupling handles that entire function. As a result, the only major control signals revolve around monitoring rotor position, activating or deactivating the breaker if abnormal conditions occur, and ensuring the DC supply is at the correct voltage levels.

[0032] Another aspect reflects the use of a DC shunt motor, rather than a synchronous motor, in a standalone arrangement. In such an embodiment, the rotor speed is regulated by a speed controller that senses the output frequency or motor speed. By incrementally adjusting motor voltage or field current, the invention can set the frequency of the AC output to a fixed target (for example, 50 Hz for many countries, or 60 Hz for others). In remote locations where no external grid reference is available, this approach assures that loads will see a stable AC source. Moreover, the DC shunt motor experiences minimal loading from the stepped output current, as all major currents flow through the rotating brushes and battery or capacitor taps, leaving the motor free merely to spin with a minimal torque.

[0033] An additional aspect is the introduction of diodes between each battery or capacitor sub- bank tap and the circular connector. These diodes serve to isolate each voltage stage from the others, preventing short-circuits when brushes connect multiple segments simultaneously. They also keep blocking the current from flowing backward into lower- voltage or discharged stages, a scenario that could otherwise degrade or damage the energy storage media. Because no high-frequency switching is involved, the thermal and EMI constraints on these diodes are far less stringent than on conventional inverter power devices, which face rapid dV / dt and high current transients.

[0034] Beyond these characterizing features, the system is typically completed by a reactor inductor placed at or near the AC output. This reactor may be sized based on the number of discrete steps in the waveform and the maximum load current. A higher number of battery or capacitor segments yields a closer approximation to a sinusoidal waveform before filtration, thereby reducing the size or rating of the inductor needed. Should further harmonic mitigation be necessary, additional filters or reactive components can be added, but the base design contemplates a single reactor as sufficient to achieve satisfactory waveform quality. In grid-connected cases, a step-up transformer is added after the reactor to elevate the voltage to the utility’s line level. This arrangement allows straightforward integration with distribution or transmission lines, while also offering a means of galvanic isolation to satisfy safety and regulatory standards.

[0035] The advantages of the proposed system are considerable. First, it eliminates the intense switching losses associated with high-frequency power electronic converters, since the primary stepping action is achieved through mechanical rotation rather than semiconductor gating. Second, the risk of electromagnetic interference is substantially diminished, as the switching transitions occur at low frequency — namely, the rotor’s rotational speed correlated with line frequency — and not at tens of kilohertz. Third, the invention notably simplifies the control scheme, especially for grid synchronization. By harnessing the rotor speed of a synchronous motor for alignment, the design avoids complex digital controllers, gating algorithms, or real-time sensors that might otherwise be prone to error or require sophisticated software.

[0036] A further advantage lies in its scalability for different power levels. When used as a standalone generator, it can be sized for small, remote loads or islanded microgrids by selecting a DC shunt motor with a modest rating, along with a battery or capacitor bank sized to store or supply the required energy. In large-scale setups, it can be integrated with extensive photovoltaic fields or energy storage arrays, using a synchronous motor that drives the cyclic -connector assembly at high power. The mechanical design of the brushes and semi-segmented slip rings can be adapted accordingly — replacing carbon brushes with copper-graphite composite if heavier currents are expected, implementing forced cooling if continuous high-power operation is needed, or adding redundancy in brush sets to ensure reliability.

[0037] The invention’s applications extend across several domains. In renewable energy systems, it can provide an alternative to conventional multi-level inverters for feeding solar or windgenerated DC power into a grid, doing so in a manner that reduces the failure risks tied to high-speed switching components. In standalone battery systems, the DC shunt motor variant acts as a stable AC source for remote communities, telecommunication facilities, or emergency backup solutions, reducing reliance on complex electronics. Microgrids can benefit from the inherent robust synchronization method, particularly in locations where stable synchronization and low EMI are a premium. Additionally, the system can be adapted for industries requiring variable frequency outputs if a controllable DC shunt motor or a specialized wound-rotor motor is used to vary the rotational speed more freely. Even as a teaching tool or demonstration system, the invention offers clear visual and conceptual insight into how mechanical rotation can be harnessed to produce stepped AC waveforms without the usual complexities of solid-state switching.

[0038] In some embodiments, advanced monitoring electronics or a microcontroller -based system (112C) might still be included to supervise overall behaviour, check battery state of charge, detect motor shaft speed, and manage protective devices. However, unlike traditional multilevel power electronics inverters, which rely on microseconds or nanoseconds gating signals, the present system focuses on low-frequency mechanical synchronization. This difference not only lowers cost but also can increase the durability of the hardware under harsh environmental conditions, especially in regions with high temperature, dust, or humidity, where power semiconductors and their accompanying gate drivers might face reliability challenges.

[0039] Because the synchronous or DC shunt motor sees primarily mechanical load from the friction of semi-segmented slip rings and windage losses, the overall electrical demand on the motor is relatively low compared to the main output power rating. This design choice allows the system to be dimensioned such that the motor’s size is much smaller than would be the case in typical motor-generator sets, where the motor must carry the full electrical load. Consequently, the invention offers a cost advantage in certain high -power scenarios. Maintenance routines revolve mainly around ensuring good brush contact, checking for wear on the slip rings, and occasionally inspecting the bearings or motor couplings. The simplified nature of the rotating brush assembly, coupled with robust materials, can render the system suitable for prolonged operation without frequent part replacement.

[0040] Additional derivatives of the present invention could incorporate alternative energy storage media, like supercapacitors in combination with batteries, to handle transient loads or to facilitate ride-through during short power outages. If isolation from the grid is a priority, an isolation transformer can be placed before or after the reactor, depending on the arrangement that best suits local regulations and the practical constraints of design. Furthermore, the system could be integrated with external power management systems that coordinate battery charging from solar sources, schedule dispatch of power to the grid, or limit output during certain times. Although the fundamental electromechanical principle remains the same, there is a wide latitude to customize the arrangement for different commercial, industrial, and utility-scale applications.

[0041] Brief Summary of the Drawings

[0042] The invention will be further understood from the following detailed description of a preferred embodiment taken in conjunction with an appended drawing, in which:

[0043] Figure 1 shows a prior art single -phase multi-level inverter system, illustrating how multiple power semiconductor switches (e.g., IGBTs or MOSFETs) are used to generate a stepped AC output waveform.

[0044] Figure 2 depicts a prior art three-phase multi-level inverter system, where each phase requires its own set of high-frequency switching devices.

[0045] Figure 3a is a block diagram of an electrodynamically synchronized DC to AC inverter / converter system (100) configured for standalone applications.

[0046] Figure 3b is similar in concept but for grid-connected high-power scenarios. Instead of a DC shunt motor, a synchronous motor (112SM) is driven by the grid supply. By locking the motor’s rotor to the grid frequency, the cyclic connector (114) produces a stepped AC waveform automatically synchronized with the grid.

[0047] Figure 4 provides a more detailed depiction of the standalone inverter system shown in Figure 3a. Multiple battery units (106) are connected through diodes to a circular special segmented connector (190).

[0048] Figure 5 presents the detailed grid-connected embodiment from Figure 3b. It highlights how a synchronous motor (112SM) draws power from the grid, thereby establishing a rotor speed that aligns exactly with grid frequency.

[0049] Figures 6a and 6b illustrate the electrical connections of the battery bank (104) and capacitor bank (104), respectively, to the cyclic connector (114). Figure 7 presents a representative three-phase stepped output (180), showing multiple discrete voltage levels derived from segmented DC taps.

[0050] Figure 8 displays the smoothed near-sinusoidal AC output (200) after the stepped waveform has been processed by the reactor (140), thus illustrating the high power-quality capability of the proposed electrodynamically synchronized DC to AC inverter / converter system.

[0051] Detailed Description of the Invention

[0052] The present disclosure emphasises that its application is not restricted to specific details of construction and component arrangement, as illustrated in the drawings. It is adaptable to various embodiments and implementations. The phraseology and terminology used should be regarded for descriptive purposes, not as limitations.

[0053] The terms "including," "comprising," or "having" and variations thereof are meant to encompass listed items and their equivalents, as well as additional items. The terms "a" and "an" do not denote quantity limitations but signify the presence of at least one of the referenced items. Terms like "first," "second," and "third" are used to distinguish elements without implying order, quantity, or importance.

[0054] The present invention relates to a DC to AC inverter / converter system (100) designed to minimize switching losses and electromagnetic interference by employing a Synchronous Cyclic -Connector Controller (110). This controller relies on rotating brushes, slip rings, and segmented DC voltage stages to generate a stepped AC output (180), which is then smoothed into a near-sinusoidal waveform (200). The system is particularly suitable for applications involving solar photovoltaic sources (or any DC source 102) and may be configured either as a standalone system powered by a DC shunt motor (112DM) or as a grid-connected system using a synchronous motor (112SM).

[0055] In an exemplary embodiment, a DC source (102), such as a solar photovoltaic array, is arranged to charge or supply a battery bank or capacitor bank (104). The battery bank (104) is subdivided into multiple voltage stages, each capable of providing a certain fraction of the total direct current voltage. Diodes (DO, DI, D2 ... Dn) may be placed between these stages and the circular special segmented connector (190) to prevent reverse current flow or inadvertent short circuits. The number of stages can be scaled depending on the desired resolution of the stepped AC output and the anticipated system power rating. The bank (104) thus forms the energy storage medium or the primary DC source for producing multilevel voltages.

[0056] In order to convert this multi-level DC power into AC power, the invention employs a Synchronous Cyclic-Connector Controller (110) that includes a motor (112) and a cyclic connector (114). A shaft (118) couples the motor (112) mechanically to the rotating brush assembly. The cyclic connector (114) in turn comprises a circular special segmented connector (190) possessing multiple conductive segments corresponding to each voltage stage of the battery or capacitor bank (104). By aligning each segment to the brushes (R, R', Y, Y', B, B') at precisely timed intervals, the system forms a stepped AC waveform (180). Because the motor (112) rotates continuously, the brushes sweep over the circular connector’s (190) segments in a manner that systematically and repeatedly adds or subtracts the voltage contributed by each DC stage.

[0057] The specific motor (112) employed can be either a DC shunt motor (112DM) or a synchronous motor (112SM). In standalone applications, the DC shunt motor (112DM) is powered from the battery bank or capacitor bank (104) itself. The motor speed sets the fundamental frequency of the inverter output, enabling off-grid operation where no external AC supply is available. In grid-connected configurations, the system uses a synchronous motor (112SM) whose stator is energized by an external AC supply (for example, at 50 Hz or 60 Hz). The rotor is fed by the battery bank (104) to create a magnetic field that locks with the rotating stator field at grid frequency. As a result, the shaft (118) and the cyclic connector (114) rotate precisely at the grid’s frequency, thereby inherently synchronizing the stepped AC output (180) with the grid voltage. The precise alignment of the rotor position, circular special segmented connector (190) position and rotating brushes (R, R', Y, Y', B, B') and semi-segmented slip rings (195R, 195Y, 195B) and stationary brushes (Al, A2, Bl, B2, Gl, G2) positions are vital to produce faithful synchronization with grid supply. This arrangement bypasses the need for complex digital phase -locked loops or high-frequency gating signals typically required in semiconductor-based inverter designs.

[0058] A key element of the cyclic connector (114) is the rotating brush assembly, which includes brushes (R, R', Y, Y', B, B') that move along semi-segmented slip rings (195R, 195Y, 195B). These semi-segmented slip rings are half-segmented in some embodiments to optimize conduction intervals and reduce sparking or wear. Stationary brushes (Al, A2, Bl, B2, Gl, G2) are arranged to collect the resulting AC output as the semi-segmented slip rings rotate. The stepped AC output (180), which inherently has multiple discrete voltage levels corresponding to the battery or capacitor stages, is then guided through a reactor (140) to remove higher-frequency components. The reactor (140), often implemented as an inductor bank or choke, filters the stepped waveform into a near-sinusoidal output voltage (200). By increasing the number of stages in the battery or capacitor bank (104), the difference between each step is reduced, thereby lowering total harmonic distortion after the reactor.

[0059] To protect the system from abnormalities, protective devices (116), such as circuit breakers or fuses, are installed. In a grid-connected scenario, these devices may be opened upon detecting excessive current, short circuits, or large deviations in grid frequency. The controller (112C) monitors such conditions by measuring signals from the rotor, the output voltage (200), or the grid lines. If a transient or fault occurs, the controller (112C) can immediately trip the breaker (116) to isolate the in verter / con verter system (100) and prevent damage. Once safe conditions return, the controller may allow reconnection by reenergizing the motor (112) and realigning the cyclic connector (114) with the appropriate battery or capacitor stages.

[0060] When the system is connected to the grid in a high-power application, a step-up transformer (130S) can be used to raise the output voltage (200) to the grid’s line voltage. Alternatively, for certain sensitive loads or safety requirements, an isolation transformer (1301) provides galvanic isolation between the inverter output and the load or grid. The choice between isolation and step-up transformers (130) depends on specific system objectives, power levels, and regulatory standards. The transformer (130) is typically placed downstream of the reactor (140) so that the AC waveform feeding the transformer is already smoothed.

[0061] The motor (112) itself need not handle the entirety of the load current, because the main load current is carried through the cyclic connector (114) and battery or capacitor bank (104). As a consequence, the motor (112) experiences minimal mechanical load, primarily the friction of the brush assembly, semi-segmented slip rings (195R, 195Y, 195B), and any windage or bearing losses. This design choice significantly improves system efficiency, particularly at higher output currents, since the motor’s electrical consumption remains relatively small. In grid-connected scenarios, the synchronous motor (112SM) effectively runs at no load with respect to torque demand from the stepped AC output, making it economically viable and reliable even for large-scale power generation from solar arrays or other DC sources.

[0062] Referring to Figures

[0063] In Figure 3a, an exemplary standalone configuration of the electrodynamically synchronized DC to AC in verter / con verter system (100) is depicted. A DC source (102), such as a solar photovoltaic array or battery charger, feeds a battery bank or capacitor bank (104). This bank (104) is subdivided into multiple voltage stages, each corresponding to a specific portion of the overall DC voltage. A DC shunt motor (112DM) connects to the system and has its shaft (118) mechanically coupled to a Synchronous Cyclic -Connector Controller (110). Within this controller (110), the cyclic connector (114) includes a circular special segmented connector (190) divided into conductive segments. Each segment is associated with a voltage tap from the battery bank (104). As the motor (112DM) rotates, brushes (R, R', Y, Y', B, B') sweep over these segments to create a stepped AC output (180). Diodes (not explicitly labelled in Figure 3a, but referred to as DO, DI, D2 ... Dn in the specification) are installed at each tap to prevent undesired current flow between the voltage stages. Once the stepped output (180) is generated, it is passed through a reactor (140) to reduce harmonic distortion and produce an approximately sinusoidal output voltage (200). If isolation from the load is necessary, an isolation transformer (1301) can be employed between the inverter output (200) and the external AC distribution line.

[0064] When observing Figure 3b, one sees a variation suitable for high-power applications that require grid connection. Instead of a DC shunt motor, a synchronous motor (112SM) is used. Its stator windings are connected to a three-phase grid supply (400), and its rotor is excited by a DC source drawn from the battery bank or capacitor bank (104). Once energized, the stator and rotor fields lock to the grid frequency, causing the shaft (118) to rotate at synchronous speed. Because the same rotating shaft (118) drives the cyclic connector (114), the stepped AC output (180) is inherently synchronized with the grid. A step-up transformer (130S) may raise the voltage level, allowing the inverter to inject power at the appropriate grid line voltage. Protective devices (116), including breakers or fuses, are placed in line to interrupt current if a fault condition arises or if the controller (112C) detects abnormal grid frequency deviations.

[0065] Turning to Figure 4, we see a more detailed circuit arrangement for a standalone system. The battery bank (104) is shown with multiple sub-units (106) or taps, each at a different voltage potential. These sub-units (106) connect through diodes to a circular special segmented connector (190) indicated by KI. The motor (112DM) is directly powered by the same DC source, thus enabling the shaft (118) to rotate the brushes (R, R', Y, Y', B, B') relative to the circular special segmented connector (190). As each brush set makes contact with a different segment, the output voltage increments or decrements by the value of that battery subunit. This series of discrete steps (180) is then transferred to stationary brushes (Al, A2, Bl, B2, Gl, G2) via half-segmented semi-segmented slip rings (195R, 195Y, 195B). The Brushes R & R’, Y & Y’ and B & B’ are connected to Brushes Al & A2, B 1 & B2 and Gl & G2 respectively through the semi-segmented slip rings (195R, 195Y, 195B). Brushes Al & A2, Bl & B2 and Gl & G2 are connected to 1R & 2R, 1Y & 2Y and IB & 2B terminals respectively.After the reactor (140) smooths the waveform, the final AC output (200) is available for the load. An optional isolation transformer (1301) and breaker (116) can be placed in the output path to provide safety and compliance with local electrical standards. The figure also indicates that the motor (112DM) runs under near no-load conditions with respect to inverter output current, drawing only minimal power to overcome its own mechanical friction.

[0066] Moving to Figure 5, a similar layout applies to a high -power, three-phase setup intended for grid feeding. In this embodiment, the same multi-level battery or capacitor bank (104) supplies the cyclic connector (114) via diodes (DO, DI, D2 ... Dn). However, the motor is now shown as a synchronous motor (112SM). Its stator terminals (Ul, VI, Wl, etc.) connect to the grid, creating a rotating magnetic field at the grid frequency. The rotor windings are excited by the DC supply so that the rotor locks magnetically to the stator’s rotating field. Consequently, the brushes (R, R', Y, Y', B, B') on the shaft (118) rotate at the same speed as the grid frequency dictates. The Brushes R & R’, Y & Y’ and B & B’ are connected to Brushes Al & A2, Bl & B2 and Gl & G2 respectively through the semisegmented slip rings (195R, 195Y, 195B). Brushes Al & A2, Bl & B2 and Gl & G2 are connected to 1R & 2R, 1Y & 2Y and IB & 2B terminals respectively. The stepped output (180) that results is inherently phase-aligned with the grid, removing the need for the elaborate phase-locked loop electronics customary in solid-state inverters. This output is then stepped up by a transformer (130S) to the appropriate line voltage before reaching the grid connection (400). As in the standalone design, a reactor (140) sits upstream of the transformer (130S) to suppress high-frequency components. A breaker or fuse (116) ensures that short-circuit current or anomalous conditions do not damage the motor (112SM) or the multi-level battery bank (104). The controller (112C) continuously monitors rotor position, output voltage, and grid parameters. If it detects unacceptable frequency excursions, it signals the protective device (116) to open the circuit, isolating the inverter until safe conditions are restored.

[0067] Figures 6a and 6b illustrate, respectively, the general arrangement of a battery bank (104) and capacitor bank (104) when joined with the Synchronous Cyclic -Connector Controller (110). In both scenarios, the core principle is consistent: multiple voltage stages are tapped via diodes, and the rotating brushes (R, R', Y, Y', B, B') in cooperation with the circular special segmented connector (190) produce a stepped AC voltage. A smoothing inductor or reactor (140) then filters these steps. The Brushes R & R’, Y & Y’ and B & B’ are connected to Brushes Al & A2, Bl & B2 and G1 & G2 respectively through the semi-segmented slip rings (195R, 195Y, 195B). Brushes Al & A2, Bl & B2 and G1 & G2 are connected to 1R & 2R, 1Y & 2Y and IB & 2B terminals respectively. Figure 6a emphasizes how the battery sub-units (El, E2, E3, En) align with the rotating semi-segmented slip rings (195R, 195Y, 195B), whereas Figure 6b shows a similar scheme using capacitor segments (Cl, C2, C3, Cn). In both figures, once the semi-segmented slip rings are turned by the motor shaft (118), the combination of brush contact and diode structure (DO, DI, D2 ... Dn) arranges for each step to be added or removed from the output waveform in a specific timed sequence.

[0068] In Figure 7, an illustrative stepped three-phase output waveform (180) is shown, highlighting how many discrete levels can be produced if sufficient battery or capacitor stages are provided. The example indicates up to nineteen voltage levels in a single half- cycle, thereby reducing total harmonic distortion even prior to filtering. Figure 8 shows the smoothed sinusoidal output (200) once the waveform has been processed by the reactor (140). The dashed lines or transitional steps in the waveform are greatly diminished, evidencing that the final delivered current and voltage more closely match a pure sine wave. This reduction in harmonic content eases stresses on downstream equipment, mitigates electromagnetic interference, and improves overall power quality.

[0069] In practice, each figure underscores the flexible nature of the invention. Figure 3a may be preferred for residential or off-grid locations with moderate loads where a simple DC shunt motor (112DM) suffices to establish the desired frequency. Figure 3b becomes more relevant for large-scale renewable energy projects or industrial sites that must feed surplus power into a utility grid at a higher voltage level. Figures 4 and 5 show detailed connections for each scenario, clarifying how breakers (116), transformers (130), and reactors (140) may be positioned. Meanwhile, Figures 6a and 6b provide insights into the internal wiring for battery or capacitor banks (104), which can be scaled by increasing or decreasing the number of voltage stages. Finally, Figures 7 and 8 demonstrate the important transformation from stepped to sinusoidal output, the essence of high-performance power electronics solutions.

[0070] Overall, the referenced figures collectively illustrate how the electrodynamically synchronized DC to AC in verter / con verter system (100) operates under various conditions and configurations. They also reveal the distinct advantages of adopting a motor -driven cyclic -connector (114) approach to generate a stepped waveform with minimal reliance on high-frequency semiconductor switches. By unifying established mechanical rotation principles with carefully spaced voltage taps, the invention achieves reliable output frequencies and automatic synchronization in grid-connected environments, all while reducing switching losses and electromagnetic interference.

[0071] Method of Manufacturing

[0072] In one exemplary method of manufacturing the electrodynamically synchronized DC to AC inverter / converter system (100), a series of assembly steps are carried out to ensure proper mechanical alignment, electrical integrity, and functional reliability. First, multiple battery cells or capacitor modules are selected and arranged into a battery bank or capacitor bank (104). Each sub-unit is sized and configured to provide a particular voltage stage, so that when they are combined in series or a series -parallel combination, the total DC voltage meets the design criteria. At designated tapping points, diodes (DO, DI, D2 ... Dn) are installed to prevent unwanted current flow between these voltage stages. These sub-units, plus the associated diodes, are fastened to a stable frame or housing that accommodates both mechanical support and thermal management.

[0073] Next, a motor (112) is prepared. In a standalone system, this motor (112) is a DC shunt motor (112DM), whereas in a grid-synchronized system, the motor (112) is a synchronous motor (112SM). The rotor shaft (118) of the selected motor is aligned with precision bearings to ensure minimal friction and vibration. A circular special segmented connector (190) is then provided, subdivided into conductive segments corresponding to each voltage stage from the battery or capacitor bank (104). This circular special segmented connector (190) is affixed co-axially onto or with the motor shaft (118) so that, when the motor rotates, each connector segment can be indexed properly relative to the rotating brush assembly. Subsequently, the brush assembly is mounted to interact with the circular special segmented connector (190). Rotating brushes (R, R', Y, Y', B, B') and semi-segmented slip rings (195R, 195Y, 195B) are attached to the shaft (118), while stationary brushes (Al, A2, Bl, B2, Gl, G2) are anchored to a fixed bracket. The semi-segmented slip rings (195R, 195Y, 195B) are often segmented or half-segmented to optimize current flow conduction. Brush holders, typically constructed from metal or composite brackets, are secured in place to maintain consistent contact pressure between the brush tips and the corresponding surfaces on the semi-segmented slip rings (195R, 195Y, 195B) or circular special segmented connector (190). Materials such as copper-graphite or carbon composites may be selected for the brushes to achieve low friction and longer service life. Wiring is routed from each brush to the external terminals where the stepped AC output (180) is collected. The Brushes R & R’, Y & Y’ and B & B’ are connected to Brushes Al & A2, Bl & B2 and Gl & G2 respectively through the semi-segmented slip rings (195R, 195Y, 195B). Brushes Al & A2, Bl & B2 and Gl & G2 are connected to 1R & 2R, 1Y & 2Y and IB & 2B terminals respectively.

[0074] Once the basic rotating elements are in place, a reactor (140), frequently an inductor with a carefully selected inductance rating, is installed in the output line to smooth the stepped AC signal (180) into an output voltage (200) that approximates a sinusoidal waveform. If galvanic isolation or voltage transformation is necessary, either an isolation transformer (1301) or a step-up transformer (130S) is added downstream of the reactor (140). These transformers are typically mounted within the same enclosure or in a proximate cabinet, depending on power rating and cooling requirements. Meanwhile, protective devices (116), including circuit breakers and fuses, are placed in series with the battery or capacitor outputs and the final AC line to protect against short circuits or overcurrent conditions.

[0075] Following the mechanical and electrical assembly, a controller (112C) is integrated. This controller may be microcontroller -based or rely on analog sensors to track rotor position, output voltage, and, in grid-tied systems, synchronization parameters. During manufacturing, the controller is configured to initiate and halt the motor (112), to supervise voltage levels and frequencies, and to trip the protective devices (116) as needed. Wiring harnesses, sensor cables, and ground connections are organized to avoid electromagnetic interference and to comply with electrical safety standards. In grid-connected embodiments, the stator terminals of a synchronous motor (112SM) are wired to the external three-phase supply, while the rotor windings receive DC from the battery or capacitor bank (104). For standalone embodiments, the motor (112DM) is simply fed from the battery bank and regulated by a speed control subsystem.

[0076] Finally, upon completing all connections, alignment checks and functional tests are conducted. The manufacturer energizes the battery or capacitor bank (104) at a controlled voltage level, verifies brush contacts against special segmented commutator or slip-ring segments, and ensures the motor (112) reaches the intended rotational speed with minimal vibration. The stepped AC waveform (180) is measured at various load conditions to confirm that the reactor (140) and any associated transformer (130) produce an acceptable output (200). If grid integration is required, synchronization tests verify that the synchronous motor (112SM) aligns properly with grid frequency and that the breaker (116) disconnects the system under simulated fault scenarios. This thorough testing process helps confirm that the assembled system (100) satisfies performance, reliability, and safety requirements before release for commercial or industrial use.

[0077] 5. CLAIMS

[0078] I / We Claim:

[0079] 1. A DC to AC inverter / converter system (100) for converting a direct current input from a DC source (102) into an alternating current output, wherein the said system (100) comprising: a battery bank or capacitor bank (104) for storing electrical energy, Synchronous Cyclic-Connector Controller (110) and at least one transformer (130),

[0080] Characterized in that, the system comprises a Synchronous Cyclic-Connector Controller (110) including a motor (112) and a cyclic connector (114) with a circular special segmented connector (190) having multiple conductive segments corresponding to voltage stages of the battery bank or capacitor bank (104), a rotating brush assembly comprising at least one set of brushes (R, R', Y, Y', B, B') arranged on a shaft (118) mechanically coupled to said motor (112), and semi-segmented slip rings (195R, 195Y, 195B) for tapping the voltage stages in a timed sequence, a reactor (140) arranged to smooth a stepped AC output (180) generated by sequential connections of the battery or capacitor voltage stages through the rotating brush assembly, thereby producing a near-sinusoidal output voltage (200), and protective devices (116) configured to isolate or protect the system (100) from overcurrent, short-circuit, or abnormal grid or load conditions.

[0081] 2. The system (100) according to claim 1, wherein the motor (112) is a DC shunt motor (112DM) supplied by said battery bank or capacitor bank (104) for standalone applications, such that the motor speed determines the output AC frequency.

[0082] 3. The system (100) according to claim 1, wherein the motor (112) is a synchronous motor (112SM) having its stator windings connected to an external AC grid (400) through transformer (130S), and its rotor supplied by the battery bank or capacitor bank (104), thereby causing the motor to lock its rotational speed to the frequency of said external AC grid. 4. The system (100) according to claim 1, wherein the cyclic connector (114) comprises diodes (DO, DI, D2, ,Dn) interposed between each voltage stage of the battery bank or capacitor bank (104) and the circular special segmented connector (190) to prevent reverse current flow or unwanted short-circuit paths.

[0083] 5. The system (100) according to claim 1, wherein the semi-segmented slip rings (195R,

[0084] 195Y, 195B) are half-segmented and cooperate with stationary brushes (Al, A2, Bl, B2, Gl, G2) to control conduction intervals for each voltage stage, thereby forming the stepped AC output (180).

[0085] 6. The system (100) according to claim 1, wherein the motor (112) experiences substantially no load from the main inverter output current, thereby reducing mechanical stress and requiring power primarily to overcome friction and windage in the rotor and rotating brush assembly.

[0086] 7. The system (100) according to claim 1, wherein the at least one transformer (130) is selected from an isolation transformer (1301) or a step-up transformer (130S) to provide galvanic isolation or match output voltage levels to the grid or load requirements.

[0087] 8. The precise alignment of the rotor position, circular special segmented connector (190) position and rotating brushes (R, R', Y, Y', B, B') and semi-segmented slip rings (195R, 195Y, 195B) and stationary brushes (Al, A2, Bl, B2, Gl, G2) positions produce faithful synchronization with grid supply.

[0088] 9. The system (100) according to claim 1, wherein a controller (112C) monitors rotor position, output voltage (200), and grid frequency or load conditions, and coordinates the protective device (116) to disconnect the system (100) upon detecting frequency deviations or overcurrent events.

[0089] 10. The system (100) according to claim 1, wherein the battery bank or capacitor bank (104) is arranged in a plurality of series -connected segments to provide multi-level DC voltages, such that increasing the number of said segments proportionally increases the resolution of the stepped AC output (180) and reduces total harmonic distortion after smoothing by the reactor (140). 11. A method of manufacturing the DC to AC in verter / con verter system (100) of claim 1, comprising: assembling a battery bank or capacitor bank (104) with a plurality of voltage stages, each stage capable of being tapped via a circular special segmented connector (190); mounting a motor (112) on a shaft (118) in mechanical communication with a rotating brush assembly, the rotating brush assembly comprising brushes (R, R', Y, Y', B, B') and semi-segmented slip rings (195R, 195Y, 195B); wiring said circular special segmented connector (190) to the battery bank or capacitor bank (104) through diodes (DO, DI, D2, ,Dn) to prevent reverse current flow, and connecting the rotating brush assembly so that sequential rotation of the shaft (118) creates a stepped AC output (180); installing a reactor (140) in series with the stepped AC output for smoothing into a near-sinusoidal output (200), and incorporating at least one transformer (130) for isolation or step-up functionality; providing protective devices (116) such as circuit breakers or fuses to safeguard the system (100) from overcurrent or grid abnormalities; and integrating a controller (112C) configured to monitor operating parameters, including rotor position and output voltages, and to coordinate the protective devices (116) when conditions deviate from safe operating thresholds.

[0090] 6. DATE AND SIGNATURE

[0091] Dated this 18thday of February 2025 i

[0092] Mr. Si' i n i vas Maddipati IN / PA 3124 Agent for applicant

Claims

5. CLAIMSI / We Claim:

1. A DC to AC inverter / converter system (100) for converting a direct current input from a DC source (102) into an alternating current output, wherein the said system (100) comprising: a battery bank or capacitor bank (104) for storing electrical energy, Synchronous Cyclic-Connector Controller (110) and at least one transformer (130),Characterized in that, the system comprises a Synchronous Cyclic-Connector Controller (110) including a motor (112) and a cyclic connector (114) with a circular special segmented connector (190) having multiple conductive segments corresponding to voltage stages of the battery bank or capacitor bank (104), a rotating brush assembly comprising at least one set of brushes (R, R', Y, Y', B, B') arranged on a shaft (118) mechanically coupled to said motor (112), and semi-segmented slip rings (195R, 195Y, 195B) for tapping the voltage stages in a timed sequence, a reactor (140) arranged to smooth a stepped AC output (180) generated by sequential connections of the battery or capacitor voltage stages through the rotating brush assembly, thereby producing a near-sinusoidal output voltage (200), and protective devices (116) configured to isolate or protect the system (100) from overcurrent, short-circuit, or abnormal grid or load conditions.

2. The system (100) according to claim 1, wherein the motor (112) is a DC shunt motor (112DM) supplied by said battery bank or capacitor bank (104) for standalone applications, such that the motor speed determines the output AC frequency.

3. The system (100) according to claim 1, wherein the motor (112) is a synchronous motor (112SM) having its stator windings connected to an external AC grid (400) through transformer (130S), and its rotor supplied by the battery bank or capacitor bank (104), thereby causing the motor to lock its rotational speed to the frequency of said external AC grid.

4. The system (100) according to claim 1, wherein the cyclic connector (114) comprises diodes (DO, DI, D2, ,Dn) interposed between each voltage stage of the battery bank or capacitor bank (104) and the circular special segmented connector (190) to prevent reverse current flow or unwanted short-circuit paths.

5. The system (100) according to claim 1, wherein the semi-segmented slip rings (195R,195Y, 195B) are half-segmented and cooperate with stationary brushes (Al, A2, Bl, B2, Gl, G2) to control conduction intervals for each voltage stage, thereby forming the stepped AC output (180).

6. The system (100) according to claim 1, wherein the motor (112) experiences substantially no load from the main inverter output current, thereby reducing mechanical stress and requiring power primarily to overcome friction and windage in the rotor and rotating brush assembly.

7. The system (100) according to claim 1, wherein the at least one transformer (130) is selected from an isolation transformer (1301) or a step-up transformer (130S) to provide galvanic isolation or match output voltage levels to the grid or load requirements.

8. The precise alignment of the rotor position, circular special segmented connector (190) position and rotating brushes (R, R', Y, Y', B, B') and semi-segmented slip rings (195R, 195Y, 195B) and stationary brushes (Al, A2, Bl, B2, Gl, G2) positions produce faithful synchronization with grid supply.

9. The system (100) according to claim 1, wherein a controller (112C) monitors rotor position, output voltage (200), and grid frequency or load conditions, and coordinates the protective device (116) to disconnect the system (100) upon detecting frequency deviations or overcurrent events.

10. The system (100) according to claim 1, wherein the battery bank or capacitor bank (104) is arranged in a plurality of series -connected segments to provide multi-level DC voltages, such that increasing the number of said segments proportionally increases the resolution of the stepped AC output (180) and reduces total harmonic distortion after smoothing by the reactor (140).

11. A method of manufacturing the DC to AC in verter / con verter system (100) of claim 1, comprising: assembling a battery bank or capacitor bank (104) with a plurality of voltage stages, each stage capable of being tapped via a circular special segmented connector (190); mounting a motor (112) on a shaft (118) in mechanical communication with a rotating brush assembly, the rotating brush assembly comprising brushes (R, R', Y, Y', B, B') and semi-segmented slip rings (195R, 195Y, 195B); wiring said circular special segmented connector (190) to the battery bank or capacitor bank (104) through diodes (DO, DI, D2, ,Dn) to prevent reverse current flow, and connecting the rotating brush assembly so that sequential rotation of the shaft (118) creates a stepped AC output (180); installing a reactor (140) in series with the stepped AC output for smoothing into a near-sinusoidal output (200), and incorporating at least one transformer (130) for isolation or step-up functionality; providing protective devices (116) such as circuit breakers or fuses to safeguard the system (100) from overcurrent or grid abnormalities; and integrating a controller (112C) configured to monitor operating parameters, including rotor position and output voltages, and to coordinate the protective devices (116) when conditions deviate from safe operating thresholds.

6. DATE AND SIGNATUREDated this 18thday of February 2025 iMr. Si' i n i vas Maddipati IN / PA 3124 Agent for applicant

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