Planetary engine and control system for managing torque output

Abstract

An electric motor or engine, and more particularly to a planetary motor or engine, or to a hybrid planetary and axial / radial flux motor or engine that are controlled by a control system that combines a planetary gear system with an axial / radial flux motor to improve and manage torque output more efficiently than with conventional axial or radial flux motors.

Description

[0001] Planetary Engine And Control System For Managing Torque Output

[0002] PRIORITY

[0003] This application claims the benefit of priority under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application No. 63 / 672,394, filed on July 17, 2024, which is incorporated herein by reference in its entirety.

[0004] FIELD

[0005] The present invention relates to motors or engines and more particularly to planetary motors or engines and control systems that combines a planetary gear system with an axial flux motor and a hybrid axial flux and radial flux motor to improve and manage torque output more efficiently than with conventional axial flux motors or radial flux motors. The planetary axial flux motor and hybrid axial flux and radial flux motors of the present invention is able to be used on various types of equipment including but not limited to conventional vehicles, electrical vehicles, generators, and the like.

[0006] BACKGROUND

[0007] Conventional electrical motors typically comprise radial flux motors and axial flux motors. Regardless of the type of conventional electric motor used, most vehicle manufactures combine the motor with two-step gearboxes to efficiently transmit power from the electric motor to a vehicle’s wheels. The two-step gearboxes have been used in order to tune the electric motor for better torque delivery at higher speeds. However, these gearboxes come with several shortcomings that have led manufacturers to explore alternatives solutions to improve the performance of electric vehicles (“EVs”) motors. One of the biggest shortcomings is that they are prone to breaking, creating repair issues for manufacturers and dissatisfied customers. One solution used by EV manufacturers is to combine the electric motor with a single speed gearbox in order to avoid the repair, complexity and cost issues of the two-step gearboxes.

[0008] Whether a vehicle manufacturer uses a conventional radial flux motor, axial flux motor, or if they combine one of the foregoing with a two-step gearbox or a single speed gear box, they still have suboptimal torque output performance issues. The reason for the poor torque performance, regardless of the configuration, is that both radial flux motors and conventional axial flux motors use a single armature configuration. One significant limitation of single armature electric motors is that they are restricted in relation to their torque output. Their design favors high torque ratings at low rotations per minute (“RPM”) but fall off at high RPMs. To achieve high RPMs, the eddy-current timing can be synchronized, resulting in less torque and additional power requirements to compensate.

[0009] While axial flux motors have gained attention in recent years due to their compact design and potential for high power density, they are not without their shortcomings. One significant limitation is their susceptibility to overheating. The compact design of axial flux motors often results in limited space for effective cooling mechanisms, leading to increased operating temperatures. This compact design can degrade the performance and lifespan of the motor, posing a significant challenge, particularly in applications requiring sustained high-power output.

[0010] Another drawback of current axial flux motors is their current manufacturing complexity and cost. While the design offers advantages in terms of size and weight, the intricate arrangement of coils, magnets, and cores currently makes manufacturing them challenging and expensive. Achieving precise alignment of these components is crucial for optimal performance, adding to the complexity and cost of production. As a result, the initial investment required for conventional axial flux motors is prohibitive for some applications, limiting their widespread adoption.

[0011] The complexity of current axial flux motors also creates challenges in terms of scalability and standardization. Variations in design and manufacturing processes among different manufacturers has led to inconsistencies in performance and compatibility with existing systems. This lack of standardization complicates integration into various applications and hinders interoperability. Furthermore, the scaling up of axial flux motors for larger applications, such as electric vehicles or industrial machinery, has presented additional engineering hurdles and increased costs. The present invention addresses each of these shortcomings thereby providing a new axial flux motor, and a hybrid axial flux and radial motor, that arc able to be used in diverse applications. What is needed is a novel Planetary Axial Flux motor / generator (“PAFM” or “PAFG”) or a Hybrid Axial Flux and Radial Motor / Generator (“HAFRM” or “HAFRG”) that reduce or eliminate many of the above shortcomings of using conventional gearboxes.

[0012] What is also needed is a PAFM / PAFG / HAFRM / HAFRG that improves battery efficiency and range performance by utilizing the motor’s torque more effectively.

[0013] Still, what is needed is a PAFM / PAFG / HAFRM / HAFRG Motor that addresses the limitations of the conventional axial flux motors, further enhances the performance, efficiency, and reliability of electric propulsion systems in electrical vehicles and other power generation applications.

[0014] The object of the present invention is to address one or more of the above problems, while maintaining the advantages of the prior art.

[0015] SUMMARY OF THE INVENTION

[0016] The Planetary Axial Flux electric motor or generator (hereinafter “PAF / PAG motor / generator”) of the present invention, is an electrical motor that combines multiple armatures into a motor body rotating on a single stator, as opposed to a single armature to single stator that is seen in conventional electric motors. Combining the multiple armatures as disclosed herein, modifies the production of torque. In one example embodiment, if the PAF / PAG motor / generator of the present invention is used to index, as with a stepper motor or servo motor, the PAF / PAG motor / generator of the present invention has, for example, 16 times greater positioning accuracy of a conventional stepper motor or servo motor. With the PAF / PAG motor / generator of the present invention, the interactions of the armatures and coils have a longer duration, allowing for increased synchronization of the eddy-current event. The Hybrid Axial Flux and Radial Motor / Generator (“HAFRM” or “HAFRG”) combines a radial flux motor with the PAF / PAG.

[0017] The PAF / PAG motor / generator of the present invention is designed to address the challenges of conventional electric motor torque delivery, to include low and high RPMs. The present invention’s ability to control torque delivery at low and high RPMs have comprehensive applicability in transportation, power generation, manufacturing, among others. In transportation, the PAF / PAG motor / generator of the present invention is able to replace current electric motors that have variable speed or power output, including electric powertrains. The PAF / PAG motor / generator of the present invention is also able to generate power on internal combustion engine.

[0018] The PAF / PAG motor / generator of the present invention is able to generate power having various properties, including but not limited to 3-Phase 60 Hz power at 1,440 RPM. This is a reduction of 2.5 times the RPM required of conventions power generators operating at 60 Hz.

[0019] Within automation and motion control systems, the novel design of the PAF / PAG motor / generator of the present invention can be operationally coupled together with a finer step ratio gear to produce even greater motor torque. The present invention also allows heavier motion limits while permitting greater speeds, accelerations, and positional accuracy.

[0020] BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The invention will be described in more detail in the detailed description below with reference to the appended drawings, in which:

[0022] FIG. 1A is a perspective view of the motor of the present invention used with an automobile, as disclosed herein;

[0023] FIG. IB is a perspective view of the motor of the present invention used with a motorcycle, as disclosed herein;

[0024] FIG. 2A is a perspective view an interior view of the automobile wheel with the motor of the present invention removed therefrom;

[0025] FIG. 2B is an exploded view of the motor of the present invention;

[0026] FIG. 2C is a perspective view of the motor of the present invention coupled to a rotor;

[0027] FIG. 2D is a perspective view of the motor of the present invention coupled to a rotor;

[0028] FIG. 3A is an exploded view of the motor of the present invention illustrating a carriage assembly of the present invention; FIG. 3B is an exploded view of the carriage assembly or stator of the present invention;

[0029] FIG. 3C is an exploded view of the carriage assembly or stator of the present invention;

[0030] FIG. 3D is close up view of the carriage assembly or stator of the present invention;

[0031] FIG. 3E is a perspective view of the carriage assembly or stator of the present invention;

[0032] FIG. 4A is a front plan view of a planetary drive assembly of the present invention illustrating placement and orientation of armatures having magnet members coupled thereto;

[0033] FIG. 4B is a rear plan view of a planetary drive assembly of the present invention illustrating placement and orientation of armatures having magnet members coupled thereto;

[0034] FIG. 4C is a front view of an armature with separate magnet members illustrated in the dashed and dotted circle;

[0035] FIG. 4D is a perspective view of an armature with separate magnet members illustrated in the dashed and dotted circle and a single magnet member exploded away from the armature;

[0036] FIG. 5A is a front plan view of a first stator and armature assembly of the present invention illustrating coil placement for interaction with the magnet members of the planetary armatures;

[0037] FIG. 5B is a front plan view of stator and coil assembly of the present invention;

[0038] FIG. 5C is a perspective view of stator and coil assembly of the present invention;

[0039] FIG. 5D is an exploded view of stator and coil assembly of the present invention;

[0040] FIG. 5E is a perspective view of the first and second stator and armature assemblies of the present invention stacked together;

[0041] FIG. 6A is a perspective view of the first and second stator and armature assemblies;

[0042] FIG. 6B is a perspective view of the first and second stator and armature assemblies, illustrating coil placement with respect to the assemblies; FIG. 7A is a front plan view of a planetary armature assembly illustrating placement and orientation of the magnetic poles of magnet members coupled thereto;

[0043] FIG. 7B is a perspective view of a planetary armature assembly illustrating placement and orientation of the magnetic poles of magnet members coupled thereto;

[0044] FIG. 8A is a partial cross section view illustrating coil placement;

[0045] FIG. 8B is a partial cross section view illustrating coil placement;

[0046] FIG. 9 is a front view illustrating movement of the present invention; and

[0047] FIG. 10 is a schematic of an example circuit of the present invention.

[0048] DETAILED DESCRIPTION

[0049] The detailed description and specific examples contained herein, while indicating example embodiments of the apparatus, systems and methods, are intended only for the purpose of illustration and are not intended to limit the scope or breadth of the invention. Features, aspects, and advantages of the present invention are discussed in the following description, claims, and the accompanying figures. The figures are for illustration purposes only and are not drawn to scale. Identical reference numbers are used throughout the figures and description to indicate same or similar parts.

[0050] The present invention, illustrated in FIGS. 1A - 10, is directed to a number of new and novel planetary axial flux electrical motors or generators (“PAF Motor(s) PAG Generator(s)” or “motor” or “generator”) and / or Hybrid Axial Flux and Radial Motor / Generator (“HAFRM” or “HAFRG”) that combine a new radial flux motor with the new PAF / PAG also of the present invention, both of which arc an improvement over conventional axial flux electrical motors or generators. The motors and generators of the present invention are not limited to any particular type of vehicle or device. For example, as illustrated in FIGS. 1A and IB, the motor or generators of the present invention can be operatively coupled to one or more wheels of an automobile A, or the wheels of a motorcycle, B. Additionally, the motor of the present invention can be employed to drive various types of machinery that is able to take advantage of its improved features. Turning to FIG. 2 A, an example motor (or generator)p 10 of the present invention is illustrated separated away from a vehicle wheel or tire A to which it is usually mounted. As provided in the illustrated example embodiment, motor 10 generally comprises a housing or support assembly 12 having a front housing segment or plate 14a and a rear housing segment or plate 14b that are coupled together by one or more fasteners 16. When the front housing segment or plate 14a and second housing segment or plate 14b are coupled or fastened together they define an interior or space 18 that is configured to house or retain one or more planetary motor or drive assemblies 40. As illustrated in FIGS. 2A-2B, and as will be described in more detail below, drive assemblies 40 can arranged or oriented in a stacked configuration.

[0051] In one example embodiment, one or more posts or spacers 20 are formed on or coupled to one or both of housing segments or plates 14a and 14b. The size (e.g., length, height, etc.) of spacers 20 can be varied to provide an adjustable or selective size of space 18. As particularly illustrated in FIG. 2 A, fasteners 16 may extend through bores extending through spacers 20 and housing plates 14a and 14b to selectively secure the components together.

[0052] Housing assembly 12 also comprises an arbor, spindle, or axle assembly 22 that is configured to couple or fasten housing motor 10 to a component such as a suspension system of a vehicle or a housing of mechanical device. In one example embodiment, as illustrated in FIGS. 2 A and 2B, axle assembly 22 comprises a hub 24 having one or more fasteners or bolts 26. As illustrated in FIG. 2B, axle assembly 22 extends through an opening or hole 14c extending through housing segment or plate 14a and extends to and at least partially into housing segment or plate 14b. As particularly illustrated in FIG. 2B, hub 24 is set or pressure fitted into a bearing 28 seated in opening or hole 14c of housing segment or plate 14a. Bearing 28 permits rotational movement of motor 10 and housing assembly 12.

[0053] Turning to FIGS. 2B and 2C, housing segment or plate 14b is operatively coupled to a wheel hub or brake rotor assembly 30 comprising a body 32 and one or more fasteners or bolts 34 that are configured to receiving a rim of a wheel A. Wheel nuts (not shown) are then fastened to the ends of the fasteners or bolts 34 of wheel hub or brake rotor assembly 30 that is coupled to our fastened to a rim of a wheel A.

[0054] As will now be explained, drive assemblies 40 of the prevention are configured to generate the torque necessary for moving one or more wheels A of a vehicle or a drive shaft of a piece of machinery. As particularly illustrated in FIG. 3A, housing or support assembly 12 is able to house one or more planetary motor drive assemblies 40 and should only be considered limited by the needs of a particular design.

[0055] In FIG. 3 A, housing assembly 12 is illustrated in a partially disassembled condition showing drive assemblies 40 of the present example embodiment, positioned or oriented in the interior or space 18 of housing assembly 12. Drive assemblies 40 can be positioned at least partially beneath a portion of hub 24 of axle assembly 22. In one example embodiment of the invention, components of axle assembly 22 are assembled together by one or more fasteners 28 (see FIG. 3C).

[0056] While two drive assemblies 40 are illustrated in the figures, one skilled in the art will appreciate that one or more than two drive assemblies 40 may be used. Disassembly of axle assembly 22 enables a user to easily add, remove, or replace one or more drive assemblies 40. In one example embodiment of the invention, motor 10 can be customized, wherein a user is able to purchase one or more drive assemblies 40, which can be used to increase the number of drive assemblies 40 in motor 10, or to replace one or more drive assemblies 40. Replacement of one or more drive assemblies 40 may be for any purpose, including but not limited to repairing motor 10 or changing its parameters, (e.g., increase or decrease in a desired amount of torque).

[0057] FIGS. 3B and 3C illustrate a front perspective view (FIG. 3A) and rear perspective view (FIG. 3B) of housing assembly 12 separated from drive assemblies 40. As is particularly illustrated, drive assemblies 40 are positioned or mounted about a portion of axle assembly 22. As will be explained in more detail below, this configuration or arrangement permits housing assembly 12, wheel hub assembly 30, and drive assemblies 40 to rotate about a fix point on axle assembly 22, which is fixed to a point on a vehicle A or B, or a piece of machinery.

[0058] As particularly illustrated in FIGS. 4A and 4B, each drive assembly 40 of motor 10 comprises one or more armatures 42. Each armature 42 comprises one or more of a body or plate 44 rotatably mounted or coupled to a spindle 46 having a plurality of outwardly radiating teeth 48. In another example embodiment, a gear having a plurality of teeth are coupled to a portion of spindle 46. Spindle 46 of each armature 42 is operatively positioned about a central stationary sun stator 60 having a plurality of outwardly teeth 62. Teeth 48 of each spindle 46 of armatures 42 are spaced apart and configured to mate with teeth 62 of stationary sun stator 60. As particularly illustrated in FIG. 4A, this configuration permit armatures 42 to move or rotate clockwise in a clockwise direction about an outer periphery of stationary sun stator 60 during operation.

[0059] Turning to FIGS. 5A-5D, rotation of armatures 42 about stator or gear 60 is accomplished by an electro-magnet propulsion system or assembly 70 (hereinafter, “propulsion assembly”). An example propulsion assembly 70 of the present invention comprises one or more magnet members 72 that are coupled to or disposed on armatures 42. Magnet members 72 are propelled by one or more electromagnetic coils 80 coupled to or disposed on a portion of stator 60. Electromagnetic coils 80 are operatively coupled to a power supply or source 90 that supplies energy to coils 80 for the purpose of creating a magnetic field that propels or moves magnet members 72, thereby causing armatures 42 to rotate about stator 60.

[0060] In one example embodiment, as illustrated in FIGS. 4C and 4D, magnet members 72 include a plurality of a north pole magnet members 74a (indicated by an “N”) and a plurality of south pole magnet members 74b (indicated by a “S”). Magnet members 74a and 74b are arranged with alternating magnetic fields such that no immediately adjacent armature magnets 74a and 74b have the same magnetic direction field. The example orientation or configuration of the magnet members 74a and 74b illustrate that magnet members 74a and 74b follow a North / South magnetic pole alternation between adjacent magnet members 74a and 74b.

[0061] Magnet members 72 may comprise any shape or configuration. An example shape of magnet members 42 includes but is not limited to the generally disc-shaped magnets illustrated in FIG. 4D. One skilled in the art will appreciate that magnet members 72 can take any shape and can be oriented in any configuration.

[0062] As particularly illustrated in FIG. 4D, magnet members 72 are contained or positioned within openings or cavities 76 formed in the surface of armature 42. Magnet members 42 may be positioned proximate to a perimeter edge 52 of armatures 42. In one example embodiment of the invention, magnet members 72 (e.g., 74a and 74b) have indicia 78 formed on their surface(s) to indicate various characteristics of magnet members 72. For example, indica 78 can indicate a magnet member’s 78 pole, orientation, or magnetic field strength. Indicia 78 enables a user to quickly identify, repair, or replace one or more magnet members 78.

[0063] As illustrated in FIGS. 5A-5D, coils 80 are configured or arranged in a spaced apart pattern about a portion of stator 60. As particularly illustrated in FIG. 5A, coils 80 are position beneath or below magnet members 72. Figures 5C and 5D illustrate an example configuration and orientation of coils 80 with respect to stator 60. Different configurations and orientations are also within the spirit and scope of the invention and the examples provided should not be considered limiting.

[0064] In FIG. 5D, coils 80 are unseated from stator 60 and illustrate that coils 80 are contained or positioned within cavities or recesses 82 formed in stator 60. Coils 80 are connected by a connecting portion or wire 84 of coils 80. Connecting portion or wires 84 are positionable or extend through channels 85 formed in stator 60. Channels 85 interconnect recesses 82. At least some of coils 80 include an end or tail 86 that extend away from coils 80 and are coupled or connected to power supply 90. Tails 86 extend along and / or into a collar 88 of stator 60. In one example embodiment of the invention, power supply 90 includes wires that extend through and / or connect with tails 86 in bores 92 formed in collar 88.

[0065] Figures 5E-6B illustrate an example stacking of drive assemblies 40 and the orientation and configuration of its components (e.g., armatures 42 and stators 60). In one example embodiment, drive assemblies 40 are stacked directly above each other in a generally vertical fashion or configuration. Other configurations are also possible including but not limited to drive assemblies 40 having their planar surfaces or orientations positioned at an angle with respect to each other (e.g., 45 degrees or 90 degrees). In an angular configuration, motors 10 are able to drive different axles or shafts that operate different components. For example, motors 10 in this configuration may have one motor 10 powering the wheels A of a vehicle and another motor 10 power pumps, fans, propellers, etc.

[0066] In another example embodiment of the invention, as illustrated in FIGS. 7A and 7B, an embodiment of a motor 100 is coupled to a centrally located hub assembly 130 that is coupled to a wheel or rotatable device. Hub assembly 130 comprises a central axle 132 that is operatively coupled to a drive assembly 140 comprising a stator 160 having a central opening 162 and a lip or flange 164 formed therein extending from stator 160 towards a central axis of central opening 162. Flange 164 includes recesses 182 formed therein for receiving and holding coils 180.

[0067] In this particular embodiment, drive assembly 130 also comprises at least two armatures 142 that are rotatably positioned above coils 180 seated in recesses 182. Similar to other embodiments, armatures 142 include one or more magnet members 172 coupled or attached to armatures 142 that are moved or propelled by energizing coils 180 to create a magnetic field. As particularly illustrated in FIGS. 7A and 7B, armatures 142 are coupled to shaft or spindle 143 that is operatively coupled to central axle 132 of hub assembly 140.

[0068] In use, when energy from a power supply 90 is supplied to coils 80 and 180 a magnetic field is created around coils 80 and 180. The magnetic field creates eddy currents that dictates the amount of torque transmitted to magnet members 72 and 172 of armatures 42 and 142. Magnet members 72 and 172 of each armature 42 or 142 participates in the eddy current event at every stage of rotation (see FIGS. 4A, and 7A). Armatures 42 and 142 are timed and geared to the primary axle or stator 60 and 160. The gearing provides a portion of the motion forces transmitted to armatures 42 and 142 and thus to wheel hub assembly 30 and 130 and their axles. Rotational forces are applied at a radius of the axle location on body 32. The eddy current event translates the additional portion of the forces. These rotational forces are applied at the radius of the eddy current event. The speed of motor 10 and 100 can be increased by increasing the amount of energy supplied to coils 80 and 180. Similarly, a speed of motor 10 and 100 can be reduced by a reduction in the amount of energy supplied to coils 80 and 180.

[0069] Wiring from power supply 90 to coils 80 or 180 in a number of ways, including but not limited to routing wires though a primary axle or shaft to stators 60 or 160. Wires are able to be fed through holes or bores 92 extending through collar 88 of stators 60 and 160, where they are connected to tails or ends 86 of coils 80 or 180. Various drive gears may be attached to a vehicle’s primary axle.

[0070] The term “Gear' or Gearing” applies to gears, chains / sprockets, timing belts and pulleys or similar means of synchronizing motion. While the invention has been described as controlling rotational movement or speed of a wheel, one skilled in the art will appreciate that motor 10 or 10 can be used in conjunction with any device that is able to be controlled by direct or indirection rotational movement or force.

[0071] Stator 60 and 160 is described as being a separate stationary component of drive assemblies 40 and 140. However, stators 60 and 160 can also be a component on a primary axle and can be an integrated component to the primary axle. As mentioned above any gear may be attached to or integrated with armatures 40 and 140 or stators 60 and 160.

[0072] An advantage of the current invention is that multiple drive assemblies 40 and 140 (comprising armatures 40 or 140 and stators 60 or 160) may be stacked along a primary axial plane. Addition, removal, and / or exchange of drive assemblies 40 or 140 enable a user to customize motors 10 or 100 for a desired motor characteristic.

[0073] Stators 60 and 160 will hold a stationary gear with a ratio in relations of coils 80 and 180 to armature 42 and 142 magnet member 72 and 172 positions. In one example embodiment, a ratio of 3:1 is used. However, one skilled in the art will appreciate that any desired ratio may be utilized.

[0074] In one example embodiment, as illustrated in FIGS. 8 A and 8B, winding of coils 80 and 180 favor the eddy currents forming North pole and South pole magnetic fields, in the axle plane. Coils 80 and 180 are able to be created or formed in a number of winding configurations or patterns. For example, coils 80 and 180 may be arranged in a helical winding pattern, orthocyclic winding pattern, wild winding pattern, or a “Star Coil” connection or pattern, using 200a, 200b, and 200c wires. A number of windings per coil may be the same or different depending upon the desired characteristic of the magnetic field.

[0075] Coils 80 and 180 maybe also be separated to trigger only a portion at a time (e.g., using Star Coil connection properties). This would allow motor 10 or 100 to lower its torque at startup. A partial coil trigger would result in a “Soft Start.” Referring to FIG. 9, coils 80 and 180 can be separated into separate winding or coil assemblies 280. For example, FIG. 9 illustrates three coil assemblies 282a, (“CA”), 282b, (“CB”), and 282c, (“CC”), where each respective coil assemblies 282a-282c is connected and able to controlled separately from the other coil assemblies 282a-282c. The above configuration enables operation of motor 10 as explained below.

[0076] Continuing with FIG. 9, an example operation of drive assembly 40 of motor 10 is illustrated showing rotational movement of armature 42 around stator 60. Rotation of armature 42 accomplished, in this example, by the timing of each energizing each of coil assemblies 282a-282c by a controller 200 in communication with power supply 90. Electrical timing of coil assemblies 282a-282c may be synchr onized as “Leading” or “Trailing”. In one example embodiment of the invention, the phasing for motor 10 requires 6 phases in leading synchronization (+) Coil would represent the N pole based on direction of current path (-) Coil would represent the S pole based on direction of current path. An example timing pattern is illustrated below: cA+c B-; cC+c B-; cC+ cA-; cB+ cA-;cB+ cC-; cA+ cC-

[0077] Controller 200 is configured to control circuits connected to each coil assembly 282a- 282c. Electrical connections can be accomplished by a star or delta circuit similar to the one illustrated in FIG. 10. Controller 200 is able to produce the following outputs for coil assemblies 282a-282c:

[0078] Output High U for cA+; Output High V for cB+; Output High W for cC+; Output Low X for cA-; Output Low Y for cB-; Output Low Z for cC-

[0079] When an armature 42 is positioned as illustrated in FIG. 9 there can be at least three forces operating simultaneously on armature 42. For example, in the positioning of armature 42 in FIG. 9, coil assemblies immediately adjacent to armature 42 (i.e., cC and c B) can be controlled, energized, or powered to have the following magnetic fields CB+ cC-; with coil assembly cC 282c having a negative magnetic field and coil assembly cB 282b having a positive magnetic field. The magnetic fields of 282c and 282b will act with the magnetic pole of the closest magnet member 72 to either push or pull armature 42 in a particular direction. In the example of FIG. 9, the negative magnetic field created by coil assembly cC 282c will pull armature 42 toward it because of the orientation of the N+ pole of magnet member 72. Similarly, the positive magnetic field created by coil assembly cB 282b will push armature 42 away from it because of the orientation of the N+ pole of magnet member 72. As can be seen the selective and controllable trigging of coil assemblies 282a-282c will continue and change to continue to propel armature 42 about stator 60. While the present invention has been described as being as a motor for generating movement, it can also be used to convert external movement into energy. For example, it can be used to generate energy through various systems and processes, including but not limited to wind turbines, hydroelectric turbines, and other hydrokinetic energy devices, thermal, geothermal or steam turbines.

[0080] In an example system, the present invention is able to act as a direct drive system for wind turbines. Current wind turbines rotate at 6-10 RPM and generate a significant amount of torque. Planetary gear boxes are used to translate the 6-10 RPM of the wind turbine to 3600 RPM, which is needed by the electric generator. The problem with the current system is that the planetary gear boxes have a high failure rate. The present invention, however, acting as a planetary axial generator or PAG, only needs to be geared at 1400 RPM in order to generate the 60 Hz needed to match the standard in the power grid. Significant benefit on time, wear, heat generation, etc. The present invention is able to be used with any system that is able to take movement and convert it into energy.

[0081] The present invention can also be used to control and power movement of devices, including but not limited to movement and operation of robotics. Currently, robotics utilize stepper or servo motors for movement. These motors only provide 200 steps per rotation of the motor. The motor 10 of the present invention, however, is capable of providing 800 steps per rotation, providing a smoother and wider range of movement. In one example embodiment of the present invention, motor 10 is geared with a servo motor, thereby creating an even greater number of steps per rotation.

[0082] In yet another example embodiment of the invention, motor 10 improves air movement (e.g., helicopters, drones, etc.) because of its ability to interact with multiple magnets at a time and its selective control of torque. The motors 10 ability to operate or function at low torque provides many advantages to pilots that typically control ascent and descent by controlling a motor’s RPMs. The current invention is able to provide better control at higher RPMs by being able to better control the delivered torque. Additionally, its light weight provides an advantage of improved torque delivery with less weight, which is important for any aircraft. The motor 10 of the present invention also includes multiple drive assemblies 40, each acting as an engine. As a result, the motor 10 has the built-in redundance desired for aircraft. If one of the drive assemblies 40 stops working, a disengagement assembly (e.g., shearing pins, springs, spring arms, etc.) are able to disengage the non-functioning drive assembly 40, permitting the other drive assemblies 40 to continue to operate, thereby preventing an engine failure.

[0083] The present invention is also used for regenerative energy systems, including but not limited to capturing energy from vehicles, braking, and energy loss or waste in the form of heat (e.g., coal, steam, and nuclear power plants). The motor 10 of the present invention is able to be connected to a regenerative energy system that, through an exchanging mechanism (e.g., heat exchanger, turbines, etc.) recapture and / or convert potentially lost energy and redirect into a system to be used or into the energy grid to be used by consumers.

[0084] The present invention is advantageous in that it is able to be used with or without ferrous materials in operative communication with coils 80. For example, in robotic applications, ferrous materials can be used that are selectively protected in a shielding system or housing configured to hold and shield a ferrous material when not needed and then to manipulate the ferrous material out of the shielding housing into operative position with respect to coils 80 (e.g., inserted into the coil). This configuration provides a dual function or purpose motor that eliminates the current need of using two or more different electric motors in various system (e.g., in electric vehicles that use motors with ferrous materials in some rearwardly positioned electric motors).

[0085] The motor 10 of the present invention can be used in hybrid systems. Motor 10 can also be completely enclosed, with or without venting, for use where external contaminants may negatively interfere with its operation.

[0086] In one example hybrid system of the present invention, illustrated in FIGS. 11A-11B, the motors 10 of the present invention can include a radial flux motor system 300 combined therein. The radial flux motor / generator system 300 is configured to mount to or inside housing assembly 312 that includes one or more walls or plates 314a and 314b to define an interior 315 that may be entirely or partially enclosed. A stator 316 is included that is mount to a portion of the housing assembly 312. In one example embodiment, the stator 316 comprises a hub portion 317a coupled or mated to one or more plates 317b. The plates 317b include a plurality of teeth 319. The hub portion 317a and / or the plates 317b include a plurality of spaced apart coils 320 disposed about a circumference of the stator 316. Depending upon the need, the stator 316 is coupled to a portion of the housing assembly 312. In one example embodiment, the hub portion 317a includes a plurality of recess 318a formed therein for holding the coils 320. In one example embodiment, the recess 318a are formed by a bottom wall or surface 318b of the hub portion 317a and side walls 318c extending generally up from the bottom wall 318b and extending at least partially about a portion of the coils 320

[0087] The motor 300 also includes one or more planetary drive assemblies 330 rotatably positioned in the interior 318 of the housing assembly 312. The planetary drive assemblies 330 generally comprise at least one rotatable drive plate 332a and / or 332b that is in operative communication with the plurality of teeth 319 of the stator 316. As illustrated in FIGS. 11 A and 11B, a plurality of magnetic members 336 having alternating poles are disposed about a circumference of the at least one drive plate 332a and 332b. The plurality of magnetic members 336a and 336b are generally positionable proximate to the plurality of coils 320 so that their magnetic fields overlap.

[0088] The planetary drive assemblies 330 can also include one or more shafts 340 coupled to the at least one rotatable drive plate 332a and 332b and coupled to and extending between a portion of the housing assembly 312. As illustrated in FIG. 11C, the shaft 340 comprises one or more magnetic rod members 350a and 350b that can be covered by or housed within a sheath 352. The magnetic rod members 350a and 350b can extend a portion of a length or an entire length of the shaft 340. The magnetic rod members 350a and 350b are in operative communication with a portion of the plurality of coils 340 of the stator 316.

[0089] Figure 11C illustrates an example configuration of the magnet members 336a and 336b and the magnetic rod members 350a and 350b, with the magnetic rod members 350a and 350b being centrally located to the magnet members 336a and 336b. The illustration also demonstrates the alternating poles of the magnet members 336a and 336b and magnetic rod members 350a and 350b. Other configurations are also possible depending upon the particular needs, magnetic fields, desired torque, etc.

[0090] In one example embodiment, a power source and its wires 360 are in operative communication with the plurality of spaced apart coils 320 for the purpose of creating a magnetic field that overlaps with the magnetic field of the magnetic members 336a and 336b, and the magnetic rod members 350a and 350b. Energizing the coils 320 of the stator 316 causes the plurality of magnet members 336a and 336b, and the magnetic rod members 350a and 350b to be pulled and repealed, thereby moving or causing the rotatable drive plate 332a and 332b to rotate.

[0091] In one example embodiment, the coil 320 size can be altered or changed. Coils 320 may also include a ferrous metal core to enhance the magnetic field strength and inductance of the coil 320. Different materials in various shapes and sizes can be used to adjust the magnetic field strength and inductance of the coil 320.

[0092] As particularly illustrated in FIG. 11B, two rotatable drive plates 332a and 332b are spaced apart of stacked on the shaft 340 to create a compact design for smaller motors 10. This combined or stacked configuration allows for the inclusion of core magnets, which perform as a Radial Flux (“RF”) component. Additional magnets can be added in the axial flux region to favorably influence the eddy current field. In this particular embodiment, gearing can be relocated from the rotatable drive plates 332a and 332b (or "Planets") to the shaft (or axle) 340. In this embodiment, a shaft gear 360 having teeth 362 can be coupled to a portion of the shaft 340. Bearings 364a and 364b can be coupled to the shaft 340 to aid in shafts rotation. Oils or lubricants can also be used to reduce the amount of friction between components of the motors 10 or 300.

[0093] The motors 10 and 300 can be used for various purposes including operating other equipment, devices, or machines. As illustrated in FIG. 1 ID, a drive gear 400 can be coupled or mounted to housing assembly 12 or 312 to drive another component such as a drive shaft 410. Gear 400 can comprise any type of driving mechanism, including but not limited to spur gears, rack gears, internal toothing, worm gears, bevel gears, screw gears, screw bevel gears, helical gears, planetary gears, miter gears, and the like.

[0094] The invention can use a basic MOSFET circuit but can also use dedicated gate drivers. In one example embodiment, the motors 10 or 300 can be configured uses a 4- way halfbridge control in Wye setup, with a center lead serving as the "null phase." Coil firing sequence may include 14-phase per quarter turn (90° rotation). Example configurations include the following:

[0095] The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof, and it is, therefore, desired that the present embodiment be considered in all respects as illustrative and not restrictive. Similarly, the above-described methods and techniques for forming the present invention are illustrative processes and are not intended to limit the methods of manufacturing / forming the present invention to those specifically defined herein.

Claims

CLAIMSWhat is claimed is:1 . A motor device comprising: a housing assembly comprising one or more walls defining an interior; a stator comprising: a plate having a plurality of teeth and a plurality of spaced apart coils disposed about a circumference of the stator, wherein the stator is coupled to a portion of the housing assembly; a planetary drive assembly comprising: at least one rotatable drive plate in operative communication with the plurality of teeth of the stator; a plurality of magnetic members having alternating poles disposed about a circumference of the at least one drive plate and positionable proximate to the plurality of coils, a magnetic shaft coupled to the at least one rotatable drive plate and coupled to a portion of the housing; a power source in operative communication with the plurality of spaced apart coils; and wherein energizing the coils of the stator causes the plurality of magnet members to move the at least one rotatable drive plate.

2. The motor of claim 1, wherein the one or more walls of the housing comprise spaced apart housing plates having one or more fasteners configured to fasten to a component of a piece of equipment.

3. The motor of claim 1, wherein the housing is operatively coupled to a drive gear to drive a drive shaft.

4. The motor of claim 1, wherein the at least one drive assembly comprises a plurality of drive assemblies spaced about the stator, wherein one or more of the plurality of drive assemblies are replaceable.

5. The motor of claim 3, wherein rotation of the at least one drive assembly rotates the housing, wherein the housing rotates the drive gear and drive shaft.

6. The motor of claim 5, wherein the magnetic shaft comprises a radial flux motor comprising one or more magnetic rod members extending through a length of the magnetic shaft, wherein the magnetic rod members are in operative communication with a portion of the plurality of coils of the stator.

7. The motor of claim 5, wherein at least a pair of drive plates are coupled to and space apart on the magnetic shaft, wherein the one or more magnetic rod members extend between the at least a pair of drive plates.

8. The motor of claim 1 , wherein stator comprises a plurality of recesses configured to hold the plurality of coils, wherein a surface of each of the plurality of coils are exposed to the plurality of magnet members.

9. The motor of claim 8, wherein at least two surfaces of the each of the plurality of coils is exposed to the plurality of magnet members.

10. The motor of claim 6, wherein stator comprises a plurality of recesses configured to hold the plurality of coils, wherein at a top surface, bottom surface and a portion of a side surface of each of the plurality of coils is exposed to the magnet members and to the one or more magnetic rod members.

11. The motor of claim 10, wherein the stator comprises a hub portion and one or more gear portions coupled to the hub portion, wherein the plurality of recesses extend into and are spaced about the hub portion.

12. The motor of claim 10, wherein the stator comprises a hub portion and one or more gear portions coupled to the hub portion, wherein the plurality of recesses extend into and are spaced about the gear portion.

13. The motor of claim 6, further comprising one or more bearings being coupled to ends of the magnetic shaft to permit it to rotate.

14. The motor of claim 1 , further comprising one or more gears having teeth being mounted to a portion of the shaft, wherein the teeth of the gear being in operative communication with the plurality of teeth of the stator.

15. A motor device comprising: a housing assembly comprising one or more walls defining an interior; a stator comprising: a plate having a plurality of teeth and a plurality of spaced apart coils disposed about a circumference of the stator, wherein the stator is coupled to a portion of the housing assembly; a planetary drive assembly comprising: at least one rotatable drive plate in operative communication with the plurality of teeth of the stator; a plurality of magnetic members having alternating poles disposed about a circumference of the at least one drive plate and positionable proximate to the plurality of coils, a magnetic shaft coupled to the at least one rotatable drive plate and coupled to a portion of the housing, the magnetic shaft comprising one or more magnetic rod members extending through a length of the shaft, wherein the magnetic rod members are in operative communication with a portion of the plurality of coils of the stator.; a power source in operative communication with the plurality of spaced apart coils; and wherein energizing the coils of the stator causes the plurality of magnet members to move the at least one rotatable drive plate.

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