Modular motor with multi-stage stator and rotor sections and method for controlling magnetic commutation of the modular motor

Abstract

The present patent application relates to an electric motor (1) comprising a modular structure (2) that incorporates four rotor sections: a primary section (3), a secondary section (4), a tertiary section (5), and a quaternary section (6). These sections are arranged in two magnetostatic cells, namely a primary magnetostatic cell (7) and a secondary magnetostatic cell (8), mounted axially and rotated relative to one another by 11.25º. The motor (1) is designed to operate with direct current (DC) at an operating voltage of between 12 V and 25 V, withstanding peaks of up to 50 V for 60 seconds. Its operation is based on repetitive cycles of magnetic attraction and repulsion controlled by an electronic board (P). Aluminium housings (21, 22), in addition to having a structural function, act as heat sinks to reduce heating during operation. The rotor sections (3, 4, 5, 6) are interconnected by a central shaft (EC), which is provided with bearings (10, 19), spacers (11, 13), and a shaft seal (20), ensuring stable rotation and protection against external contaminants. Magnetic commutation is precisely controlled by reflective optical sensors (SO) mounted on the electronic board (P), switching being performed by MOSFET transistors (43) and supervised by a microcontroller (44), responsible for monitoring the temperature of the system by means of digital thermal sensors (47). The motor provides high torque of 5.8 Nm at 25 V and 11.6 Nm at 50 V, exhibiting high energy efficiency and operational reliability, and is suitable for applications in devices that require high performance with low electricity consumption.

Description

[0001] Modular Electromagnetic Motor with Multistage Rotor Sections and Magnetic Commutation Control Process of the Modular Electromagnetic Motor

[0002] BRIEF PRESENTATION

[0003]

[0001] The present invention relates to an electromagnetic motor with a multi-stage segmented rotor. The motor has a modular structure composed of four rotor sections—primary, secondary, tertiary, and quaternary—arranged in axially mounted magnetostatic cells, 11.25° out of phase with each other. The operating principle is based on repetitive cycles of magnetic attraction and repulsion, controlled by an electronic board that processes signals from reflective optical sensors. These sensors continuously monitor the angular position of each rotor section, allowing precise actuation of the magnetic commutation stages. This configuration enables the generation of high torque with low heat dissipation, ensuring high energy efficiency. The motor is designed to operate on direct current (DC), with a nominal voltage range between 12 V and 25 V, supporting peaks of up to 50 V for a maximum period of 60 seconds.Due to its robustness and reliability, it is suitable for applications that demand high operational performance, such as drones and robots. Furthermore, its modular architecture facilitates maintenance and eventual component replacements.

[0004] FIELD OF THE INVENTION

[0005]

[0002] The invention described in this patent application is geared towards the field of electric motors applied in automation systems and high energy efficiency equipment. The described modular electromagnetic-static motor offers versatility for a wide range of applications in various sectors, such as: industrial machinery (compressors, pumps and presses); automation (industrial robots and process control systems); transportation (electric vehicles, such as cars and bicycles); manufacturing (cutting and assembly machines); and construction (cranes and construction elevators).

[0006]

[0003] Additionally, the invention can also be applied to air conditioning systems (fans and air conditioners) and processing equipment (grinders and mixers), promoting high energy efficiency with low electrical consumption, which makes its use viable in contexts that demand greater efficiency and lightness of the equipment.

[0007] BACKGROUND OF THE INVENTION

[0008]

[0004] Electric motors, both direct current (DC) and alternating current (AC), are widely used in various industrial and commercial applications due to their versatility and performance. However, these motors present a number of disadvantages and recurring problems that limit their efficiency and durability under certain operating conditions. Among the main technical problems faced, overheating stands out, frequently caused by overload, insufficient ventilation, or electrical faults, resulting in reduced efficiency and a shorter motor lifespan. This problem is especially critical in direct current motors due to the presence of commutators and brushes, which make heat dissipation more difficult.

[0009]

[0005] Another limiting factor is related to the need for regular maintenance, especially in wound-rotor motors, which have brushes and slip rings that require care to avoid operational failures. This aspect represents an additional cost and an operational challenge in industrial environments. Furthermore, induction motors require a very high starting current, which can overload the electrical network and cause incompatibility in sensitive systems.

[0010]

[0006] Finally, electromagnetic interference generated by brushes in wound-rotor motors can cause unwanted noise in controlled environments and pose a risk of sparks in potentially explosive atmospheres.

[0011] CURRENT STATE OF THE ART

[0012]

[0007] Document P11105383-6, published on 03 / 06 / 2014, is known from the current state of the art. It describes a magnetic motor composed of a set of two mounting configurations with differentiated angular or radial rings, with a housing, which is the structure of the assembly, a shaft, a connecting flange support, and a magnet support flange for the rotation of the system, the connecting flange, for joining and separating the angular or radial ring, the fan ring, the angular or radial ring, which is the support for the permanent magnets and magnet support, the fan ring to provide internal ventilation of the housing, the magnet support flange, which serves as a support for the permanent ring magnet support, the fixing support, for supporting the shaft and fixing it to the housing, the regulating ring, for adjusting the axial suspension of the shaft, the magnet support, for fixing the permanent magnet to the angular or radial ring, the permanent magnet flange, fixed to the angular or radial ring, through the magnet support,The permanent ring magnet support, installed on the magnet support flange; the shaft key, fixed to the shaft to lock the union flange and magnet support flange to the shaft; the housing electromagnet, fixed in the existing housing in the housing; the flange electromagnet, fixed in the existing housing of the support bracket; the permanent ring magnet shaft, one fixed to the shaft and the other fixed to the regulating ring, with the same polarities between the magnets; the flange fastening assembly, composed of screw, nut and washer, to fix the union flange with the angle ring or radial ring, fan ring and the magnet support flange; the magnet support fastening assembly, composed of screw, nut and washer, to fix the magnet support with the permanent magnet in the angle ring or radial ring; the housing electromagnet fastening assembly, composed of screw and washer, to fix the housing electromagnet to the housing; the support electromagnet fastening assembly, composed of screw and washer, to fix the support electromagnet with the support bracket.The flange stud bolt, for securing the union flange and magnet support flange to the shaft; the mounting bracket assembly, consisting of a bolt, nut, and washer, for securing the mounting bracket to the housing; and the ring mounting assembly, consisting of a bolt, nut, and washer, for securing the adjusting ring to the mounting bracket.

[0013]

[0008] Document BR 102013030129-9, published on 20 / 10 / 2015, describes an axial magnetic flux electric motor, the electric motor comprising at least one stator crown defining a contact surface, a plurality of magnets associated with the contact surface of the stator crown. The electric motor is configured to further comprise a rotor crown having a plurality of through cavities. The electric motor further comprises a plurality of teeth individually arranged in each of the through cavities and electrically associated on at least one of their surfaces with at least one copper coil.

[0009] The plurality of teeth comprises a shape cooperating with the shape of the through cavity.

[0014]

[0010] Document BR 102015012292-6, published on 06 / 28 / 2016, describes an electric motor that has a stator winding and an external rotor. A stator core has inner and outer annular portions. Toothed portions extend radially outward from the outer annular portion. Connecting arms interconnect the inner and outer annular portions. The width of the connecting arms is less than the width of the toothed portions.

[0015]

[0011] The ratio of tooth height to the distance between the bases of adjacent teeth is in the range of 1.0 to 1.3. The ratio of tooth width to the distance between the bases is in the range of 0.8 to 1.0. The ratio of tooth width to the distance between the bases is in the range of 0.5 to 0.6. The ratio of tooth width to the outer diameter of the stator core is in the range of 0.07 to 0.1.

[0016]

[0012] The present invention differs technically from the prior art documents P11105383-6, BR 102013030129-9 and BR 102015012292-6 in several fundamental aspects. Firstly, the modular electromagnetic static motor described in the present application uses an innovative magnetic commutation control system by means of reflective optical sensors and precise magnetic attraction and repulsion cycles between solenoid armatures and permanent magnets, whereas the cited documents focus on structural configurations of permanent magnets, without the dynamic and electronic control of the magnetic cycle as in the present invention.Furthermore, document P11105383-6 deals with a motor with angular and radial ring assemblies for internal ventilation, focusing on a rigid magnet support structure, while the present invention employs a modular structure, allowing the integration of multiple rotor sections (primary, secondary, tertiary and quaternary) and favoring heat dissipation with functional aluminum fairings as heat sinks, without the need for fan rings.

[0017]

[0013] Compared to document BR 102013030129-9, which describes an axial magnetic flux motor with through cavities and teeth arranged in its cavities, the present invention differs by using radial magnetic cycles in the rotor sections in multiple stages, optimizing torque and energy efficiency through commutation controlled by reflective optical sensors, which is not mentioned in the prior art. Document BR 102015012292-6 addresses an electric motor with an external winding stator and rotor, focusing on the geometric relationship of the stator teeth and windings. In contrast, the present invention uses solenoid armatures with cylindrical coils and does not present the geometric limitations described in that document, which allows for optimized operation over a wider voltage range, in addition to promoting more efficient heat dissipation through its enclosures, without the structural restrictions presented in prior art motors.

[0018]

[0014] Document US11870368B2, published on 05 / 08 / 2021, describes an electrostatic motor composed of a set of rotor and stator plates arranged alternately along an axis, forming a capacitor arrangement. The rotor plates have electrodes on their surfaces facing the stator plates, which also contain electrodes. The motor is configured so that the rotor plates move relative to the stators, generating torque according to the capacitive interaction between the electrodes. The size of the gap between the stator and rotor plates, which can be less than 3 mm, plays a crucial role in the amount of torque generated. The motor structure allows for optimized mounting with axial freedom to facilitate the manufacturing and assembly process.

[0019]

[0015] However, document US11870368B2 describes an electrostatic motor that uses rotor and stator plates arranged alternately along an axis, interacting electrostatically to generate torque; however, the present invention relates to a modular electromagnetic-static motor, composed of multiple rotor sections (primary, secondary, tertiary, and quaternary), operating in magnetostatic cells with magnetic commutation. In the present invention, the system is controlled by reflective optical sensors and digital thermal sensors, which manage the commutation in the solenoid armature coils. This management aims to optimize motor efficiency and prevent overheating, presenting an approach not taught in document US11870368B2, which focuses exclusively on electrostatic interactions and capacitors.Furthermore, the present invention utilizes direct current (DC) with control via MOSFET transistors, whereas the document described deals with a purely electrostatic arrangement without details on thermal management or dynamic current control.

[0020] OBJECTIVES OF THE INVENTION

[0021]

[0016] To provide a modular electromagnetic-static motor designed to maximize energy efficiency by reducing energy consumption compared to conventional direct current (DC) and alternating current (AC) electric motors, minimizing heat generation, and increasing durability.

[0022]

[0017] Avoid frequent maintenance with a modular structure, increasing reliability and facilitating assembly.

[0023]

[0018] Reducing motor weight for use in smaller and lighter devices, without compromising power or efficiency, ensuring greater flexibility.

[0024]

[0019] Implement modern technologies, such as reflective optical sensors, advanced electronic control, lightweight materials and 3D printing, with the aim of simplifying assembly and maintenance, as well as speeding up and making production more efficient.

[0025]

[0020] To increase the commercial viability of the electromagnetic static motor by offering a product with low production and maintenance costs, high energy efficiency and optimized performance, enabling its application in sectors such as automation, transportation and industrial machinery.

[0026]

[0021] Enable the motor to operate with controlled drive current, avoiding overloads on the electrical network and compatibility problems, in addition to providing a starting torque higher than the nominal value.

[0027] OF THE INVENTION

[0028]

[0022] The present invention falls within the field of electromagnetic motors, more specifically in the development of a modular electromagnetic-static motor, composed of rotor sections arranged in multiple stages. This motor was developed to overcome common limitations in conventional direct current (DC) electric motors, such as overheating, high maintenance requirements, and low energy efficiency. The electromagnetic-static motor can operate with a fixed or variable supply voltage, in the range of 12 V to 25 V, supporting peaks of up to 50 V for a maximum period of 60 seconds. Under these conditions, it exhibits an average torque of 5.8 Nm at 25 V and 11.6 Nm at 50 V, with 150 W and 600 W of electrical power consumption, respectively. The motor can be powered by batteries, DC-DC converters, or AC-DC sources connected to the electrical grid.The invention features a modular structure formed by four rotor sections—primary, secondary, tertiary, and quaternary—which, when coupled, constitute the complete rotor together with the central shaft and two housings, each housing two stators. The magnetostatic cells—primary and secondary—are composed of the stators, fixed inside the housing, and the respective rotor sections, which interact magnetically with these stators. The magnets, both those present in the rotor sections and in the stators, are neodymium permanent magnets. Each stator is composed of solenoid armatures and armatures equipped with fixed magnets. The electronic control system for magnetic commutation, which uses reflective optical sensors, is installed in the secondary cell. The motor also has thermal protection based on digital temperature sensors integrated into a microcontroller.The project stands out for its high energy efficiency, weight reduction, greater operational reliability, and low maintenance requirements. Its modular architecture allows for applications in compact devices, offering a significantly higher power-to-weight ratio than conventional electric motors.

[0029] ADVANTAGES OF THE INVENTION

[0030]

[0023] The present invention offers the following advantages:

[0031] Efficient heat dissipation: reduces overheating through aluminum fairings configured as heat sinks;

[0032] High magnetostatic potential energy density: ensures operation with high torque and minimal heat generation, even under overload or shaft locking conditions;

[0033] Efficiency exceeding 500%: ensures high energy efficiency with minimal losses. This feature allows operation with significantly reduced electricity consumption, enabling a substantial decrease in the capacity and number of batteries required for its operation; Modular structure: the motor design facilitates assembly and maintenance, employing advanced technologies that simplify the development and production of components, reducing manufacturing costs;

[0034] Integrated protections: includes protection against accidental reverse polarity, overvoltage and overheating, managed by an advanced electronic control system;

[0035] Optimized electronic control: utilizes reflective optical sensors immune to magnetic fields, ensuring continuous and efficient torque during operation;

[0036] Weight reduction: the significant decrease in motor mass makes it feasible to use it in smaller and lighter devices, such as drones, robots, and electric vehicles, without compromising performance;

[0037] Enhanced commercial viability: low production costs, reduced maintenance, and optimized energy efficiency give the engine greater competitiveness in the market;

[0038] DESCRIPTION OF THE FIGURES

[0039]

[0024] The following figures are presented to better explain the patent application in an illustrative and non-limiting manner:

[0040] Fig. 1: shows an exploded perspective view of the modular electromagnetic motor with multi-stage rotor sections;

[0041] Fig. 2: shows an exploded perspective view of the primary magnetostatic cell;

[0042] Fig. 3: shows the front view of the stage;

[0043] Fig. 4: shows the representative diagram of the electromagnetic motor with the four stages in their respective magnetostatic cells;

[0044] Fig. 5: shows a perspective view of the movable magnet in the center, between the terminations of the solenoid armature;

[0045] Fig. 6: shows a perspective view of the moving magnet moving towards the armature equipped with fixed magnets;

[0046] Fig. 7: shows a perspective view of the moving magnet reaching the center, between the terminations of the subsequent solenoid armature; Fig. 8: shows a perspective view of the modular electromagnetic motor with sections of the multi-stage rotor;

[0047] Fig. 9: shows the operational block diagram of the electromagnetic motor;

[0048] Fig. 10: shows the timing diagram for the commutation of the armature-solenoid coils of the four stages;

[0049] Fig. 11: shows the graph of axial torque as a function of angular displacement, in normal operation, with a supply voltage of 25 V;

[0050] Fig. 12: shows the graph of the internal axial force as a function of angular displacement, in normal operation, with a supply voltage of 25 V;

[0051] Fig. 13: shows the graph of axial torque as a function of angular displacement, corresponding to the complete 360° rotation of the central shaft, resulting from the application of external force, with the motor in the off condition.

[0052] DETAILED DESCRIPTION OF THE INVENTION

[0053]

[0025] The MODULAR ELECTROMAGNETOSTATIC MOTOR WITH MULTISTAGE ROTOR SECTIONS AND MAGNETIC COMMUTING CONTROL PROCESS OF THE MODULAR ELECTROMAGNETOSTATIC MOTOR, consists of an electromagnetic static motor (1) that has a modular structure (2) which integrates four rotor sections: primary (3), secondary (4), tertiary (5) and quaternary (6). The primary (3) and secondary (4) sections are located in the primary magnetostatic cell (7), while the tertiary (5) and quaternary (6) sections are located in the secondary magnetostatic cell (8).

[0054]

[0026] The magnetostatic cells (7, 8) are axially aligned and mounted with an angular phase shift of 11.25 o each other.

[0055]

[0027] The primary magnetostatic cell (7) is mounted in a primary aluminum housing (21), forming the stator assembly (E), while the secondary magnetostatic cell (8) is mounted in a secondary aluminum housing (22), forming the stator assembly (E1).

[0056]

[0028] Each magnetostatic cell (7, 8) is formed by an aluminum casing subdivided into two internal compartments, called stages (25), which house two identical circular arrangements — the stators (37) — separated from each other by a spacing of 2 mm, as well as by an angular phase shift of 22.5°. The said stators (37) are formed by eight pairs of armatures, each pair consisting of a solenoid armature (26), provided with identical terminations (27) at both ends, and an armature equipped with fixed magnets (28), in addition to two corresponding rotor sections. The rotor sections (3, 4, 5, 6) consist of an aluminum core in the shape of an eight-pointed star (29), in each of which a support (30) is fixed to house a movable magnet (31), whose magnetic poles are oriented parallel to the central axis (EC).When mounted on the central axis (EC), the aforementioned rotor sections (3, 4, 5, 6) remain axially aligned, without angular phase shift between them. Each support (30) consists of a strap (32), a protective cover (33) and a fastening element (34), all made of non-ferromagnetic materials.

[0057]

[0029] Both the primary aluminum casing (21) and the secondary aluminum casing (22) comprise semicircular seats (23) and straight seats (24), arranged in an alternating fashion, intended for mounting the stators (37). The solenoid armatures (26) are fixed internally to the casings (21, 22), in the semicircular seats (23) using a two-component, thermally conductive and electrically insulating adhesive. Subsequently, the armatures equipped with fixed magnets (28) and the copper wire splices (36) are added, all these components being encapsulated together by means of thermoplastic or resin. This encapsulation ensures structural rigidity, electrical insulation, effective heat dissipation and preserves the internal space suitable for the operation of the rotor sections (3, 4, 5, 6).

[0058]

[0030] The rotor sections (3, 4, 5, 6) are inserted into their respective stages (25), with each magnetostatic cell (7, 8) configured to accommodate two stages (25), thus enabling the integration of the four rotor sections (3, 4, 5, 6) into the modular structure (2) of the electromagnetic motor (1).

[0059]

[0031] The tertiary section (5) comprises a central shaft (EC) which connects all sections of the rotor of the modular structure (2), said central shaft (EC) being provided with bearings (10, 19), spacers (11, 13) and a reflector ring (12), the latter coupled to the quaternary section (6). Additionally, the electromagnetic static motor (1) incorporates an electronic board (P), a rear cover (14), a cable gland (15) and a threaded sealing plug (16), as well as a front cover (17) equipped with fastening elements (18) and shaft seal (20), enabling the central shaft (EC) to perform rotary motion smoothly and protected against the entry of external contaminants.

[0060]

[0032] The primary (3), secondary (4), tertiary (5) and quaternary (6) rotor sections operate in conjunction with four reflective optical sensors (SO), installed on the electronic board (P), which, by means of the reflector ring (12), continuously monitor the angular position of said sections and transmit electrical signals in real time to the electronic board (P). In addition, the electromagnetic static motor (1) comprises two digital thermal sensors (STD) positioned on the secondary aluminum casing (22), in proximity to the armature-solenoid coil (26), which monitor the temperature and act to shut down the electromagnetic static motor (1), when necessary, in order to ensure thermal protection.

[0061]

[0033] The central axis (EC) secures all rotor sections (3, 4, 5, 6) by means of spacers (11, 13) and fastening elements, ensuring the integrity of the assembly. The reflector ring (12), positioned in the quaternary section of the rotor (6), close to the rear cover (14), is detected by reflective optical sensors (SO), which provide precise real-time electrical signals about the angular position of all rotor sections (3, 4, 5, 6).

[0062]

[0034] The movable magnets (31) interact directly with the solenoid armatures (26) and armatures equipped with fixed magnets (28), arranged radially around the rotor sections (3, 4, 5, 6). The solenoid armatures (26) consist of a coil with 500 turns of enameled copper wire wound around a ferromagnetic core, while the armatures equipped with fixed magnets (28) consist of ferromagnetic armatures in which two identical rectangular magnets (35) are mounted in parallel, with defined spacing to maximize magnetic interaction, having their magnetic poles oriented radially and in opposite directions. All armatures made of ferromagnetic material exhibit high magnetic permeability.

[0035] The modular structure (2) of the electromagnetic static motor (1) is designed to operate on direct current (DC), in a working voltage range between 12 V and 25 V, and can withstand peaks of up to 50 V for 60 seconds.When powered at 25 V, the electromagnetic motor (1) develops an average torque of 5.8 Nm, with a power consumption of 150 W. When powered at 50 V, the torque produced doubles to 11.6 Nm with a consumption of 600 W. The electromagnetic motor (1) can be powered by batteries, DC-DC converters or AC-DC power supplies connected to the mains, provided they are rated to supply a direct current of 12 A, ensuring full operation.

[0063]

[0036] The control of the entire system is carried out by the electronic board (P), which receives electrical signals from the reflective optical sensors (SO), mounted on the board itself. The aforementioned sensors continuously monitor the angular position of the primary (3), secondary (4), tertiary (5) and quaternary (6) sections, sending signal pulses to the D flip-flops (40, 41), with the reflective optical sensors (SO) 1 and 2 being directly connected to the D flip-flops (40) 1 and 2, while the sensors (SO) 3 and 4 are connected to the D flip-flops (41) 3 and 4. The outputs of the D flip-flops (40, 41) are connected to the buffers (42), which control the MOSFET transistors (43) 1, 2, 3 and 4, responsible for switching the electric current in the coils (X) of the solenoid armatures (26) of the four stators (37), located in the corresponding stages (25).The microcontroller (44), which receives data from the digital thermal sensors (47), acts on the buffers (42), deactivating them when it detects critical temperature levels and reactivating them when the temperature returns to safe operating values. In this way, the microcontroller temporarily deactivates the system, protecting the components of the electromagnetic motor (1) against thermal damage.

[0064]

[0037] The electronic board (P) is powered by a DC-DC converter (45), which provides a voltage of 5 V for the operation of the components, considering that the supply voltage at the input of the electromagnetic motor (1) can vary between 12 V and 25 V, and may reach 50 V for brief periods. The circuit of the electronic board (P) also incorporates an EMI filter for reducing electromagnetic noise and a reverse polarity protection diode (46), ensuring the integrity of the system. The terminals of the coil assemblies (X) are connected directly to the MOSFET transistors (43) and to the DC power supply input, with voltages up to 50 V.

[0065]

[0038] The electromagnetostatic motor (1) operates by means of repetitive cycles of magnetic attraction and repulsion between the movable magnets (31), the solenoid armatures (26), and the armatures equipped with fixed magnets (28) distributed in the four stages (25). This cycle begins when the movable magnets (31), positioned on the eight supports (30) of the star-shaped aluminum core (29), interact magnetically with the solenoid armatures (26), generating rotational movement. In each stage (25), the eight movable magnets (31) of the respective rotor section perform simultaneous magnetic cycles, producing torque resulting from the sum of the forces acting on that section. As the stators (37) of the primary, secondary, tertiary and quaternary stages (25) are out of phase with each other, the torques generated in the rotor sections (3, 4, 5, 6) alternate.During a complete rotor rotation, each section performs eight cycles of combined forces, due to the 45° angular spacing between the moving magnets (31). The sum of these torques, considering the four rotor sections (3, 4, 5, 6) during a complete rotation and under a working voltage of 25 V, is represented in the graph of Fig. 11. The central shaft (CS) is also subject to internal axial forces, which alternate in both directions, generated by periodic oscillations along the shaft during operation with a working voltage of 25 V. The graph of these forces is illustrated in Fig. 12. When the motor is de-energized, the axial torque as a function of angular displacement, represented in Fig. 13, shows that the application of an external force to the shaft causes alternation between the holding torque and the residual magnetic torque, resulting, over a complete rotation, in a zero average torque.

[0066] FROM THE ASSEMBLY

[0067]

[0039] The sequential assembly of the modular structure (2) of the electromagnetic motor (1) begins with the pre-assembly of the stators (E, E1) of the magnetostatic cells (7, 8) and the four rotor sections (3, 4, 5, 6), ensuring that all parts are prepared before the final assembly stage. During the pre-assembly of the stators (E, E1), the solenoid armatures (26) are fixed to the semicircular seats (23) of the aluminum casings (21, 22) by the coils, which are joined with a two-component, thermally conductive and electrically insulating adhesive. The armature terminations (27) are positioned facing the center. Then, the armatures equipped with fixed magnets (28) and the copper wire splice terminals (36), responsible for the electrical connection of the coils, are inserted. All components, fixed with adhesive and inserted, are encapsulated inside the fairings (21, 22), using materials such as thermoplastic or epoxy resin.This process maintains an internal cylindrical space. During the adhesive curing and subsequent encapsulation, a specially designed tool is used to act as a jig and mold, ensuring precision in the alignment and conformity of the components. During the pre-assembly of the primary (3), secondary (4), tertiary (5) and quaternary (6) sections of the rotor, eight magnets (31) are distributed and fixed to the ends of each aluminum core (29) with cyanoacrylate-based adhesive, strictly observing the orientation of the magnetic poles, according to the polarization scheme of each stage of the motor. The straps (32) are also adhered to the magnets (31) and the cores (29), using the same adhesive and ensuring a secure and uniform fixation. Then, the protective covers (33) are fitted and firmly fixed to the cores (29) by means of semi-tubular rivets (34).Thus, the installation of the thirty-two supports (30) is completed, each accommodating a magnet (31) in the four sections of the rotor (3, 4, 5, 6). The assembly begins with the fixing of a spacer (11) on the central shaft (EC) positioned next to the tertiary section (5). Next, the reflector ring (12) is installed on the quaternary section (6) using four fastening elements (9). The assembly formed by the tertiary section (5), spacer (11) and central shaft (EC) is then inserted into the internal space of the stator (E1). The quaternary section (6), equipped with the reflector ring (12), is also inserted inside the stator (E1), being fitted onto the central shaft (EC) and fixed to the tertiary section (5) by means of two screws. Subsequently, the second spacer (13), the secondary section (4) and the third spacer (11), which is fixed to the central shaft (EC) by two screws, are fitted onto the central shaft (EC), next to the tertiary section (5).In this step, the primary aluminum casing (21) containing the stator (E) is connected to the secondary aluminum casing (22) containing the stator (E1), with alignment ensured by three fixing pins. The secondary section (4) is positioned in the internal space of the stator (E). Next, the primary section (3) is fitted onto the central shaft (EC), moved into the internal space of the stator (E) and fixed to the secondary section (4) using two screws. The bearings (10, 19) are installed at opposite ends of the central shaft (EC), one on each side, thus completing the rotor and the magnetostatic cells (7, 8). The electronic control board (P) and the digital thermal sensors (STD) are fixed to the secondary aluminum casing (22), while the enameled copper wires from the magnetostatic cells (7, 8) are soldered to the electronic control board (P).Next, the rear cover (14), equipped with cable gland (15), electrical cable and threaded sealing plug (16), is fitted to the secondary aluminum casing (22). Finally, the shaft seal (20) is installed on the front cover (17), which is fitted to the primary aluminum casing (21). The fastening elements (18) ensure the firm union between the magnetostatic cells (7, 8) and the covers (14, 17), thus completing the assembly of the electromagnetostatic motor (1).

[0068] HOW IT WORKS

[0069]

[0040] The operation of the electromagnetostatic motor (1) is based on magnetic interaction cycles between the movable magnets (31) present in the rotor sections (3, 4, 5, 6) and the stators (37), which are made up of eight pairs of armatures. Each pair consists of a solenoid armature (26) and an armature equipped with fixed magnets (28). When a continuous electric current flows through the coils of the solenoid armatures (26), a magnetic field is generated that opposes the field of the movable magnets (31), which are positioned in the center, between the terminations (27) of the solenoid armatures (26). This interaction produces a tangential force responsible for propelling the movable magnets (31) of the four rotor sections in a circular trajectory, as illustrated in Fig. 5. Each moving magnet (31) is subjected to attractive and repulsive forces as it moves between consecutive solenoid armatures (26), reaching the maximum tangential force in the initial angular range of 22.5°.Point from which the direct current is switched off, so that the movable magnet (31) is attracted by the armature equipped with fixed magnets (28) and then by the subsequent solenoid armature (26), completing the 45° cycle and starting the next cycle, as illustrated in Figs. 6 and 7.

[0070]

[0041] The magnetic cycle repeats continuously as the moving magnets (31) move between the solenoid armatures (26). The commutation of the electric current in the coils of these armatures is carried out precisely, strategically adjusted according to the angular position of the rotor sections (3, 4, 5, 6), being controlled by four reflective optical sensors (SO), together with a reflector ring (12) that rotates synchronously with the central axis (EC). The angular phase shift of 22.5° between the stators (37) of the cells (7, 8) and the phase shift of 11.25° between the cells themselves (7, 8), establishes a precise timing relationship for the electrical commutation in the stage coils (25), as illustrated in Fig. 10.

[0071]

[0042] This commutation control is essential to ensure a continuous flow of torque and maximize the efficiency of the electromagnetic static motor (1).

[0072] OF THE PROCESS

[0073]

[0043] Because the system has a process comprised of the following steps:

[0074] • generate a magnetic field by applying direct electric current to the coils of the solenoid armatures (26), initiating the magnetic interaction cycle with the movable magnet (31), which travels an arc of 22.5°, at which point the current is switched off, the movable magnet (31) continuing along its path until it reaches the same initial position in the subsequent solenoid armature (26), completing the 45° cycle and starting the next cycle;

[0075] • interact the magnetic field generated by the solenoid armature coils (26) with the movable magnets (31) arranged in the primary (3), secondary (4), tertiary (5) and quaternary (6) sections, so as to propel the movable magnets (31) in a circular path;

[0076] • perform the switching of the electric current in the solenoid armature coils (26) in each stage (25) of the magnetostatic cells (7, 8), switching it according to the angular position of the rotor section corresponding to the respective stage; • control the switching sequence of the solenoid armatures (26) by means of the electronic board (P), which receives signals from the reflective optical sensors (SO) that monitor the angular position of the primary (3), secondary (4), tertiary (5) and quaternary (6) sections, allowing the activation of the MOSFET transistors (43);

[0077] • adjust the electric current in the solenoid armature coils (26) according to the temperature measured by the digital thermal sensors (STD), interrupting the operation of the electromagnetic static motor (1) in case of overheating detection;

[0078] • power the electronic board (P) by means of a DC-DC converter (45), incorporating an EMI filter and a reverse polarity protection diode (46).

[0079]

[0044] In summary, the electromagnetic motor (1) was designed to operate with high energy efficiency and exceptional mechanical performance, employing neodymium permanent magnets in the rotor and stator, together with solenoid armatures (26) equipped with enameled copper wire coils. Among its main advantages are the high magnetostatic potential energy density, combined with low electrical consumption, enabling operation with high torque and minimal heat generation, even under overload or shaft locking conditions. The electromagnetic motor (1) has an efficiency greater than 500%, being able to provide starting torque above the nominal value, in addition to having an integrated protection system against reverse polarity, overvoltage and overheating, managed by advanced electronic control that uses reflective optical sensors (SO), digital thermal sensors (STD) and a microcontroller (44).The project's central objectives include: maximizing energy efficiency, reducing the machine's weight, enabling its application in smaller equipment such as drones and robots; simplifying development and maintenance through the use of modern technologies such as 3D printing, automation, robotics, and modular design; and ensuring commercial viability by offering a lightweight, efficient, and low-cost product, considering factors such as acquisition, maintenance, productivity, and lifespan.

Claims

CLAIMS 1) MODULAR ELECTROMAGNETOSTATIC MOTOR WITH MULTISTAGE ROTOR SECTIONS, consists of an electromagnetic static motor (1) characterized by having a modular structure (2) equipped with four rotor sections, composed of: primary section (3), secondary section (4), tertiary section (5) and quaternary section (6); by the primary section (3) and secondary section (4) being allocated in a primary magnetostatic cell (7); by the tertiary section (5) and quaternary section (6) being allocated in a secondary magnetostatic cell (8); by the primary magnetostatic cell (7) and the secondary magnetostatic cell (8) being mounted axially, rotated by 11.25°, relative to each other; by the primary section (3) and secondary section (4), as well as the tertiary section (5) and quaternary section (6), being included in the stages (25) of the magnetostatic cells (7, 8) respectively; because the stages (25) have a spacing of 2 mm between them;because the modular structure (2) is designed to operate on direct current (DC), with a working voltage between 12V and 25V, being able to withstand peaks of up to 50V for 60 seconds; because the tertiary section (5) has a central shaft (EC), which connects all sections of the rotor (3, 4, 5, 6) of the modular structure (2). This central shaft (EC) receives bearings (10, 19) and spacers (11, 13), also comprising a reflector ring (12) coupled to the quaternary section (6); because the reflector ring (12) is positioned close to the four reflective optical sensors (SO) mounted on the electronic board (P), in addition to a rear cover (14) of the modular structure (2) equipped with a cable gland (15) and a threaded sealing plug (16); also, because it comprises a front cover (17) provided with fastening elements (18) and shaft seal (20). 2) MODULAR ELECTROMAGNETOSTATIC MOTOR WITH MULTISTAGE ROTOR SECTIONS, according to claim 1, characterized in that the primary magnetostatic cell (7) is mounted in a primary aluminum casing (21), which constitutes the stators (E), while the secondary magnetostatic cell (8) is mounted in a secondary aluminum casing (22), which constitutes the stators (E1), both casings being configured so as to also act as heat sinks; because the primary magnetostatic cell (7) and the secondary magnetostatic cell (8) have their components fixed to their respective aluminum housings by means of a two-component adhesive, thermally conductive and electrically insulating; and also because the primary aluminum housing (21) and the secondary aluminum housing (22) comprise semicircular seats (23) and straight seats (24) interspersed for mounting the stators of the magnetostatic cells (7, 8). 3) MODULAR ELECTROMAGNETOSTATIC MOTOR WITH MULTISTAGE ROTOR SECTIONS, according to claims 1 and 2, characterized in that the rotor sections — primary (3), secondary (4), tertiary (5) and quaternary (6) — operate in conjunction with reflective optical sensors (SO), installed on the electronic board (P), which, by means of the reflector ring (12), allow continuous monitoring of the angular position of said rotor sections (3, 4, 5, 6). 4) A MODULAR ELECTROMAGNETOSTATIC MOTOR WITH MULTISTAGE ROTOR SECTIONS, according to claims 1, 2 and 3, is characterized in that the primary magnetostatic cell (7) is formed by two identical circular arrangements called stators (37), composed of solenoid armatures (26), which have terminations (27) at both ends, and armatures equipped with fixed magnets (28); by the stages (25) that contain the said stators (37) phase-shifted by an angle of 22.5°, as well as the rotor sections — primary (3) and secondary (4) — located at the center of each corresponding stage (25); because the rotor sections (3, 4, 5, 6) consist of an eight-pointed star-shaped aluminum core (29), where each point receives a support (30) that accommodates a magnet (31) with axially oriented magnetic poles;because the support (30) consists of a strap (32), a protective cover (33) and a fastening element (34), all made of non-ferromagnetic materials.; 5) A MODULAR ELECTROMAGNETOSTATIC MOTOR WITH MULTISTAGE ROTOR SECTIONS, according to claims 1 and 4, is characterized in that the primary magnetostatic cell (7) and the secondary magnetostatic cell (8) have movable magnets (31) that interact directly with the solenoid armatures (26) and with armatures equipped with fixed magnets (28) arranged radially around each section of the rotor; because the solenoid armatures (26) are made up of a coil with 500 turns of enameled copper wire, wound around a ferromagnetic core; and because the armatures equipped with fixed magnets (28) are made up of a ferromagnetic armature, in which two identical rectangular magnets (35) are mounted in parallel, spaced apart and with the magnetic poles oriented radially and oppositely. 6) A MODULAR ELECTROMAGNETOSTATIC MOTOR WITH MULTISTAGE ROTOR SECTIONS, according to claims 1, 4 and 5, is characterized in that the solenoid armatures (26) have their power supply controlled by the electronic board (P) as a function of the magnetic cycle. 7) A MODULAR ELECTROMAGNETOSTATIC MOTOR WITH MULTISTAGE ROTOR SECTIONS, according to claim 1, is characterized in that the reflector ring (12) operates in conjunction with reflective optical sensors (SO), which detect the rotation of said ring and provide electrical signals, in real time, to the electronic board (P), indicating the angular position of the primary (3), secondary (4), tertiary (5) and quaternary (6) sections. 8) A MODULAR ELECTROMAGNETOSTATIC MOTOR WITH MULTISTAGE ROTOR SECTIONS, according to claims 1, 3, 4, 5 and 6, is characterized in that the modular structure (2) operates by means of repetitive cycles of magnetic attraction and repulsion between the movable magnets (31), the solenoid armatures (26) and the armatures equipped with fixed magnets (28) in each section of the rotor; the cycle of which begins with the movable magnets (31), positioned on the supports (30) of the eight points of the aluminum core (29) of the respective section of the rotor, being subjected to magnetic repulsion from the solenoid armatures (26) when their coils are traversed by direct current. 9) MAGNETIC COMMUTING CONTROL PROCESS OF THE MODULAR ELECTROMAGNETOSTATIC MOTOR, by the electromagnetic-static motor (1) according to claim 1, being characterized by comprising the following steps: • generate a magnetic field by applying direct electric current to the solenoid armature coils (26); • interact the generated magnetic field with the moving magnets (31), arranged in the primary (3), secondary (4), tertiary (5) and quaternary (6) rotor sections, so as to propel them in a circular path; • perform the switching of the electric current in the coils of the solenoid armatures (26), interrupting it when the movable magnets (31) reach the angular position of 22.5°, being then subjected to magnetic attraction by the armatures equipped with fixed magnets (28) and, subsequently, by the subsequent solenoid armatures (26), completing the 45° cycle and starting the next one (Figs. 5, 6, 7); • control the switching sequence in the solenoid armature coils (26) by means of an electronic board (P), which receives signals from the reflective optical sensors (SO) to monitor in real time the angular position of the primary (3), secondary (4), tertiary (5) and quaternary (6) sections, adjusting the drive of the MOSFET transistors (43); • adjust the electric current in the solenoid armature coils (26) as a function of the temperature measured by the digital thermal sensors (STD), interrupting the operation of the electromagnetic static motor (1) in case of overheating; • supply the electronic board (P) by means of a DC-DC converter (45), comprising an EMI filter (46) and a reverse polarity protection diode (46).

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