Electric motor / generator with ac-to-ac converter

Abstract

An electrical machine comprising at least one stator and at least one module attached to the stator. Each module comprises at least one electromagnetic coil and at least one power converter having at least one switch and at least one control information generator. The switch connects to input terminals coupled to phases of an AC power source or load. The control information generator generates control information to control the switch. At least one rotor with a plurality of magnets is in spaced relation to the modules and in a rotational, linear, or movement relationship with the stator. The quantity and configuration of modules is determined based on one or more operating parameters. Each module is capable of being independently controlled and reconfigured during operation based on operating parameters, performance parameters, or combinations thereof. The power converter may convert AC power without intermediate DC conversion. Other embodiments are also disclosed.

Description

ELECTRIC MOTOR / GENERATOR WITH AC-TO-AC CONVERTER

[0001] This application claims priority from Australian Provisional Patent Application No. 2025900995, filed 27 March 2025, the entire disclosure of which is incorporated herein by reference.

[0002] This disclosure relates generally to electric motors / generators adapted for various applications as well as to related methods and / or systems. Certain embodiments of the present disclosure relate to electric motors / generators which are: 1) reversible, 2) able to efficiently produce high torque in portions of the power and / or RPM range, 3) able to efficiently produce power in portions of the power and / or RPM range, 4) able to efficiently produce high torque substantially throughout the whole of a defined extended power and / or RPM range, 5) able to efficiently produce power substantially throughout the whole of a defined extended power and / or RPM range, 6) are compact, 7) are modular, 8) have an AC to AC converter without an intermediate DC stage, 9) have an integrated transformer, 10) combinations thereof. Certain embodiments are able to be employed, for example, as motors to drive a range of industrial, commercial and agricultural equipment examples of which are pumps, fans, compressors, grinders, mills and conveyor belts, as generators to produce electricity from for example wind, hydro and geothermal.

[0003] The use of electric motors / generators in a number of application areas is known. For example, in industrial equipment or wind generators. Traditional electric motors / generators typically work reasonably well at particular speeds and power requirements. However, as the speed or power output is varied the efficiency of these traditional motors / generators drops. To ensure that the device keeps operating at high efficiency most devices are often run at higher speeds even when less would suffice, wasting energy, or are coupled to expensive and heavy transmission systems which require ongoing maintenance and greatly increase the number of moving parts increasing the risk of failure.

[0004] Modifying existing motor drive systems such that they are capable of Variable Speed Drive (VSD) can introduce energy savings depending on the application. However, adding VSD to traditional motors is an expensive exercise. The power supply’s frequency has to be modified, requiring high current switching, which use large and expensive electronic switches. Further once the speed of the motor is adjusted the motor may no longer be operating at its peak efficiency therefore the energy savings of running the motor slower may be offset by running the motor in a region that is less efficient. The cabling from the VSD to the motor contains harmonics that may be harmful to other equipment therefore shielded cabling needs to be added increasing installation costs.

[0005] Various configurations of electric motors are known. At present, the majority of industrial motors used, for example, in pumps and fans are synchronous induction motors. In common with other synchronous designs, these may suffer from conduction losses and heat generation during high power operation. Generally speaking, induction machines are more difficult to control, the control laws being more complex and less amenable to modelling. Interior permanent magnet synchronous machines rotor cooling is more difficult than with brushless Alternating Current (AC) motors and peak point efficiency is generally lower. Achieving stability over a suitable torque-speed range and controlling temperature is more difficult than with brushless alternating-current motors. Induction machines and switched-reluctance machines have been used for many years, but require modification to provide suitable optimal performance in, for example, industrial applications.

[0006] Current state of the art industrial drive train consists of an AC source or load connected to control electronics, the control electronics modulate the voltage to the required frequency to drive the electric motor, the output of the electric motor. The electric motor is often then coupled to the input of a gear set which then drives the device at the desired speed and torque.

[0007] In an application such as wind powered electric generation, these systems tend to be bulky and costly to repair. They also typically require a gear box, a motor, an inverter and / or a transformer making them fairly complex systems that are subject to greater chances of malfunction.

[0008] There is a need for improved systems, devices and methods directed to electric motors / generators. The present disclosure is directed to overcome and / or ameliorate at least one of the disadvantages of the prior art as will become apparent from the discussion herein.

[0009] This summary is meant to be exemplary of certain embodiments. Devices, methods of use, methods of manufacture and / or systems are disclosed in the specification. Some embodiments may not be disclosed in this summary but are disclosed in other examples or other portions of this disclosure.

[0010] Certain embodiments are directed to devices, methods, and / or systems that use electrical machines. For example, certain embodiments are directed to an electrical machine comprising: at least one stator; at least one module, the at least one module comprising at least one electromagnetic coil and at least one power converter, the at least one power converter comprising at least one switch and at least one control information generator, the at least one switch connects to a plurality of input terminals to the at least one electromagnetic coil, the plurality of input terminals being respectively coupled to phases of an AC power source or load, the at least one control information generator configured to generate control information to control the at least one switch, the at least one module being attached to the at least one stator, at least one rotor with a plurality of magnets attached to the at least one rotor, wherein the at least one module is in spaced relation to the plurality of the magnets; and the at least one rotor being in a rotational relationship with the at least one stator, wherein the quantity and configuration of the at least one module in the electrical machine is determined based in part on one or more operating parameters; wherein the at least one module is capable of being independently controlled; and wherein the at least one module is capable of being reconfigured based at least in part on one or more of the following: at least one operating parameter during operation, at least one performance parameter during operation, or combinations thereof.

[0011] Certain embodiments are directed to devices, methods, and / or systems that use electrical machines. For example, certain embodiments are directed to an electrical machine comprising: at least one stator; at least one module, the at least one module comprising at least one electromagnetic coil and at least one power converter, the at least one power converter comprising at least one switch and at least one control information generator, the at least one switch connects to a plurality of input terminals to the at least one electromagnetic coil, the plurality of input terminals being respectively coupled to phases of an AC power source or load, the at least one control information generator configured to generate control information to control the at least one switch, the at least one module being attached to the at least one stator, at least one slider with a plurality of magnets attached to the at least one slider, wherein the at least one module is in spaced relation to the plurality of the magnets; and the at least one slider being in a linear relationship with the at least one stator.

[0012] Certain embodiments are directed to devices, methods, and / or systems that use electrical machines. For example, certain embodiments are directed to an electrical machine comprising: at least one stator; at least one module, the at least one module comprising at least one electromagnetic coil and at least one power converter, the at least one power converter comprising at least one switch and at least one control information generator, the at least one switch connects to a plurality of input terminals to the at least one electromagnetic coil, the plurality of input terminals being respectively coupled to phases of an AC power source or load, the at least one control information generator configured to generate control information to control the at least one switch, the at least one module being attached to the at least one stator, at least one platter with a plurality of magnets attached to the at least one platter, wherein the at least one module is in spaced relation to the plurality of the magnets; and the at least one platter being in a movement relationship with the at least one stator.

[0013] Certain aspects are directed to the electric machine, wherein the electrical machine can be configured to fit into a housing that is substantially the same as standard IEC or NEMA induction motor housing and is connected to the electricity grid like a standard induction motor but unlike a standard induction motor is variable speed. Also disclosed are methods of using and manufacturing the embodiments disclosed herein.

[0014] Certain embodiments are directed to a modular, more flexible, more adaptable electric motor.

[0015] A comparison between certain of the embodiments of the present disclosure extending an existing induction motor production line to produce them could result in estimated savings of 100s of millions of US dollars.

[0016] A comparison between the certain embodiments of the present disclosure and other state of the art electric drive trains could reduce the production and installation cost of a variable speed motor by 10%, 25%, 35%, 50%, 60%, 75% or more. For example, a one-megawatt variable speed motor can be installed in the same space as just the equivalent one-megawatt motor without the need for an additional fridge sized Variable Speed Drive (VSD) and harmonic filtering reducing installed footprint by 50%. In this example the shielded cabling coupling the VSD to the induction motor is not required and the additional concrete slab to mount the VSD can reduce installation cost by over 50%.

[0017] A comparison between the certain embodiments of the present disclosure and current electric induction motor indicates that certain embodiments have 25%, 33%, 50%, 80% less active material than a state-of-the-art induction motor of a similar power rating.

[0018] In certain embodiments, a typical arrangement of brushless, axial-flux electric motor comprises one or more rotors in the form of circular plates (these may be substantially flat, disk-shaped) rotationally supported on a shaft, the rotor having a circular array of high energy permanent magnets embedded around its periphery with alternating polarity, the axes of the magnets being parallel to the shaft; one or more stators in the form of circular plates fixed parallel to the rotors and separated by a small air gap, each of the stators having a circular array of electromagnetic coils embedded around its periphery on the same centre diameter as the magnets; sensing ways (or means) to detect absolute or relative position and rotational speed of the rotors; and a control system which, in response to inputs from the sensing ways (or means) and power and rotational direction commands, energises the magnetic coils to attract and repel the magnets for the purpose of generating rotary motion. One advantage of certain configurations is its high power and / or torque density, the magnitude of torque generated being proportional to the strength of the magnetic flux generated by the coils, the strength of the magnetic flux of the permanent magnets, the effective diameter of the coil and magnet arrays and the gap between them. At the same time, the use of electronic commutation to control the current flows to individual stator coils confers high energy efficiency over a wide power and RPM range, resulting in essentially flat efficiency curves.

[0019] Certain embodiments of the present disclosure are directed to configurations of brushless, axial-flux, alternating-current electric motors which have one or more of the following characteristics: high power and / or torque densities; which combines rapid acceleration with an extended RPM range; which has low weight and / or compact form, making it suitable for a variety of applications; which employs complex control mechanisms (or means) to obtain high efficiency throughout the desired range of operational parameters; which has minimal cooling requirements; which is robust and mechanically and electrically reliable; which is capable of being manufactured through the assembly of standard components in a range of configurations suitable for employment in industrial equipment such as pumps, fans, compressors and wind turbines; able to optimise driving and generation efficiency throughout a range of highly variable driving and generating conditions and which may be manufactured at a competitive cost.

[0020] According to certain embodiments, a brushless, axial flux, alternating-current electric motor comprises: one or more disc-shaped stators around the periphery of which a circular array of equally-spaced (or substantially equally spaced) electromagnetic coils may be embedded; one or more disc-shaped rotors around the periphery of which a circular array of equally-spaced (or substantially equally spaced) magnets may be embedded, the array having the same, or substantially the same centre diameter as that of the electromagnetic coils and the magnets having alternating pole orientation; the rotors being rotationally supported parallel (or substantially parallel) to the stators with an air gap between them. The circuit boards are supported from the stators concentrically with the shaft, the circuit boards may incorporate solid-state switches which may be activated by command signals from a control system to power the electromagnetic coils to cause the rotors to rotate. In certain embodiments, one or more sensor may be provided to generate signals relating to the absolute and instantaneous positions of the rotors. In certain embodiments, one or more sensor may be provided to generate signals relating to the substantially absolute and / or substantially instantaneous positions of the rotors. In certain embodiments, the permanent magnets are sufficiently powerful and may be of the rare earth type and the electromagnetic coils are of a form generating high levels of magnetic flux, but having low magnetic reluctance permitting rapid switching or reversal of polarity. In certain embodiments, the permanent magnets may be sufficiently powerful and / or may be of the rare earth type wherein the one or more of the electromagnetic coils are of a form generating sufficiently high levels of magnetic flux. In certain embodiments, permanent magnets and / or electromagnetic coils of conventional form are optionally employed in electric motors for lower cost applications or those required to meet different operational parameters.

[0021] The positioning of the switches immediately adjacent the electromagnetic coils provide conduction paths of low resistance with minimal losses. In certain embodiments, the positioning of the switches adjacent (or substantially adjacent) one or more of the electromagnetic coils provides conduction paths of suitably low resistance with suitably minimal losses. In certain embodiments, the positioning of the switches above the rotor reduces the external circumference of the motor to ensure a small packaging fit while maintaining a suitably low resistance with suitably minimal losses. In certain embodiments, the combination of one or more of the features provides an electric motor of high-power density and / or one able to operate efficiently over an extended RPM range. In certain embodiments, the control system of the alternating current electric motor may be made to be continuously adaptive, utilising complex logic to determine the most efficient mode of operation in relation to prevailing operational parameters. In certain embodiments, the control system of the alternating current electrical machine may be sufficiently continuously (or substantially continuously) adaptive, utilising logic to determine or estimate the appropriately efficient mode of operation in relation to one or more prevailing operational parameters.

[0022] Certain embodiments are directed to an electrical machine, wherein the at least one power converter further comprises a plurality of bidirectional switches each having a conducting direction controllable by the plurality of switching elements, the plurality of bidirectional switching elements connects to a plurality of input terminals and to the at least one electromagnetic coil, wherein the bidirectional switching elements control the direction of current flowing through the at least one electromagnetic coil, wherein the at least one power converter converts the input AC power source or load to a change of voltage or a change of frequency of the terminals of the at least one electromagnetic coil without an intermediate conversion into DC.

[0023] Certain embodiments are directed to an electrical machine, wherein the output power of the electrical machine is at between 30 to 1, 45 to 22, 120 to 30, 1500 to 500, 5 to 0.01, 50000 to 1000, or 650.4 to 40.4 kilowatts.

[0024] Certain embodiments are directed to an electrical machine, wherein the plurality of input terminals is coupled through at least one transformer to an AC source, wherein the at least one module houses the secondary windings of the at least one transformer.

[0025] These and other features, aspects, and advantages of the present disclosure will become better understood with regard to the following description, appended claims, and accompanying figures where:

[0026] is a schematic showing the geometric properties of a magnet shape placed in a circular array, according to certain embodiments.

[0027] is a schematic showing the geometric properties of a magnet shaped to produce a sinusoidal back emf placed in a circular array, according to certain embodiments.

[0028] is a side view of an electrical machine that is made up of two electrical machines that are back-to-back and share a common rotor shaft, according to certain embodiments.

[0029] is a side view of the electrical machine illustrated inbut these embodiments share a common magnet rotor.

[0030] is a graph that shows how the total magnet count decreases as the number of coil stages increases, according to certain embodiments.

[0031] is a torque comparison graph, according to certain embodiments.

[0032] is an isometric projection showing the geometric properties of a switched reluctance rotor of certain embodiments.

[0033] illustrates a gap in the conductive region of the stator, according to certain embodiments.

[0034] is a view of the electromagnetic core constructed of stamped I pieces and coils around a bobbin, according to certain embodiments of the present disclosure.

[0035] illustrates a cross-section view of a rotor platter configuration according to certain embodiments.

[0036] illustrates a cross-section view of two rotor platters configuration according to certain embodiments.

[0037] illustrates a cross-section view of a three rotor platters configuration according to certain embodiments.

[0038] is a face view of a rotor of the electric motor of, according to certain embodiments.

[0039] shows a schematic top view of a rotor platter and coil configuration, according to certain embodiments.

[0040] shows a perspective view of the configuration of

[0041] shows in side view an example of the magnetic field lines between two magnetic rotors and one coil platter, without end caps, according to certain embodiments.

[0042] shows in side view an example of the magnetic field lines between two magnetic rotors and one coil platter, with ferrous steel end caps, according to certain embodiments.

[0043] shows an example of the magnetic field lines between two magnetic rotors and one coil platter, with the top rotor consisting of magnets aligned in a Halbach array, according to certain embodiments.

[0044] shows an example of a 3-phase H-bridge switch topology that may be used with certain embodiments.

[0045] illustrates an exemplary Motor Control Unit (MCU), Coil Control Unit (CCU), coil driver controller architecture, according to certain embodiments.

[0046] illustrates a CCU’s architecture, according to certain embodiments.

[0047] shows one or more individual MCUs and CCUs in a 1:1:1 configuration, according to certain embodiments.

[0048] shows switches controlled by one CCU, with the one CCU being controlled by one or more MCU in a 1:1:n configuration, according to certain embodiments.

[0049] shows switches controlled by CCUs, with the CCUs being controlled by one or more MCU in a 1:m:n configuration, according to certain embodiments.

[0050] shows an exemplary controller configurations, whereby switches are controlled directly by one or more MCUs in a 1:n configuration.

[0051] illustrates a CCU without the need for a master controller, according to certain embodiments.

[0052] shows a configuration where a single motor control unit is connected to a common communication bus, which is connected to one or more of the coil control units, according to certain embodiments.

[0053] shows a configuration where multiple motor control units are connected to a common communication bus, which is connected to one or more of the coil control units, according to certain embodiments.

[0054] illustrates a configuration wherein each coil control unit is connected directly to some or all other coil control units, according to certain embodiments.

[0055] illustrates a configuration wherein a central communication bus (token ring) is used, according to certain embodiments.

[0056] illustrates a configuration with three redundant communication buses, according to certain embodiments.

[0057] is an exploded view of the electric motor made in accordance with certain embodiments.

[0058] is an exploded view of the magnetic assembly of the electric motor in

[0059] illustrates an isometric view of the Coil Control Unit mounted in an electrical machine illustrated in, according to certain embodiments.

[0060] is a face view of a rotor, according to certain embodiments.

[0061] is a schematic diagram of the electrical and electronic systems of the electric motor of

[0062] illustrates the electrical machine detailed in, according to certain embodiments.

[0063] illustrates the possible back-to-back arrangements of two IGBTs to make a bidirectional switch.

[0064] is a schematic of a 3-phase power converter.

[0065] is a photo of a linear solenoid configuration of an electrical machine, according to certain embodiments.

[0066] is a schematic in top view of a linear solenoid configuration of an electrical machine, according to certain embodiments.

[0067] is a schematic in partial side view of the linear solenoid configuration of

[0068] is a schematic of a linear generator electrical machine, according to certain embodiments, being applied to harness electrical energy from waves.

[0069] is a top schematic view of a design for a module that includes a CCU and a coil driver unit, according to certain embodiments.

[0070] is a cut away top view of

[0071] is a cut away side view of the module inwhich illustrates the internal structure of the module as well as the alignment of the magnets on the rotor.

[0072] is a cut away end view of the module in

[0073] is an isometric view of a three-phase generator, according to certain embodiments.

[0074] is of a multi platter embodiment, composed by stacking several of the embodiments shown in

[0075] The present disclosure will now be described in detail with reference to one or more embodiments, examples of which are illustrated in the accompanying drawings. The examples and embodiments are provided by way of explanation and are not to be taken as limiting to the scope of the disclosure. Furthermore, features illustrated or described as part of one embodiment may be used by themselves to provide other embodiments and features illustrated or described as part of one embodiment may be used with one or more other embodiments to provide a further embodiment. It will be understood that the present disclosure will cover these variations and embodiments as well as other variations and / or modifications. It is also to be understood that one or more features of one embodiment may be combinable with one or more features of the other embodiments. In addition, a single feature or combination of features in certain embodiments may constitute additional embodiments.

[0076] The features disclosed in this specification (including accompanying claims, abstract, and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example of a generic series of equivalent or similar features.

[0077] The subject headings used in the detailed description are included only for the ease of reference of the reader and should not be used to limit the subject matter found throughout the disclosure or the claims. The subject headings should not be used in construing the scope of the claims or the claim limitations.

[0078] Certain embodiments are directed to devices, methods, and / or systems that use electrical machines. For example, certain embodiments are directed to an electrical machine comprising: at least one stator; at least one module, the at least one module comprising at least one electromagnetic coil and at least one power converter, the at least one power converter comprising at least one switch and at least one control information generator, the at least one switch connects to a plurality of input terminals to the at least one electromagnetic coil, the plurality of input terminals being respectively coupled to phases of an AC power source or load, the at least one control information generator configured to generate control information to control the at least one switch, the at least one module being attached to the at least one stator, at least one rotor with a plurality of magnets attached to the at least one rotor, wherein the at least one module is in spaced relation to the plurality of the magnets; and the at least one rotor being in a rotational relationship with the at least one stator, wherein the quantity and configuration of the at least one module in the electrical machine is determined based in part on one or more operating parameters; wherein the at least one module is capable of being independently controlled; and wherein the at least one module is capable of being reconfigured based at least in part on one or more of the following: at least one operating parameter during operation, at least one performance parameter during operation, or combinations thereof.

[0079] Certain embodiments are directed to devices, methods, and / or systems that use electrical machines. For example, certain embodiments are directed to an electrical machine comprising: at least one stator; at least one module, the at least one module comprising at least one electromagnetic coil and at least one power converter, the at least one power converter comprising at least one switch and at least one control information generator, the at least one switch connects to a plurality of input terminals to the at least one electromagnetic coil, the plurality of input terminals being respectively coupled to phases of an AC power source or load, the at least one control information generator configured to generate control information to control the at least one switch, the at least one module being attached to the at least one stator, at least one slider with a plurality of magnets attached to the at least one slider, wherein the at least one module is in spaced relation to the plurality of the magnets; and the at least one slider being in a linear relationship with the at least one stator.

[0080] Certain embodiments are directed to devices, methods, and / or systems that use electrical machines. For example, certain embodiments are directed to an electrical machine comprising: at least one stator; at least one module, the at least one module comprising at least one electromagnetic coil and at least one power converter, the at least one power converter comprising at least one switch and at least one control information generator, the at least one switch connects to a plurality of input terminals to the at least one electromagnetic coil, the plurality of input terminals being respectively coupled to phases of an AC power source or load, the at least one control information generator configured to generate control information to control the at least one switch, the at least one module being attached to the at least one stator, at least one platter with a plurality of magnets attached to the at least one platter, wherein the at least one module is in spaced relation to the plurality of the magnets; and the at least one platter being in a movement relationship with the at least one stator.

[0081] Certain aspects are directed to the electric machine, wherein the electrical machine can be configured to fit into a housing that is substantially the same as standard IEC or NEMA induction motor housing and is connected to the electricity grid like a standard induction motor but unlike a standard induction motor is variable speed. Also disclosed are methods of using and manufacturing the embodiments disclosed herein.

[0082] Certain embodiments are directed to a modular, more flexible, more adaptable electric motor.

[0083] A comparison between certain of the embodiments of the present disclosure extending an existing induction motor production line to produce them could result in estimated savings of 100s of millions of US dollars.

[0084] A comparison between the certain embodiments of the present disclosure and other state of the art electric drive trains could reduce the production and installation cost of a variable speed motor by 10%, 25%, 35%, 50%, 60%, 75% or more. For example, a one-megawatt variable speed motor can be installed in the same space as just the equivalent one-megawatt motor without the need for an additional fridge sized Variable Speed Drive (VSD) and harmonic filtering reducing installed footprint by 50%. In this example the shielded cabling coupling the VSD to the induction motor is not required and the additional concrete slab to mount the VSD can reduce installation cost by over 50%.

[0085] A comparison between the certain embodiments of the present disclosure and current electric induction motor indicates that certain embodiments have 25%, 33%, 50%, 80% less active material than a state-of-the-art induction motor of a similar power rating.

[0086] In certain embodiments, a typical arrangement of brushless, axial-flux electric motor comprises one or more rotors in the form of circular plates (these may be substantially flat, disk-shaped) rotationally supported on a shaft, the rotor having a circular array of high energy permanent magnets embedded around its periphery with alternating polarity, the axes of the magnets being parallel to the shaft; one or more stators in the form of circular plates fixed parallel to the rotors and separated by a small air gap, each stator having a circular array of electromagnetic coils embedded around its periphery on the same centre diameter as the magnets; sensing ways (or means) to detect absolute or relative position and rotational speed of the rotors; and a control system which, in response to inputs from the sensing ways (or means) and power and rotational direction commands, energises the magnetic coils to attract and repel the magnets for the purpose of generating rotary motion. One advantage of certain configurations is its high power and / or torque density, the magnitude of torque generated being proportional to the strength of the magnetic flux generated by the coils, the strength of the magnetic flux of the permanent magnets, the effective diameter of the coil and magnet arrays and the gap between them. At the same time, the use of electronic commutation to control the current flows to individual stator coils confers high energy efficiency over a wide power and RPM range, resulting in essentially flat efficiency curves.

[0087] Certain embodiments of the present disclosure are directed to configurations of brushless, axial-flux, alternating-current electric motors which have one or more of the following characteristics: high power and / or torque densities; which combines rapid acceleration with an extended RPM range; which has low weight and / or compact form, making it suitable for a variety of applications; which employs complex control mechanisms (or means) to obtain high efficiency throughout the desired range of operational parameters; which has minimal cooling requirements; which is robust and mechanically and electrically reliable; which is capable of being manufactured through the assembly of standard components in a range of configurations suitable for employment in industrial equipment such as pumps, fans, compressors and wind turbines; able to optimise driving and generation efficiency throughout a range of highly variable driving and generating conditions and which may be manufactured at a competitive cost.

[0088] According to certain embodiments, a brushless, axial flux, alternating-current electric motor comprises: one or more disc-shaped stators around the periphery of which a circular array of equally-spaced (or substantially equally spaced) electromagnetic coils may be embedded; one or more disc-shaped rotors around the periphery of which a circular array of equally-spaced (or substantially equally spaced) magnets may be embedded, the array having the same, or substantially the same centre diameter as that of the electromagnetic coils and the magnets having alternating pole orientation; the rotors being rotationally supported parallel (or substantially parallel) to the stators with an air gap between them. The circuit boards are supported from the stators concentrically with the shaft, the circuit boards may incorporate solid-state switches which may be activated by command signals from a control system to power the electromagnetic coils to cause the rotors to rotate. In certain embodiments, one or more sensor may be provided to generate signals relating to the absolute and instantaneous positions of the rotors. In certain embodiments, one or more sensor may be provided to generate signals relating to the substantially absolute and / or substantially instantaneous positions of the rotors. In certain embodiments, the permanent magnets are sufficiently powerful and may be of the rare earth type and the electromagnetic coils are of a form generating high levels of magnetic flux, but having low magnetic reluctance permitting rapid switching or reversal of polarity. In certain embodiments, the permanent magnets may be sufficiently powerful and / or may be of the rare earth type wherein the one or more of the electromagnetic coils are of a form generating sufficiently high levels of magnetic flux. In certain embodiments, permanent magnets and / or electromagnetic coils of conventional form are optionally employed in electric motors for lower cost applications or those required to meet different operational parameters.

[0089] The positioning of the switches immediately adjacent the electromagnetic coils provide conduction paths of low resistance with minimal losses. In certain embodiments, the positioning of the switches adjacent (or substantially adjacent) one or more of the electromagnetic coils provides conduction paths of suitably low resistance with suitably minimal losses. In certain embodiments, the positioning of the switches above the rotor reduces the external circumference of the motor to ensure a small packaging fit while maintaining a suitably low resistance with suitably minimal losses. In certain embodiments, the combination of one or more of the features provides an electric motor of high-power density and / or one able to operate efficiently over an extended RPM range. In certain embodiments, the control system of the alternating current electric motor may be made to be continuously adaptive, utilising complex logic to determine the most efficient mode of operation in relation to prevailing operational parameters. In certain embodiments, the control system of the alternating current electrical machine may be sufficiently continuously (or substantially continuously) adaptive, utilising logic to determine or estimate the appropriately efficient mode of operation in relation to one or more prevailing operational parameters.

[0090] Certain embodiments are directed to an electrical machine, wherein the at least one power converter further comprises a plurality of bidirectional switches each having a conducting direction controllable by the plurality of switching elements, the plurality of bidirectional switching elements connects to a plurality of input terminals and to the at least one electromagnetic coil, wherein the bidirectional switching elements control the direction of current flowing through the at least one electromagnetic coil, wherein the at least one power converter converts the input AC power source or load to a change of voltage or a change of frequency of the terminals of the at least one electromagnetic coil without an intermediate conversion into DC.

[0091] Certain embodiments are directed to an electrical machine, wherein the output power of the electrical machine is at between 30 to 1, 45 to 22, 120 to 30, 1500 to 500, 5 to 0.01, 50000 to 1000, or 650.4 to 40.4 kilowatts.

[0092] Certain embodiments are directed to an electrical machine, wherein the plurality of input terminals is coupled through at least one transformer to an AC source, wherein the at least one module houses the secondary windings of the at least one transformer.

[0093] Certain embodiments are directed to adaptive magnetic flux arrays wherein the device, methods, and / or systems permit real time, or substantially real time, software reconfigurable electrical motor / generator. The disclosed devices, methods and / or systems may be used as both a motor and a generator may also be referred to as an electrical machine. One advantage of certain embodiments is the ability of those embodiments to reconfigure itself in real time, or substantially real time, this permits the machine, method and / or system to find its optimal settings across very wide operating speeds and / or loads. Such flexibility results in energy savings across a plethora of industries. Other advantages of certain embodiments disclosed herein are: reduce cost by reducing the amount of copper in the windings; the amount of electrical steel; the size of the package required to house it or combinations thereof.

[0094] For example, the weight of the copper windings in an electrical machine is proportional to the size of current, greater the current the heavier the wire. This relationship is quadratic, not linear. Certain embodiments effectively divide and conquer this relationship. In certain embodiments each (or one or more) independent coil handles relatively small amounts of current. By using numerous small coils, the overall current through each coil (or one or more) remains low, but the total current for the whole system scales linearly, along with the quantity of material and / or the cost of the electrical machine. By overcoming this quadratic relationship much larger electrical machines may be built at more affordable prices.

[0095] For example, a traditional 3-phase 100kw electrical machine operating off a 400v AC supply requires an RMS current through each phase of the coil of 110 amps. In one exemplary embodiment, the windings are distributed across 38 coils, the RMS current per coils is 12 amps. To have the same, substantially the same, or similar, resistive power loss through the two configurations, the traditional electrical machine requires about 3.3 times the weight of wire. Certain embodiments are directed to an electrical machine wherein the resistive power loss is substantially the same as the resistive power loss of a traditional electrical machine but the electrical machine requires at least 20, 10, 5, 3.3, 2, 1.5 times less weight of wire. Certain embodiments are directed to an electrical machine that uses substantially less copper wherein the resistive power loss is substantially the same as the resistive power loss of a similar machine with fewer coils. The copper saved is proportional to the weight of coilscmthe embodiment contains compared to the weight of coils contained in a comparable machinedm. The potential savings are up todmdivided bycmtimes the copper. In certain embodiments, the electrical machine requires between 20 to 10, 10 to 30, 5 to 10, 15 to 25, 4 to 2.5, 2.25 to 1.75, 1.5 to 1.75, 7.5 to 1.5, 5.0 to 2.5, 2.0 to 1.15, 1.5 to 1.05 times less weight of wire as compared with an induction three phase electrical machine with similar power.

[0096] In the example above, as there is 3 times less wire, the volume of iron core required to wrap the wire around is decreased therefore reducing core losses. Subsequently the entire unit can fit into a substantially smaller enclosure further reducing the mass of materials. In this example, the exemplary electrical machine disclosed herein reduces the weight of a 110kw electrical machine from about 1000 kilograms to about 300 kilograms. Certain embodiments disclosed herein provide an electrical machine that may produce substantially the same power output of a traditional electrical machine but with a weight that is reduced by at least 95%, 90%, 85%, 80%, 70%, 60%, 50%, 40%, 30%, or 20%. Certain embodiments disclosed herein provide an electrical machine that may produce substantially the same power output of a traditional electrical machine but with a weight that is reduced by between 95% to 20%, 90% to 70%, 85% to 60%, 90% to 50%, 80% to 40%, 70% to 50%, 60% to 30%, 50% to 20%, 40% to 20%, or 30% to 20%.

[0097] Another advantage of certain embodiments is the ability to independently control each coil, when less torque is required or available, sections of the electrical machine may be powered down. In certain embodiments the ability to independently control one or more coils, when less torque is required or available, then sections of the electrical machine may be powered down. Certain embodiments are directed to an electrical machine with the ability to independently control one or more coils. Certain embodiments are directed to an electrical machine with the ability to independently control one or more coils. Certain embodiments are directed to an electrical machine with the ability to independently control at least 70%, 80%, 90%, 95%, 98% or 100% of one or more coils in a plurality of coils. Certain embodiments are directed to an electrical machine with between 1000 to 100, 10 to 100, 20 to 50, 50 to 200, 20 to 60, 30 to 80, or 30 to 60 coils wherein the electrical machine is configured to independently control at least 70%, 80%, 90%, 95%, 98% or 100% of the coils. Because certain disclosed embodiments have numerous coils, substantially finer control over optimising the efficiency of the machine is available.

[0098] Traditional electrical machines control their peak efficiency by varying the timing of the switching between phases of their coils. As the timing is traditionally set at assembly or installation either by the brushes or the frequency of the drive circuit, variations of velocity and power reduces the peak efficiency of the electrical machine. Another advantage of certain embodiments is that they may be configured to continuously optimize the timing of the coils, this can provide efficiency savings of up to, for example, 40% when summed over the entire operating region of a comparatively powered electrical machine. Certain embodiments may be configured to optimize the timing of a plurality of coils substantially continuously, sufficiently continuously, continuously, non-continuously, or intermediately. In certain embodiments the ability to optimize the timing of a plurality of coils substantially continuously, sufficiently continuously, continuously, non-continuously, or intermediately provides an efficiency savings of up to 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, or 60% when summed over the entire operating region of a comparatively powered electrical machine.

[0099] In an axial configuration, certain embodiments of the present disclosure may reduce the total number of permanent magnets by a minimum of 25%. The total saving percentage increases with the number of rotors required. This may be achieved through sharing of common rotors, making use of both sides of a rotors magnetic field rather than one. For example, in a two stator, 4 rotor motor, one rotor is eliminated for a saving of 25%. For 6 stator, 12 rotor motor, 5 rotors are eliminated for a saving of 41%. In certain embodiments, the total number of permanent magnets may be reduced by a minimum of 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60% or 70% and still provide comparable power output.

[0100] Certain embodiments of the present disclosure may accommodate magnets of various shapes. For example, the shape may be a cylinder, cuboid, segmented, trapezoidal or other suitable shapes.

[0101] Magnet Volume Reduction

[0102] In regards to efficiency the ideal switching waveform inside a coil is a sine wave. The sine wave has only one frequency component, the fundamental frequency, ensuring that higher frequency harmonics may not be contained in the signal. An ideal square wave may be made up of the fundamental frequency (the frequency of the square wave) plus an infinite sequence of higher frequency harmonics contained in its Fourier series. There are a number of drawbacks in terms of high frequency harmonics. High frequency signals tend to travel along the outer edge of the conductor known as the skin effect. The higher the frequency the closer to the skin the signal travels. The resistance of a wire is proportional to the cross-sectional area where the electrons are travelling. The resistance of the wire is therefore proportional to the frequency through that wire. Further high frequency signals tend to radiate away from the device causing interference to other devices. These radiated effects need to be contained and filtered to pass CE, FCC, C-tick and other compliance standards. Magnets or coils could be shapes such that their shape creates a sinusoidal back Electro Motive Force (EMF) when the magnetic field generated by the magnet moves past the coil to create a nice sine wave output. A consequence of modifying the shape of the magnet is reduced total magnet volume, now referring to Figure 1 we have 24 trapezoidal magnets (only 4 are shown in blue) passing past 26 trapezoidal cores with windings. Volume of trapezoidal magnet: When a magnetic field changes through a material a current is induced that opposes that change in magnetic fields. This results in eddy currents forming in the conductive material. The larger the surface area of the conductive material the larger the eddy current. Magnets are susceptible to these eddy currents and as the magnets move through the magnetic fields being produced by the coil eddy currents are induced in the magnets. These fields produce heating inside the material hence reducing efficiency. Further certain classes of magnets are adversely affected by heat as they risk demagnetisation as they approach their Curie temperature.

[0103] The magnets can be segmented into multiple sections to reduce their surface area. The magnets need to be electrically isolated from the platter that they are attached to. In certain embodiments an epoxy coating may be applied to the magnet to electrically isolate them from the platter. Segmenting the magnets further reduces the volume of magnets. In certain embodiments splitting the magnets radially into 3 segments results in a further reduction of the magnet mass by 4% while reducing the eddy current induced in the magnets.

[0104] Referring towe have a similar diagram to; however, the magnets have been modified to provide a sinusoidal back EMF when passing a trapezoidal core and segmented. Volume of these curved magnets are 0.87 times the volume of the trapezoidal cores.

[0105] In certain embodiments the shape of the magnets inmay have some curves flattened to approximate the shape of the magnets so that they produce the same or substantially the same, or similar to a sinusoidal back EMF. The simplification of the shape of the magnets may simplify production.

[0106] In certain embodiments, this saving can be substantial, for example if we compare a trapezoidal magnet to a curved magnets the curved segmented magnets can reduce the mass of the magnets by 16.5%. In certain embodiments the magnetic material is the most expensive material in the embodiment reducing the material while improving harmonics and reducing losses is highly desirable.

[0107] In regards to peak power, more power may be transferred in a square wave than in a sine wave. The effective power that may be imparted into the coil by a sine wave is 1 divide by a square root of 2 (approximately 2 / 3) while the effective power of a square wave is 1. In terms of the effectiveness of the mechanical energy that can be converted by a square wave vs. a sine wave is dependent at least in part on the design of the coils and the magnets.

[0108] Magnets Saving Through Shared Platter Stacks

[0109] In certain embodiments, the device may be extended to provide more power by connecting two motors back-to-back as illustrated inA weight and / or cost saving may be achieved by sharing of rotors as illustrated inIn this example, the total number of magnets is reduced by sharing the inner rotors, segments 1 and 2, combining them into one rotor, segment 3. Further, only the outer platters, segments 4 require back irons to contain the magnetic field inside the device, as opposed to the unshared configuration which requires all rotors to be shielded (a total of 4 plates). Typically, the back irons are heavy and thus there is a substantial weight saving through sharing inner rotors. Further the device is more compact, saving the mass of the associated materials. In other words: Total number of magnets (unshared):

[0110]

[0111] Total number of magnets (shared centre rotor platter):

[0112]

[0113] :

[0114]

[0115]

[0116] :

[0117]

[0118]

[0119] is a graph that illustrates the reduction in the number of magnets when common magnetic rotors are shared between multiple stators. This example is based on rotors with 18 magnets, but the general trends hold true for a range of embodiments. The x axis illustrates the number of stators, and the Y axis indicates the number of magnets. A comparison is made between a configuration sharing common internal rotor platters 6, to a configuration without shared rotor platters 7. It illustrates that there are significant savings in the number of magnets required, and thus cost, space and weight savings, when the platters are shared. This saving tends linearly towards almost 50% or more as more platters are used.

[0120] Torque Smoothing

[0121] Permanent magnet motors have issues with cogging. When the magnets align with the coil the motor tends to lock in that position.

[0122] In this exemplary embodiment it is assumed that for the number of phases in a motor, the power applied is constant. As the numbers of phases in the motor are increased, the power is distributed and applied more evenly. For a four-pole permanent magnet motor it provides maximum power and torque to the shaft 6 times per rotation. Since certain embodiments of the present disclosure may have at least 11 to 1024 independently controllable phases. Certain embodiments may have between 17 to 1021, 19 to 1181, 29 to 109, 53 to 127, 89 to 257, 211 to 331, 199 to 577, 433 to 751, 577 to 1051, 613 to 757, 619 to 919, 773 to 857, 787 to 1021, or 811 to 1283 independently controllable phases. Certain embodiments may have between 10 to 1050, 20 to 40, 30 to 50, 50 to 1200, 75 to 150, 200 to 500, 400 to 1200, 600 to 900, or 700 to 1100. This distributes power more evenly throughout a single rotation and results in smooth torque being applied to a load.

[0123] A simple comparison of maximum producible instantaneous torque throughout a motor’s rotation is presented inThis graph demonstrates the relative torque on the y axis a similarly rated single phase 11, three phase 9 and 17 phase electrical machine 10. The x axis indicates the motors angular position over a range of 0 to 360 degrees. Because the 17-phase electrical machine configuration effectively has more phases than the other electrical machine configurations it has a more constant producible torque and a much smoother torque without any smart software control or otherwise controlling the electrical machine. In certain applications the achievable torque may be even smoother with the aid of software algorithms and feedback control. Although the peak instantaneous torque producible of the other motor configurations is larger than that of the 17-phase electrical machine, the power being delivered is approximately the same, the power from the other motor types is applied largely in short bursts making it harder to control.

[0124] One of the features of certain disclosed embodiments is that there may be an offset between a coil and a pair of magnets, i.e.: if there are n coils and n+1 magnets, then the magnets may not be perfectly aligned with the coils. This ensures that the electrical machine of these embodiments will be able to turn on at least one coil to turn the machine, while also having the effect of smoothing the torque applied to the machine. Because there is an offset between coils and magnets, it has the effect of making the motor into an n phase motor. In a traditional permanent magnet motor, when less power is required, the amount of power applied in each rotation to the motor is reduced. This reduces the produced torque non-linearly. In certain disclosed embodiments as one or more coils (or each coil) are able to be digitally controlled, coils that produce less optimal instantaneous torque onto their corresponding magnet may be turned off. This causes a non-linear reduction in torque with respect to reduction in power.

[0125] Torque smoothing vs. Operating frequency

[0126] Because torque applied at any instantaneous moment is a function of the angle of the motor platter, the apparent torque smoothing will vary with frequency, i.e.: as the motor speeds up, the variations in torque will become less obvious. Since certain embodiments may be operated with n phases, one or more coils (or each coil) may operate n times faster than it would on a three-phase motor. The torque may be further smoothed by using digital algorithms to limit the maximum power applied to a coil in the optimal position. This may have the effect of slightly reducing the maximum torque, but would substantially smooth the torque output.shows a graph that demonstrates the superior torque smoothing of certain digital axial flux motor embodiment compared to some standard motor types. One of the advantages of the motors in these embodiments is that it can individually control power to each coil (or one or more coils), allowing it to maintain suitably high output powers and / or torques while keeping its n phase torque smoothing characteristics. These embodiments have the ability to change on the fly, for lower rpm’s where torque smoothing is more important, the motor may intelligently apply a smoothing profile, or a profile for suitable maximum torque and / or output power as it is required, or at higher rpms.

[0127] Rotor

[0128] Exemplary embodiments of the present disclosure may consist of one or more rotors. One of their purposes is to create a magnetic field in the vicinity of the electromagnets, such that the stator coils induce torque in the rotor. Magnets may be secured within the rotor via multiple methods. For example, by gluing; clamping (between two or more rotor layers) and / or interference fit (with the surrounding hole); mechanically fixing (for example, bolted, threaded or other suitable ways); welding (when applicable to chosen magnet and / or rotor material); sintering; other effective means or combinations thereof.

[0129] The rotor may be constructed from a number of materials. Construction materials chosen for the rotor may vary depending on the application of the motor, as well as the chosen magnetic field strength between the rotors. In certain embodiments, the chosen material will typically be of sufficient Young’s Modulus (stiffness) to prevent unacceptable deformation or substantial deformation due to the axial magnetic forces between two separate rotor platters. Materials used may include (but are not limited to): cast iron; glass reinforced polymers such as fiberglass; aluminium; polymers, such as HDPE (High density polyethylene); other suitable materials or combinations thereof. The choice of material and proximity to varying magnetic fields needs to be considered to minimise induced eddy current.

[0130] Magnetic Rotors: In certain embodiments, the need for separate magnets (which are then attached to the rotors) may be eliminated (or reduced) through the use of sintering to bond separate magnets and the mechanical casing into substantially one structure. A finishing surface may then be applied (for example, nickel, epoxy) to increase mechanical strength, resistance to corrosion and / or durability.

[0131] Reluctance configuration: With reference to, in certain embodiments, it is possible for the magnets to be replaced in whole or in part with ferrous strips, resulting in a reluctance motor configuration. The platter can be constructed out of electrical steel that is coiled into a cylinder with notches cut to mimic the shape of the magnetic platter. The platter could also be made of multiple layers of electrical steel curved into a circular or almost circular shape. Glue between layers of the coiled or stacked electrical steel or an electrically isolated backing plate may be added to keep the coil from deforming under the force of magnets.

[0132] Inductance configuration: In certain embodiments, by replacing one or more, a substantial portion of, or all of the magnets in the rotors with coils, the stator coils magnetic fields will induce magnetic fields in the rotor coils. By wiring the rotor coils to their symmetric or offset equivalent coils (with respect to the rotor), opposing magnetic fields may be induced, resulting in rotational forces. Material Reduction: for certain applications it may be advantageous to reduce the rotational inertia of the rotor and / or shaft assembly. To this end the rotor discs may have their shape changed to remove excess material which is not necessary to the mechanical structure of the disk.

[0133] Shaft and Spacers: In certain embodiments, the rotor assembly may be located within or partial within the motor enclosure through the use of a shaft. This shaft may have a non-uniform diameter such that translational movement of the rotor magnet platters in the rotational axis of the shaft is reduced, substantially prevented or prevented. The translational forces may be absorbed from the shaft into the casing. Methods include (but not limited to): axial thrust bearings or other ball, pin or conical bearings; interference between shaft and assembly with low friction surface; the shaft may be of sufficient diameter and / or stiffness such that bending due to magnetic forces between rotor platters does not occur or is sufficiently reduced. In certain embodiments, the materials that may be used for shafts and / or spacers include metals (such as steel, aluminium), polymers or other suitable materials.

[0134] Torque transmission: In certain embodiments, once torque is induced in the rotor it may be transmitted either mechanically through direct fixture to a shaft, via magnetic couple to an external magnetic platter, mechanical coupling to a shaft (e.g. via a clutch), other suitable means or combinations thereof. In certain embodiments, it is possible for the shaft to be removed entirely (or partially) and replaced with a spacer, or multiple spacers, to separate two or more rotor platters. In these configurations the assembly may be located within the enclosure through the use of magnetic suspension. Alternatively, in certain embodiments, an annular bearing supporting the outer radial edge of the rotors (or a substantial portion of the rotors) may be used. These configurations may or may not use a centre spacer to separate rotors axially, depending on the number of bearings used.

[0135] Magnets

[0136] Certain embodiments of the electrical machine disclosed herein may incorporate different types and / or shapes of magnets. One of the purposes of the magnets is to induce a magnetic field, through which suspended electromagnetic coils can pass (thus inducing kinetic forces on the coils / rotors). Applicable types of magnets include, for example: rare earth magnets including but not limited to Neodymium, Neodymium-boron, Samarium-cobalt alloys or combinations thereof; various types of superconducting magnets; standard and / or permanent magnets made of materials such as but not limited to Alnico, Bismano, Cunife, Ferico, Heusler, Metglas, and other magnetic alloys or combinations thereof; electromagnets, such as wire coils, that may induce an electromagnetic field; magnetic fields resulting from materials with encoded quantum spin effects; induction magnets, in which ferrous material exposed to a perpendicular, or substantially perpendicular, electromagnetic field may be subject to a force pulling it towards the centre of the electromagnetic field; other suitable magnets; or combinations thereof.

[0137] In certain embodiments, magnet shapes that could be used but not limited to are: cylinders; cuboids (suitable 3D shapes); segmented, where the magnet is made up of in whole or in part a cluster of smaller magnets; curved in such way that the back EMF is sinusoidal; trapezoidal; solid or hollow (e.g. toroidal shape or hollow cylinder); groups, either of substantially the same polarity or opposing; angular and / or radially offset repetition of above arrangements; other suitable shapes for a particular application; or combinations thereof. The thickness of magnets may be either equal to or not be equal to the stator mount / platter thickness. The thickness of coils may be variable to suit the application. In certain embodiments, the number of magnets and coils may or may not be set such that: the number of coils never is the same as the number of magnets, to ensure one or more, a substantially plurality or all the magnets and coils never completely align; if number of coils is equal to number of magnets, the magnet or coil position is geometrically offset to substantially prevent, prevent, or reduce their concentric alignment or combinations thereof. In certain embodiments, the magnets and / or coils may be aligned such that: magnets may suitably axially aligned with coils or vice-versa, such as in an axial flux configuration; magnets are suitably axially misaligned with coils or vice-versa up to 20, 25, 30, 35, 40, 45, 50, 55, 60, or 65 degrees; aligned, or substantially aligned, with the platter; substantially perpendicular, or perpendicular, to platter; other suitable configurations or combinations thereof.

[0138] Stator

[0139] Certain embodiments of the disclosed electrical machines may incorporate one or more stators which may be used to locate the electric coils. The stator may be incorporated directly into the casing, independent or a combination thereof. As such the materials chosen for the stator follow the same convention outlined in the ‘Material’ section of the casing description or disclosed elsewhere herein. The chosen material may be highly (or suitably) conductive both electrically and / or thermally. In certain embodiments, the one or more stators may be used as electrical conductor (power delivery), as heat sinks (from the electronics and coils to casing), as well as mechanically supporting the coils and electronics or combinations thereof. In certain embodiments, the one or more stators may allow transmission of communication signals, either digital or analogue, superimposed on the power layer, on its own layer, or combinations thereof. Thus, layers in the stator may be electrically insulated from each other, if they are used for electrical conduction purposes. In certain embodiments, methods of insulation may include: hard anodisation; using insulating materials between layers such as plastics or combinations thereof. In certain embodiments, gaps may be included in the one or more stators to reduce material required and / or the weight. When the stator is constructed out of conductive material gaps may be added to eliminate eddy currents from forming around the coil. For example, as shown ina gap 14 in the conductive stator 15 is introduced in the stator near the location of the mounting hole for the magnetic coil 16 breaking the conduction path of the eddy current 17 induced when a current flows through the magnetic coil. In certain embodiments, the gaps are located such that two concentric annular rings are not formed radially on either side of the ring formed by the coils.

[0140] Coils

[0141] Certain embodiments of the disclosed electrical machines may incorporate different types and / or shapes of inductive coils, the purpose of which is to by use of electric current, induce and / or alter an existing electromagnetic field, creating a force which causes the rotor of the motor to turn. In certain embodiments, the coils may be constructed of sufficient materials to handle both the heat and the electric current requirements of the motor; the coils may be constructed so as to lower the electrical resistance to ensure there is minimal power loss due to resistive heating; the coil may be constructed such that they produce a magnetic field sufficiently large enough to create sufficient force or combinations thereof. One exemplary pair of coils are shown in

[0142] In certain embodiments, coils may be constructed as an air core, the conductive material is wrapped or rolled in such a way that there is an air gap in the middle of the coil; solid core, there is no (or suitably little) air gap in the middle of the coil. In certain embodiments, the core may either be made of the conductive material used or be a non-conductive material, either ferrous or nonferrous. Ferrous materials with a high magnetic permeability increase the magnitude of the magnetic field. In certain embodiments, the coil may be interleaved, the coil is made from conductive ribbon and / or sheet. The ribbon is coiled from the centre core to the outside while interleaving layers of insulated ferrous materials. The ferrous material acts as an insulator and as a core material to enhance magnetic field proportional to the number of loops of the ribbon. The magnetic field may reach its maximum magnitude at the centre of the coil with a sine distribution on either side. Combinations of the various constructions disclosed herein are also contemplated. The coils may be constructed in one or more of the following shapes: round / cylindrical, square / cuboid, trapezoidal, stepped trapezoidal, solid or hollow (air gap) / annular, and other suitable shapes.

[0143] In certain embodiments, the electromagnetic coils may be wound, bent and / or otherwise constructed from one or more pieces of a conducting material, or a sufficiently conducting material. The coils may be 3D printed or otherwise made. The conductor may be 3D printed along with a core (if 2 material (or more) 3D printing is used). The conductor may be 3D printed and the core added in a separate process. 3D printing refers to selective laser sintering, selective electron beam melting and / or other selective deposition techniques.

[0144] In certain embodiments, coils may be affixed to the stator by: a glue / bonding agent, clamping, mechanically, welded, 3D printed directly with the stator plate, or combinations thereof.

[0145] Coil and / or Magnet Positions

[0146] In certain embodiments, coils and / or magnets may be arranged / varied in many different physical configurations. In certain embodiments, an axial flux configuration may be used comprising: at least one, two or multiple rotor platters of magnets creating an alternating magnetic field parallel, or substantially parallel, to the axel; and a plurality of coils between magnetic fields.

[0147] ,andexemplify a number of different configurations of the electrical machine.illustrates a cross-section view of a rotor platter configuration according to certain embodiments. The platter 18 has a shaft 19 and a plurality of alternating pole orientation magnets 20 and 21 (in this exemplary embodiment 18 magnets are present) and coils 22 (in this exemplary embodiment 23 coils are present). The magnets are arranged in a substantial concentric configuration arrangement near the outer edge of the platter.is similar to, but has two rotor, element 8 which create a more concentrated magnetic field across the coils, 22. Also shown is a spacer 12 between the two platters.is similar toin a triple rotor platter configuration. This configuration permits more power to be added by adding appending extra coil platters.

[0148] shows a top-down view of the rotor platter 18 in the configurations illustrated in Figures 10 to 12. Shown are the 18 alternating polarity magnets 20 and 21, distributed radially on the rotor platter 18. Also shown is the location of the shaft 19.

[0149] Certain embodiments of the disclosed electrical machines may be configured in a substantially circular array (radially aligned) wherein: a plurality of magnets and a plurality of coils may be axially perpendicular (or substantially perpendicular) to at least one rotor shaft’s primary axis. In these embodiments, the magnetic properties of a normal axially aligned stator motor are present with the added benefits of fine grained adaptive magnetic flux control.shows a schematic top view of a rotor platter 23 wherein the magnets 24 and 25 are axially perpendicular (or substantially perpendicular) to the rotor’s shaft 19 and are at least partially within the platter, according to certain embodiments. Also shown are a plurality of coils 22 that are also axially perpendicular (or substantially perpendicular) to the rotor’s shaft 19 and are configured concentrically around the outer radius of the platter embodiments. The stator 26 can be seen holding coils 22 radially around the magnets. A clearance gap 27 can be seen between the magnets and the coils.shows a perspective view of the configuration of

[0150] Certain embodiments of the disclosed electrical machines may be configured in a substantially circular array (radially aligned) wherein: a plurality of magnets and a plurality of coils may be axially perpendicular (or substantially perpendicular) to at least one rotor shaft’s primary axis. Such embodiments have the magnetic properties of a normal axially aligned stator motor, with the added benefits of fine grained adaptive magnetic flux control.

[0151] End Caps

[0152] Magnetic fields that are not constrained may couple onto conductive surfaces and induce eddy currents which may create magnetic fields opposing the motion of the magnets. For example,is a side cross-sectional magnetic field diagram of a linear array of evenly distributed magnets, where consecutive magnets 20 have their north pole facing up, and the rest of the magnets 21 have their north pole facing down, with electromagnetic coils in the middle inducing a magnetic field north 28 and south 29.illustrates the external radiating magnetic field 30 without any shielding.illustrates the reduction in radiated electromagnetic energy in the scenario described inwith ferrous shielding plates 31 added. In certain embodiments, a Halbach array arrangement may be used instead of the ferrous shielding.illustrates the reduction in radiated electromagnetic energy in the application described inwith a Halbach array arrangement of magnets used on the top platter. The Halbach array arrangement may use smaller magnets 32, and opposite polarity magnets 33. The smaller magnet is positioned between the two larger magnets with a magnetic field substantially perpendicular to those of the bigger magnets. The smaller magnet bends the magnetic field lines from the first large magnet to the next large magnet and reduces the distance to which the flux loops past the end of the plate. This has close to the same effect of adding a ferrous shield to the system, and may dramatically reduce the external electromagnetic energy; this has the effect of saving the weight of the ferrous shielding plates that would otherwise be used in this application. Ferrous shielding 31 is used on the bottom layer of magnets for comparison.

[0153] Enclosure or Housing

[0154] The enclosures or housings discussed herein serve numerous purposes. In certain embodiments, it may be designed to cover or enclose (partially, substantially or fully) the moving parts and circuit boards, it can also hold one or more coils in place, the electronics in place, provides a source of heat sinking away from the coils and / or electronics, it can support the bearings and / or absorb axial forces on the shaft, it may be used as a conductor to shunt electrical power to and / or from the electronics, or combinations thereof. The enclosure may be constructed from materials (or combinations of materials) which are sufficiently strong to resist (or substantially resist) deformation due to loads applied from the half shafts. Additionally, in certain embodiments, it is desirable for the casing to sufficiently resist thermal fluctuations resulting in part from the electronics current draw. Example materials that match these properties include, but are not limited to: cast iron, aluminium, polymers or other suitable materials.

[0155] In certain embodiments, the enclosure may or may not be electrically conductive. In certain embodiments, power and signal lines may route placements but the casing itself is not used as a conductor. In certain embodiments, the casing itself may be used as a conductor. In certain embodiments, portions of the enclosure may be electrically conductive, typically with conductive parts separated by insulating layers. Such configurations allow power to be supplied directly (or indirectly) to the electronics through the casing. In certain embodiments, conductive mount points may be attached directly (or indirectly) to the outside and / or inside of the casing. In certain embodiments, portions of the casing may be used as conductors for, for example, signal transmission. Nonconductive sections may be used to isolate conductive sections to allow multiple signal ‘lines’ through the casing. In certain embodiments, power configuration and / or electronic communication and / or other signals may be multiplexed onto the power lines at a higher frequency by means of a suitable technology such as Direct Sequence Spread Spectrum (DSSS). The present disclosure also contemplates combinations the enclosure configurations discussed herein. In certain embodiments, one or more circuit boards may be replaced with conductive / tracks / pads routed and / or etched directly into the device casing. In certain embodiments, at least a substantial portion of the circuit boards may be replaced with conductive / tracks / pads routed and / or etched directly into the device casing.

[0156] In certain embodiments, one of the purposes of the casing may be to extract heat from the electronics (for example, the coils). It is useful if this heat is transferred to the environment surrounding the casing as efficiently as possible. In certain embodiments, methods of cooling that may be implemented include one or more of the following: active cooling (forced air flow); active cooling (force liquid flow); active cooling (refrigeration); passive cooling (heat pipe / pump transfer); passive cooling (convective heat fins, ribs); passive cooling (convection holes); active or passive cooling (convection channels); chambered (sealed static fluid with high thermal conductivity to concentrate and / or direct heat flow); and entire enclosure sealed with non-electrically conductive fluid.

[0157] In certain embodiments, circuit boards (and their attached electronics) may be mounted such that they do not move when subject to external or internal forces (linear or angular accelerations of the motor) or vibrations. In certain embodiments, circuit boards (and their attached electronics) may be mounted such that they do not substantially move when subject to external and / or internal forces (linear or angular accelerations of the motor) or vibrations. In certain embodiments, circuit boards (and their attached electronics) may be mounted such that they are sufficiently stable when subject to external and / or internal forces (linear or angular accelerations of the motor) or vibrations. In certain embodiments, circuit boards (and their attached electronics) may be mounted using one or more of the following methods: specifically shaped cavities in the casing such that circuit boards can slot in with a transition or interference fit; modular inserts; circuit boards sandwiched between two casing components; mechanically fastened or clipped; glued, or otherwise permanently joined.

[0158] illustrates the configuration of switches and coils where the CCU 38 and coils 22 are integrated and mounted onto modular circuit boards. For applications that are not as mechanically constrained this represents a more flexible electrical and mechanical solution. In certain embodiments, electronic components (and / or circuit boards) may be attached to modular inserts that may be slot / snap / or be otherwise attached to the primary casing externally, without the need to disassemble other inserts and / or the primary casing. In certain embodiments, electronic components (and / or circuit boards) may be configured as a modular insert that may be attached to the primary casing externally, without the need to disassemble other inserts and / or the primary casing.

[0159] In certain embodiments, the electrical machine may include at least one electrical bus and / or at least one optical bus. For example, when multiple microcontrollers are used, inter communication between microprocessors typically may occur over a bus. This bus may be mounted and constructed in one or more of the following ways: for electrical conductor (groove cut for circuit board, or other form of conductor to mount); for optical conductor (cut directly into casing, with reflective coatings applied to cut surfaces, and / or inserted into groove in casing); other suitable methods for mounting the conductor. In certain embodiments, when an optical bus is in use, optical transceivers on one or more Coil Control Units (CCUs) may be mounted to interface with the bus. Thus, the CCU positions may be tangentially arrayed around the optical bus.

[0160] In certain embodiments, another function of the casing may be to protect one or more internal components from external damage. It may be desirable that the seams of the casing be waterproof. It may also be desirable that the casing be covered in, and / or made partially of, vibration / impact absorbing coating (e.g. elastomer polymers). In certain applications, the casing may be an optional mounting point for master power cutoff switch.

[0161] In certain embodiments, one or more power and / or control signals may pass through the enclosure. In certain embodiments, at least a substantial portion of the power and / or control signals may pass through the enclosure. Mounts can be provided for these connections using one or more of the following: lugs / clips, bolts, rings / sockets / clamps, weld points, and other suitable ways for mounting. Also, for external control and / or information mounts one or more of the following may be used: switch mounts, calibration mounts (variable, quasi fixed controls), and embedded displays (LCD, or other). For Micro Bus Interfaces one or more of the following may be used: galvanically isolated connections (optical, radio), USB, Serial, other digital and analogue connections, and other suitable ways or structures. In certain embodiments, for mechanical outputs when applicable, the primary shaft may pass through the casing via one or more of the following ways: optionally, a bearing seal, variable diameters, unsealed pass-through hole (exposed inner assembly) and other ways of sealing shaft passthrough point. In certain embodiments, the enclosure may also have mounting points for magnetic coupling platters.

[0162] Switch Architecture

[0163] In certain embodiments, a power converter consisting of one or more electronically controlled switches may be used to control the size and direction of the current through the coils. These switches may be made up of discrete components (e.g., transistors and / or other silicon switch technology) including one or more of the following: IGBT’s or other similar technology; FET’s or other Channel / Field effect transistor based device (MOSFETS etc); BJT’s or other bi-polar transistor based device; ECP or other emitter coupled transistor device; digital switches such as transistors; silicon carbide transistors; diamond switches; Triacs; Diodes; SCRs; other suitable electronically controlled switching technology; and electromechanical relays. In certain embodiments, the one or more switches may be used to drive the electromagnetic coils and may be implemented in different ways and may be comprised totally or partially from one or more of the following configurations / devices: single switch; an H-bridge (full bridge); a Half bridge; a Half bridge with a high and a low side switching; bilateral switch configurations, single phase voltage source inverter, half bridge voltage source inverter, AC chopper regulation and other various one two, three phase and multiphase configurations.

[0164] The switches may be obtained without their plastic packaging and embedded directly into the one or more coils. Switches may be integrated into the body of the one or more coils, either after or during the construction process of the one or more coils. In certain embodiments referencingwhere the high side switches 35 and driver 36, the transistors may be biased to the high side of the coils. When using Positive Field Effect Transistor (PFET) or Positive Negative Positive (PNP) Bi Junction Transistors (BJTs), a negative voltage is applied in reference to their positive input and the control pin may turn on the gates. PNP BJTs and PFETs are generally more expensive than Negative Positive Negative (NPN) BJTs, Negative FETs and IGBTs. These devices would turn on if the voltage at their controlling terminal is greater than the voltage at their negative terminal by a few volts. In certain embodiments, to achieve this one or more of the following may be used: a charge pump; an isolated DC-DC converter; a separate power supply; and other voltage boost methods may be used. It is possible to vary the current flowing through the coil by use of pulse width modulation. In certain embodiments, the switches may be turned on and off at a high frequency, and by controlling the duty cycle (the time the switch is on compared to the time the switch is off) the amount of current flowing through the coil is controlled by this duty cycle. If the switches are just on (100% duty cycle), then the maximum current flows through the coil. If the switches are off (0% duty cycle), then no current will flow through the coil. If the switches are on half the time and off half the time the current could be 50% of the full current but may depend if the inductance of the coil at the switching frequency is too high or too low. In certain embodiments, when the direction of current through the coil does not need to be reversed, a single switch can be used between the voltage source, the coil and the ground. This reduces the component count by three switches. In a single-phase AC configuration, the voltage can be half rectified to create a positive rail and a negative rail. The two rails can then be switched through the coil to ground effectively changing the direction of the current. This reduces the number of switches required by two. In certain three phase star configurations, the phase with the nearest ideal voltage may be switched so that power can flow from that phase to ground. In certain delta three phase configurations, two switches may be required on either end of the coil to each phase, in this configuration current can be selected to flow from one or more phases to one or more other phases.

[0165] Control

[0166] In certain embodiments, one or more control mechanics may be used with respect to the driving operation of one or more electronic components. The one or more control mechanics may be implemented either at a hardware or software level, or both. In certain embodiments, the number of coils activated at a particular instance may be varied from 0 to the total number of coils. The choice of this number may be based at least in part upon the currently active control scheme. This decision may be made at the Main Control Unit (MCU), Coil Control Unit (CCU) and / or an external level. In certain embodiments, motors may be configured to operate in the clockwise, counter clockwise, or both directions. In certain embodiments, in order to produce motion, coils may be switched on and off at specific instants. These instances may be determined by one or more of the following:

[0167] A. stored sequences including: observed (obtained via sensor feedback); streamed (obtained via external devices); precomputed (stored within the motor electronics);

[0168] B. computed sequences including: sequential based activation (coils are toggled sequentially in a rotary fashion with alternating polarity); Optimal force activation (coils are activated when their individual feedback data indicates an optimal force will be applied to the rotor); optimal efficiency activation (coils are activated in a manner to maintain target operating motor dynamics whilst minimizing power consumption); and random based activation (coils are activated randomly); pattern based sequence (coils are sequenced in a predetermined pattern); feedback frequency based (Coils are activated based on a driving analogue frequency signal); and

[0169] C. Other suitable driving sequence which achieves desirable motor performance.

[0170] In certain embodiments, feedback may be used to generate and / or choose optimal driver routines / patterns to adapt the device to changing conditions such as but not limited to: changing temperature or other temporary forces / stress’ that may alter motor operational performance; a depleted battery / changing voltage supply; an increase in demand on a generator or for mechanical output in an application; change in parameters of the device caused by damage and / or general wear and tear; or combinations thereof.

[0171] In certain embodiments, certain electrical machine parameters may be calibrated using sensor feedback or other ways of tuning. For example, the use of machine learning techniques, and / or other automated tuning, operating internally, externally or combinations thereof may be used.

[0172] In certain embodiments, the active control scheme can utilize several techniques to reduce power consumption and / or better optimize power consumptions. For example, one or more of the following may be used: dynamic reduction of active coil count (lower power per torque); dynamic reduction of active coil power percentage (smoother torque); back EMF reproduction / elimination optimization; and pulse width modulation of the coil driving signal to allow precision control on power applied to coils.

[0173] In certain embodiments, feedback monitoring may be used to detect faults and automatically power off faulting devices. For example, one or more of the following: coil current overflow protection / detection; over-voltage / Over power protection; overheating protection; and velocity overspin protection. In certain embodiments, arbitrated master mechanisms may be used such as master controllers may be non-singular, with the resulting control signal arbitrated using a 3-way voting mechanism to ensure redundancy of the master controller. In certain embodiments, an external signal may be applied to bypass one or more single controllers with the purpose of shutting down, restarting, or reconfiguring the one or more controllers.

[0174] Feedback

[0175] In certain embodiments, feedback may be useful for optimal operation under one or more conditions, but may be only cost effective for incorporation into certain devices. When feedback is not required, a standard open loop control may be used. Feedback may be utilized by the controllers, either by CCUs or MCUs or both. In certain embodiments, feedback may be collected local to each device or remotely and used in either hardware and / or software as outlined in the control sections. In certain embodiments, feedback may be collected local to one or more devices or remotely and used in either hardware and / or software as discussed herein. In certain embodiments, feedback may be measured and / or obtained in one or more of the following ways: instantaneous voltage across a coil via a ADC, or otherwise, at any time or substantially any time; current through a coil or power supply, by either contactless (hall effect) or contact current measurement; back EMF measurement, may be done while coil is not in a powered state; angular position, obtained by a sensor as discussed herein; magnetic field strength or angle; temperature; and vibrations via accelerometers or otherwise. In certain embodiments, angular positions of the rotor may be obtained by measuring one or more of the following: absolute angle or position; relative angle or position; and velocity. In certain embodiments, readings may be achieved through the use of sensors such as one or more of the following: Hall effect and / or other magnetic sense technology, such as GMR, AMR; rotary and / or quadrature encoder, optical or otherwise; position / velocity detection sensors such as laser / optical trackers currently used in computer mice; and cameras in combination with software processing.

[0176] Controller Architecture

[0177] In certain embodiments, axial flux electrical machines may comprise: coil driving controllers, Coil Control Units (CCU’s) and / or Motor Control Units (MCU’s). In certain embodiments, the layout of the controllers may be varied, while maintaining control of each coil individually). In certain embodiments, the layout of the controllers may be varied, while maintaining control of one or more coils individually. In certain embodiments, the layout of the controllers may be varied, while maintaining control of at least a substantial number of the coils individually. In certain embodiments, the layout of the controllers may be varied, while maintaining control of at least 50%, 60%, 70%, 80%, 90%, 95%, 98%, 99% or 100% individually. The controllers drive ‘switches’ as described in this disclosure, allowing control of the coils, as described in this disclosure.illustrates one exemplary relationship between an exemplary Motor Control Unit (MCU) 37, Coil Control Unit (CCU) 38 the communications buses 39, 40 that are available to them. One or more MCU’s may be communicating with one of more CCU’s. Also illustrated is the coil driver architecture, according to certain embodiments, which includes a one or more coil drivers for one or more coils 22. The signalling between CCU’s, MCU’s 47 and coil drivers may be galvanically isolated.illustrates a CCU architecture 38, according to certain embodiments.

[0178] A Microcontroller coupled with an FPGA 43 may be used to control the device; it incorporates an Analogue to digital converters (ADC) 44 for collecting data from sensors 45. A Communications transceiver 46 is connected to the microcontrollers serial bus 47 allowing it to receive commands and exchange data with an MCU. The microcontroller controls a coil driver 41 by use of a digital bus or PWM. The coil driver takes a high voltage input 48 and controls the supply of that to the coil 22. The microcontroller and other peripheral low power devices may be supplied by a high efficiency DC to DC converter 49. Galvanic isolation is optional at several points 42. In certain embodiments, the number of controllers used may be varied depending on specific needs of the application.shows a 1:1:1 configuration such that one individual Motor Control Unit (MCU) 37 communicates with one Coil Control Units (CCU) 38, which in turn controls for each switch and or switch driver in a 1:1:1 configuration. (for example, as shown in); many switches controlled by one or more CCU’s, in a 1:n (for example as shown in) or m:n configuration (for example as shown in Figures 24 and 25); motor Control Unit (MCU) may control CCU’s, giving velocity and / or other commands; and MCU’s may directly control one or more coils, bypassing the need for CCU’s.

[0179] In certain embodiments, the controllers may be implemented through multiple ways, examples include one or more of the following: utilization of software and / or hardware features in an embedded system such as a microcontroller or microprocessor; the use of an FPGA, CPLD, ASIC or other VLSI or programmable logic device; an analogue system, such as the use of classical electrical feedback topologies to create basic control loops; and combinations thereof.

[0180] illustrates a certain embodiment, in which there is multiple microprocessor configurations, the master controlling processor may be, for example, a CCU 38. In certain embodiments, CCU’s may act independently, without the need for a master controller. In certain embodiments, CCU’s may act independently, without the need for a master controller wherein synchronous behaviour may be achieved through the use of common sensors, or sensors with predictable and consistent readings related to the electrical machine’s behaviour. In certain embodiments, where the motors speed and / or power is uniform (or substantially uniform), and the only input to the system is that the power is on or off, a common communication bus may not be required.

[0181] Certain embodiments are directed to an MCU’s (Motor Control Unit) in a standard master slave configuration where a single motor control unit is connected to a common communication bus, which is connected to one or more coil control units. Certain embodiments are directed to an MCU’s (Motor Control Unit) in a standard master slave configuration where a single motor control unit is connected to a common communication bus, which is connected to at least 70%, 80%, 90%, 95%, 98%, 99% or 100% of the coil control units.shows a configuration where a single motor control unit (MCU) 37 is connected to a common communication bus 47, which is connected to each of the coil control units (CCU) 38. Certain embodiments are directed to redundant master slave configuration where multiple masters arbitrate to come to an accepted value. For example, 2, 3, 4, 5, 6, 7, 8, 9, or 10 MCU’s may calculate commands to the CCU’s, but only one MCU’s commands are used by means of an arbitration method. In this way in the event of failure the failed MCU will be ‘outvoted’ and their commands discarded, possibly even being powered off by the other MCU’s. Other embodiments may include redundant MCU’s in case of failure, which only actively send commands when another MCU has failed.shows a configuration where 3 motor control units (MCU) 37 are connected to a common communication bus 47, which is connected to each of the coil control units (CCU) 38. In certain embodiments, it is possible to have configurations wherein one or more of the coil control units are not in communication with the plurality of motor control units. In certain embodiment, one or more of the CCU’s may act together as a group, sharing sensor data and / or providing common output. In such embodiments, communication may occur via a common bus or direct peer to peer. In such embodiments, a motor control unit may not be required.illustrates a configuration wherein no central communication bus is present and communication from each CCU 38 is point to point 50.illustrates a configuration wherein a central communication bus (token ring) 51 is used for communication between CCUs 38. In bothand 30 a MCU is not required.

[0182] In certain embodiments, power systems for supplying the digital logic and / or other devices in the CCU’s and / or the MCU’s may need to convert a higher or lower voltage to the operating voltage of the devices used, and can take one or more of the following the topologies: DC-DC converters, switching such as buck or boost; linear regulation or otherwise; transformers; resistive supply (by division); and optical power transfer. In certain embodiments, power may be supplied to the control units, CCU’s, MCU’s, an overall motor and / or another device. Such implementations may include one or more of the following: using the same (or substantially the same) supply the switches use, such as when switches are mounted to a motor casing; from RF / EM ‘waste’ or ‘background’ energy harvesting; via EM induction / generation, such as in the application of a generator; batteries, either per CCU / MCU device and / or otherwise, rechargeable or non-rechargeable; solar, wind, hydro and / or other forms of renewable energy sources; and mains supply, single phase, three phase at a variety of different voltages.

[0183] In certain embodiments, power supplies for switches and / or CCU’s / MCU’s may also have power control overrides, as a safety feature, allowing power to be turned off to one or more CCUs or coils. This can be implemented via suitable switching topology, for example, as discussed herein.

[0184] In certain embodiments, communications between a MCU and an external controller, MCU and internal CCU and / or other devices may be galvanically isolated by using one or more of the following methods: optical (IR or other spectrums) over a physical medium as a light guide like fibre or shaped plastic, through space / air or otherwise; radio Frequency of suitable spectrums, physical layer technology, and / or encoding method, such as Direct Sequence Spread Spectrum (DSSS), O-QPSK or otherwise; conductive, via wires and / or other electrically conductive material, and isolated via the use of a galvanically isolating technology such as: RF isolation IC’s, transformers, capacitive, optical isolation IC’s, or combinations thereof.

[0185] illustrates a configuration with three redundant communication buses 52. In certain embodiments, the communication layers may have 2, 3, 4, 5, 6, 7, 8, 9, 10 or more redundant layers.

[0186] In certain embodiments, communications inside the devices between controllers / drivers / MCU’s 37 and / or CCU’s 38 and / or to external devices, (e.g. vehicle control unit to MCU) may involve one or more of the following technologies and / or communications protocols in combination with one or more of the physical layer implementations disclosed herein: single ended, serial and / or parallel (for example UART, SPI, or I2C), differential signalling, (for example CAN bus or RS485 protocols), optical point to point and / or optical bus and RF communications or communications over the power lines. With reference tocommunications to external devices may be through a gateway 56.

[0187] With reference toand, a brushless, axial flux, alternating-current electric motor wherein the electrical machine can be configured to fit into a housing that is substantially the same as standard IEC or NEMA induction motor housing or enclosure 53 comprises one or more disc-shaped stators 54. The stator may be constructed out of a non-conductive material, for example, aluminium oxide bonded with a polymer, nylon 12, fibreglass composite, Kevlar composite, other suitable materials, or combinations thereof may also be used to prevent (substantially prevent, sufficiently prevent or reduce) the generation of an electrical eddy current around one of more of the electromagnetic coils.

[0188] Around the periphery of the stators is embedded a circular array of equally-spaced, or substantially equally-spaced, electromagnetic coils 22, heat from the coils may be conducted out to the exterior surface of the annular conductive elements by means of a channel inside the coil. Conductive elements 55 connect to Coil Control Units 38. The Coil Control Units consist of one or more stacked circuit boards. These stacked circuit boards may be parallel, substantially parallel and / or other suitable configurations. In certain embodiments, (not shown), the circuit boards may be partially, or wholly, replaced by a system of internal conductors. In certain embodiments, (not shown) the circuit boards may be supported by the solder tags of solid-state switches being soldered to them, the switches, in turn, being fixed (as described elsewhere herein) to a heat sink element. In certain embodiments, (not shown) the circuit boards are supported from the stators by a suitable structure, including conductive brackets, insulating brackets, pillars, struts or combinations thereof. In certain embodiments the circuit board can have an aluminium substrate, with an electrically insulating and thermally conducting material deposited on one side of the substrate. On the other side of the insulator copper traces can be etched. On the circuit board there may be a power converter that may consist of twelve solid state switches soldered to the etched copper traces such as IGBTs or MOSFETs in a single output three input power converter configuration. The circuit board may also have drive circuitry and circuitry for an AC-DC voltage converter to supply power DC power to microcontrollers or other digital electronics also soldered to it. The aluminium substrate can then be placed against the housing 71 either directly or through a thermally conductive interface material such as silicone grease or a thermal pad. Heat from the switches may therefore exit the housing through the aluminium substrate to the housing. Along one edge of the circuit board there are several connectors made out of a conductive material such as gold-plated copper that permits the connectors 59 to connect to a power distribution circuit board 62. The power distribution circuit board may have multiple distribution paths to wire different input phases to the Coil Control Units. The power distribution circuit board may also contain inductors and capacitors and common mode chokes to cancel unwanted frequencies from coupling onto the input power lines.

[0189] In certain embodiments, the power distribution circuit board may be annular bus bars with insulating materials surrounding them. The insulating layer may be made from a mechanically tough material having a high dielectric value, such as Acetal. Other suitable materials may also be used. In certain embodiments, (not shown) the stators may be electrically separated by hard anodising of their surfaces with care taken to ensure that the anodising extends substantially, or sufficiently, to their edges, the anodising being employed alternatively and / or in addition to the insulating layer.

[0190] With further reference toduring assembly and / or maintenance a single Coil Control Unit can be removed by disengaging the retaining mechanisms (not shown) and sliding the Coil Control Unit out thereby removing the Coil Control Unit from the device. To install reverse this process, slide the Coil Control Unit in and engage the retaining mechanism.

[0191] The electric motor may further comprise one or more disc-shaped rotors 18 around the periphery of which may be embedded in a circular array of equally-spaced (or substantially equally-spaced), north pole facing 20 and south pole facing 21 permanent magnets, the array may have the same, or substantially the same, centre diameter as that of the electromagnetic coils and the magnets may have alternating pole orientation. In certain embodiments, (not shown), the centre diameters of the arrays of permanent magnets and electromagnetic coils may be made unequal but such that the magnetic fields of the magnets and coils intersect. In certain embodiments (not shown), the poles of the permanent magnets in the array may have like orientation. In certain embodiments, (not shown), the permanent magnets in the array may be made in groups, the polar orientation of the magnets being common in each group while the polar orientation of adjacent groups may be opposed. In certain embodiments, (not shown), the permanent magnets in the array may be made in groups, the polar orientation of the magnets being common in one or more of the groups while the polar orientation of adjacent groups may be opposed. In certain embodiments, (not shown), the permanent magnets may be arranged in groups of unequal numbers, the polar orientation of the magnets in a group being common. In certain embodiments, (not shown), the permanent magnets pass through the whole of the axial depth of the rotors and may be orientated parallel, or substantially parallel, to the rotational axis, but with their centre distances randomly displaced (displaced inwardly or outwardly in a radial sense) up to half their radial depth. In certain embodiments, the displaced (displaced inwardly or outwardly in a radial sense) may be up to 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8 or 0.9 of their radial depth. In certain embodiments, (not shown), the permanent magnets in an array pass through the whole of the axial depth of the rotor and may be displaced in common from being parallel (or substantially parallel) with the rotational axis by a deflection in various senses of between zero and 30 degrees. In certain embodiments, the deflection in various senses of may be between zero and 30 degrees, zero to 20 degrees, zero to 40 degrees, 5 to 40 degrees, 5 to 30 degrees, 5 to 10 degrees, 10 to 30 degrees, 20 to 35 degrees or other suitable ranges. In certain embodiments, (not shown), the permanent magnets in an array pass only partly through the axial depth of a rotor, their inner ends optionally abutting a back iron of suitable magnetically permeable material embedded in the rotor. In certain embodiments, (not shown), the permanent magnets and the electromagnetic coils may be arranged in possible combination of the embodiments disclosed herein.

[0192] In certain embodiments the stator, rotor, power distribution circuit board may be assembled around a shaft to create a magnetic assembly 72 that may be slid into a housing 71 that has flats or other features that the stator can be attached to so that it would not rotate in relation to the housing.

[0193] In certain embodiments the coil may consist of a core made up from thin sheets of steel. The steel may be fabricated into I shapes of various width.shows a possible core. The steel may be cold rolled grain oriented electrical steel where the grains are oriented perpendicular or substantially perpendicular to the I shape or other steel that has high electrical resistance and good magnetic properties. The core can then be assembled by stacking the varying width of I’s so that they make a trapezoidal or mostly trapezoidal shape. The ends of the trapezoidal shape may be filleted by varying the width of the I’s so that wire windings may be easily wrapped around the core. The core of stacked I shapes may then be covered in a non-electrically conductive but thermally conductive material. This may be achieved by for example injection moulding a thermally conductive plastic or casting it in aluminium oxide or wrapping it in a tape such as Kapton tape.shows an embodiment of the core coated with a thermally conductive plastic. The core may then have an insulated electrical conduct for example enamelled copper wire wrapped around it. The profile of the wire may be circular or for better packing factor square or rectangular. The rectangular wire can be bent along the shorter diameter to produce an edge wound core. Edge wound cores have better thermal performance because each wind is at the edge of the core where heat can be effectively dissipated away from the wind.

[0194] In certain embodiments the cores may be wound in pairs such that there is a single conductor across two cores with a small length of connecting wire between the two. The two cores can then be aligned next to each other such that the winds from one goes down and back up on the other so that they can easily be connected to a Coil Control Unit. In certain embodiments three, four, five, six, seven, eight or greater than eight cores can be wound together. In certain embodiments the cores can be aligned in a line so that they are all connected across multiple stators. In certain embodiments the cores can be aligned next to each other and in a line so that they can go down through platters and back up to connect to a Coil Control Unit.

[0195] In certain embodiments the wound cores may then have a sheet of electrically isolating and thermally conductive sheet such as aluminium nitride or aluminium oxide placed on the outer edge and the coil may be over-moulded with a non-electrically conductive but thermally conductive material. This may be achieved by for example injection moulding a thermally conductive plastic or casting it in aluminium oxide. The sheet of electrically isolating material ensures that there is a controlled distance between the windings and the housing.

[0196] In certain embodiments the over-moulded coil or coils would have features such that the coils can interlock with each other. Further features such as flats may be added to lock the coils onto the housing or onto an alignment plate.

[0197] In certain embodiments one or more bearings 77 may be sandwiched between two alignment plates 78 such that the alignment plates only make contact with the external race of the bearing such that the internal race of the bearing can freely rotate while axially constraining the bearing. The alignment plate may have the over-moulded coils 22 placed around them such that the features in the over-moulded coils stop the coils from moving in the axial direction in relation to the bearing.

[0198] In certain embodiments a spring is placed between the coil and the alignment plate to apply force on the coils radially away from the alignment plate. In certain embodiments the springs can be made of spring steel, a compressible O-ring 60, or other material that will create a force away from the alignment plate in a radial direction.

[0199] In certain embodiments the rotors 18 may consist of a plate 31 of ferromagnetic material, the ferromagnetic material may have several radial ridges 70 towards the outer edge of the rotor. These ridges when rotating introduces turbulence to the air inside the housing circulating the hot air that raises to the top of the housing maintaining a more even air temperatures inside the housing. In certain embodiments a number of bosses may be added on the outer edge of the rotor, these bosses can be trimmed to dynamically balance the rotor. In certain embodiments the rotor has a conical boss with an annular opening in the centre. The annular opening may have a keyway 63 or spline or other feature or friction weld to couple a shaft to. In certain embodiments, one or more nuts 80 in threaded engagement with the shaft may be used to axially constrain one or more of the rotors and / or bearings on the shaft. In other embodiments, the shaft may be free or substantially free to move in the axial direction to accommodate thermal expansion during operation. The height and diameter of the conical boss is such that when concentrically aligned with a bearing and a shaft the boss only makes contact with the inner race of the bearing. In certain embodiments the rotors may be made of cast iron, cast iron has good magnetic performance, reasonable thermal conductivity while having lower electrical conductivity and may reduce eddy currents from stray magnetic fields. In certain embodiments the rotor may be cast with all the afore mentioned features, or these features may be attached using glues or bolts or other attachment methods or a combination of these methods.

[0200] In certain embodiments the rotor may have a retaining plate 64 of a similar shape to the rotor. The retaining plate has a series of concentric or near concentric cutouts in the shape and slightly larger than the magnets to be used on the rotor creating pockets for the magnets. One or more plates may be attached to the rotor using glue or screws or rivets or other attachment methods or a combination of these methods.

[0201] In alternative embodiments (not shown) in the rotors having a face not immediately adjacent the stator, the back irons may be deleted and the magnets take the form of suitable Halbach arrays.

[0202] In certain embodiments the rotor with attached retaining plates may have magnets placed inside the pockets. The magnets attach themselves to the ferromagnetic plate due to magnetic attraction. The retaining plate ensures that the magnets do not slide radially outwards. Additional adhesive may be used to further retain the magnets.

[0203] In certain embodiments the magnets may be positioned onto the rotor and the magnets are over-moulded with plastic or polymer or ceramic.

[0204] In certain embodiments a shaft 19 is placed inside the bearing inside the stator. The shaft may have splines or keyways or other methods of attaching the shaft to the rotor. One or two rotors are lowered onto the shaft till the rotors annular boss rests axially on the inner race of the bearing with the rotor parallel (or substantially parallel) to the stators with an air gap between the electromagnetic coils and the permanent magnets. When two rotors are used on both side of the stator the magnetic attraction between the rotors should cancel out and the radial load across the bearings is close to zero. The only load on the bearing is axially on the outer race and inner race.

[0205] In certain embodiments the conductors from the coils have a second insulator placed around it to ensure that the conductor does not make contact with the rotor or the housing. One example the second insulator may be in the shape of a tube of a similar diameter of the wire. Another example is for a larger tube the size of the diameter of the stator and another of a similar diameter of the rotor, with all the wires passing between the larger and smaller tubes.

[0206] In certain embodiments the conductors from the coils may be attached to the power distribution circuit board through crimping or soldering or welding or another method of connecting a conductor to another conductor. The coil conductor may then be routed to a connector that connects to the Coil Control Unit.

[0207] In certain embodiments the stator, rotor, power distribution circuit board and shaft make up the magnetic assembly 72. The magnetic assembly can be tested and dynamically balanced by mounting it in a test jig.

[0208] In certain embodiments the magnetic assembly has an encoder wheel 75 attached to the shaft 19, the encoded wheel could consist of a series of cogs that can be detected with a hall effect sensor or a series of slots that can be detected with an optical sensor or a series of magnets that can be detected by a GMR sensor or use of other methods for absolute or relative positioning of the shaft.

[0209] In certain embodiments the magnetic assembly does not have an encoder wheel and instead relies on measuring the back EMF from the coils during non-excitation periods of the coil to detect the position of the magnetic field to the rotor.

[0210] In certain embodiments the motor does not require to detect the position of magnets to the rotor and is instead driven with no feedback.

[0211] In certain embodiments the magnetic assembly 72 and encoder wheel 75 is picked up by a special assembly tool that has a series of prongs that align with a series of holes in the rotor and stator and applies radial pressure towards the shaft to compress the springs between the coils and the alignment plate 78 to reduce the diameter to below the inner diameter of the housing. The compressed magnetic assembly may then be inserted into a housing that have matching or substantially matching flats on the inside circumference of the housing. Thermally conductive compound or pads for example silicone grease or thermal pads may be placed between the outer circumference of the housing. The thermally conductive compound ensures effective heat transfer from the coils to the housing and the springs force the coils onto the outer walls of the housing.

[0212] In certain embodiments there are bearings 67 mounted on the shaft 19 and end covers 66 at either end of the motor housing 71 the bearings are concentric or substantially concentric to each other. The internal bearing inside the magnetic assembly can align concentrically or substantially concentrically to the other bearings by compressing the springs between the coils and the alignment plate.

[0213] In certain embodiments one of the bearings 67 between the shaft 19 and the end covers 66 has a wave washer 58 and the bearing is free or substantially free to move in the axial direction of the end cover. This ensures that if the housing and the shaft have different rates of thermal expansion the shaft or housing is not adversely affected and the bearings are not unnecessarily loaded in the axial direction. The shaft may also have rubber seals 57 to protect the motor from ingress and the bearings may be held between inner and outer bearing caps 68. The shaft may also have a key 69 to assist in the transfer of torque from the motor to an external shaft.

[0214] In certain embodiments the magnetic assembly 72 is free or substantially free to move in the axial direction in relation to the housing. This ensures that if the housing and the shaft have different rates of thermal expansion the internal bearings are not unnecessarily loaded in the axial direction.

[0215] In certain embodiments the internal bearings and rotors are able to slide along the shaft in the axial direction in relation to the housing. This ensures that if the housing and the shaft have different rates of thermal expansion the internal bearings are not unnecessarily loaded in the axial direction.

[0216] In certain embodiments the shaft exits the housing on both ends. The shaft on one side may be attached to the device it is driving and the shaft on the other end has a radial fan 65 attached to it to provide air flow over the motor to cool the housing. A cowling 73 may be attached to the housing to guide the airflow over the fins of the housing to cool the motor.

[0217] In certain embodiments there is one bearing attached to the end cover 66 the housing and the shaft is supported by the internal bearing of the magnetic assembly. On the other end of the housing a shaft driven by a second motor (not shown) may be installed with a fan attached to it. This fan may then operate at a different speed to cool the housing of the first motor. This may be useful in situations where the first motor is running at low speeds and high torques and the speed of the first motor is not high enough to circulate enough air to cool the housing.

[0218] In certain embodiments the second motor shaft may be coupled to the first motors shaft through a mechanical coupling for example a clutch, such that the fan is spun by the first motor except when the second motor is spinning faster than the first motors shaft. In that way the second motor is only powered when the speed of the first motor drops below a speed where adequate cooling is provided by the fan.

[0219] In certain embodiments the second motor may be mounted on the cowling rather than in the housing.

[0220] In certain embodiments the housing has fins running in the axial direction along the external circumference of the motor on all four quadrants of the housing. A junction box 74 is attached to the housing 71 in the junctions between two quadrants with wiring to attach the power distribution circuit board to an external power source. The junction box may be sealed with the use of one or more rubber seals 57.

[0221] In certain embodiments the junction box is attached to the housing with a small cross-sectional area in the direction of air flow along the fins with the bulk of the housing supported by the attachment point such that the junction box does not substantially disturb the flow of air over the housing.

[0222] In certain embodiments the junction box has fins on the back of the housing to assist in cooling any electronics that are inside the junction box.

[0223] In certain embodiments one or more Motor Controller Units 37 is housed inside the junction box 74. The one or more Motor Control Units communicate between the Coil Control Units and the exterior of the motor.

[0224] In certain embodiments, the input power connections to the electrical machine may be made via a terminal block 81 housed within the junction box 74, wherein the terminal block is configured to accept single phase, three phase or other suitable power supply connections.

[0225] In certain embodiments the Motor Control Unit has an input device for example a slider switch or a rotary switch to control the direction of the motor. In certain embodiments the Motor Control Unit Controller may have an input device for example a rotary dial to control the speed of the motor.

[0226] In certain embodiments the Motor Control Unit may be connected to another device that can connect the system to an external data communication bus or buses. Some examples of these external busses are Modbus, EtherCAT, ethernet and CAN bus. In certain embodiments the Motor Control Unit may have an input device for example a key switch to disconnect the output and / or the input from the device connected to an external data communication bus from the Motor Control Unit. In this way all communications to the motor can be islanded so that the device is safer or substantially safer from cyber-attacks.

[0227] In certain embodiments the digital signals from the Motor Control Unit are distributed through the data distribution circuit board.

[0228] In certain embodiments the data distribution circuit board may be a part of the power distribution circuit board or may use wires, RF, or data over the power lines.

[0229] In certain embodiments the Coil Control Units 38 plug into the data distribution circuit board and power distribution circuit board 62. The Coil Control Units are positioned radially around the inside of the housing on the opposite end of the housing.

[0230] In certain embodiments the Coil Control Units are positioned on either end of the housing (not shown). This configuration is of advantage when there is more than one stator that require to be powered independently.

[0231] In certain embodiments the Coil Control Units can be stacked axially along the inner surface of the housing with multiple power and data distribution circuits boards.

[0232] In certain embodiments the power and data distribution circuit boards are instead a set of radial bus bars that are arranged near the inner circumference of the housing with a suitable insulator. The Coil Control Units couple to the power distribution bars by means of an electrical contact.

[0233] In certain embodiments the solid-state switches are activated by command signals from a control system (not shown) to power the electromagnetic coils and thereby cause the rotors to rotate. Suitable sensors (not shown) are provided to generate signals that are transmitted to the control system to provide data as to the absolute and instantaneous positions of the rotors. In certain embodiments, one or more suitable sensors (not shown) may be provided to generate signals that may be transmitted to the control system to provide data as to the absolute, substantially absolute, or sufficiently absolute and / or instantaneous, substantially instantaneous, suitably instantaneous, relative, or substantially relative positions of one or more of the rotors, or any combination thereof. In certain embodiments, the sensors take the form of one or more optical sensors and / or one or more Hall-effect sensors. In certain embodiments, (not shown), rotor position may be determined by reference to the back EMF generated in undriven coils.

[0234] In certain embodiments, the permanent magnets may take the form of powerful, or sufficiently powerful, rare earth-type magnets and may be secured in position within the axial depth of the rotors by, for example, bonding, by suitable mechanical fastenings or by imprisonment between two parts clamped together. In certain embodiments, (not shown) which may be employed in lower cost applications and / or those required to meet different operational parameters, the magnets take a conventional form. The body parts of the rotors are made sufficiently strong and / or rigid to suitably resist magnetic forces generated during operation and / or when the rotors are at rest. The rotor body parts are optionally made solid and / or partially hollow with radial ribbing to reduce rotating mass and / or confer stiffness.

[0235] In certain applications, the centre diameters of the arrays of permanent magnets and arrays of electromagnetic coils fall in the range 15 to 90 centimetres, the number of the coils being odd and the number of the magnets being one more than the number of coils. In certain applications the number of the coils are twice a prime number and there are 2 more magnets. Other suitable ranges may also be used. In certain embodiments, 24, 28, 36 or 40 magnets may be employed. In certain other embodiments employing similar operating principles, the numbers of the permanent magnets and the electromagnetic coils may optionally be doubled, tripled or quadrupled and the coils powered as required to generate a desired torque and RPM. In certain applications, the number of the permanent magnets and the number of electromagnetic coils may be 1, 2, 3, 4, 5, 6, 8, 10, 12, 14, 20, or more and the coils powered as required to generate a desired torque and RPM. Similarly, in other alternative embodiments, the permanent magnets and the electromagnetic coils may optionally be made in equal numbers. Similarly, in other alternative embodiments, the permanent magnets and the electromagnetic coils may optionally be made in equal numbers, but with locational asymmetry to prevent magnetic stasis at start-up. In certain applications, the greater centre diameter of the arrays of permanent magnets and electromagnetic coils, the greater the torque able to be generated. The arrangement of the electric motor permits many combinations to be created from specially designed components, standard components, or combinations thereof - from a single rotor and stator combination to combinations employing at least 10 rotors. In certain applications the number of rotors may be at least 5, 10, 15, 20, or 25. The combinations employing larger numbers of rotors and stators may be used in large devices such as wind generators, crushers and mills

[0236] In certain embodiments, the solid-state switches employed to provide electronic commutation may be insulated-gate bipolar transistors (IGBT) with a freewheeling diode which may be capable of handling the supply voltages required by the electric motor. Although both p-type (P-FET) and n-type (N-FET) field-effect transistors may be suitable for the application, in the certain embodiments, IGBTs may be employed in a three-phase full bridge arrangement with powering of the high side of each IGBT by an integrated circuit incorporating a charge pump. In the certain embodiments, IGBTs may be employed in a three-phase full bridge arrangement with powering of the high side of one or more of the IGBT by, for example, an integrated circuit incorporating a charge pump or from a DC to DC or AC to DC isolated converter. The positioning of the IGBTs within close proximity to the electromagnetic coils may provide short, efficient conduction paths of low resistance. Other positioning may also be used such as substantially adjacent, suitably adjacent or in communication with. The type of the IGBTs employed may provide large tabs intended as heat sinks, but which may be also electrically conductive. The tabs may be therefore fixed directly, or indirectly, to the fingers of annular conductive elements, thereby providing the IGBTs with an efficient electrical current supply path with low resistance, making efficient use of space and / or providing an efficient thermal conduction path out to the finned or ribbed exterior surfaces of the annular conductive elements.

[0237] In certain embodiments with additional reference totwo IGBTs with co-packed or separate flyback diodes can be placed back-to-back to create a bidirectional switch.

[0238] In certain embodiments with additional reference tothe power converter of the Coil Control Unit (CCU) comprises of three input terminals 113. The three input terminals are connected through the power distribution circuit board to for example three phases of an AC power source or load. The three terminals are protected from high currents through the use current limiting devices for example fuses 114. The three terminals may have at least two current sensors 115 (the third phase may be calculated from the current measurement on the other two phases) to detect how much current is flowing into the CCU, and voltage measurement across each terminal 120.

[0239] A secondary voltage measurement 122 may be included to more accurately detect when the voltage of one phase crosses the other phase voltage or the zero crossing. This may be implemented with a comparator connected to a one or more resistors across two of the input terminals. With adequate filtering for example using a resistor capacitor the voltage crossover of the two phases can be accurately measured to within a few microseconds. Three such comparators and filters may be implemented to accurately detect all three phase crossing points. A similar circuit connected to the midpoint of the three terminals through a large resistor for example 1 megaohm will permit the detection of the zero crossing of each phase. With the six cross over points, the phase currents and phase voltages measured commutation pattern can be calculated by the control information generator 123.

[0240] In certain embodiments the control information generator may for example be constructed using a Complex Programable Logic Device CPLD or a Field Programable Gate Array FPGA coupled to a microcontroller.

[0241] With further reference totwo IGBTs are arranged in a back-to-back configuration that permits the IGBTs to block current in both directions when turned off and can be arranged in these two configurations. These pairs of IGBTs are attached to the three phase input terminals in a three-phase full bridge configuration 35 and 116. The six crossover points dictates which IGBTs must be in a blocking state to stop current from flowing across the three phases form the input terminal without passing through the coil 22. The six crossover points also dictate which IGBTs require to be activated to pass current through the coil from one pair of phases or another pair of phases.

[0242] In certain embodiments these combinations may be implemented in an FPGA or CPLD so that very fast commutation of the IGBTs can be implemented without having to wait for a microprocessor to calculate the combinations. This may be necessary to ensure that there is no high current discharge through the IGBTs between phases should the signals to change IGBT states was not fast enough.

[0243] In certain embodiments a microcontroller with the measured current 115 and measured voltages of the phases 120 as well as the measured current 125 and voltage 124 of the coil can control which pairs of phases the current comes from (or goes to in generation). The microcontroller can then employ a control algorithm which outputs pulse width modulations to the FPGA or CPLD 123 to request that a certain current waveform is generated in the coil while pulling a sinusoidal current waveform from the input phases with a specific phase angle between the voltage and current on those phases. The CPLD or FPGA converts the requested pulses into pulses to control the appropriate IGBTs while handling phase crossovers and zero crossovers of phases without the intervention of the microcontroller.

[0244] In certain embodiments the FPGA or CPLD attempts to keep as many IGBTs on during non-conduction periods to ensure that any currents can freewheel through the IGBTs during switching. This is essential to ensure that the blocking voltage across the IGBTs is not exceeded during switching.

[0245] In certain embodiments different control techniques are used to control the current in the phase such as a Proportional – Integral – Derivative PID controller with look ahead to ensure that the requested current on the coil is as closely matched to measured current of the coil.

[0246] In certain embodiments MOSFETs or SICFETs or other switching circuitry are used instead of IGBTs.

[0247] In certain embodiments a pair of comparators are connected to the current sensers to detect a threshold current and if greater than the threshold disables some or all of the IGBTs.

[0248] In certain embodiments a Transient Voltage Suppression (TVS) device such as a Metal Oxide Varistor (MOV) or gas discharge tube or a combination (GMOV) or a Zener diode is placed across the input phases and the output to the coil so when the circuit is suddenly opened for example during an overcurrent event the IGBTs are protected.

[0249] In certain embodiments the output of the Coil Control Unit is connected to the coils using connectors 127 with a current limiting device 126 for example a fuse to ensure that the coil will fail open circuit should a single CCU fail in a shorted state across the coil outputs. This is useful for single CCU fault tolerance.

[0250] In certain embodiments the above circuit can perform commutation if the input is switched from 3-phase AC to DC or if one of the three phases is no longer present. The controller can detect such an event and drive the IGBTs to handle such a situation.

[0251] This could be useful in situations where a system is connected to both the grid and a battery or solar panels. The motor can be driven directly from the DC source without having losses during conversion.

[0252] In certain embodiments DC to DC isolated converters and high voltage step-down regulator circuit boards may be mounted to the circuit boards. Independent power supplies may be employed to prevent, or substantially prevent, the existence of a closed conductive loop, thereby preventing (substantially preventing or sufficiently preventing) induced current from adversely affecting electronic functions. Similarly, to prevent, substantially prevent, or sufficiently prevent induced current from interfering with command and feedback signals, inner and / or outer circuits may be galvanically isolated. In some embodiments, the galvanic isolation is achieved through the use of infra-red transmitting circuit and receiving circuit, with one such pair provided for each Coil Control Unit. In the certain embodiments, control signals from microcontrollers on the Coil Control Unit on the insides of the stators may be galvanically isolated using electromagnetic (RF) isolation structures or techniques. In alternative embodiments (not shown), the galvanic isolation may be achieved through the use of optical, capacitance, induction, electromagnetic, acoustic, mechanical structures or techniques or combinations thereof adapted for the purpose.

[0253] With additional reference to, in the certain embodiments, a current of 10 Amperes at between 200 and 450 Volts may be supplied to the electromagnetic coils to achieve a maximum power output. In the certain embodiments 11 coil pairs may be wound up from 1.2mm diameter copper enamelled wire. The core material of 0.19mm grain-oriented silicon steel specially cut to I sections. The steel is often supplied coated with an insulating compound to stop eddy currents.

[0254] In certain embodiments the electromagnetic coils may be wound with copper foil to reduce inductance effects and, thereby, to increase the maximum rate of polarity switching. In certain embodiments, a maximum switching rate of 400 Hz being achieved. In certain embodiments, a maximum switching rate of 100 Hz, 200 Hz, 400 Hz, 500 HZ, 600 Hz or 800 Hz may be achieved. In certain embodiments (not shown) to meet different operational parameters, higher or lower switching rates may be achieved. By also reducing back EMF, the voltage required to operate the electric motor at a given speed may be reduced with a thickness of 0.23 millimetres, the volume of the grain-oriented silicon steel within the electromagnetic coil is sufficient to allow generation of the necessary magnetic flux strength. The thicknesses of the copper foil and the grain-oriented silicon steel may be intended as substantially only indicative and, in alternative embodiments, thicker or thinner materials are optionally employed. In certain embodiments electromagnetic coils of conventional wire-wound or ribbon-wound, bobbin construction may be employed, with an air core or core made from a suitable magnetically permeable material. In another alternative embodiment, the electromagnetic coils may be made with high-temperature superconducting windings. The coils may be made with an air core and / or liquid nitrogen cooling techniques or means may be employed to maintain a suitable operating temperature.

[0255] With additional reference to, in certain embodiments, powerful (or sufficiently powerful) permanent magnets 20, 21 may be embedded in the rotor disc 8 as described herein. Suitable slots 76 may be provided in the rotor disc to reduce the rotating mass and thereby the angular momentum of the rotors and to permit an axial flow of air within the electric motor casing. The centre bore 93 of the rotor disc is splined to accommodate complementary splining of the shaft. With additional reference to, in certain embodiments, powerful permanent magnets 20, 21 may be made more or less trapezoidal in shape and abutting each other with alternating pole orientation. In certain implementations, one or more of the magnets may be abutting. In certain applications, the magnets may be made more or less trapezoidal in shape and abutting, substantially abutting, each other with alternating pole orientation. In these embodiments, the radially inner edges of the permanent magnets may be shaped to engage (or communicate with) a complementary shape formed in the outer edge of the rotor disc, the side edges of the magnets may be shaped to engage (or communicate with) complementary shaping of adjacent the magnets in an array and the magnets may be retained in place on the rotor disc by a circumferential restraining band (not shown) of a high-strength metal material. The central bore 93 of the rotor disc is splined to accommodate complementary splining of the shaft. In certain embodiments (not shown), the powerful permanent magnets may be shaped approximately trapezoidal, but with the axis of one or more inclined to a radial passing through it by an angle of between 2.5 and 20 degrees. Other ranges of angles may also be used, for example, an angle of between 2.5 to 5 degrees, 5 to 25 degrees, 5 to 10 degrees, or 15 to 20 degrees.

[0256] In certain embodiments (not shown), the IGBTs may be made integrally with the copper of the electromagnetic coils.

[0257] With reference to, reflective optical position sensor 82 and Hall-effect or GMR sensor 96 provide rotor position-related signals to microprocessor-based control unit 97. The control unit optionally takes the form of a microcontroller and / or programmable logic device and / or programmable gate array and / or other custom-built unit. From the interior 100 of the electric motor, the control unit transmits data via galvanic isolation transmitter 98 to galvanic isolation receiver 102 on the exterior 84 of the electric motor and thence to microcontroller unit 105. Similarly, microcontroller unit 105 transmits data to control unit 97 via galvanic isolation transmitter 103 and galvanic isolation receiver 83. Separate bi-directional galvanic isolation means may be required for each stator. From microcontroller unit 105, data is transmitted to and from a master control unit via conductors. Microcontroller unit 105 optionally takes the form of a microcontroller and / or programmable logic device and / or other purpose-built logic device. Control unit 97 communicates with switch drivers 110 via galvanic isolation unit 42. The galvanic isolation units optionally employ one or more of the operating principles described herein and the galvanic isolation unit is provided for one or more of the stators. Electrical current is supplied to a three-phase full bridge arrangement of switches via terminals 113 and switches 35 and 116 are controlled by the switch drivers 36 and 117. Electromagnetic coil 22 is connected to the full bridge such that current flow reversal via switching reverses the magnetic polarity of the coil. Electrical current is supplied to DC to DC down-converter 107 via conductors 106 and the down-converter supplies current to isolated DC to DC down-converter (switching) 108 and isolated DC to DC down-converter (logic) 109. The down-converter (switching) supplies electrical current to galvanic isolation unit 42, the switch drivers and the IGBTs and the down-converter (logic) supplies electrical current to control unit 97.

[0258] Control unit 97 permits arbitrary switching of one or more of the electromagnetic coils independently of the other the coils. Using pulse-width modulation, excitation waveforms can be generated and used to drive the coil. A wide variety of coil drive profiles can be employed for the real-time maximisation of efficiency and power output over a wide range of RPM and operating temperatures. In certain embodiments of the operating method of the electric motor, maximum power may be maintained by simultaneously powering the electromagnetic coils except one, the magnetic polarity of the powered coils being alternating. The un-powered coil is then re-powered with opposite magnetic polarity such that it opposes the magnetic polarity of the preceding the coil (proceeding in the sense of the direction of rotation of the rotors) while the next coil (next in the same rotational sense) is de-powered. The process is continued with each successive coil being de-powered and then re-powered with opposite polarity to complete a movement of the one or more permanent magnets from one the coil to the next. Thus, for a complete rotation of the rotors, the number of the coil de-powerings and re-powerings (with opposite polarity) in the coil array is given by the square of the total number of the coils in the array. Where the number of powered the coils in an array is n, the electric motor is thereby electromechanically geared, in effect, by a ratio of n:1. In certain embodiments of the operating method of the electric motor, minimum power is maintained by powering one or more of the electromagnetic coils only once per rotation of the rotor such that each the coil attracts only one the magnet in the peripheral array of magnets. The electric motor is thereby electromechanically geared, in effect, by a ratio of 1:1. Various sequences or combinations of the coil powerings and de-powerings may be employed to achieve a nominated electromechanical gearing.

[0259] In certain embodiments (not shown), to reduce cogging effects and / or to maximise efficiency, the back EMF of an unpowered the electromagnetic coil is recorded at a representative range of speeds using the analogue-to-digital converter in the microcontroller. During operation, the electromagnetic coils in an array that are normally un-powered may be powered to a level at which the magnetic flux generated equals, or substantially equals, the back EMF effect of the coil, thereby neutralizing the magnetic interaction between the un-powered coils and the permanent magnets. The mechanism is also used in regenerative braking permitting the wave to be analysed and then switched into the correct power planes. The characteristics of the back EMF of the coils may be further analysed during run time for a specific velocity, power requirement and operating temperature, and an optimal or near optimal wave generated using pulse-width modulation to, as far as is possible, maximise the efficiency of the electric motor. In the certain embodiments, such analysis may be performed automatically, substantially automatically, on a continuous basis, on a discontinuous basis or other suitable intervals. Pre-computed or partially pre-computed waveform patterns may be stored in a look-up table and may be recalled when specific velocity, power requirement, operating temperature and, optionally, back EMF, or combinations of these, is detected. The look-up tables are optionally optimised through the use of meta-heuristic algorithms, evolutionary algorithms, traditional, deterministic algorithms, other suitable optimisation techniques or combinations thereof. In certain embodiments, adaptive control may be implemented by performing optimisation at run time through the use of an incorporated support vector machine, through the use of neural network technology, through the use of fuzzy logic technology, through the use of other suitable application of machine learning technology, through the use of suitable adaptive control techniques or through combinations thereof.

[0260] In certain embodiments (not shown), a supply of clean cooling air may be supplied to the interior of the motor casing as required to maintain the stators at a predetermined temperature. The cooling air may be exhausted via a suitable valve which maintains a predetermined minimum pressure within the casing to prevent, or substantially reduce, ingress of contaminants. The supply of cooling air is optionally cooled in a refrigerated heat exchanger before being supplied to the electric motor casing. In another certain embodiment (not shown), a flow of liquefied refrigerant may be supplied to galleries formed in the casing walls and / or stators of the electric motor and may be allowed to boil off as it takes up heat from the casing. Vapour formed by the cooling process may be drawn off, compressed and cooled in suitable heat exchange configuration or means to re-liquefy it. In these embodiments, the liquefied refrigerant is optionally a conventional refrigerant or, where high-temperature superconducting coils are employed, liquid nitrogen. In certain embodiments (not shown), a flow of a suitable liquid coolant may be circulated through galleries formed in the casing walls and / or stators of the electric motor, heat taken up by the coolant subsequently being dissipated via suitable air-cooled heat-exchange configuration or means.

[0261] In certain embodiments (not shown), the electric motor may be employed as an electrical generator and one or more of the operating principles may be employed to maximise electric power generation efficiency during rapidly varying generating conditions. Such variable generating conditions may be, for example, those experienced during regenerative braking.

[0262] Method Of Design and Manufacture of Certain Exemplary Embodiments

[0263] The following examples are included to be illustrative of the variety of devices that may be designed and / or manufactured using certain disclosed embodiments. By using the approaches disclosed herein, it is contemplated that a large number of devices may be designed and constructed using the technology disclosed herein.

[0264] A. In this exemplary method of manufacture, one or more design requirements are supplied. For example, these requirements may including: size of the device, weight of the device, the maximum power of the device, the voltage it needs to operate off or generate, the peak current draw or supply (controls the maximum power), the number of connections to the power supply (DC, single phase, three phase), the range of angular velocities which the device will run at, the amount of torque that needs to be delivered, the maximum torque the shaft needs to be absorbed, or combinations thereof. It is to be understood that other features may be used in designing and manufacturing the device.

[0265] This information may then be processed in the following way: First a suitable module is selected such that it is capable of handling the voltage required and has enough contacts and switches, (for example, two for single phase and DC, three for three phase delta, four for three phase star). The power rating of each module is then divided into the maximum power required. The maximum size of the motor is then taken into consideration to decide the number of coils that can fit into a circular arrangement, this becomes the size of the platter. The number of platters is the number of coils per platter divided into the total number of coils. This number of coils is then checked against the maximum angular velocity ensuring that the inductance of the coil in the module is not such that it cannot switch at that desired frequency. If it is too high, the diameter can be reduced to result in less number of coils per platter, resulting in lower frequency of operation. This provides the design information that may then be used to construct the device.

[0266] B. In this exemplary method of manufacture, one or more specifications are provided. In this example, the device to be built specifies a motor 30kW, needs to fit into a standard IEC 200ML housing with a top angular velocity 1500 RPM equivalent to a 4-pole induction motor, continuous torque of 191Nm and an overload torque of 2.5 times continuous torque for 30 seconds. The device is to be air cooled. Three phase 400 volts RMS AC power source at 50Hz in a delta configuration. The AC source with a delta configuration results in three inputs.

[0267] 30kW at 400VRMS 3 phase AC requires 30kW / 400V=75 Amperes RMS into three phase delta configuration 75Amps divided by the number of phases 3 multiplied by the number conducting 2 is 50 Amperes per phase. The next step is to decide how much current is required per Coil Control Unit. It is easy to air cool units that are operating a continuous peak current under 10 Amperes. Splitting the 75 Amperes RMS into 11 units results in the unit operating at 6.8 Amperes RMS which is a peak continuous of 9.6 Amperes and an overload current of 24 Amperes for 30 seconds. The use of a prime number here 11 works, repetition every 11 rotations, harmonic at maximum angular velocity 1.5Hz.

[0268] Next the number of coils is selected. The coils are coupled together to assist in simplicity of winding using paired coils so that winds end up at the top. The paired coils also reduce magnetic coupling between individual coils thereby simplifying control. Therefore, there are 22 coils,

[0269] Next the number of magnets is selected. At least one more magnet per platter is 23 but the magnets selected in this example are an even number so that they have alternating fields around the platter therefore 24 magnets.

[0270] This results in a final configuration of 1 stator of 22 coils and two platters of magnets of 24 magnets. Based on this design a device may be built with a platter stator for coils accommodating 22 coils. The next step is to design and manufacture magnetic platter accommodating 24 magnets and to design and manufacture a housing or enclosure and bearing supports to hold the device together. Next assemble the coils into stator platters, magnets into rotor platters and build the device. The next step is to modify software to control 22 coils and to switch to generation mode on braking.

[0271] C. In this exemplary manufacture a specification is set forth that specifies 3MW, weight is not a consideration, needs to fit into a diameter less than 2000mm, rotation up to 120 RPM, output voltage should be 3000 volts RMS 650Amps at 50Hz to match mains, three phase. The specification further specifies high voltage at low speed, specifies iron core, lots of windings, low current to optimise efficiency and a three-phase source therefore specifies three outputs.

[0272] This indicates to select iron core 4000v, 10A three phase module. Run at 3000 volts, max current of 10A, peak power is 30kw. This also indicates a minimum of 100 coils. Furthermore, to maximise angular velocity over the coils to maximise voltage generation, a large diameter platter is well suited for this application. Since torque smoothness is not of as much concern, but harmonics in large blades can be of concern, this example indicates one more magnet than coil per platter.

[0273] Based on this information, the next step is to calculate the number of magnets that can be arranged in a circle of diameter of 2000mm, find that up to 104 can fit. Since the number of coils is typically prime to minimise harmonics, 101 works in this example.

[0274] This results in a final configuration of, 1 stator platter of 101 coils, and 2 rotor platters of 102 magnets.

[0275] The next step is to design and manufacture platter stator for coils accommodating 101 coils. Design and manufacture magnetic platters accommodating 102 magnets. Design and manufacture enclosure and bearing supports to hold the device together. Assemble the coils into stator platters, magnets into rotor platters and put it together. Modify the software to control 101 coils and to synchronise to the grid and ensure voltage is maintained at 3000V RMS.

[0276] D. In this exemplary example the specification specifies 1GW, weight not a problem, size not a problem, rotation up to 300 RPM, output voltage should be 3000 volts RMS 333333Amps at 50Hz primary driver of mains frequency, three phase. There are not many constraints in this specification so it is possible to vary several parameters. However, this example uses the process outlined in example C. Another factor is to ensure that diameter is big enough for a shaft that is strong enough to not shear when 1GW of rotational power is being put into the shaft. This example may use 512 stacks of 101 coils, total modules 5221.

[0277] E. In this exemplary example the specification specifies 2Kw, max diameter 400mm, rotation up to 300 RPM, input voltage single phase 230v AC 50hz, price constraint. Choose small modules, air core, 1 amp max per coil. Total per coil 230w, require about 10, pick 17 to ensure that the dead points in the single phase do not affect the overall power output. To minimise cost, combine switches and processor onto single circuit board and arrange coils around stator.Examples

[0278] Example 1A.1 An electrical machine comprising: at least one stator; at least one module, the at least one module comprising at least one electromagnetic coil and at least one power converter, the at least one module being attached to the at least one stator; at least one rotor with a plurality of magnets attached to the at least one rotor, wherein the at least one module is in spaced relation to the plurality of the magnets; the at least one rotor being in a rotational relationship with the at least one stator; the at least one power converter comprising at least one switch and at least one control information generator; the at least one switch connects to a plurality of input terminals to the at least one electromagnetic coil; the plurality of input terminals being respectively coupled to phases of an AC power source or load; the at least one control information generator configured to generate control information to control the at least one switch; wherein the quantity and configuration of the at least one module in the electrical machine is determined based in part on one or more operating parameters; wherein the at least one module is capable of being independently controlled; wherein the at least one module is capable of being reconfigured based at least in part on one or more of the following: at least one operating parameter during operation, at least one performance parameter during operation, and combinations thereof.

[0279] Example 1A.2 An electrical machine comprising: at least one stator; at least one module, the at least one module comprising at least one electromagnetic coil and at least one power converter, the at least one module being attached to the at least one stator; at least one slider with a plurality of magnets attached to the at least one slider, wherein the at least one module is in spaced relation to the plurality of the magnets; the at least one slider being in a linear relationship with the at least one stator; the at least one power converter comprising at least one switch and at least one control information generator; the at least one switch connects to a plurality of input terminals to the at least one electromagnetic coil; the plurality of input terminals being respectively coupled to phases of an AC power source or load; the at least one control information generator configured to generate control information to control the at least one switch; wherein the quantity and configuration of the at least one module in the electrical machine is determined based in part on one or more operating parameters; wherein the at least one module is capable of being independently controlled; wherein the at least one module is capable of being reconfigured based at least in part on one or more of the following: at least one operating parameter during operation, at least one performance parameter during operation, and combinations thereof.

[0280] Example 1A.3 An electrical machine comprising: at least one stator; at least one module, the at least one module comprising at least one electromagnetic coil and at least one power converter, the at least one module being attached to the at least one stator; at least one platter or rotor with a plurality of magnets attached to the at least one platter or rotor, wherein the at least one module is in spaced relation to the plurality of the magnets; and the at least one platter or rotor being in a movement relationship with the at least one stator; the at least one power converter comprising at least one switch and at least one control information generator; the at least one switch connects to a plurality of input terminals to the at least one electromagnetic coil; the plurality of input terminals being respectively coupled to phases of an AC power source or load; the at least one control information generator configured to generate control information to control the at least one switch; wherein the quantity and configuration of the at least one module in the electrical machine is determined based in part on one or more operating parameters; wherein the at least one module is capable of being independently controlled; and wherein the at least one module is capable of being reconfigured based at least in part on one or more of the following: at least one operating parameter during operation, at least one performance parameter during operation, or combinations thereof.

[0281] Example 2A.1 The electrical machine of one or more of the above examples 1A.1 to 1A.3, wherein the at least one power converter further comprises a plurality of bidirectional switches each having a conducting direction controllable by the plurality of switching elements, the plurality of bidirectional switching elements connects to a plurality of input terminals and to the at least one electromagnetic coil; wherein the bidirectional switching elements control the direction of current flowing through the at least one electromagnetic coil; wherein the at least one control information generator configured to generate control information to control the plurality of bidirectional switches to control the frequency and magnitude of the current flowing through the at least one electromagnetic coil; wherein the at least one control information generator configured to generate control information to control the plurality of bidirectional switches so that the current from each of the plurality of input terminals is synchronised to or partially synchronised to the at least one performance parameter of the phase current and / or the phase angle in relation to phase voltage of the AC power source or load.

[0282] Example 2A.2 The electrical machine of one or more of the above examples 1A.1 to 1A.3, wherein the at least one power converter converts the input AC power source or load to a change of voltage or a change of frequency of the terminals of the at least one electromagnetic coil without an intermediate conversion into DC.

[0283] Example 2A.3 The electrical machine of one or more of the above examples 1A.1 to 1A.3, wherein the plurality of input terminals being respectively coupled to a DC power source or load.

[0284] Example 2A.4 The electrical machine of one or more of the above examples 1A.1 to 1A.3, wherein the at least one operating parameter during operation may be selected from one or more of the following: maximum angular velocity, average angular velocity, minimum angular velocity, maximum power output, average power output, minimum power output, maximum input voltage, average input voltage, minimum input voltage, phase angles of input voltage, maximum generation voltage, average generation voltage, minimum generation voltage, shape and frequency of generated voltage, peak input current, average input current, minimum input current, phase angles of input current, maximum generation current, average generation current, minimum generation current, phase angles of generation current, maximum torque, average torque, minimum torque, torque smoothness, activation sequence, rate of acceleration, order of accuracy of hold angle, minimising the variation of angular velocity, rate of deceleration during braking, diameter of the shaft, maximum radius of the electrical machine, maximum length of the electrical machine, maximum depth of the electrical machine, maximum height of the machine, maximum slide distance, minimum slide distance, maximum weight of the machine, minimum weight of the machine, minimum resistive power loss, maximum resistive power loss, and unit redundancy and overall price.

[0285] Example 2A.5 The electrical machine of one or more of the above examples 1A.1 to 1A.3, wherein the at least one performance parameter during operation may be selected from one or more of the following: maximum angular velocity, maximum power output, deviation from output voltage during generation, maintaining a required generation voltage, torque smoothness, rate of acceleration, accuracy of hold angle, minimising the variation of angular velocity, matching requested rate of deceleration during braking, minimising resistive power loss, overall efficiency, power factor correction, mechanical harmonic cancelation, electrical harmonic cancelation, accuracy of reproduced output voltage wave, and accuracy of generated frequency.

[0286] Example 2A.6 The electrical machine of one or more of the above examples 1A.1 to 1A.3, wherein the output power of the electrical machine is at between 30 to 1, 45 to 22, 120 to 30, 1500 to 500, 5 to 0.01, 50000 to 1000, or 650.4 to 40.4 kilowatts.

[0287] Example 2A.7 The electrical machine of one or more of the above examples 1A.1 to 1A.3, further comprising at least one sensor to detect absolute or relative position of the at least one rotor; and at least one control system which, in response to inputs from the one or more of the following: the at least one sensor, at least one power command, at least one mode command comprising one or more of the following: at least one drive, generate, braking and hold command, and at least one rotational direction command.

[0288] Example 2A.8 The electrical machine of example 2A.7, wherein the at least one control system is configured to be in a drive configuration or has the at least one drive mode command, the at least one control system activates at least one switch which energises one or more of the magnetic coils to attract and repel the magnets for the purpose of generating motion.

[0289] Example 2A.9 The electrical machine of example 2A.7, wherein the electrical machine is configured to be in a generation configuration or has at least one mode command to generate power, the at least one control system activates at least one switch which connects one or more coils to the external power rails.

[0290] Example 2A.10 The electrical machine of example 2A.7, wherein the electrical machine is configured to be in a braking configuration or has the at least one mode command to brake, the at least one control system activates at least one switch which connects one or more of the magnetic coils terminals together to oppose motion.

[0291] Example 2A.11 The electrical machine of example 2A.7, wherein the electrical machine is configured to be in a holding configuration or has the at least one mode command to hold, the at least one control system activates at least one switch energises one or more of the magnetic coils to attract and repel magnets for the purpose of stopping motion.

[0292] Example 3A.1 The electrical machine of one or more of the above examples 2A.1 to 2A.11, wherein the at least one control system in operation is determining one or more appropriately efficient modes of operation in relation to the at least one operating parameters, the at least one performance parameter or combinations thereof on a substantially continuous basis during operating periods.

[0293] Example 3A.2 The electrical machine of one or more of the above examples 2A.1 to 2A.11, wherein the electrical machine has a power density of between 100 to 20,000, 100 to 200, 100 to 500, 250 to 500, 500 to 1000, 500 to 2000, 1000 to 10,000, 1000 to 5000, 2000 to 5000, 5000 to 10,000, 5000 to 15,000, 10,000 to 20,000, or 10,000 to 30,000 kw / meter cubed.

[0294] Example 3A.3 The electrical machine of one or more of the above examples 2A.1 to 2A.11, wherein one or more of the at least one operating parameter, the at least one performance parameter or combinations thereof of the electrical machine may be reconfigured in substantially real time.

[0295] Example 3A.4 The electrical machine of one or more of the above examples 2A.1 to 2A.11, wherein the at least one control system provides individual control over at least 30%, 40%, 50%, 60%, 70%, 80%, 90%, 95% or 100% of the plurality of coils.

[0296] Example 3A.5 The electrical machine of one or more of the above examples 2A.1 to 2A.11, wherein the module coil activation sequence is computed during machine operation the order of modules activating being sequentially based on their geometric position in the module array.

[0297] Example 3A.6 The electrical machine of one or more of the above examples 2A.1 to 2A.11, wherein the module coil activation sequence is computed during machine operation, the order of modules activating being based upon sensor feedback.

[0298] Example 3A.7 The electrical machine of one or more of the above examples 2A.1 to 2A.11, wherein the module coil activation sequence is computed during machine operation and the order of the at least one modules activating being determined by at least in part one or more sequence patterns.

[0299] Example 3A.8 The electrical machine of one or more of the above examples 2A.1 to 2A.11, wherein the total number of the at least one electromagnetic coils powered in the active sequence may vary during operation from the total number of coils, to none.

[0300] Example 3A.9 The electrical machine of one or more of the above examples 2A.1 to 2A.11, wherein the control of the electrical machine is centralised on at least one control module.

[0301] Example 3A.10 The electrical machine of one or more of the above examples 2A.1 to 2A.11, wherein one or more modules may be individually removed, added, or replaced during operation of the machine, without substantially affecting the operational state of the machine.

[0302] Example 3A.11 The electrical machine of one or more of the above examples 2A.1 to 2A.11, wherein the at least one module is capable of being reconfigured based at least in part on one or more of the following: at least one operating parameter during operation, wherein the at least one operating parameter during operation may be selected from one or more of the parameters listed in example 2A.4; at least one performance parameter during operation, wherein the at least one performance parameter during operation may be selected from one or more of the parameters listed in example 2A.5; or combinations thereof.

[0303] Example 3A.12 The electrical machine of one or more of the above examples 3A.1 to 3A.11, wherein the electrical machine can be configured to fit into a housing that is substantially the same as standard IEC or NEMA induction motor housing, is connected to the electricity grid like a standard induction motor but unlike a standard induction motor is variable speed.

[0304] Example 3A.13 The electrical machine of one or more of the above examples, wherein the plurality of input terminals is coupled through at least one transformer to an AC source.

[0305] Example 3A.14 The electrical machine of Example 3A.13 wherein the at least one module houses the secondary windings of the at least one transformer.

[0306] Example 5A The electrical machine of one or more of the above examples, wherein the at least one electromagnetic coil comprises a plurality of electromagnetic coils that are in a substantially circular arrangement or an axial flux arrangement.

[0307] Example 6A The electrical machine of one or more of the above examples, wherein the at least one electromagnetic coil and the plurality of magnets are in an angular or a radially offset arrangement.

[0308] Example 7A The electrical machine of one or more of the above examples, wherein the number of coils in the at least one electromagnetic coil is not the same number as the number of magnets in the plurality of magnets.

[0309] Example 8A The electrical machine of one or more of the above examples, wherein the number of coils in the plurality of electromagnetic coils is the same number as the number of magnets in the plurality of magnets and the spaced relation between the plurality of electromagnetic coils and the plurality of magnets is geometrically offset to prevent concentric alignment.

[0310] Example 9A The electrical machine of one or more of the above examples, wherein the number of coils in the at least one electromagnetic coil is at least one less than the number of magnets in the plurality of magnets.

[0311] Example 10A The electrical machine of one or more of the above examples, wherein the plurality of electromagnetic coils are arranged in an axially aligned arrangement with the plurality of magnets.

[0312] Example 11A The electrical machine of one or more of the above examples, wherein the plurality of electromagnetic coils are arranged in axially misaligned arrangement by at least 5, 10, 15, 20, 25, 30, 35, 40, or 45 degrees with the plurality of magnets.

[0313] Example 12A The electrical machine of one or more of the above examples, wherein the plurality of electromagnetic coils are axially aligned with the at least one stator and the plurality of magnets are axially aligned with the at least one rotor.

[0314] Example 13A The electrical machine of one or more of the above examples, wherein the plurality of electromagnetic coils are substantial perpendicular or perpendicular with the at least one stator and the plurality of magnets coils are substantial perpendicular or perpendicular with the at least one rotor.

[0315] Example 14A The electrical machine of one or more of the above examples, further comprising an enclosure that is mechanically sufficient to suitably resist deformation from mechanical forces when in operation.

[0316] Example 15A The electrical machine of one or more of the above examples, further comprising an enclosure that is thermally conductive.

[0317] Example 16A The electrical machine of one or more of the above examples, further comprising an enclosure that may be used as a conductor for one or more electronic switches.

[0318] Example 17A.1 The electrical machine of one or more of the above examples, wherein the power to weight ratio of the electrical machine is at least 0.01, 0.1, 0.25, 0.5, 1, 2, 3, 3.4, 4, 4.5, 5, 6, 7, 8, 8.4, 9, 10, 11, 12, 13, 14, or 15 kilowatts per kilogram. 17A.2 The electrical machine of one or more of the above examples, wherein the power to weight ratio of the electrical machine is at between 10 to 1, 15 to 3, 10 to 0.5, 9 to 4, 5 to 0.01, 3.4 to 6, or 8.4 to 3.4 kilowatts per kilogram.

[0319] Example 18A.1 The electrical machine of one or more of the above examples, wherein the power to weight ratio of the electrical machine is 10%, 25%, 50%, 100%, 125%, 150%, 200%, 250%, 300%, 500%, 1000% greater than a brushless permanent magnet three phase electrical machine with a substantially similar size and weight. 18A.2 The electrical machine of one or more of the above examples, wherein the power to weight ratio of the electrical machine is between 10% to 1000%, 10 to 25%, 10% to 100%, 25% to 50%, 25% to 150%, 50% to 250%, 50% to 100%, 100% to 125%, 100% to 250%, 125% to 150%, 150% to 300%, 200% to 1000%, 250% to 500%, 250% to 1000%, or 500% to 1000% greater than a brushless permanent magnet three phase electrical machine with a substantially similar size and weight.

[0320] Example 19A.1 The electrical machine of one or more of the above examples, further comprising at least one sensor to detect absolute or relative position of the at least one rotor; and at least one control system which, in response to inputs from the one or more of the following: the at least one sensor, at least one power command, at least one mode command comprising one or more of the following: at least one drive, generate, braking and hold command, and at least one rotational direction command. 19A.2 The electrical machine of example 19A.1, wherein the at least one control system is configured to be in a drive configuration or has the at least one drive mode command, the at least one control system activates at least one switch which energises one or more of the magnetic coils to attract and repel the magnets for the purpose of generating motion. 19A.3 The electrical machine of example 19A.1, wherein the electrical machine is configured to be in a generation configuration or has at least one mode command to generate power, the at least one control system activates at least one switch which connects one or more coils to the external power rails. 19A.4 The electrical machine of example 19A.1, wherein the electrical machine is configured to be in a braking configuration or has the at least one mode command to brake, the at least one control system activates at least one switch which connects one or more of the magnetic coils terminals together to oppose motion. 19A.5 The electrical machine of example 19A.1, wherein the electrical machine is configured to be in a holding configuration or has the at least one mode command to hold, the at least one control system activates at least one switch energises one or more of the magnetic coils to attract and repel magnets for the purpose of stopping motion.

[0321] Example 20A.1 The electrical machine of one or more of the above examples, wherein the at least one control system in operation is determining one or more appropriately efficient modes of operation in relation to the at least one operating parameter on a substantially continuous basis during operating periods.

[0322] Example 20A.2 The electrical machine of one or more of the above examples, wherein the at least one control system in operation is determining one or more appropriately efficient modes of operation in relation to the at least one operating parameters, the at least one performance parameter or combinations thereof on a substantially continuous basis during operating periods.

[0323] Example 21A The electrical machine of one or more of the above examples, wherein the electrical machine is capable of being operated efficiently over 50%, 60%, 70%, 80%, 90%, 95%, 98%, or 100% of the RPM ranges of the electrical machine.

[0324] Example 22A.1 The electrical machine of one or more of the above examples, wherein the electrical machine has a power density of about 100, 500, 1000, 2000, 5000, 10000, or 20000 kw / meter cubed. 22A.2 The electrical machine of one or more of the above examples, wherein the electrical machine has a power density of at least 100, 500, 1000, 2000, 5000, 10000, or 20000 kw / meter cubed. 22A.3 The electrical machine of one or more of the above examples, wherein the electrical machine has a power density of between 100 to 20,000, 100 to 200, 100 to 500, 250 to 500, 500 to 1000, 500 to 2000, 1000 to 10,000, 1000 to 5000, 2000 to 5000, 5000 to 10,000, 5000 to 15,000, 10,000 to 30,000 or 10,000 to 20,000 kw / meter cubed.

[0325] Example 23A.1 The electrical machine of one or more of the above examples, wherein one or more of the at least one operating parameter of the electrical machine may be reconfigured in substantially real time. 23A.2 The electrical machine of one or more of the above examples, wherein one or more of the at least one operating parameter, the at least one performance parameter or combinations thereof of the electrical machine may be reconfigured in substantially real time.

[0326] Example 24A The electrical machine of one or more of the above examples, wherein the at least one control system provides individual control over at least 30%, 40%, 50%, 60%, 70%, 80%, 90%, 95% or 100% of the plurality of coils.

[0327] Example 25A The electrical machine of one or more of the above examples, wherein the at least one operating parameter of the electrical machine may be reconfigured in substantially real time and the optimal settings for performance determined and implemented across 50%, 60%, 70%, 80%, 90%, 95%, 98%, or 100% of one or more of the following: operating speeds and loads.

[0328] Example 26A.1 The electrical machine of one or more of the above examples, wherein the timing of the plurality of coils may be reconfigured in substantially real time in order to continuously optimize the timing of the plurality of coils. 26A.2 The electrical machine of one or more of the above examples, wherein the timing of the at least one coil may be reconfigured in substantially real time in order to continuously optimize the timing of the at least one of coil.

[0329] Example 27A.1 The electrical machine of one or more of the above examples, wherein the total number of permanent magnets may be reduced by a minimum of 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60% or 70% and still provide comparable power output to a brushless permanent magnet three phase electrical machine. 27A.2 The electrical machine of one or more of the above examples, wherein the total number of permanent magnets may be reduced by a minimum of between 10% to 70%, 10% to 25%, 20% to 50%, 15% to 35%, 20% to 55%, 25% to 50%, 30% to 60%, 35% to 50%, 40% to 60%, 45% to 70%, or 50% to 70%, and still provide comparable power output to a brushless permanent magnet three phase electrical machine.

[0330] Example 28A.1 The electrical machine of one or more of the above examples, wherein the plurality of coils has about 1000, 500, 100, 50, 40, 35, 30 25, 20, 15, 10, 5, times less variation in torque through a rotation than a brushless permanent magnet three phase electrical machine with comparable power output.

[0331] Example 28A.2 The electrical machine of one or more of the above examples, wherein the plurality of coils has between 1000 to 100, 1000 to 100, 500 to 100, 500 to 20, 100 to 5, 100, to 30, 50 to 10, 40 to 15, 35 to 10, 30 to 15, 25 to 10, 20 to 5, 15 to 5, or 10 to 5 times less variation in torque through a rotation than a brushless permanent magnet three phase electrical machine with comparable power output.

[0332] Example 29A.1 The electrical machine of one or more of the above examples, wherein the material savings in the magnets would be at least 10%, 15%, 20%, 30%, 40%, 50%, or 60% of a brushless permanent magnet permanent magnet three phase electrical machine with comparable power output. 29A.2 The electrical machine of one or more of the above examples, wherein the material savings in the magnets would be between 10% to 60%, 10% to 30%, 15% to 30%, 20% to 50%, 30% to 50%, 40% to 60%, or 50% to 70% of brushless permanent magnet three phase electrical machine with comparable power output.

[0333] Example 30A.1 The electrical machine of one or more of the above examples, wherein the material savings in the copper would be at least 10%, 15%, 20%, 30%, 40%, 100%, 200%, 1000% more than that of a similar brushless permanent magnet 3-phase electrical machine with similar resistive power loss per power output. 30A.2 The electrical machine of one or more of the above examples, wherein the material savings in the copper would be between 10% to 100%, 15% to 40%, 20% to 100%, 20% to 200%, 30% 1000%, 40% to 150%, 100% to 200%, 200% to 500%, 200% to 1000%, 500% to 1000% more than that of a similar brushless permanent magnet 3-phase electrical machine with similar resistive power loss per power output.

[0334] Example 31A The electrical machine of one or more of the above examples, wherein the stator can be manufactured out of aluminium, steel, copper, polyethylene, acrylic, polymer reinforced carbon fibre, polymer reinforced fiberglass, other metallic, plastic and / or composite materials or combinations thereof, and the stator has suitable rigidity.

[0335] Example 32A The electrical machine of one or more of the above examples, wherein the rotor can be manufactured out of aluminium, steel, copper, polyethylene, acrylic, polymer reinforced carbon fibre, polymer reinforced fiberglass, other metallic, plastic and / or composite materials or combinations thereof and the rotor has suitable rigidity.

[0336] Example 33A The electrical machine of one or more of the above examples, wherein the enclosure can be manufactured out of aluminium, steel, copper, polyethylene, acrylic, polymer reinforced carbon fibre, polymer reinforced fiberglass, other metallic, plastic and / or composite materials or combinations thereof and the enclosure has suitable rigidity.

[0337] Example 34A The electrical machine of one or more of the above examples, wherein the magnetic field in the rotor or slider can be produced through the use of rare earth or other conventional forms of permanent magnets.

[0338] Example 35A The electrical machine of one or more of the above examples, wherein the plurality magnetic field generators are one or more of the following: loops or coils of a metallic material that induce a current in the loops to produce a magnetic field.

[0339] Example 36A The electrical machine of one or more of the above examples, wherein the plurality magnetic field generators are strips of ferromagnetic material that redirect magnetic fields.

[0340] Example 37A.1 The electrical machine of one or more of the above examples, wherein to save space, cost or both, the at least one switches for the at least one module is fabricated on the same circuit board.

[0341] Example 37A.2 The electrical machine of one or more of the above examples, wherein, the at least one switch for the at least one module is fabricated on the same circuit board.

[0342] Example 38A.1 The electrical machine of one or more of the above examples, wherein to save space, cost or both, at least one electromagnetic coil of the at least one module is fabricated as a single unit. 38A.2 The electrical machine of one or more of the above examples, wherein the at least one electromagnetic coil of the at least one module is fabricated as a single unit.

[0343] Example 39A The electrical machine of one or more of the above examples, wherein the at least one module has an enclosure that may be attached to one or more other modules in order to construct the at least one stator without having to have a separate stator structure.

[0344] Example 40A The electrical machine of one or more of the above examples, wherein one or more of the plurality of magnets have an enclosure around them such that one or more of the magnets may be attached to one or more other magnets to create at least one rotor that may be connected to at least one shaft.

[0345] Example 41A The electrical machine of one or more of the above examples, wherein the physical location of the at least one module in reference to the other modules and the at least one stator is hard coded into the control software.

[0346] Example 42A The electrical machine of one or more of the above examples, wherein the physical location of the at least one module in reference to one or more of the other modules and the at least one stator is encoded by one or more sequences of electrical connections that may be constructed using switches, solder bridges, jumpers, cutting printed circuit tracks, other suitable ways of making and breaking electrical connections, or combinations thereof.

[0347] Example 43A The electrical machine of one or more of the above examples, wherein the physical location of the at least one module in reference to one or more of the other modules and the at least one stator is detected by the location that the at least one module is inserted into in the at least one stator by a series of electrical contacts, optical reflections, magnetic forces or combinations thereof encoding the position of the module.

[0348] Example 44A The electrical machine of one or more of the above examples, that are one or more combinations of examples 41A, 42A and 43A.

[0349] Example 45A The electrical machine of one or more of the above examples, wherein the at least one electromagnetic coil is arranged around the periphery of the at least one stator.

[0350] Example 46A The electrical machine of one or more of the above examples, further comprising at least one shaft.

[0351] Example 47A The electrical machine of one or more of the above examples, wherein the plurality of magnets are arranged around the periphery of the at least one rotor and have substantially the same centre diameter as that of one or more of the at least one electromagnetic coil, a plurality of the at least one electromagnetic coils, or a substantial portion of the plurality of the at least one electromagnetic coils.

[0352] Example 49A The electrical machine of one or more of the above examples, wherein the plurality of magnets are arranged around the periphery of the at least one rotor and have substantially the same centre diameter as that of one or more of the at least one electromagnetic coil, a plurality of the at least one electromagnetic coils, or a substantial portion of the plurality of the at least one electromagnetic coils and two or more of the magnets have alternating pole orientation.

[0353] Example 50A The electrical machine of one or more of the above examples, wherein two or more of the magnets of the plurality of magnets have alternating pole orientation.

[0354] Example 51A The electrical machine of one or more of the above examples, wherein there is a gap between the at least one stator and the at least one rotor.

[0355] Example 52A.1 The electrical machine of one or more of the above examples, wherein the relative weight of the at least one electromagnetic coil is approximately equal to an inverse of the total number of coils as compared to a single-phase electrical machine with a substantially similar resistive loss. 52A.2 The electrical machine of one or more of the above examples, wherein the electrical machine has (n) coils and a weight of approximately 1 / (n-1) to 1 / (n+1) relative to a single-phase motor with substantially the similar resistive loss.

[0356] Example 53A.1 The electrical machine of one or more of the above examples, wherein one or more module coil activation sequences are computed during operation of the electrical machine and the order of the at least one module activating being sequentially based on its geometric position in a module array. 53A.2 The electrical machine of one or more of the above examples, wherein the module coil activation sequence is computed during machine operation the order of modules activating being sequentially based on their geometric position in the module array.

[0357] Example 54A.1 The electrical machine of one or more of the above examples, wherein the one or more module coil activation sequence is computed during electrical machine operation, the order of at least one module activating being based at least in part on sensor feedback. 54A.2 The electrical machine of one or more of the above examples, wherein the module coil activation sequence is computed during machine operation, the order of modules activating being based upon sensor feedback.

[0358] Example 55A.1 The electrical machine of one or more of the above examples, wherein the module coil activation sequence is computed during machine operation, the order of modules activating being determined by a sequence pattern. 55A.2 The electrical machine of one or more of the above examples, wherein the module coil activation sequence is computed during machine operation and the order of the at least one modules activating being determined by at least in part one or more sequence patterns.

[0359] Example 56A.1 The electrical machine of one or more of the above examples, wherein the module coil activation sequence is computed during machine operation and the order of modules activating being determined based at least in part on one or more optimal power usage scenarios.

[0360] Example 57A.1 The electrical machine of one or more of the above examples, wherein the module coil activation sequence is predetermined and stored, and the sequence is sourced at least in part from sensor feedback.

[0361] Example 58.A.1 The electrical machine of one or more of the above examples, wherein the module coil activation sequence is predetermined and stored, the nature of the sequence being sourced from precomputed data stored within the module.

[0362] Example 58.A.2 The electrical machine of one or more of the above examples, wherein the module coil activation sequence is predetermined and stored, and the nature of the sequence being sourced at least in part from precomputed data stored within the module.

[0363] Example 59A.1 The electrical machine of one or more of the above examples, wherein the module coil activation sequence is predetermined and stored, the nature of the sequence being sourced from external modules over a communications bus.

[0364] Example 59A.2 The electrical machine of one or more of the above examples, wherein the module coil activation sequence is predetermined and stored, and the nature of the sequence being sourced from one or more external modules over one or more communications busses.

[0365] Example 60A The electrical machine of one or more of the above examples, wherein the module coil activation sequence is determined based on one or more of the above examples, sourced based on one or more of the above examples or both.

[0366] Example 61A.1 The electrical machine of one or more of the above examples the total number of powered coils in the active sequence can vary during operation from the total number of coils, to none.

[0367] Example 61A.2 The electrical machine of one or more of the above examples, wherein the total number of the at least one electromagnetic coils powered in the active sequence may vary during operation from the total number of coils, to none.

[0368] Example 62A The electrical machine of one or more of the above examples, wherein the number of the at least one electromagnetic coils active may or may not be based upon sensor feedback.

[0369] Example 63A The electrical machine of one or more of the above examples, wherein the control of the electrical machine is centralised on at least one control module.

[0370] Example 64A The electrical machine of one or more of the above examples, wherein the control of the electrical machine is distributed to one or more of the modules, with one or more modules acting independently.

[0371] Example 65A The electrical machine of one or more of the above examples, wherein the control of the electrical machine is arbitrated between two or more designated modules.

[0372] Example 66A The electrical machine of one or more of the above examples, wherein one or more modules may be individually removed, added, or replaced during operation of the machine, without substantially affecting the operational state of the machine.

[0373] Example 67A The electrical machine of example 66A, wherein 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 modules may be individually removed, added, or replaced during operation of the machine, without substantially affecting the operational state of the machine.

[0374] Example 68A The electrical machine of example 66A, wherein 20, 30, 40, 50, 60, 70, 80, 90, or 100 modules may be individually removed, added, or replaced during operation of the machine, without substantially affecting the operational state of the machine.

[0375] Example 69A The electrical machine of one or more of the above examples, wherein one or more of the at least one modules may be individually removed, added, or replaced while the machine is powered off.

[0376] Example 70A The electrical machine of one or more of the above examples, wherein one or more of the at least one operational parameter used by individual modules are tuned dynamically during operation of the electrical machine, based at least in part on sensor feedback.

[0377] Example 71A The electrical machine of one or more of the above examples, wherein one or more of the at least one operational parameter used by individual modules are tuned dynamically during operation of the electrical machine, and the tuning methods used may or may not involve the use of machine learning algorithms.

[0378] Example 72A The electrical machine of one or more of the above examples, wherein the machines control system permits the motor to operate in both the clockwise and counter-clockwise direction with respect to the rotational axis of the primary output or input.

[0379] Example 73A The electrical machine of one or more of the above examples, wherein one or more of the at least one modules further comprises one or more safety systems implemented in hardware, software, or both to allow automatic power cut-off with respect to the coil, in the event of a feedback-based event.

[0380] Example 74A The electrical machine of one or more of the above examples, wherein one or more of the at least one modules further comprises one or more external power safety cut-off control inputs on one or more of the modules. The inputs taking the form of tactile switches or digital touch panels or communications buses, the cut offs being designed such that they bypass the primary controller in each module.

[0381] Example 75A The electrical machine of one or more of the above examples, wherein one or more of the at least one modules further comprises one or more external power safety cut-off control inputs on one or more of the modules and the inputs may be one or more of the following: tactile switches, digital touch panels, communications buses, or combinations thereof, wherein the cut offs are designed such that they bypass the primary controller in one or more of the at least one module.

[0382] Example 76A The electrical machine of one or more of the above examples, wherein the at least one module further comprises at least one sensor for detecting the back EMF from the modules coil in order to reduce cogging effects to improve efficiency, and the back-EMF of an unpowered coil is recorded at a representative range of speeds using the analogue-to-digital converter in at least one coil control unit during operation; the un-powered coil is then powered to a voltage that substantially negates the back-EMF thereby neutralizing the magnetic interaction between the un-powered coil and the magnets; and optional this procedure may be repeat for one or more coils in the array in order to reduce cogging effects.

[0383] Example 77A Any of the above examples implemented in hardware, software, or combinations thereof.

[0384] Example 78A The electrical machine of one or more of the above examples, wherein the at least one module further comprises one or more sensors for detecting the voltage across the at least one module’s coil.

[0385] Example 79A The electrical machine of one or more of the above examples, wherein the at least one module further comprises one or more sensors for detecting the current flowing across the at least one module’s coil.

[0386] Example 80A The electrical machine of one or more of the above examples, wherein the at least one module further comprises one or more sensors for detecting the back EMF from the at least one module’s coil.

[0387] Example 81A The electrical machine of one or more of the above examples, wherein the at least one module further comprises one or more sensors for detecting the absolute or relative position of the machine’s the at least one rotor in relation to the at least one module’s position.

[0388] Example 82A The electrical machine of one or more of the above examples, wherein the at least one module further comprises one or more sensors for detecting the velocity of the machines the at least one rotor in relation to the at least one module’s position.

[0389] Example 83A The electrical machine of one or more of the above examples, wherein the at least one module further comprises one or more sensors for detecting the thermal temperature around the at least one module or other surfaces within the electrical machine.

[0390] Example 84A The electrical machine of one or more of the above examples, wherein the at least one module further comprises one or more sensors for detecting one or more of the following: the magnitude, the angle and the direction of at least one magnetic field.

[0391] Example 85A The electrical machine of one or more of the above examples, wherein the at least one module further comprises one or more sensors for detecting accelerations, for the purpose of vibration detection.

[0392] Example 86A A method of use that uses the electrical machine of one or more of the above examples or combinations of the features disclosed herein.

[0393] Example 87A A system that uses the electrical machine of one or more of the above examples or combinations of the features disclosed herein.

[0394] Example 88A A module that incorporates the features of one or more of the above examples or combinations of the module features disclosed herein.

[0395] Example 89A A control systems for an electrical machine that incorporates the features of one or more of the above examples or combinations of the control features disclosed herein.

[0396] Example 90A A control systems for a module that incorporates the features of one or more of the above examples or combinations of the control features disclosed herein.

[0397] Example 91A The electrical machine of one or more of the above examples, wherein at least one adaptive control is implemented by performing optimisation during machine operation through the use of one or more of the following: at least one support vector machine, neural network algorithm, a fuzzy logic algorithm, of machine learning algorithms and through the use of other suitable adaptive control techniques.

[0398] Example 1B.1 An electrical machine comprising: plurality of stators; plurality of modules, the plurality of modules comprising plurality of electromagnetic coils and plurality of power converters, the plurality of modules being attached to the plurality of stators; plurality of rotors with a plurality of magnets attached to the plurality of rotors, wherein the plurality of modules is in spaced relation to the plurality of the magnets; the plurality of rotors being in a rotational relationship with the plurality of stators; the plurality of power converters comprising plurality of switches and plurality of control information generators; the plurality of switch connects to a plurality of input terminals to the plurality of electromagnetic coils; the plurality of input terminals being respectively coupled to phases of an AC power source or load; the plurality of control information generators configured to generate control information to control the plurality of switches; wherein the quantity and configuration of the plurality of modules in the electrical machine is determined based in part on one or more operating parameters; wherein the plurality of modules are capable of being independently controlled; wherein the plurality of module are capable of being reconfigured based at least in part on one or more of the following: plurality of operating parameter during operation, plurality of performance parameter during operation, and combinations thereof.

[0399] Example 1B.2 An electrical machine comprising: plurality of stators; plurality of modules, the plurality of modules comprising plurality of electromagnetic coils and plurality of power converters, the plurality of modules being attached to the plurality of stators; plurality of sliders with a plurality of magnets attached to the plurality of sliders, wherein the plurality of modules are in spaced relation to the plurality of the magnets; the plurality of sliders being in a linear relationship with the plurality of stators; the plurality of power converters comprising plurality of switches and plurality of control information generators; the plurality of switches connects to a plurality of input terminals to the plurality of electromagnetic coil; the plurality of input terminals being respectively coupled to phases of an AC power source or load; the plurality of control information generators configured to generate control information to control the plurality of switch; wherein the quantity and configuration of the plurality of modules in the electrical machine is determined based in part on one or more operating parameters; wherein the plurality of module is capable of being independently controlled; wherein the plurality of modules are capable of being reconfigured based at least in part on one or more of the following: plurality of operating parameters during operation, plurality of performance parameters during operation, and combinations thereof.

[0400] Example 1B.3 An electrical machine comprising: plurality of stators plurality of modules, the plurality of modules comprising plurality of electromagnetic coils and plurality of power converters, the plurality of modules being attached to the pluralities of stator; plurality of platters or rotors with a plurality of magnets attached to the plurality of platters or rotors, wherein the plurality of module is in spaced relation to the plurality of the magnets; and the plurality of platter or rotor being in a movement relationship with the plurality of stator; the plurality of power converters comprising plurality of switches and plurality of control information generator; the plurality of switches connects to a plurality of input terminals to the plurality of electromagnetic coils; the plurality of input terminals being respectively coupled to phases of an AC power source or load; the plurality of control information generator configured to generate control information to control the plurality of switches; wherein the quantity and configuration of the plurality of module in the electrical machine is determined based in part on one or more operating parameters; wherein the plurality of module is capable of being independently controlled; and wherein the plurality of modules are capable of being reconfigured based at least in part on one or more of the following: plurality of operating parameters during operation, plurality of performance parameters during operation, or combinations thereof.

[0401] Example 2B.1 The electrical machine of one or more of the above examples 1B.1 to 1B.3, wherein the at least one power converter further comprises a plurality of bidirectional switches each having a conducting direction controllable by the plurality of switching elements, the plurality of bidirectional switching elements connects to a plurality of input terminals and to the at least one electromagnetic coil; wherein the bidirectional switching elements control the direction of current flowing through the at least one electromagnetic coil; wherein the at least one control information generator configured to generate control information to control the plurality of bidirectional switches to control the frequency and magnitude of the current flowing through the at least one electromagnetic coil; wherein the at least one control information generator configured to generate control information to control the plurality of bidirectional switches so that the current from each of the plurality of input terminals is synchronised to or partially synchronised to the at least one performance parameter of the phase current and / or the phase angle in relation to phase voltage of the AC power source or load.

[0402] Example 2B.2 The electrical machine of one or more of the above examples 1B.1 to 1B.3, wherein the at least one power converter converts the input AC power source or load to a change of voltage or a change of frequency of the terminals of the at least one electromagnetic coil without an intermediate conversion into DC.

[0403] Example 2B.3 The electrical machine of one or more of the above examples 1B.1 to 1B.3, wherein the plurality of input terminals being respectively coupled to a DC power source or load.

[0404] Example 2B.4 The electrical machine of one or more of the above examples 1B.1 to 1B.3, wherein the at least one operating parameter during operation may be selected from one or more of the following: maximum angular velocity, average angular velocity, minimum angular velocity, maximum power output, average power output, minimum power output, maximum input voltage, average input voltage, minimum input voltage, phase angles of input voltage, maximum generation voltage, average generation voltage, minimum generation voltage, shape and frequency of generated voltage, peak input current, average input current, minimum input current, phase angles of input current, maximum generation current, average generation current, minimum generation current, phase angles of generation current, maximum torque, average torque, minimum torque, torque smoothness, activation sequence, rate of acceleration, order of accuracy of hold angle, minimising the variation of angular velocity, rate of deceleration during braking, diameter of the shaft, maximum radius of the electrical machine, maximum length of the electrical machine, maximum depth of the electrical machine, maximum height of the machine, maximum slide distance, minimum slide distance, maximum weight of the machine, minimum weight of the machine, minimum resistive power loss, maximum resistive power loss, and unit redundancy and overall price.

[0405] Example 2B.5 The electrical machine of one or more of the above examples 1B.1 to 1B.3, wherein the at least one performance parameter during operation may be selected from one or more of the following: maximum angular velocity, maximum power output, deviation from output voltage during generation, maintaining a required generation voltage, torque smoothness, rate of acceleration, accuracy of hold angle, minimising the variation of angular velocity, matching requested rate of deceleration during braking, minimising resistive power loss, overall efficiency, power factor correction, mechanical harmonic cancelation, electrical harmonic cancelation, accuracy of reproduced output voltage wave, and accuracy of generated frequency.

[0406] Example 2B.6 The electrical machine of one or more of the above examples 1B.1 to 1B.3, wherein the output power of the electrical machine is at between 30 to 1, 45 to 22, 120 to 30, 1500 to 500, 5 to 0.01, 50000 to 1000, or 650.4 to 40.4 kilowatts.

[0407] Example 2B.7 The electrical machine of one or more of the above examples 1B.1 to 1B.3, further comprising at least one sensor to detect absolute or relative position of the at least one rotor; and at least one control system which, in response to inputs from the one or more of the following: the at least one sensor, at least one power command, at least one mode command comprising one or more of the following: at least one drive, generate, braking and hold command, and at least one rotational direction command.

[0408] Example 2B.8 The electrical machine of example 2B.7, wherein the at least one control system is configured to be in a drive configuration or has the at least one drive mode command, the at least one control system activates at least one switch which energises one or more of the magnetic coils to attract and repel the magnets for the purpose of generating motion.

[0409] Example 2B.9 The electrical machine of example 2B.7, wherein the electrical machine is configured to be in a generation configuration or has at least one mode command to generate power, the at least one control system activates at least one switch which connects one or more coils to the external power rails.

[0410] Example 2B.10 The electrical machine of example 2B.7, wherein the electrical machine is configured to be in a braking configuration or has the at least one mode command to brake, the at least one control system activates at least one switch which connects one or more of the magnetic coils terminals together to oppose motion.

[0411] Example 2B.11 The electrical machine of example 2B.7, wherein the electrical machine is configured to be in a holding configuration or has the at least one mode command to hold, the at least one control system activates at least one switch energises one or more of the magnetic coils to attract and repel magnets for the purpose of stopping motion.

[0412] Example 3B.1 The electrical machine of one or more of the above examples 2B.1 to 2B.11, wherein the at least one control system in operation is determining one or more appropriately efficient modes of operation in relation to the at least one operating parameters, the at least one performance parameter or combinations thereof on a substantially continuous basis during operating periods.

[0413] Example 3B.2 The electrical machine of one or more of the above examples 2B.1 to 2B.11, wherein the electrical machine has a power density of between 100 to 20,000, 100 to 200, 100 to 500, 250 to 500, 500 to 1000, 500 to 2000, 1000 to 10,000, 1000 to 5000, 2000 to 5000, 5000 to 10,000, 5000 to 15,000, 10,000 to 20,000, or 10,000 to 30,000 kw / meter cubed.

[0414] Example 3B.3 The electrical machine of one or more of the above examples 2B.1 to 2B.11, wherein one or more of the at least one operating parameter, the at least one performance parameter or combinations thereof of the electrical machine may be reconfigured in substantially real time.

[0415] Example 3B.4 The electrical machine of one or more of the above examples 2B.1 to 2B.11, wherein the at least one control system provides individual control over at least 30%, 40%, 50%, 60%, 70%, 80%, 90%, 95% or 100% of the plurality of coils.

[0416] Example 3B.5 The electrical machine of one or more of the above examples 2B.1 to 2B.11, wherein the module coil activation sequence is computed during machine operation the order of modules activating being sequentially based on their geometric position in the module array.

[0417] Example 3B.6 The electrical machine of one or more of the above examples 2B.1 to 2B.11, wherein the module coil activation sequence is computed during machine operation, the order of modules activating being based upon sensor feedback.

[0418] Example 3B.7 The electrical machine of one or more of the above examples 2B.1 to 2B.11, wherein the module coil activation sequence is computed during machine operation and the order of the at least one modules activating being determined by at least in part one or more sequence patterns.

[0419] Example 3B.8 The electrical machine of one or more of the above examples 2B.1 to 2B.11, wherein the total number of the at least one electromagnetic coils powered in the active sequence may vary during operation from the total number of coils, to none.

[0420] Example 3B.9 The electrical machine of one or more of the above examples 2B.1 to 2B.11, wherein the control of the electrical machine is centralised on at least one control module.

[0421] Example 3B.10 The electrical machine of one or more of the above examples 2B.1 to 2B.11, wherein one or more modules may be individually removed, added, or replaced during operation of the machine, without substantially affecting the operational state of the machine.

[0422] Example 3B.11 The electrical machine of one or more of the above examples 2B.1 to 2B.11, wherein the at least one module is capable of being reconfigured based at least in part on one or more of the following: at least one operating parameter during operation, wherein the at least one operating parameter during operation may be selected from one or more of the parameters listed in example 2B.4; at least one performance parameter during operation, wherein the at least one performance parameter during operation may be selected from one or more of the parameters listed in example 2B.5; or combinations thereof.

[0423] Example 3B.12 The electrical machine of one or more of the above examples 3B.1 to 3B.11, wherein the electrical machine can be configured to fit into a housing that is substantially the same as standard IEC or NEMA induction motor housing, is connected to the electricity grid like a standard induction motor but unlike a standard induction motor is variable speed.

[0424] Example 3B.13 The electrical machine of one or more of the above examples, wherein the plurality of input terminals is coupled through at least one transformer to an AC source.

[0425] Example 3B.14 The electrical machine of Example 3B.13 wherein the at least one module houses the secondary windings of the at least one transformer.

[0426] Example 1C.1 An electrical machine comprising: at least one stator; at least one module, wherein a substantial portion of the modules comprise at least one electromagnetic coil and at least one power converter, the at least one module being attached to the at least one stator; at least one rotor with a plurality of magnets attached to the at least one rotor, wherein the at least one module is in spaced relation to the plurality of the magnets; the at least one rotor being in a rotational relationship with the at least one stator; the at least one power converter comprising at least one switch and at least one control information generator; the at least one switch connects to a plurality of input terminals to the at least one electromagnetic coil; the plurality of input terminals being respectively coupled to phases of an AC power source or load; the at least one control information generator configured to generate control information to control the at least one switch; wherein the quantity and configuration of the at least one module in the electrical machine is determined based in part on one or more operating parameters; wherein the at least one module is capable of being independently controlled; wherein the at least one module is capable of being reconfigured based at least in part on one or more of the following: at least one operating parameter during operation, at least one performance parameter during operation, and combinations thereof.

[0427] Example 1C.2 An electrical machine comprising: at least one stator; at least one module, wherein a substantial portion of the modules comprise at least one electromagnetic coil and at least one power converter, the at least one module being attached to the at least one stator; at least one slider with a plurality of magnets attached to the at least one slider, wherein the at least one module is in spaced relation to the plurality of the magnets; the at least one slider being in a linear relationship with the at least one stator; the at least one power converter comprising at least one switch and at least one control information generator; the at least one switch connects to a plurality of input terminals to the at least one electromagnetic coil; the plurality of input terminals being respectively coupled to phases of an AC power source or load; the at least one control information generator configured to generate control information to control the at least one switch; wherein the quantity and configuration of the at least one module in the electrical machine is determined based in part on one or more operating parameters; wherein the at least one module is capable of being independently controlled; wherein the at least one module is capable of being reconfigured based at least in part on one or more of the following: at least one operating parameter during operation, at least one performance parameter during operation, and combinations thereof.

[0428] Example 1C.3 An electrical machine comprising: at least one stator; at least one module, wherein a substantial portion of the modules comprise at least one electromagnetic coil and at least one power converter, the at least one module being attached to the at least one stator; at least one platter or rotor with a plurality of magnets attached to the at least one platter or rotor, wherein the at least one module is in spaced relation to the plurality of the magnets; and the at least one platter or rotor being in a movement relationship with the at least one stator; the at least one power converter comprising at least one switch and at least one control information generator; the at least one switch connects to a plurality of input terminals to the at least one electromagnetic coil; the plurality of input terminals being respectively coupled to phases of an AC power source or load; the at least one control information generator configured to generate control information to control the at least one switch; wherein the quantity and configuration of the at least one module in the electrical machine is determined based in part on one or more operating parameters; wherein the at least one module is capable of being independently controlled; and wherein the at least one module is capable of being reconfigured based at least in part on one or more of the following: at least one operating parameter during operation, at least one performance parameter during operation, or combinations thereof.

[0429] Example 1C.4 An electrical machine comprising: plurality of stators; plurality of modules, wherein a substantial portion of the modules comprise plurality of electromagnetic coils and plurality of power converters, the plurality of modules being attached to the plurality of stators; plurality of rotors with a plurality of magnets attached to the plurality of rotors, wherein the plurality of modules is in spaced relation to the plurality of the magnets; the plurality of rotors being in a rotational relationship with the plurality of stators; the plurality of power converters comprising plurality of switches and plurality of control information generators; the plurality of switch connects to a plurality of input terminals to the plurality of electromagnetic coils; the plurality of input terminals being respectively coupled to phases of an AC power source or load; the plurality of control information generators configured to generate control information to control the plurality of switches; wherein the quantity and configuration of the plurality of modules in the electrical machine is determined based in part on one or more operating parameters; wherein the plurality of modules are capable of being independently controlled; wherein the plurality of module are capable of being reconfigured based at least in part on one or more of the following: plurality of operating parameter during operation, plurality of performance parameter during operation, and combinations thereof.

[0430] Example 1C.5 An electrical machine comprising: plurality of stators; plurality of modules, wherein a substantial portion of the modules comprise plurality of electromagnetic coils and plurality of power converters, the plurality of modules being attached to the plurality of stators; plurality of sliders with a plurality of magnets attached to the plurality of sliders, wherein the plurality of modules are in spaced relation to the plurality of the magnets; the plurality of sliders being in a linear relationship with the plurality of stators; the plurality of power converters comprising plurality of switches and plurality of control information generators; the plurality of switches connects to a plurality of input terminals to the plurality of electromagnetic coil; the plurality of input terminals being respectively coupled to phases of an AC power source or load; the plurality of control information generators configured to generate control information to control the plurality of switch; wherein the quantity and configuration of the plurality of modules in the electrical machine is determined based in part on one or more operating parameters; wherein the plurality of module is capable of being independently controlled; wherein the plurality of modules are capable of being reconfigured based at least in part on one or more of the following: plurality of operating parameters during operation, plurality of performance parameters during operation, and combinations thereof.

[0431] Example 1C.6 An electrical machine comprising: plurality of stators plurality of modules, wherein a substantial portion of the modules comprise plurality of electromagnetic coils and plurality of power converters, the plurality of modules being attached to the plurality of stator; plurality of platters or rotors with a plurality of magnets attached to the plurality of platters or rotors, wherein the plurality of module is in spaced relation to the plurality of the magnets; and the plurality of platter or rotor being in a movement relationship with the plurality of stator; the plurality of power converters comprising plurality of switches and plurality of control information generator; the plurality of switches connects to a plurality of input terminals to the plurality of electromagnetic coils; the plurality of input terminals being respectively coupled to phases of an AC power source or load; the plurality of control information generator configured to generate control information to control the plurality of switches; wherein the quantity and configuration of the plurality of module in the electrical machine is determined based in part on one or more operating parameters; wherein the plurality of module is capable of being independently controlled; and wherein the plurality of modules are capable of being reconfigured based at least in part on one or more of the following: plurality of operating parameters during operation, plurality of performance parameters during operation, or combinations thereof.

[0432] Example 2C.1 The electrical machine of one or more of the above examples 1C.1 to 1C.6, wherein the at least one power converter further comprises a plurality of bidirectional switches each having a conducting direction controllable by the plurality of switching elements, the plurality of bidirectional switching elements connects to a plurality of input terminals and to the at least one electromagnetic coil; wherein the bidirectional switching elements control the direction of current flowing through the at least one electromagnetic coil; wherein the at least one control information generator configured to generate control information to control the plurality of bidirectional switches to control the frequency and magnitude of the current flowing through the at least one electromagnetic coil; wherein the at least one control information generator configured to generate control information to control the plurality of bidirectional switches so that the current from each of the plurality of input terminals is synchronised to or partially synchronised to the at least one performance parameter of the phase current and / or the phase angle in relation to phase voltage of the AC power source or load.

[0433] Example 2C.2 The electrical machine of one or more of the above examples 1C.1 to 1C.6, wherein the at least one power converter converts the input AC power source or load to a change of voltage or a change of frequency of the terminals of the at least one electromagnetic coil without an intermediate conversion into DC.

[0434] Example 2C.3 The electrical machine of one or more of the above examples 1C.1 to 1C.6, wherein the plurality of input terminals being respectively coupled to a DC power source or load.

[0435] Example 2C.4 The electrical machine of one or more of the above examples 1C.1 to 1C.6, wherein the at least one operating parameter during operation may be selected from one or more of the following: maximum angular velocity, average angular velocity, minimum angular velocity, maximum power output, average power output, minimum power output, maximum input voltage, average input voltage, minimum input voltage, phase angles of input voltage, maximum generation voltage, average generation voltage, minimum generation voltage, shape and frequency of generated voltage, peak input current, average input current, minimum input current, phase angles of input current, maximum generation current, average generation current, minimum generation current, phase angles of generation current, maximum torque, average torque, minimum torque, torque smoothness, activation sequence, rate of acceleration, order of accuracy of hold angle, minimising the variation of angular velocity, rate of deceleration during braking, diameter of the shaft, maximum radius of the electrical machine, maximum length of the electrical machine, maximum depth of the electrical machine, maximum height of the machine, maximum slide distance, minimum slide distance, maximum weight of the machine, minimum weight of the machine, minimum resistive power loss, maximum resistive power loss, and unit redundancy and overall price.

[0436] Example 2C.5 The electrical machine of one or more of the above examples 1C.1 to 1C.6, wherein the at least one performance parameter during operation may be selected from one or more of the following: maximum angular velocity, maximum power output, deviation from output voltage during generation, maintaining a required generation voltage, torque smoothness, rate of acceleration, accuracy of hold angle, minimising the variation of angular velocity, matching requested rate of deceleration during braking, minimising resistive power loss, overall efficiency, power factor correction, mechanical harmonic cancelation, electrical harmonic cancelation, accuracy of reproduced output voltage wave, and accuracy of generated frequency.

[0437] Example 2C.6 The electrical machine of one or more of the above examples 1C.1 to 1C.6, wherein the output power of the electrical machine is at between 30 to 1, 45 to 22, 120 to 30, 1500 to 500, 5 to 0.01, 50000 to 1000, or 650.4 to 40.4 kilowatts.

[0438] Example 2C.7 The electrical machine of one or more of the above examples 1C.1 to 1C.6, further comprising at least one sensor to detect absolute or relative position of the at least one rotor; and at least one control system which, in response to inputs from the one or more of the following: the at least one sensor, at least one power command, at least one mode command comprising one or more of the following: at least one drive, generate, braking and hold command, and at least one rotational direction command.

[0439] Example 2C.8 The electrical machine of example 2C.7, wherein the at least one control system is configured to be in a drive configuration or has the at least one drive mode command, the at least one control system activates at least one switch which energises one or more of the magnetic coils to attract and repel the magnets for the purpose of generating motion.

[0440] Example 2C.9 The electrical machine of example 2C.7, wherein the electrical machine is configured to be in a generation configuration or has at least one mode command to generate power, the at least one control system activates at least one switch which connects one or more coils to the external power rails.

[0441] Example 2C.10 The electrical machine of example 2C.7, wherein the electrical machine is configured to be in a braking configuration or has the at least one mode command to brake, the at least one control system activates at least one switch which connects one or more of the magnetic coils terminals together to oppose motion.

[0442] Example 2C.11 The electrical machine of example 2C.7, wherein the electrical machine is configured to be in a holding configuration or has the at least one mode command to hold, the at least one control system activates at least one switch energises one or more of the magnetic coils to attract and repel magnets for the purpose of stopping motion.

[0443] Example 3C.1 The electrical machine of one or more of the above examples 2C.1 to 2C.11, wherein the at least one control system in operation is determining one or more appropriately efficient modes of operation in relation to the at least one operating parameters, the at least one performance parameter or combinations thereof on a substantially continuous basis during operating periods.

[0444] Example 3C.2 The electrical machine of one or more of the above examples 2C.1 to 2C.11, wherein the electrical machine has a power density of between 100 to 20,000, 100 to 200, 100 to 500, 250 to 500, 500 to 1000, 500 to 2000, 1000 to 10,000, 1000 to 5000, 2000 to 5000, 5000 to 10,000, 5000 to 15,000, 10,000 to 20,000, or 10,000 to 30,000 kw / meter cubed.

[0445] Example 3C.3 The electrical machine of one or more of the above examples 2C.1 to 2C.11, wherein one or more of the at least one operating parameter, the at least one performance parameter or combinations thereof of the electrical machine may be reconfigured in substantially real time.

[0446] Example 3C.4 The electrical machine of one or more of the above examples 2C.1 to 2C.11, wherein the at least one control system provides individual control over at least 30%, 40%, 50%, 60%, 70%, 80%, 90%, 95% or 100% of the plurality of coils.

[0447] Example 3C.5 The electrical machine of one or more of the above examples 2C.1 to 2C.11, wherein the module coil activation sequence is computed during machine operation the order of modules activating being sequentially based on their geometric position in the module array.

[0448] Example 3C.6 The electrical machine of one or more of the above examples 2C.1 to 2C.11, wherein the module coil activation sequence is computed during machine operation, the order of modules activating being based upon sensor feedback.

[0449] Example 3C.7 The electrical machine of one or more of the above examples 2C.1 to 2C.11, wherein the module coil activation sequence is computed during machine operation and the order of the at least one modules activating being determined by at least in part one or more sequence patterns.

[0450] Example 3C.8 The electrical machine of one or more of the above examples 2C.1 to 2C.11, wherein the total number of the at least one electromagnetic coils powered in the active sequence may vary during operation from the total number of coils, to none.

[0451] Example 3C.9 The electrical machine of one or more of the above examples 2C.1 to 2C.11, wherein the control of the electrical machine is centralised on at least one control module.

[0452] Example 3C.10 The electrical machine of one or more of the above examples 2C.1 to 2C.11, wherein one or more modules may be individually removed, added, or replaced during operation of the machine, without substantially affecting the operational state of the machine.

[0453] Example 3C.11 The electrical machine of one or more of the above examples 2C.1 to 2C.11, wherein the at least one module is capable of being reconfigured based at least in part on one or more of the following: at least one operating parameter during operation, wherein the at least one operating parameter during operation may be selected from one or more of the parameters listed in example 2C.4; at least one performance parameter during operation, wherein the at least one performance parameter during operation may be selected from one or more of the parameters listed in example 2C.5; or combinations thereof.

[0454] Example 3C.12 The electrical machine of one or more of the above examples 3C.1 to 3C.11, wherein the electrical machine can be configured to fit into a housing that is substantially the same as standard IEC or NEMA induction motor housing, is connected to the electricity grid like a standard induction motor but unlike a standard induction motor is variable speed.

[0455] Example 3C.13 The electrical machine of one or more of the above examples, wherein the plurality of input terminals is coupled through at least one transformer to an AC source.

[0456] Example 3C.14 The electrical machine of Example 3C.13 wherein the at least one module houses the secondary windings of the at least one transformer.

[0457] Example 1D.1 An electrical machine comprising: at least one stator; at least one module, each module comprising at least one electromagnetic coil and at least one power converter, the at least one module being attached to the at least one stator; at least one rotor with a plurality of magnets attached to the at least one rotor, wherein the at least one module is in spaced relation to the plurality of the magnets; the at least one rotor being in a rotational relationship with the at least one stator; the at least one power converter comprising at least one switch and at least one control information generator; the at least one switch connects to a plurality of input terminals to the at least one electromagnetic coil; the plurality of input terminals being respectively coupled to phases of an AC power source or load; the at least one control information generator configured to generate control information to control the at least one switch; wherein the quantity and configuration of the at least one module in the electrical machine is determined based in part on one or more operating parameters; wherein the at least one module is capable of being independently controlled; wherein the at least one module is capable of being reconfigured based at least in part on one or more of the following: at least one operating parameter during operation, at least one performance parameter during operation, and combinations thereof.

[0458] Example 1D.2 An electrical machine comprising: at least one stator; at least one module, each module comprising at least one electromagnetic coil and at least one power converter, the at least one module being attached to the at least one stator; at least one slider with a plurality of magnets attached to the at least one slider, wherein the at least one module is in spaced relation to the plurality of the magnets; the at least one slider being in a linear relationship with the at least one stator; the at least one power converter comprising at least one switch and at least one control information generator; the at least one switch connects to a plurality of input terminals to the at least one electromagnetic coil; the plurality of input terminals being respectively coupled to phases of an AC power source or load; the at least one control information generator configured to generate control information to control the at least one switch; wherein the quantity and configuration of the at least one module in the electrical machine is determined based in part on one or more operating parameters; wherein the at least one module is capable of being independently controlled; wherein the at least one module is capable of being reconfigured based at least in part on one or more of the following: at least one operating parameter during operation, at least one performance parameter during operation, and combinations thereof.

[0459] Example 1D.3 An electrical machine comprising: at least one stator; at least one module, each module comprising at least one electromagnetic coil and at least one power converter, the at least one module being attached to the at least one stator; at least one platter or rotor with a plurality of magnets attached to the at least one platter or rotor, wherein the at least one module is in spaced relation to the plurality of the magnets; and the at least one platter or rotor being in a movement relationship with the at least one stator; the at least one power converter comprising at least one switch and at least one control information generator; the at least one switch connects to a plurality of input terminals to the at least one electromagnetic coil; the plurality of input terminals being respectively coupled to phases of an AC power source or load; the at least one control information generator configured to generate control information to control the at least one switch; wherein the quantity and configuration of the at least one module in the electrical machine is determined based in part on one or more operating parameters; wherein the at least one module is capable of being independently controlled; and wherein the at least one module is capable of being reconfigured based at least in part on one or more of the following: at least one operating parameter during operation, at least one performance parameter during operation, or combinations thereof.

[0460] Example 1D.4 An electrical machine comprising: plurality of stators; plurality of modules, each module comprising a plurality of electromagnetic coils and plurality of power converters, the plurality of modules being attached to the plurality of stators; plurality of rotors with a plurality of magnets attached to the plurality of rotors, wherein the plurality of modules is in spaced relation to the plurality of the magnets; the plurality of rotors being in a rotational relationship with the plurality of stators; the plurality of power converters comprising plurality of switches and plurality of control information generators; the plurality of switch connects to a plurality of input terminals to the plurality of electromagnetic coils; the plurality of input terminals being respectively coupled to phases of an AC power source or load; the plurality of control information generators configured to generate control information to control the plurality of switches; wherein the quantity and configuration of the plurality of modules in the electrical machine is determined based in part on one or more operating parameters; wherein the plurality of modules are capable of being independently controlled; wherein the plurality of module are capable of being reconfigured based at least in part on one or more of the following: plurality of operating parameter during operation, plurality of performance parameter during operation, and combinations thereof.

[0461] Example 1D.5 An electrical machine comprising: plurality of stators; plurality of modules, each module comprising a plurality of electromagnetic coils and plurality of power converters, the plurality of modules being attached to the plurality of stators; plurality of sliders with a plurality of magnets attached to the plurality of sliders, wherein the plurality of modules are in spaced relation to the plurality of the magnets; the plurality of sliders being in a linear relationship with the plurality of stators; the plurality of power converters comprising plurality of switches and plurality of control information generators; the plurality of switches connects to a plurality of input terminals to the plurality of electromagnetic coil; the plurality of input terminals being respectively coupled to phases of an AC power source or load; the plurality of control information generators configured to generate control information to control the plurality of switch; wherein the quantity and configuration of the plurality of modules in the electrical machine is determined based in part on one or more operating parameters; wherein the plurality of module is capable of being independently controlled; wherein the plurality of modules are capable of being reconfigured based at least in part on one or more of the following: plurality of operating parameters during operation, plurality of performance parameters during operation, and combinations thereof.

[0462] Example 1D.6 An electrical machine comprising: plurality of stators plurality of modules, each module comprising a plurality of electromagnetic coils and plurality of power converters, the plurality of modules being attached to the plurality of stator; plurality of platters or rotors with a plurality of magnets attached to the plurality of platters or rotors, wherein the plurality of module is in spaced relation to the plurality of the magnets; and the plurality of platter or rotor being in a movement relationship with the plurality of stator; the plurality of power converters comprising plurality of switches and plurality of control information generator; the plurality of switches connects to a plurality of input terminals to the plurality of electromagnetic coils; the plurality of input terminals being respectively coupled to phases of an AC power source or load; the plurality of control information generator configured to generate control information to control the plurality of switches; wherein the quantity and configuration of the plurality of module in the electrical machine is determined based in part on one or more operating parameters; wherein the plurality of module is capable of being independently controlled; and wherein the plurality of modules are capable of being reconfigured based at least in part on one or more of the following: plurality of operating parameters during operation, plurality of performance parameters during operation, or combinations thereof.

[0463] Example 2D.1 The electrical machine of one or more of the above examples 1D.1 to 1D.6, wherein the at least one power converter further comprises a plurality of bidirectional switches each having a conducting direction controllable by the plurality of switching elements, the plurality of bidirectional switching elements connects to a plurality of input terminals and to the at least one electromagnetic coil; wherein the bidirectional switching elements control the direction of current flowing through the at least one electromagnetic coil; wherein the at least one control information generator configured to generate control information to control the plurality of bidirectional switches to control the frequency and magnitude of the current flowing through the at least one electromagnetic coil; wherein the at least one control information generator configured to generate control information to control the plurality of bidirectional switches so that the current from each of the plurality of input terminals is synchronised to or partially synchronised to the at least one performance parameter of the phase current and / or the phase angle in relation to phase voltage of the AC power source or load.

[0464] Example 2D.2 The electrical machine of one or more of the above examples 1D.1 to 1D.6, wherein the at least one power converter converts the input AC power source or load to a change of voltage or a change of frequency of the terminals of the at least one electromagnetic coil without an intermediate conversion into DC.

[0465] Example 2D.3 The electrical machine of one or more of the above examples 1D.1 to 1D.6, wherein the plurality of input terminals being respectively coupled to a DC power source or load.

[0466] Example 2D.4 The electrical machine of one or more of the above examples 1D.1 to 1D.6, wherein the at least one operating parameter during operation may be selected from one or more of the following: maximum angular velocity, average angular velocity, minimum angular velocity, maximum power output, average power output, minimum power output, maximum input voltage, average input voltage, minimum input voltage, phase angles of input voltage, maximum generation voltage, average generation voltage, minimum generation voltage, shape and frequency of generated voltage, peak input current, average input current, minimum input current, phase angles of input current, maximum generation current, average generation current, minimum generation current, phase angles of generation current, maximum torque, average torque, minimum torque, torque smoothness, activation sequence, rate of acceleration, order of accuracy of hold angle, minimising the variation of angular velocity, rate of deceleration during braking, diameter of the shaft, maximum radius of the electrical machine, maximum length of the electrical machine, maximum depth of the electrical machine, maximum height of the machine, maximum slide distance, minimum slide distance, maximum weight of the machine, minimum weight of the machine, minimum resistive power loss, maximum resistive power loss, and unit redundancy and overall price.

[0467] Example 2D.5 The electrical machine of one or more of the above examples 1D.1 to 1D.6, wherein the at least one performance parameter during operation may be selected from one or more of the following: maximum angular velocity, maximum power output, deviation from output voltage during generation, maintaining a required generation voltage, torque smoothness, rate of acceleration, accuracy of hold angle, minimising the variation of angular velocity, matching requested rate of deceleration during braking, minimising resistive power loss, overall efficiency, power factor correction, mechanical harmonic cancelation, electrical harmonic cancelation, accuracy of reproduced output voltage wave, and accuracy of generated frequency.

[0468] Example 2D.6 The electrical machine of one or more of the above examples 1D.1 to 1D.6, wherein the output power of the electrical machine is at between 30 to 1, 45 to 22, 120 to 30, 1500 to 500, 5 to 0.01, 50000 to 1000, or 650.4 to 40.4 kilowatts.

[0469] Example 2D.7 The electrical machine of one or more of the above examples 1D.1 to 1D.6, further comprising at least one sensor to detect absolute or relative position of the at least one rotor; and at least one control system which, in response to inputs from the one or more of the following: the at least one sensor, at least one power command, at least one mode command comprising one or more of the following: at least one drive, generate, braking and hold command, and at least one rotational direction command.

[0470] Example 2D.8 The electrical machine of example 2D.7, wherein the at least one control system is configured to be in a drive configuration or has the at least one drive mode command, the at least one control system activates at least one switch which energises one or more of the magnetic coils to attract and repel the magnets for the purpose of generating motion.

[0471] Example 2D.9 The electrical machine of example 2D.7, wherein the electrical machine is configured to be in a generation configuration or has at least one mode command to generate power, the at least one control system activates at least one switch which connects one or more coils to the external power rails.

[0472] Example 2D.10 The electrical machine of example 2D.7, wherein the electrical machine is configured to be in a braking configuration or has the at least one mode command to brake, the at least one control system activates at least one switch which connects one or more of the magnetic coils terminals together to oppose motion.

[0473] Example 2D.11 The electrical machine of example 2D.7, wherein the electrical machine is configured to be in a holding configuration or has the at least one mode command to hold, the at least one control system activates at least one switch energises one or more of the magnetic coils to attract and repel magnets for the purpose of stopping motion.

[0474] Example 3D.1 The electrical machine of one or more of the above examples 2D.1 to 2D.11, wherein the at least one control system in operation is determining one or more appropriately efficient modes of operation in relation to the at least one operating parameters, the at least one performance parameter or combinations thereof on a substantially continuous basis during operating periods.

[0475] Example 3D.2 The electrical machine of one or more of the above examples 2D.1 to 2D.11, wherein the electrical machine has a power density of between 100 to 20,000, 100 to 200, 100 to 500, 250 to 500, 500 to 1000, 500 to 2000, 1000 to 10,000, 1000 to 5000, 2000 to 5000, 5000 to 10,000, 5000 to 15,000, 10,000 to 20,000, or 10,000 to 30,000 kw / meter cubed.

[0476] Example 3D.3 The electrical machine of one or more of the above examples 2D.1 to 2D.11, wherein one or more of the at least one operating parameter, the at least one performance parameter or combinations thereof of the electrical machine may be reconfigured in substantially real time.

[0477] Example 3D.4 The electrical machine of one or more of the above examples 2D.1 to 2D.11, wherein the at least one control system provides individual control over at least 30%, 40%, 50%, 60%, 70%, 80%, 90%, 95% or 100% of the plurality of coils.

[0478] Example 3D.5 The electrical machine of one or more of the above examples 2D.1 to 2D.11, wherein the module coil activation sequence is computed during machine operation the order of modules activating being sequentially based on their geometric position in the module array.

[0479] Example 3D.6 The electrical machine of one or more of the above examples 2D.1 to 2D.11, wherein the module coil activation sequence is computed during machine operation, the order of modules activating being based upon sensor feedback.

[0480] Example 3D.7 The electrical machine of one or more of the above examples 2D.1 to 2D.11, wherein the module coil activation sequence is computed during machine operation and the order of the at least one modules activating being determined by at least in part one or more sequence patterns.

[0481] Example 3D.8 The electrical machine of one or more of the above examples 2D.1 to 2D.11, wherein the total number of the at least one electromagnetic coils powered in the active sequence may vary during operation from the total number of coils, to none.

[0482] Example 3D.9 The electrical machine of one or more of the above examples 2D.1 to 2D.11, wherein the control of the electrical machine is centralised on at least one control module.

[0483] Example 3D.10 The electrical machine of one or more of the above examples 2D.1 to 2D.11, wherein one or more modules may be individually removed, added, or replaced during operation of the machine, without substantially affecting the operational state of the machine.

[0484] Example 3D.11 The electrical machine of one or more of the above examples 2D.1 to 2D.11, wherein the at least one module is capable of being reconfigured based at least in part on one or more of the following: at least one operating parameter during operation, wherein the at least one operating parameter during operation may be selected from one or more of the parameters listed in example 2D.4; at least one performance parameter during operation, wherein the at least one performance parameter during operation may be selected from one or more of the parameters listed in example 2D.5; or combinations thereof.

[0485] Example 3D.12 The electrical machine of one or more of the above examples 3D.1 to 3D.11, wherein the electrical machine can be configured to fit into a housing that is substantially the same as standard IEC or NEMA induction motor housing, is connected to the electricity grid like a standard induction motor but unlike a standard induction motor is variable speed.

[0486] Example 3D.13 The electrical machine of one or more of the above examples, wherein the plurality of input terminals is coupled through at least one transformer to an AC source.

[0487] Example 3D.14 The electrical machine of Example 3D.13 wherein the at least one module houses the secondary windings of the at least one transformer.

[0488] The present disclosure should be taken to include feasible combinations of features described herein.

[0489] The combination of features described is such as to allow the electric motor to operate efficiently over a wide power and RPM range and, where required, with high power and torque density. Additionally, it permits combinations of standard components to be assembled together to provide a range of electric motor configurations.

[0490] The exemplary approaches described may be carried out using suitable combinations of software, firmware and hardware and are not limited to particular combinations of such. Computer program instructions for implementing the exemplary approaches described herein may be embodied on a tangible, non-transitory, computer-readable storage medium, such as a magnetic disk or other magnetic memory, an optical disk (e.g., DVD) or other optical memory, RAM, ROM, or any other suitable memory such as Flash memory, memory cards, etc.

[0491] Additionally, the disclosure has been described with reference to particular embodiments. However, it will be readily apparent to those skilled in the art that it is possible to embody the disclosure in specific forms other than those of the embodiments described above. The embodiments are merely illustrative and should not be considered restrictive. The scope of the disclosure is given by the appended claims, rather than the preceding description, and variations and equivalents that fall within the range of the claims are intended to be embraced therein.

[0492] Certain embodiments may be used to convert electrical to mechanical energy. In certain embodiments, where the electric motor is employed as an industrial motorillustrates an exemplary electrical machine that may be used in applications that require to be foot mounted such as fans and pumps. Certain embodiments are of an electrical machine that instead of having feet has an extended flange on one end of its housing and is mounted to a surface by attaching to the flange. An example of such an application is a sump pump.

[0493] Similarly, in other alternative embodiments, the magnets and the electromagnetic coils may optionally be made in equal numbers, but preferably with locational asymmetry to prevent or reduce magnetic stasis at start-up. In certain applications, the greater centre diameter of the arrays of magnets and the electromagnetic coils, the greater the torque able to be generated. The arrangement of the electric motor permits many combinations to be created from standard components - from a single rotor and stator combination to combinations employing at least 10 rotors. The combinations employing larger numbers of rotors and stators may be used in large machines, such as heavy trucks and earthmoving equipment. Other applications may be regenerative braking and / or power generation.

[0494] Certain embodiments are directed to linear solenoid configurations and related applications. These configurations may be used to convert electrical energy into substantial linear motion. One advantage over traditional solenoids is their ability to track desired positions and ‘lock’ in place using built in feedback control per coil level. These embodiments may also include feedback control that may be used on one or more of the coils. These configurations have similar power efficiency characteristics as discussed herein for other adaptive motor configurations. One application area is for power generation, e.g. wave motions. Figures 40 is a render of a single platter, single stator configuration.is a schematic top view of the same design, indicating the positions of the magnets 94 and 95.is a schematic isometric view. Shown in this view are the magnets 94 and 95 mounted on the sliding magnet mount 99. The coils 88 (also referred to herein as coils 22) are located inside the stator 101 and not shown. An example positioning of the Coil Control Units and switching electronics can be seen at 129. As with the motor configurations disclosed herein, the linear configuration may be increased in power by stacking further coil and / or magnet platters. In certain embodiments, at least 2, 3, 4, 5, 6, 8, 10, 20 or more units may be stacked. In certain embodiments, between 2 to 40, 2 to 10, 3, to 15, 3 to 6, 4 to 8, 10 to 25, or other suitable ranges of stacked units may be used in certain applications. Other uses of the linear configurations disclosed herein include: linear damper, linear spring / active suspension system, actuators, conveyor belts, escalators, fans, 3-phase for industrial / mining and other, machinery (mining and industrial), and / or magnetic inductive gearing.

[0495] Other applications may be regenerative braking and / or power generation. With respect to the renewable energy applications such as rotary mechanical energy applications, some applications are: wind power generation, hydro electricity generation, thermal power generation and / or thermal exchangers, and / or steam turbines.

[0496] shows a schematic side view of a system that may be used in wave power generation. This exemplary configuration of a wave generator using for example certain magnetic flux linear arrays disclosed herein is able to be used for continuous (or substantially continuous, or partial) power generation. In, the one or more linear arrays 130 may be attached to floats 131 that float on or near the water surface 132. The system may also be fixed to (or inserted partially into) to the floor 133 of the body of water. The figure shows one linear array 134 at full extension and two arrays 135 and 135 at full compression. As the wave passes it causes the H shaped floats 131 to rise and fall. Different configurations are contemplated, for example, a similar approach may be implemented using a rotary axial flux generator and long arms with floats attached. Certain embodiments are directed to a modular insert that may be used for power generation and in certain aspects may be suitable for large scale power generation. As discussed herein one of the features of the design for certain electrical machines disclosed is that each coil (or one or more coils) may have its own dedicated control circuitry. A coil and its supporting electronics may be incorporated into a small, hot swappable module. This is advantageous for on field assembly of large motors, and / or maintenance of large configurations (faulty coils and electronics may be replaced without full disassembly of the motor).

[0497] An exemplary three phase, single platter, two megawatt, one hundred and one modules embodiment of the electrical machine is shown in Figures 44, 45, 46, 47, and 48. Referring toThe design incorporates modules 137, consisting of one coil 88, mounting rails 140, 141, 142, 143 which also connect the module to the shared electrical rails, and a handle 138 to facilitate the easy removal or insertion of the module into the device. Each module may be self-contained. Figures 45 and 46 illustrate the positioning of the electronics contained inside the modules. The electronics are positioned on a circuit board 145. Power switches 111 are positioned such that their solder tabs are attached 139 to the power and mounting rails 144. Other electronics include power switches 112, microcontroller, isolated DC to DC converter and power supply 79, optical transceiver 119, and a Giant Magneto Resistive (GMR) position sensor 121. In alternative embodiments, a variety of alternative relative or absolute position sensors may be used.

[0498] In certain embodiments the mounting rails may be non-conductive and serve only as mechanical mounts wherein the plurality of input terminals is coupled through at least one transformer to an AC source wherein the module houses the secondary windings of the at least one transformer. (not shown)

[0499] illustrates the sliders which connects the module to the 3-phase shared rail and ground. Element 140 connects the module to ground, 141 to the first phase, 142 to the second phase, 143 to the third phase. These sliders also permit the module to be inserted or removed from the electrical machine either during operation or when the electrical machine is stationary. The rails further facilitate the dissipation of heat from the module to the electrical machine.

[0500] In certain embodiments instead of having sliders connecting the 3-phase power via a shared bus, a loop (or partial loop with air gap) of ferromagnetic material may be used as a transformer to provide power. The loop would have a primary winding in one or multiple locations. The primary windings would then be connected to a three-phase power source or load. The secondary winding may be directly on the loop to tap power to the module via connectors or there may be a cut out from the loop where a core with windings that is part of the CCU may be inserted into the cut out to complete the magnetic loop and couple onto the magnetic field generated by the primary loop. Three of such loops are required if the system were to operate off three phases.

[0501] In certain embodiments the primary winding may operate a 11,000 Volts, 22,000 Volts 1,000,000 volts, 400 volts, 240 volts or 120 volts. The secondary windings may be chosen to optimise the breakdown voltage of the IGBT or other components. The use of distributed transformers has a number of advantages, keeping the current in each secondary winding low therefore minimising current squared losses and permitting the replacement of modules during operation without running the risk of electrical arcing.

[0502] illustrates the electrical machine with 101 of the modules installed, with the ground plate, mounting base and enclosure removed for clarity. This may be multiple meters in diameter. This configuration could be used for wind generation applications. Some of the features include the modules illustrated in figures 44 through 47, a series of annularly shaped rails 147 which are insulated from each other using layers of insulation 148. The power rails can be connected to multiple metal tabs 149, 150, 151. Two rotors 8 with permanent magnets attached to their peripheries 5. Cut-outs 152 in the middle of the rotor and stator save on material and weight while maintaining structural strength.

[0503] A series of light emitting diodes (LEDs) and optical sensors may be mounted on each (or one or more) module (not shown in) align with a section of the stator (not shown in) consisting of a coded regions of reflective and less reflective surfaces or holes. When a module is powered up the microcontroller inside the module illuminates the LEDs, the sensors detect whether the coded region of the ground plate is a reflection or not from the ground plate. The microcontroller uses the information from the sensors to create an address for use on the communication bus, and to know its geometric position in the system. In alternative embodiments, the address can be hard coded in the microcontroller, be set by a series of switches, jumpers, through magnetic switches, through bus probing or measuring the propagation delay along a shared bus, and / or other suitable methods of allocating addresses to multi-master bus systems. This modular design ensures that the generator can maintain operation even if some of (or many of) the modules fail. Being able to replace the device during operation ensured that the electrical machine can keep operating for extended periods of time that might otherwise require the generator to be shut down. When modules fail, the module can communicate its failure to the maintainer of the electrical machine to instruct them to replace the module. Optional indicators on the module can assist in finding the faulty module when the replacement is being made. As the modules may be sufficiently small and / or light enough to carry, carrying replacement parts to and from hard-to-reach electrical machines, such as those in a wind generator may be easily achieved. This is a useful advantage to certain disclosed embodiments and improves repair and maintenance from a time and / or cost basis.

[0504] Certain disclosed embodiments of these generators may be linked together back-to-back on the same shaft, sharing rotors, increasing the power generation capabilities. The stacking of these generators results in certain advantages as disclose herein. A version of a 10MW generator is illustrated in 49. These modular units 153 may be stacked to produce embodiments with multiple platters along one shaft 19 of enough strength not to shear when full power is applied to the shaft. The same power rails 149 to 151 are used to connect to each generator in a line; however different conductors can be used to minimise resistive power loss. Generators or motors may be custom designed to meet almost various power or size specifications. In certain embodiments, at least 2, 3, 4, 5, 6, 7 8, 9, 10, 15, 20, 512, modular units may be combined. In certain embodiments between 2 to 40, 2 to 6, 3 to 9, 4 to 12, 5 to 16, 5 to 25, or 10 to 512 units may be combined.

[0505] Adding a capacitor to the module, and configuring the switches and the coil in either a buck, boost or a buck and boost configuration, the device may be driven by software to generate a specific dc voltage to charge batteries.

[0506] In certain embodiments, the torque required to turn the electrical machine depends on the number of coils generating. The torque required to turn the machine maybe in substantially real time (or real time) increased and / or decreased.

Claims

1.An electrical machine comprising:at least one stator;at least one module, the at least one module comprising at least one electromagnetic coil and at least one power converter, the at least one module being attached to the at least one stator;at least one rotor with a plurality of magnets attached to the at least one rotor, wherein the at least one module is in spaced relation to the plurality of the magnets;the at least one rotor being in a rotational relationship with the at least one stator;the at least one power converter comprising at least one switch and at least one control information generator;the at least one switch connects to a plurality of input terminals to the at least one electromagnetic coil;the plurality of input terminals being respectively coupled to phases of an AC power source or load;the at least one control information generator configured to generate control information to control the at least one switch;wherein the quantity and configuration of the at least one module in the electrical machine is determined based in part on one or more operating parameters;wherein the at least one module is capable of being independently controlled;wherein the at least one module is capable of being reconfigured based at least in part on one or more of the following: at least one operating parameter during operation, at least one performance parameter during operation, and combinations thereof.2.An electrical machine comprising:at least one stator;at least one module, the at least one module comprising at least one electromagnetic coil and at least one power converter, the at least one module being attached to the at least one stator;at least one slider with a plurality of magnets attached to the at least one slider, wherein the at least one module is in spaced relation to the plurality of the magnets;the at least one slider being in a linear relationship with the at least one stator;the at least one power converter comprising at least one switch and at least one control information generator;the at least one switch connects to a plurality of input terminals to the at least one electromagnetic coil;the plurality of input terminals being respectively coupled to phases of an AC power source or load;the at least one control information generator configured to generate control information to control the at least one switch;wherein the quantity and configuration of the at least one module in the electrical machine is determined based in part on one or more operating parameters;wherein the at least one module is capable of being independently controlled;wherein the at least one module is capable of being reconfigured based at least in part on one or more of the following: at least one operating parameter during operation, at least one performance parameter during operation, and combinations thereof.3.An electrical machine comprising:at least one stator;at least one module, the at least one module comprising at least one electromagnetic coil and at least one power converter, the at least one module being attached to the at least one stator;at least one platter or rotor with a plurality of magnets attached to the at least one platter or rotor,wherein the at least one module is in spaced relation to the plurality of the magnets; andthe at least one platter or rotor being in a movement relationship with the at least one stator;the at least one power converter comprising at least one switch and at least one control information generator;the at least one switch connects to a plurality of input terminals to the at least one electromagnetic coil;the plurality of input terminals being respectively coupled to phases of an AC power source or load;the at least one control information generator configured to generate control information to control the at least one switch;wherein the quantity and configuration of the at least one module in the electrical machine is determined based in part on one or more operating parameters;wherein the at least one module is capable of being independently controlled; andwherein the at least one module is capable of being reconfigured based at least in part on one or more of the following: at least one operating parameter during operation, at least one performance parameter during operation, or combinations thereof.4.The electrical machine of one or more of the above claims, wherein the at least one power converter further comprises a plurality of bidirectional switches each having a conducting direction controllable by the plurality of switching elements, the plurality of bidirectional switching elements connects to a plurality of input terminals and to the at least one electromagnetic coil;wherein the bidirectional switching elements control the direction of current flowing through the at least one electromagnetic coil;wherein the at least one control information generator configured to generate control information to control the plurality of bidirectional switches to control the frequency and magnitude of the current flowing through the at least one electromagnetic coil;wherein the at least one control information generator is configured to generate control information to control the plurality of bidirectional switches so that the current from each of the plurality of input terminals is controlled to approximate a commanded relationship with the phase voltage of the AC power source or load, the commanded relationship comprising one or more of: a commanded magnitude of phase current, a substantially zero phase angle between the phase current and the phase voltage, a non-zero commanded phase angle between the phase current and the phase voltage, or combinations thereof, the commanded relationship being determined based at least in part on one or more performance parameters of the electrical machine.5.The electrical machine of one or more of the above claims, wherein the at least one power converter converts the input AC power source or load to a change of voltage or a change of frequency of the terminals of the at least one electromagnetic coil without an intermediate conversion into DC.6.The electrical machine of one or more of claims 1 to 4, wherein the at least one power converter is further configured to receive power from a DC power source or to deliver power to a DC load through two or more of the plurality of input terminals, in addition to or as an alternative to the phases of an AC power source or load, and wherein the at least one control information generator is configured to detect the presence of a DC power source or the absence of one or more phases of the AC power source and to adjust the control information to control the at least one switch to commutate power from the DC power source through the at least one electromagnetic coil.7.The electrical machine of one or more of the above claims, wherein the at least one operating parameter during operation may be selected from one or more of the following: maximum angular velocity, average angular velocity, minimum angular velocity, maximum power output, average power output, minimum power output, maximum input voltage, average input voltage, minimum input voltage, phase angles of input voltage in reference to input current, frequency of input voltage, maximum generation voltage, average generation voltage, minimum generation voltage, shape and frequency of generated voltage, peak input current, average input current, minimum input current, phase angles of input current, maximum generation current, average generation current, minimum generation current, phase angles of generation current, maximum torque, average torque, minimum torque, torque smoothness, activation sequence, rate of acceleration, order of accuracy of hold angle, minimising the variation of angular velocity, rate of deceleration during braking, diameter of the shaft, maximum radius of the electrical machine, maximum length of the electrical machine, maximum depth of the electrical machine, maximum height of the machine, maximum slide distance, minimum slide distance, maximum weight of the machine, minimum weight of the machine, minimum resistive power loss, maximum resistive power loss, and unit redundancy and overall price.8.The electrical machine of one or more of the above claims, wherein the at least one performance parameter during operation may be selected from one or more of the following: maximum angular velocity, maximum power output, deviation from output voltage during generation, maintaining a required generation voltage, torque smoothness, rate of acceleration, accuracy of hold angle, minimising the variation of angular velocity, matching requested rate of deceleration during braking, minimising resistive power loss, overall efficiency, power factor correction, mechanical harmonic cancelation, electrical harmonic cancelation, accuracy of reproduced output voltage wave, and accuracy of generated frequency.9.The electrical machine of one or more of the above claims, wherein the output power of the electrical machine is at between 30 to 1, 250 to 22, 500 to 250, 1500 to 500, 22 to 0.01, 50000 to 1500, or 650 to 40 kilowatts.10.The electrical machine of one or more of the above claims, further comprising at least one sensor to detect absolute or relative position of the at least one rotor; and at least one control system which, in response to inputs from the one or more of the following: the at least one sensor, at least one power command, at least one mode command comprising one or more of the following: at least one drive, generate, braking and hold command, and at least one rotational direction command.11.The electrical machine of claim 10, wherein the at least one control system is configured to be in a drive configuration or has the at least one drive mode command, the at least one control system activates at least one switch which energises one or more of the magnetic coils to attract and repel the magnets for the purpose of generating motion.12.The electrical machine of claim 10, wherein the electrical machine is configured to be in a generation configuration or has at least one mode command to generate power, the at least one control system activates at least one switch which connects one or more coils to the external power rails.13.The electrical machine of claim 10, wherein the electrical machine is configured to be in a braking configuration or has the at least one mode command to brake, the at least one control system activates at least one switch which connects one or more of the magnetic coils terminals together to oppose motion.14.The electrical machine of claim 10, wherein the electrical machine is configured to be in a holding configuration or has the at least one mode command to hold, the at least one control system activates at least one switch which energises one or more of the magnetic coils to attract and repel magnets for the purpose of stopping motion.15.The electrical machine of one or more of the above claims, wherein the at least one control system in operation is determining one or more appropriately efficient modes of operation in relation to the at least one operating parameters, the at least one performance parameter or combinations thereof on a substantially continuous basis during operating periods.16.The electrical machine of one or more of the above claims, wherein the electrical machine has a power density of between 100 to 20,000, 100 to 200, 100 to 500, 250 to 500, 500 to 1000, 500 to 2000, 1000 to 10,000, 1000 to 5000, 2000 to 5000, 5000 to 10,000, 5000 to 15,000, 10,000 to 20,000, or 10,000 to 30,000 kw / meter cubed.17.The electrical machine of one or more of the above claims, wherein one or more of the at least one operating parameter, the at least one performance parameter or combinations thereof of the electrical machine may be reconfigured in substantially real time.18.The electrical machine of one or more of the above claims, wherein the at least one control system provides individual control over at least 30%, 40%, 50%, 60%, 70%, 80%, 90%, 95% or 100% of the plurality of coils.19.The electrical machine of one or more of the above claims, wherein the module coil activation sequence is computed during machine operation the order of modules activating being sequentially based on their geometric position in the module array.20.The electrical machine of one or more of the above claims, wherein the module coil activation sequence is computed during machine operation, the order of modules activating being based upon sensor feedback.21.The electrical machine of one or more of the above claims, wherein the module coil activation sequence is computed during machine operation and the order of the at least one modules activating being determined by at least in part one or more sequence patterns.22.The electrical machine of one or more of the above claims, wherein the total number of the at least one electromagnetic coils powered in the active sequence may vary during operation from the total number of coils, to none.23.The electrical machine of one or more of the above claims, wherein the control of the electrical machine is centralised on at least one control module.24.The electrical machine of one or more of the above claims, wherein one or more modules may be individually removed, added, or replaced during operation of the machine, without substantially affecting the operational state of the machine.25.The electrical machine of one or more of the above claims,wherein the at least one module is capable of being reconfigured based at least in part on one or more of the following:at least one operating parameter during operation, wherein the at least one operating parameter during operation may be selected from one or more of the parameters listed in claim 7;at least one performance parameter during operation, wherein the at least one performance parameter during operation may be selected from one or more of the parameters listed in claim 8;or combinations thereof.26.The electrical machine of one or more of the above claims, wherein the electrical machine can be configured to fit into a housing that is substantially the same as standard IEC or NEMA induction motor housing, is connected to the electricity grid like a standard induction motor but unlike a standard induction motor is variable speed.27.The electrical machine of one or more of the above claims, wherein the plurality of input terminals is coupled through at least one transformer to an AC source.28.The electrical machine of claim 27 wherein the at least one module houses the secondary windings of the at least one transformer.29.The electrical machine of one or more of the above claims, where the magnets are shaped to provide a sinusoidal (or substantially sinusoidal) back EMF when passing a trapezoidal core.30.An electrical machine comprising: at least one stator; at least one module, the at least one module comprising at least one electromagnetic coil and at least one power converter, the at least one module being attached to the at least one stator; at least one rotor with a plurality of magnets attached to the at least one rotor, wherein the at least one module is in spaced relation to the plurality of the magnets; the at least one rotor being in a rotational relationship with the at least one stator; the at least one power converter comprising a plurality of bidirectional switches each having a conducting direction controllable by a plurality of switching elements, the plurality of bidirectional switching elements connects to a plurality of input terminals and to the at least one electromagnetic coil, at least one control information generator configured to generate control information to control the plurality of bidirectional switches; wherein the plurality of bidirectional switches convert an input AC power source or load to a change of voltage or a change of frequency at the terminals of the at least one electromagnetic coil without an intermediate conversion into DC; wherein the at least one module is capable of being independently controlled; and wherein the at least one control information generator is configured to generate control information to control the plurality of bidirectional switches so that the current from each of the plurality of input terminals is controlled to approximate a commanded relationship with the phase voltage of the AC power source or load, the commanded relationship comprising one or more of: a commanded magnitude of phase current, a substantially zero phase angle between the phase current and the phase voltage, a non-zero commanded phase angle between the phase current and the phase voltage, or combinations thereof, the commanded relationship being determined based at least in part on one or more performance parameters of the electrical machine.31.A method of operating an electrical machine, the electrical machine comprising at least one stator, at least one module attached to the at least one stator, the at least one module comprising at least one electromagnetic coil and at least one power converter, at least one rotor with a plurality of magnets attached to the at least one rotor, the at least one rotor being in a rotational relationship with the at least one stator, the method comprising: receiving AC power from an AC power source through a plurality of input terminals coupled to phases of the AC power source; generating, by at least one control information generator, control information based at least in part on one or more operating parameters or one or more performance parameters; controlling, by the control information, at least one switch of at least one power converter to independently control current flowing through at least one electromagnetic coil of at least one module; and reconfiguring the at least one module during operation based at least in part on one or more of: at least one operating parameter during operation, at least one performance parameter during operation, or combinations thereof.32.The method of claim 31, further comprising: converting, by the at least one power converter, the input AC power source to a change of voltage or a change of frequency at terminals of the at least one electromagnetic coil without an intermediate conversion into DC.33.The method of claim 31, further comprising: determining, by at least one control system, one or more appropriately efficient modes of operation in relation to at least one operating parameter or at least one performance parameter on a substantially continuous basis during operating periods; and adjusting the control information to implement the determined mode of operation.34.The method of claim 31, further comprising: selectively powering down one or more of the at least one electromagnetic coils when less torque is required, wherein the number of electromagnetic coils powered during an active sequence varies during operation from a total number of coils to none.35.A method of manufacturing an electrical machine, the method comprising: determining one or more design requirements comprising one or more of: size of the electrical machine, weight of the electrical machine, maximum power, operating voltage, peak current, number of connections to a power supply, range of angular velocities, amount of torque, or combinations thereof; selecting a module configuration based at least in part on the one or more design requirements, the module comprising at least one electromagnetic coil and at least one power converter, the at least one power converter comprising at least one switch and at least one control information generator; determining a quantity of modules and a number of stator platters based at least in part on the one or more design requirements; assembling the determined quantity of modules onto at least one stator; assembling at least one rotor with a plurality of magnets; and configuring control software to independently control the determined quantity of modules.

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