High Power-Density Linear Generator Radial Winding
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Solution Overview
Problem
Current reciprocating linear power generators have low power density due to spatial inefficiencies and poor magnetic force to length ratio, leading to increased cost and internal resistance, especially at low speeds.
Innovation Solution
A high power-density power generating module is designed with a magnet unit having adjacent magnets with opposite poles and a winding unit with opposite winding directions, allowing for a relative movement between the magnet and winding units, with the angle between magnetic poles and windings greater than 0 degrees and less than 90 degrees, and incorporating a guiding slot with rollers or flanges to reduce friction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the active cell is disposed inside the winding as a multi-pole magnetized magnet or multi-pole magnetic flux distributed by claw-pole magnetic conductance, then the power generator can generate electromagnetic force, but gaps between the windings are created which reduce winding density and shorten effective winding length
Solution Approach 1:
The patent transitions from conventional parallel winding arrangement to a three-dimensional radial winding configuration where windings are distributed around the magnet in multiple layers and angular positions. This spatial reorganization eliminates gaps by utilizing the radial dimension, allowing continuous winding coverage around the magnet circumference and increasing effective winding length without increasing gap spaces.
Solution Approach 2:
The patent implements nested winding layers where multiple turns of wire are arranged concentrically around the magnet, with inner windings positioned radially inside outer windings. This nesting approach maximizes space utilization within the available radial and angular dimensions, increasing winding density while maintaining effective magnetic flux linkage.
2Strength
If silicon steel core is used to fill gaps between windings, then the structural integrity is improved, but cogging force is caused
Solution Approach 1:
The patent removes the silicon steel core filling from the gap regions between windings, eliminating the source of cogging force. Instead, the design relies on the magnetically conductive path provided by the magnet itself and the continuous winding arrangement, which maintains structural integrity through the winding support structure and magnet housing without requiring additional ferromagnetic filling materials that cause cogging.
3Power
If the stroke of the active cell is twice the length of the winding, then maximum induced output voltage is achieved, but the magnetic force to length ratio deteriorates
Solution Approach 1:
The patent transitions from linear stroke-based voltage generation to radial/rotational motion where the magnet moves in arcs or rotates around the winding. This allows the effective winding length to be increased by utilizing the circumferential dimension around the magnet, achieving maximum voltage induction with a shorter linear displacement distance, thereby improving the magnetic force to length ratio.
Solution Approach 2:
The patent employs dynamic winding configurations where the effective winding length adapts to the magnet's position during motion. The radial and angular distribution of windings ensures that active conductors are always optimally positioned relative to the moving magnet, maximizing flux linkage throughout the motion cycle and achieving high induced voltage with reduced stroke length.
4Device complexity
If the winding axis is parallel with the direction of the magnetic pole, then the structure is simplified, but gaps between windings reduce winding density
Solution Approach 1:
The patent adopts a radial winding arrangement where the winding axis is perpendicular to the magnetic pole direction, utilizing the radial dimension to distribute windings around the magnet. This three-dimensional configuration eliminates gaps by wrapping windings continuously around the magnet circumference, significantly increasing winding density while the modular radial structure maintains manufacturing simplicity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enhances power generation efficiency by maximizing magnetic flux usage, increasing the number of turns within the effective magnetic flux density, reducing internal resistance, and enabling compact integration with various devices.
Implementation Method 1
a magnet unit having a plurality of adjacent magnets with opposite magnet-pole arrangement against adjacent ones, each with a magnetic north pole and a magnetic south pole; and a winding unit having a plurality of adjacent windings with opposite winding directions around the magnet unit; wherein the magnet unit is capable of moving relatively to the winding unit
Data Source
AI summary
A high power-density power generating module, comprising: a magnet unit having a plurality of adjacent magnets with opposite magnet-pole arrangement against adjacent ones, each with a magnetic north pole and a magnetic south pole; and a winding unit having a plurality of adjacent windings around the adjacent magnets; wherein the magnet unit is capable of moving relatively to the winding unit and the angle between the linking direction of the magnetic north pole and the magnetic south pole of each magnet and the winding surface of each winding is larger than 0 degree and smaller than 90 degrees.