Large-Diameter Low-RPM Generator Assembly From Flat Stock
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Solution Overview
Problem
Conventional electric generators are inefficient at low revolutions per minute and require batteries for energy storage, leading to noise, maintenance issues, and limited power generation in low wind or human-powered applications.
Innovation Solution
A low rpm electric generator with a larger diameter, designed for 2-dimensional cutting of flat stock materials, operates without batteries, uses zig zag winding with air core magnetic circuits, and incorporates magnetically conductive box closure pieces for reduced noise and increased efficiency, eliminating the need for slip rings and reduction gears.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional electric generators are used, then power generation is efficient at high speeds, but they are inefficient at low revolutions per minute and require batteries
Solution Approach 1:
The patent changes the physical parameters of the generator by increasing its diameter and designing it for low rpm operation. The larger diameter allows the generator to effectively cut through magnetic fields at lower rotational speeds, generating sufficient voltage and power without requiring battery storage systems.
2Duration of action of moving object
If batteries are used for energy storage, then continuous power is provided, but noise and maintenance issues increase
Solution Approach 1:
The patent extracts and eliminates the battery component from the system entirely. By designing a generator that can operate continuously at low rpm without energy storage devices, the harmful factors associated with batteries (noise, maintenance, weight) are completely removed while maintaining continuous power generation capability.
3Speed
If larger diameter generators are used for low rpm operation, then power generation improves at low speeds, but manufacturing complexity increases
Solution Approach 1:
The patent segments the generator into flat stock components that can be cut from 2-dimensional materials. This segmentation allows each component to be manufactured independently using simple cutting processes, then assembled into the final larger diameter generator structure, maintaining manufacturing ease while achieving the required size.
4Ease of manufacture
If 2-dimensional cutting of flat stock materials is used, then manufacturing simplicity increases, but structural integrity may be compromised
Solution Approach 1:
The patent merges multiple flat stock components through assembly to form the complete generator structure. By combining several cut pieces into an integrated assembly with larger diameter, the structural integrity is enhanced while maintaining the manufacturing advantage of 2-dimensional cutting processes.
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
The generator effectively generates power in low wind speeds and human-powered scenarios with reduced noise and maintenance, providing continuous energy without battery reliance, and increased cooling efficiency for extended human operation.
Implementation Method 1
The rotor has a plurality of rotor magnets attached to its outer peripheral surface alternately in a first rotational direction. The stator has a plurality of windings wound around a stator core. When the rotor rotates, the changing magnetic flux through the windings induces an electromotive force, generating electrical energy.
Implementation Method 2
The generator incorporates magnetically conductive box closure pieces that provide a path for magnetic flux, reducing magnetic leakage and noise while increasing overall efficiency.
Implementation Method 3
The generator uses air core magnetic circuits where the magnetic field is generated directly by the rotor magnets and windings without ferromagnetic core materials, reducing noise and hysteresis losses.
Data Source
AI summary
Simple to manufacture electric generators or motors and methods of manufacturing such are disclosed. Such devices are preferably manufactured from 2-dimensionally cut, flat stock materiel. The generator or motor has two large diameter rotors to enable, for example, useful generation of electricity at low revolutions per minute. The frame of the generator includes stators sidewalls with castellations on the periphery of the walls. Castellated end plates removably interlock with the stators. The rotors drive magnets past the stators in the frame of the device. In preferred embodiments, rotors are driven by human legs or arms, low speed wind, or water with low or zero water drop distance.