US20110132901A1

US20110132901A1 - Transverse-moving magnet magnetic heater

Info

Publication number: US20110132901A1
Application number: US13/029,501
Authority: US
Inventors: Timothy W. Lunneborg
Original assignee: Magtec Energy LLC
Current assignee: Magtec Energy LLC
Priority date: 2002-07-23
Filing date: 2011-02-17
Publication date: 2011-06-09
Also published as: JP2009510702A; WO2007041461A3; EP1932393A2; WO2007041461A2; US7420144B2; KR20080070646A; EA012474B1; NO20082033L; US20060086729A1; US20080099467A1; CA2624640A1; CN101310566A; EA200800921A1

Abstract

A transverse-moving magnet magnetic heater is provided having a conductor assembly and a magnet assembly. The conductor assembly is operable to rotate relative to the magnet assembly about an axis so as to induce eddy currents in the conductor assembly when relative motion is produced between the conductor assembly and magnet assembly. The magnet assembly is operable to translate transversely into and out of magnetic engagement with the conductor assembly. The conductor assembly defines a fluid path therethrough operable to drive a working fluid therethrough and for the transfer of heat from the conductor assembly to the working fluid. The magnetic heater may be a component of a heat generation system comprising an internal combustion engine having a drive shaft for rotating the conductor assembly. The heat generated by the magnetic heater, as well as the heat generated by the engine from the engine exhaust and engine cooling system, is combined to heat a working fluid.

Description

RELATED APPLICATIONS

This is a continuation application claiming benefit under 35 USC §120 of U.S. Utility application Ser. No. 11/968,175, filed Jan. 1, 2008 and entitled CONTROLLED TORQUE MAGNETIC HEAT GENERATION which is in its entirety incorporated herewith by reference, which is a division of and claiming benefit to U.S. Utility application Ser. No. 11/243,394, filed Oct. 3, 2005, U.S. Pat. No. 7,420,144, and entitled CONTROLLED TORQUE MAGNETIC HEAT GENERATION, which is in its entirety incorporated herewith by reference, which is a continuation-in-part of and claiming benefit to U.S. Utility application Ser. No. 11/174,316, filed Jun. 30, 2005, U.S. Pat. No. 7,339,144, and entitled MAGNETIC HEAT GENERATION which is in its entirety incorporated herewith by reference.

FIELD

The present invention is related to devices for the production of heat, and more particularly, to methods and apparatus for generating heat using magnetic induction.

BACKGROUND

A magnetic heater generates heat by a phenomenon known as magnetic inductive heating. Magnetic inductive heating occurs in an electrically conductive member when exposed to a time-varying magnetic field. The varying magnetic field induces eddy currents within the conductive member, thereby heating it. An increase in the magnitude of the variations of the magnetic field increases the rate at which the conductive member is heated. The heated conductive member can then be used as a heat source for various purposes. The heated conductive member is often used to heat a fluid, such as air or water, which is circulated past the conductive member. The heated fluid is then used to transfer the heat from the heater for external use.
One method of exposing a conductive member to a varying magnetic field is to move a magnetic field source relative to the conductive member. This motion may be achieved by arranging magnets around the edge of a circular disk having a rotatable shaft substantially at its center, the flat surface of the disk being opposable to an essentially flat portion of the surface of the conductive member. As the shaft of the disk is rotated, the magnets move relative to the surface of the conductive member. A given point on the conductive member is exposed to a cyclically varying magnetic field as each of the magnets approach, pass over, and retreat from that given point.
The amount of heat induced within the conductive member depends on many factors, some of which include the strength of the magnetic field, the distance between the magnets and the conductive member (referred herein as the “conductor/magnet spacing”), and the relative speed of the magnets to the conductive member.
Conventional magnetic heaters suffer from several disadvantages. For example, many conventional magnetic heaters have limited precision in their control of operational parameters such as the rate of heat generation, the efficiency of heat generation, and the efficiency of heat transfer to the working fluid used to carry the heat.
A magnetic heater is needed that provides one or more of the following: improved control of the rate of heat generation, improved efficiency of heat generation, and improved efficiency of heat transfer to the working fluid used to carry the heat.

BRIEF DESCRIPTION OF THE DRAWINGS

Like reference numbers generally indicate corresponding elements in the figures.

FIG. 1 is a side view of a magnetic heater, in accordance with an embodiment;

FIG. 2 is a front view of the magnet assembly of FIG. 1;

FIG. 3 is a side view of a magnetic heater, in accordance with an embodiment;

FIG. 4 is a front view of a conductive member comprising a plurality of separate conductors, in accordance with an embodiment;

FIG. 5 is a portion of the frame with a cross-sectional view of a magnet and a protective layer provided on the exterior of the magnet, in accordance with an embodiment;

FIG. 6 is a side view of a magnetic heater, in accordance with an embodiment;

FIG. 7 is a side view of a magnetic heater, in accordance with an embodiment;

FIG. 8 is a front view of the embodiment of FIG. 7;

FIGS. 9A and 9B are side views of the magnetic heater comprising a spacing actuator for varying the conductor/magnet spacing, in accordance with an embodiment;

FIG. 10 is a side view of a radially moving magnet relative to a conductive member, in accordance with an embodiment;

FIG. 11 is a partial view of the embodiment of FIG. 10, wherein different polarities of opposing magnets face the conductive member, in accordance with an embodiment;

FIG. 12 is a multi-stage magnetic heater, in accordance with an embodiment;

FIG. 13A is a perspective view of a magnetic heater apparatus, in accordance with an embodiment;

FIG. 13B is an exploded view of the magnetic heater apparatus of FIG. 13A.

FIG. 14A is a perspective exploded view of a magnetic heater apparatus, in accordance with another embodiment;

FIG. 14B is a side cross-sectional view of the magnetic heater apparatus of FIG. 14A;

FIG. 15 is a front view of a magnetic heater, in accordance with an embodiment;

FIG. 16 is a side cross-sectional view of the magnetic heater of FIG. 15 along cut line 16-16;

FIG. 17 is a partial cutaway detailed view of the side cross-sectional view of FIG. 16;

FIG. 18 is a partially exploded view of the magnetic heater of FIG. 15;

FIG. 19 is an exploded perspective view of a rotatable magnet assembly of the magnetic heater of FIG. 15, in accordance with an embodiment;

FIG. 20 is an exploded perspective view of a conductor assembly of the magnetic heater of FIG. 15, in accordance with an embodiment;

FIG. 21 is a schematic diagram of an engine-driven heat generation system, in accordance with an embodiment;

FIG. 22 is a schematic diagram of an engine-driven heat generation system, in accordance with an embodiment;

FIGS. 23, 24 and 25 are partially exploded and assembled perspective views, respectively, of a split-conductor magnetic heater assembly comprising a split-conductor magnetic heater and a frame, in accordance with an embodiment;

FIG. 26 is a perspective view of a conductor assembly comprising a slot, in accordance with an embodiment;

FIGS. 27, 28, and 29 are perspective, front and side views, respectively, of an engine-driven heat generation system, in accordance with an embodiment;

FIGS. 30, 31 and 32 are partially exploded and two assembled perspective views, respectively, of a transverse-moving magnet magnetic heater assembly comprising a transverse-moving magnet magnetic heater and a frame, in accordance with an embodiment;

FIGS. 33, 34, and 35 are perspective, front, and side views, respectively, of an engine-driven heat generation system, in accordance with an embodiment;

FIG. 36 is an exploded view of a magnet unit comprising a plurality of pivotal magnet assemblies, in accordance with an embodiment; and

FIGS. 37 and 38 are perspective views of a pivoting-magnet magnetic heater assembly, in accordance with an embodiment.

DETAILED DESCRIPTION

FIG. 1 is a side view of an embodiment of a magnetic heater 2 in accordance with the present invention. The magnetic heater 2 comprises a magnet assembly 20 and a conductive member 14 disposed proximate the magnet assembly 20. Rotation of the magnet assembly 20 about an x-axis induces a predetermined cyclical variation of magnetic field within the conductive member 14.
FIG. 2 is a front view of the magnet assembly 20 of FIG. 1. The magnet assembly 20 comprises a disk-shaped frame 22, a plurality of magnets 12, and a shaft 18. The plurality of magnets 12 are coupled to and arranged in a planar, generally circular, spaced-apart, orientation on the frame 22. The magnets 12 each have a first magnet surface 13 in a substantially planar relationship, referred herein as the first magnet plane 21, shown in FIG. 1. The shaft 18 is coupled substantially at the center of rotation of the frame 22. The center of rotation of the frame 22 defines the x-axis which is substantially perpendicular to the first magnet plane 21. The shaft 18 is operable to couple with an energy source capable of imparting rotation to the shaft 18.
The conductive member 14 has a planar conductive member first side 15 in opposing, substantially parallel relationship with the first magnet plane 21. The conductive member first side 15 and the first magnet plane 21 are spaced-apart a predetermined distance in opposing relationship referred herein as a conductor/magnet spacing X1. The conductive member 14 comprises an electrically-conductive material.
As the shaft 18 of the frame 22 is rotated, the magnets 12 move relative to the conductive member first side 15 of the conductive member 14. A given point on the conductive member 14 will, therefore, be exposed to a cyclically varying magnetic field as each of the magnets 12 approach, pass over, and retreat from adjacent that given point. The given point on the conductive member 14 will thus be heated as long as the given point is exposed to the time-varying magnetic field.
It is appreciated that the magnet assembly 20 can comprise one or more magnets 12. One magnet 12 is sufficient to expose a cyclically varying magnetic field onto the conductive member 14. Therefore, it is appreciated that when reference is made to a plurality of magnets 12, it applies also to embodiments comprising one magnet 12, and vice-versa.
In embodiments, the magnets 12 are permanent magnets. Therefore, the magnets 12 have a substantially constant magnetic field strength. This is contrasted with an electromagnet, which has the capability of producing a range of magnetic field strength dependent on varying the current driving the electromagnet. Therefore, the strength of the magnetic field produced by the permanent magnets 12 that the conductive member 14 is exposed to primarily depends on the conductor/magnet spacing X1. The magnetic field strength of the permanent magnet 12 is referred to as the absolute magnetic field strength.
A fluid path 16 is defined such that heat transfer between the conductive member 14 and fluid moving within the fluid path 16 is enabled. Thus, as the conductive member 14 is heated, a fluid absorbs at least a portion of the heat generated. The fluid can thus be used to transport the heat to another location.
The radial and axial placement of the magnets 12 about the frame 22 as shown in FIGS. 1 and 2 is exemplary only. Placement of the magnets 12 about the frame 22 in other arrangements, orientations, spacing, among other things, in planar relationship or otherwise, is anticipated suitable for a particular purpose of imparting a magnetic field onto the conductive member 14 and/or onto additional conductive members 14. Furthermore, the magnets 12 need not be of the same size, shape, polar orientation, composition, or type, among other things.
In the embodiment of FIGS. 1 and 2, the magnets 12 are oriented such that the conductive member 14 is exposed to an alternating polarity from adjacent magnets 12, with their north poles N either pointing towards or away from the conductive member 14. Such an arrangement produces a relatively large range of variation in the magnetic field on the conductive member 14 as compared with, for example, wherein all of the magnets 12 present the same polarity to the conductive member 14.
Relative motion between the conductive member 14 and the magnets 12 is produced, wherein the magnets 12, are caused to rotate about the x-axis and holding the conductive member 14 stationary.
FIG. 3 is a side cross-sectional view of a magnetic heater 3 wherein the conductive member 14 is caused to rotate about the x-axis and holding the magnet assembly 20, and thus, the magnets 12, stationary. The conductive member 14 is coupled to a shaft 18 that is coupled to an energy source suitable for rotating the shaft 18 about the x-axis.
It is understood that relative motion between the magnets 12 and the conductive member 14 can be produced, in accordance with embodiments, by the above mentioned configurations, and by other configurations, such as, but not limited to, rotation of both the magnet assembly 20 and conductive member 14 at different rates in the same direction, and rotation of both the magnet assembly 20 and conductive member 14 in opposite directions.
The absolute magnetic field strength of the magnet 12 is a measure of the magnitude of the magnetic field generated by the magnet 12 at a point on the magnet 12. For permanent magnets, the absolute magnetic field strength is essentially fixed. For electromagnets, the absolute magnetic field strength depends on the amount of current passing through the magnets coils.
The magnetic field exerted on the conductive member 14 depends on, among other things, the absolute magnetic field strength of the magnet 12 and the conductor/magnet spacing X1 between the magnet 12 and the conductive member 14.
A variety of magnets 12 are suitable for embodiments of the present invention. Permanent magnets 12 are advantageous for certain embodiments, for at least the reason that it is not necessary to supply electrical power to the magnets 12, hence no wiring or power source is needed for such purpose.
The rate of heat generation in a magnetic heater 2, 3 in accordance with embodiments depends in part on the absolute magnetic field strength of the magnets 12. Therefore, for applications wherein a high rate of heat generation is desirable, it is also desirable that the magnets 12 have a relatively high absolute magnetic field strength.
In addition, the maximum temperature that can be generated by a magnetic heater 2, 3 according to embodiments depends in part on the heat tolerance of the magnets 12. Permanent magnets have a “maximum effective operating temperature” above which their magnetic field begins to degrade significantly.
Electromagnets likewise suffer from decreased performance with increasing temperature, though the decrease is not as well defined as that of permanent magnets. For example, the resistance of the magnetic field coils in an electromagnet gradually increases with increasing temperature, which in turn gradually reduces the current flow at a given voltage, generating still more heat. Magnets of both types are available suitable for use at elevated temperatures.
Permanent magnets known as rare earth magnets, such as, but not limited to Samarium Cobalt magnets, have a relatively high absolute magnetic field strength and operating temperature, and are suitable for the particular purpose.
The conductive member 14 comprises an electrically conductive material suitable for the particular purpose. Suitable materials include, but are not limited to, copper, aluminum, alloys of copper, alloys of aluminum, and other metallic or non-metallic, electrically conductive substances. The conductive member 14 is operable to enable induced eddy-currents within the conductive member 14 when exposed to a time-varying magnetic flux. The conductive member 14 of the embodiment of FIG. 1 is generally disc-shaped. The conductive member 14 is not particularly limited to a specific shape, size, or configuration. In other embodiments, the conductive member is formed in two or more pieces, as a thin conductive layer on a non-conductive substrate, having defined apertures therein, among other configurations.
The conductive member need not consist of a closed loop or integral piece of conductive material. FIG. 4 is a front view of a conductive member assembly 11 comprising a plurality of separate conductors 27 that are separated from one another by non-conductive material 48 in accordance with an embodiment. In such a case, each conductor 27 is heated independently.
Likewise, the conductive member 14, even if a single contiguous piece of conductive material, might be shaped with apertures, or be constructed of wires, beams, rods, etc., with empty space therebetween.
FIGS. 1 through 3 show the magnetic heater 2, 3 in simplified schematic form for clarity. It is understood that additional structure may be present to provide structural support for containment and alignment.
FIG. 5 is a cross-sectional view of a portion of the magnet assembly 20 comprising a frame 22 with a magnet 12 and a protective layer 31 provided on the exterior of the magnet 12. The protective layer 31 is selected for a particular purpose, including, but not limited to, thermal protection, additional structural integrity, and chemical protection.
A variety of materials are suitable for use as the protective layer 31, so long as they do not significantly reduce the propagation of the magnetic field of the magnet 12.
In one embodiment, the protective layer 31 comprises aluminum. It is noted that aluminum has a high reflectivity, thus inhibiting the absorption of heat by the magnet 12, and a high infrared emissivity, thus facilitating the rapid re-radiation of heat away from the magnet 12. These properties combine to provide passive cooling for the magnet 12. In addition, aluminum is relatively durable, and so a protective layer 31 of aluminum serves to protect the magnet 12 physically. Likewise, aluminum is relatively impermeable, and thus may effectively seal the magnet 12 against any potential corrosive effects due to moisture, oxygen, fluid flowing through the fluid path 16 (see below), among other things.
In addition, in other embodiments, the magnetic heater 2,3 may include an additional active or passive cooling mechanism for the magnets 12. A wide variety of cooling mechanisms are suitable for the particular purpose. For example, passive cooling mechanisms include, but are not limited to, heat sinks and radiator fins. Active cooling mechanisms include, but are not limited to, coolant loops and refrigeration units.
It is noted that the fluid path 16, as described below, may be configured to act as a cooling mechanism. In some embodiments, fluid is used to provide a mechanism for absorbing heat from the conductive member 14, and it is well suited for absorbing heat from the magnets 12 as well.
In other embodiments, heat is generated for use via direct conduction or radiation from the conductive member 14. For example, heat could be transferred from the conductive member 14 to a solid heat conductor, heat sink, or heat storage device, such as, but not limited to, a mass of ceramic, brick, stone, etc.
FIG. 6 is a side cross-sectional view of the magnetic heater 2 wherein the fluid path 16 is defined so that at least a portion thereof extends between the magnets 12 of the magnet assembly 20 and the conductive member 14 in accordance with embodiments. The fluid path 16 extends substantially parallel with the conductive member 14 and the magnets 12, between the magnets 12 and the conductive member 14.
Suitable fluids for the particular purpose include, but are not limited to, gaseous fluids such as air and liquid fluids such as water. When the conductive member 14 is heated, fluid in the fluid path 16 receives heat from conductive member 14. Heat transfer from the conductive member 14 to fluid in the fluid path 16 may occur via one or more of conduction, convection, and radiation.
FIGS. 7 and 8 are side and front views of an embodiment of the magnetic heater 2 further comprising a fluid driver 34 engaged with a fluid path 16 for driving fluid therethrough, in accordance with embodiments. The fluid driver 34 comprises a plurality of fins 35 or blades and a driver shaft 36. Examples of suitable fluid drivers 34 include, but are not limited to, finned rotors, squirrel cages, and fans. In the embodiment of FIG. 7, the driver shaft 36 extends through an aperture 37 in the conductive member 14 and is coupled to the frame 22 on which the magnets 12 are arranged. The driving action is provided by rotation of the frame 22, which turns the fluid driver 34 in a predetermined direction. Thus, the speed of operation of the fluid driver 34 therein depends on the speed of motion of the frame 22, and likewise the rate of fluid flow within the fluid path 16. In other embodiments, the driver shaft 36 is coupled to, among other things, the shaft 18 or an external energy source.
In an embodiment wherein the conductive member 14 rather than the frame 22 moves to produce the cyclically varying magnetic field, the fluid driver 34 is driven by the rotation of the conductive member 14.
It is appreciated that the temperature to which fluid passing through the fluid path 16 is heated depends on the rate of heat generation in the conductive member 14, that is, on the amount of heat available to warm the fluid. Also, the temperature of the fluid depends on the rate at which the fluid moves through the fluid path 16, that is, on how much fluid is available to absorb the heat that is generated. Further, the temperature of the fluid depends on the efficiency of the conductive member 14 is releasing its heat to the fluid.
Also because the parameters, including rate of heat generation, rate of fluid flow, and fluid temperature, are independent of one another as described in some embodiments herein, a magnetic heater 2 in accordance with embodiments is used to produce a specific temperature of fluid in combination with a specific quantity of fluid flow. Any two of the three parameters can be controlled independently of one another.
The energy source used to drive the shaft 18 can comprise any suitable means.
In embodiments, the shaft 18 is coupled with a power take-off found on some motor vehicles, such as, but not limited to, many tractors, other agricultural vehicles, and heavy work vehicles. In such vehicles, some or all of the mechanical driving force generated by the engine is transferred to the power take-off to impart rotation, such as to the shaft 18. Conventional power take-offs include a rotatable coupling or other movable component, which is engaged with a linkage to impart rotation to the shaft 18.
In other embodiments, the shaft 18 comprises a hydraulic linkage. Certain vehicles include hydraulic systems, such as, but not limited to, for actuating a snow plow or shovel blade, for tipping a truck bed, or for operating a fork lift. The hydraulic system is operable to couple with a piece of supplemental equipment, such as a hydraulic motor, with suitable linkage operable to couple with the shaft 18, to provide power thereto. Hydraulic systems and hydraulic linkages are known in the art, and are not described in detail herein.
Various embodiments are anticipated so as to control the rate of heat output of the magnetic heater 2.
FIGS. 9A and 9B are side cross-sectional views of the magnetic heater 2 of FIG. 1, further comprising a spacing actuator 26 for varying the conductor/magnet spacing X1, in accordance with an embodiment. The spacing actuator 26 varies the conductor/magnet spacing X1 between the conductive member first side 15 and the first magnet surface 13 along the x-axis.
The strength of the magnetic field exerted on a given portion of the conductive member 14 depends in part on the conductor/magnet spacing X1 between the magnets 12 and the conductive member 14. A change in the conductor/magnet spacing X1 changes the magnetic field strength to which the conductive member 14 is exposed, and thus changes the range of variation of the magnetic field over a cycle (the cyclical variation of the magnetic field), which changes the rate at which heat is generated in the conductive member 14. For permanent magnets, the cyclical variation of the magnetic field is accomplished while the absolute magnitude of the magnetic field strength remains substantially constant.
Reducing the conductor/magnet spacing X1 increases the magnetic field strength on the conductive member 14 and increases the magnetic induction, thus increasing the heating of the conductive member 14. Increasing the conductor/magnet spacing X1 reduces the magnetic field strength on the conductive member 14 and reduces the magnetic induction, thus reducing the heating of the conductive member 14.
In embodiments wherein it is desirable to enable a relatively high maximum rate of heat generation, it is desirable that a minimum value of the conductor/magnet spacing X1 between the conductive member 14 and the magnets 12 be as small as is practical. Similarly, in embodiments wherein it is desirable to enable a high range of variability in the rate of heat generation, it is desirable that the range of possible values for the conductor/magnet spacing X1 between the conductive member 14 and the magnets 12 is relatively large.
The conductor/magnet spacing X1 is a parameter that is independent of the rate of motion of the magnets 12 with respect to the conductive member 14, and thus independent of the rate of cyclical variation of the magnetic field. Thus, the rate of heat generation of the magnetic heater 2 is adjustable by varying the conductor/magnet spacing X1 without changing the period of cyclical variation of the magnet magnetic field.
Likewise, the conductor/magnet spacing X1 is independent of the absolute magnetic field strength of the magnets 12. Thus, the rate of heat generation of the magnetic heater 2 is adjustable by varying the conductor/magnet spacing X1 without changing the absolute magnetic field strength of the magnets 12. What is changing with varying the conductor/magnet spacing X1, among other things, is the magnitude of the magnetic field that the conductive member 14 is exposed to. The rate of heat generation of the magnetic heater 2 is adjustable while it is generating heat by adjusting the conductor/magnet spacing X1.
The spacing actuator 26 is engaged with either the magnet assembly 20 or the conductive member 14 so as to vary the conductor/magnet spacing X1 therebetween. In other embodiments, the magnetic heater 2 comprises separate spacing actuators 26 engaged with the magnet assembly 20 and the conductive member 14. Such arrangements facilitate adjustment of the conductor/magnet spacing X1, and consequently facilitates adjustment of the rate of heat generation. In an embodiment, the spacing actuator 26 is used to facilitate adjustment of the conductor/magnet spacing X1 while the magnetic heater 2 is generating heat.
A variety of actuators are suitable for use as the spacing actuator 26. In one embodiment, as schematically illustrated in FIGS. 9A and 9B, the spacing actuator 26 is a simple linear actuator, engaged with the conductive member 14 to move it toward or away from the magnet assembly 20, thereby adjusting the conductor/magnet spacing from X1 to X2.
In an embodiment, the spacing actuator 26 is a manual actuator, such as, but not limited to, a threaded screw controlled by a hand-turned knob. In other embodiments, the spacing actuator 26 is a powered actuator, such as, but not limited to, an electrically or hydraulically driven mechanism.
Referring again to FIG. 7, the magnetic heater 2 further comprises a controller 38. The controller 38 is in communication with the spacing actuator 26, so as to control the conductor/magnet spacing X1. The controller 38 also is in communication with the shaft 18, so as to control the speed of motion of the magnet assembly 20, and therefore, the magnets 12, which derive their motion from the shaft 18, wherein the output of the motive device driving the shaft 18 is variable and controllable.
The fluid driver 34 is engaged with the magnet assembly 20 so that the speed of operation of the fluid driver 34, and consequently the rate of fluid flow along the fluid path 16, also is determined by the speed of motion of the magnet assembly 20.
The controller 38 in FIG. 7 thus controls the rate of heat generation by controlling the conductor/magnet spacing X1, and also controls the rate of fluid flow by controlling the rate at which the fluid driver 34 operates. By controlling these two parameters independently, the temperature of the fluid also can be controlled as described previously.
A variety of devices are suitable for use as a controller 38, including, but not limited to, integrated circuits. Controllers are known in the art, and are not described further herein.
Although the embodiment in FIG. 7 shows the controller 38 in communication with various sensors 40, 42, it is emphasized that this is exemplary only. In other embodiments, the controller 38 controls the operation of the magnetic heater 2 without sensors or data therefrom. In embodiments, the controller 38 comprises stored data and/or a pre-calculated algorithm, based on, among other things, the design of the magnetic heater 2 and the performance of similar magnetic heaters 2. The controller 38 controls the magnetic heater 2 to produce the desired levels of heat generation, fluid temperature, and/or rate of fluid flow, without the need for active sensors to monitor the parameters of the magnetic heater 2 itself.
The embodiment in FIG. 7 includes a fluid temperature sensor 40, for sensing the temperature of fluid moving along the fluid path 16. It also includes a fluid flow rate sensor 42, for sensing the rate of fluid flow through the fluid path 16. It further includes a drive sensor 44, for sensing the rate at which the magnet assembly 20 is driven by the shaft 18. The controller 38 is in communication with each of the sensors 40, 42, and 44.
Based on data from the sensors 40, 42, and 44, the controller 38 adjusts the speed of the magnet assembly 20, the speed of the fluid driver 34, and/or the conductor/magnet spacing X1, so as to control heat generation, fluid temperature, and/or fluid flow.
It is emphasized that the arrangement of the sensors 40, 42, and 44 as shown is exemplary only. It is not necessary for a particular embodiment to include sensors at all, or to include each of the sensors 40, 42, and 44 shown in FIG. 7. In other embodiments, other sensors are included in the magnetic heater 2 in addition to or in place of those shown.
In an embodiment, the magnetic heater 2 comprises an additional sensor operable to sense the conductor/magnet spacing X1 between the magnets 12 and the conductive member 14.
A variety of sensors are suitable for use in a magnetic heater 2 according to embodiments, depending upon the particulars of the specific embodiment of the magnetic heater 2 and the type of information that is to be sensed. Sensors are known in the art, and are not described further herein.
FIG. 10 is a side cross-sectional view of a magnetic heater 4 in accordance with an embodiment. A conductive member 14 comprises a conductive member first side 15 a and a conductive member second side 15 b. A first magnet assembly 20 a comprising a first frame 22 a and a plurality of first magnets 12 a thereon is disposed a first spacing X3 away from the conductive member first side 15 a. Similarly, a second magnet assembly 20 b comprising a second frame 22 b and a plurality of second magnets 12 b thereon is disposed a second spacing X4 away from the conductive member second side 15 b of the conductive member 14.
The first and second magnet assemblies 20 a, 20 b are disposed adjacent the conductive member first and second sides 15 a, 15 b, respectively, such that the magnets 12 a and 12 b, respectively, are aligned with one another to form opposing pairs on each conductive member first and second sides 15 a, 15 b of the conductive member 14. In an embodiment wherein the first and second magnet assemblies 20 a, 20 b are movable, they are movable together and/or independently so as to maintain in opposing magnet pairs.
FIG. 11 is a cross-sectional partial view of the embodiment of FIG. 10, wherein different polarities of opposing first and second magnets 12 a, 12 b face the conductive member 14, to present a predetermined gradient in the magnetic field. In another embodiment (not shown), the same polarity of opposing first and second magnets 12 a, 12 b face the conductive member 14, to present a predetermined gradient in the magnetic field that is produced.
FIG. 12 is a side cross-sectional view of an embodiment of a multi-stage magnetic heater 6, in accordance with an embodiment. As with the embodiment shown in FIG. 1, the embodiment of FIG. 10 may be conveniently expanded by the use of additional conductive members 14 and magnet assemblies 20. The embodiment of FIG. 12 comprises an arrangement with three conductive members 14 a-c and four magnet assemblies 20 a-d. It is noted that the number of conductive members 14 and magnet assemblies 20 is exemplary only, and that other numbers and arrangements may be suitable for a particular purpose. A fluid driver 34 is shown adjacent the conductive members 14 and magnet assemblies 20.
The multi-stage magnetic heater 6 further comprises support bracing 90 coupling the plurality of magnet assemblies 20 a-d in relative axial alignment. It is appreciated that the operation of the magnetic heater 6 is effective whether the magnet assemblies 20 a-d or the conductive members 14 a-c are driven to rotation by the shaft 18.
FIGS. 13A and 13B are assembled and exploded views, respectively, of a magnetic heater apparatus 8 in accordance with an embodiment. The magnetic heater apparatus 8 comprises a rear housing 94, a first end panel 91, a heater housing 92, a magnetic heater 6, a second end panel 93, a blower housing 96, and an air intake screen 97.
The magnetic heater 4, in accordance with the embodiment of FIG. 10, comprises a shaft 18, a first magnet assembly 20 a, a conductive member 14, a second magnet assembly 20 b and a fluid driver 34. The first and second magnet assemblies 20 a, 20 b comprise a plurality of magnets 12. The conductive member 14 is disposed between and coaxial with the first and second magnet assemblies 20 a, 20 b. The conductive member 14 is coupled with the shaft 18 and operable to rotate with respect to the first and second magnet assemblies 20 a, 20 b. The shaft 18 is operable to couple with an energy source, such as, but lot limited to, a motor 103.
The rear housing 94 is coupled adjacent the first end panel 91, both comprising apertures to allow the shaft 18 to pass there through. The first end plate is coupled adjacent the heater housing 92 defining a volume operable to contain the first and second magnet assemblies 20 a, 20 b and conductive member 14. The second end panel 93 is coupled adjacent the heater housing 92 defining a side of the volume. The heater housing 92 comprises a fluid outlet 102. The second end panel 93 comprises a second end plate aperture 95 defining a portion of a fluid path. The fluid driver 34 is coupled to the shaft 18 and located adjacent the second end panel 93 on the opposite side from the second magnet assembly 20 b. The blower housing 96 is coupled adjacent the second end panel 93 enclosing the fluid driver 34 there between. The blower housing 96 defines a fluid inlet aperture 87 defining a portion of the fluid path. The air intake screen 97 is coupled to the blower housing 96 covering the fluid inlet aperture 87.
A fluid path is defined by the fluid inlet aperture 87, the fluid driver 34, the second end plate aperture 95, the heater housing 92 and the fluid outlet 102. Fluid is drawn into the fluid inlet aperture 87 by the rotation of the fluid driver 34. The fluid driver 34 directs the fluid through the second end plate aperture 95 and circulates the fluid past the conductive member 14 in the heater housing 92. The heater housing 92 directs the fluid to the fluid outlet 102.
The magnetic heater apparatus 8 further comprises a spacing adjustment assembly comprising a knob 99, a threaded spacer 105 having a first spacer end 108 and a second spacer end 109, a first retention coupler 107 and a second retention coupler 106. The first retention coupler 107 is positioned adjacent the first magnet assembly 20 a and the second retention coupler 106 is positioned adjacent the second magnet assembly 20 b. The threaded spacer 105 is disposed between the first and second magnet assemblies 20 a, 20 b, the first spacer end 108 coupled with the first retention coupler 107. The second spacer end 109 is passed through the second retention coupler 106 and coupled to the knob 99. Turning the knob 99 in a first direction reduces the spacing between the first and second magnet assemblies 20 a, 20 b. Turning the knob 99 in the opposite direction increases the spacing between the first and second magnet assemblies 20 a, 20 b.
FIGS. 14A and 14B are exploded perspective and cross-sectional side views, respectively, of a magnetic heater apparatus 7 in accordance with an embodiment. The magnetic heater apparatus 7 comprises a blower 199 and a magnetic heater 3. The blower 199 comprises a motor mount 191, a motor 103, a blower housing 196, blower fan 134, a blower housing sleeve 192, and an air intake screen 197. The magnetic heater 3 comprises a magnet assembly 20 and a conductive member 14 that is an element of the blower fan 134 as described below.
Those in the air-moving arts will recognize that the blower 199 is substantially of the known squirrel-cage blower configuration. The blower housing 196 defines an annular volume 195 in fluid communication with an axial inlet 193 and a tangential outlet 194.
The blower fan 134 comprises a plurality of fan blades 198 coupled to the conductive member 14. The conductive member 14 is in the form of a disk-shaped plate of substantially the same configuration as the embodiment of FIG. 3. The magnet assembly 20 is also of substantially the same configuration as the embodiment of FIG. 3. The magnet assembly 20 comprises an axial shaft annulus 23. The magnet assembly 20 is coaxially located within the annular volume 195. The blower fan 134 is coaxially located within the annular volume 195 such that the conductive member 14 of the blower fan 134 is located co-axially and adjacent magnet assembly 20. The blower housing sleeve 192 is coupled to the blower housing 196 about the axial inlet 193 located co-axially with and adjacent to the blower fan 134 and operable to guide air flow from the axial inlet 193 to the blower fan 134. The air intake screen 197 is coupled to the blower housing 196 so as to cover the axial inlet 193.
It is anticipated that in other embodiments, the blower housing sleeve 192 is an integral part of the blower housing 196 in consideration of engineering preference.
The motor mount 191 is coupled to the blower housing 196, and the motor 103 is coupled to the motor mount 191 such that a shaft 18 of the motor 103 is located coaxially with the magnet assembly 20 and the blower fan 134 extending into the annular volume 195. The shaft 18 extends into the annular volume 195, passing through the shaft annulus 23 of the magnet assembly 20, and is coupled in operative engagement to the conductive member 14, so as to rotate the conductive member 14, and thus the blower fan 134, when in operation. The magnet assembly 20 is coupled to and fixed the blower housing 196. In operation, the conductive member 14 is rotated relative to the stationary magnet assembly 20, whereby the conductive member 14 is heated due to inductive heating from a time-varying magnetic flux induced by the magnet assembly 20.
It is anticipated that in other embodiments the motor 103 is mounted to the blower housing 196 in any suitable manner, in consideration of engineering preference.
In operation, air is drawn into the axial inlet 193, directed by the blower housing sleeve 192, by the blower fan 134. The air passes over the conductive member 14 wherein the heat generated by the magnetic heater 3 is transferred to the air. The heated air is subsequently exhausted out of the tangential outlet 194. In other embodiments, the fan blades 198 are operable to act as heat sinks for the transfer of heat from the conductive member 14 to the air.
FIG. 15 is a front view of a magnetic heater 9, in accordance with an embodiment. FIG. 16 is a side cross-sectional view of the magnetic heater of FIG. 15 along cut line CL16-CL16. The magnetic heater 9 comprises a plurality of conductor assemblies 50, 50 a-b and a plurality of magnet assemblies 60, 60 a-c in closely-spaced, opposing, alternating configuration, aligned along an axis about a shaft 18. Each of the plurality of magnet assemblies 60 are coupled to the shaft 18, such that the magnet assemblies 60 rotate relative to the conductor assemblies 50 when the shaft is rotated.
It is appreciated that in other embodiments, the magnetic heater 9 may comprise one or more conductor assemblies 50 and one or more magnet assemblies 60 suitable for a particular purpose. By way of example, but not limited thereto, a magnetic heater may have one conductor assembly 50 and one magnet assembly 60; one conductor assembly 50 and two magnet assemblies 60, one magnet assembly 60 on either side of the conductor assembly 50; one magnet assembly 60 and two conductor assemblies 50, one conductor assembly 50 on either side of the magnet assembly 60; and combinations of the above. One can understand that heat output is related to the number of conductor assemblies 50 and magnet assemblies 60 and that the magnetic heater provides a modular approach for providing heat output.
FIG. 17 is a partial cutaway detailed view of the side cross-sectional view of FIG. 16. The magnet assembly 60 comprises one or more magnets 12 and is operable to dispose the one or more magnets 12 in close proximity to the conductor assembly 50.
FIG. 18 is a partially exploded view of the magnetic heater 9 of FIGS. 15-17. The magnetic heater 9 comprises a first, second and third conductor assembly 50 a-b in alternating arrangement with a first, second, third, and fourth magnet assembly 60 a-c. The conductor assemblies 50 a-b and magnet assemblies 60 a-c are disposed upon a shaft 18, which itself is supported by a pair of pillow blocks 72. The conductor assemblies 50 a-b and magnet assemblies 60 a-c are spaced apart a predetermined distance and held together as an assembly by a plurality of bushings 70, collars 71, and the pillow blocks 72. The magnetic heater 9 is operable such that the magnet assemblies 60 a-c are coupled to the shaft 18 and rotate relative to the conductor assemblies 50 a-b when the shaft 18 is rotated.
FIG. 19 is an exploded perspective view of a magnet assembly 60 of the magnetic heater 9 of FIG. 15. The magnet assembly 60 comprises a magnet plate 61 in the form of a substantially circular disk. Disposed on a side of the magnet plate 61 and a predetermined distance adjacent the magnet plate peripheral edge 69 are a plurality of magnet pockets 19 operable to at least partially receive at least one magnet 12 therein. The magnets 12 are retained within the magnet pockets 19 by a plurality of retainer plates 63. The retainer plates 63 comprise a plurality of fastener apertures 66 operable to receive suitable fasteners 64 there through. The fastener apertures 66 are operable to align with threaded bores 67 disposed in the magnet plate 61. The retainer plates 63 engage the magnets 12 and the magnet plate 61 to retain the magnets 12 within respective magnet pockets 19.
Referring again to FIG. 17, the retainer plates 63 comprise a plurality of retainer pockets 68 complementary with the magnet pockets 19 and operable to receive at least one magnet 12 therein. In other embodiments, either the magnet pockets 19 or the retainer pockets 68 are operable to receive the magnet 12 entirely therein, and either the retainer plate 63 or the magnet plate 61, respectively, comprise a substantially flat surface to contain the magnet 12 therein.
The magnet plate 61 further comprises a central shaft aperture 65 operable to receive the shaft 18 there through.
It is appreciated that in other embodiments, the magnet assembly 60 may comprise one or more magnets 12 suitable for a particular purpose. The magnet 12 provides a time-varying magnetic flux on the conductor assembly 50 when there is relative movement of the magnet 12 with respect to the conductor assembly 50. Such magnetic flux may be provided by one or more magnets 12. Further, the size and shape of the magnet 12 can be chosen to provide a predetermined magnetic flux density suitable for a particular purpose. In yet other embodiments, there is provided multiple rows of magnets 12 spaced apart in the radial direction from the shaft aperture 65.
Further, it is appreciated that in other embodiments, the magnet assembly 60 may take other forms suitable for a particular purpose for providing the magnets 12 in close proximity to the conductor assembly 50. The magnets 12 can be coupled to the magnet plate by other fastening means, including, but not limited to, fasteners, adhesives, and coatings, with or without the retainer plate 63. In embodiments wherein the magnet assembly 60 is rotated, the means of retention of the magnets 12 to the magnet plate 61 must withstand the forces tending to decouple and throw the magnets 12 from the magnet plate 61.
FIG. 20 is an exploded perspective view of a conductor assembly 50 of the magnetic heater 9 of FIG. 15. The conductor assembly 50 comprises a pair of conductor plates 52 a,52 b retained about a peripheral edge 55 in fluid-tight engagement by a frame 51. At least one of the pair of conductor plates 52 a,52 b comprises an electrically conductive material suitable for the particular purpose, operable to enable induced eddy-currents within the conductor plate 52 a,52 b when exposed to a time-varying magnetic flux which causes the conductor plate 52 a,52 b to heat up.
The frame 51 is operable to retain the conductor plates 52 a,52 b in a facing relationship a predetermined distance apart defining a fluid space 56 there between. A gasket 59 seals the peripheral edge 55 of the conductor plates 52 a,52 b such that fluid is retained within the fluid space 56. It is appreciated that suitable means for fluid-tight sealing is provided, such as, but not limited to, welding, brazing, soldering, the frame 51, coatings, and resilient sealing elements, such as, but not limited to, an “O-ring” and gasket.
The conductor plates 52 a,52 b each have a bushing aperture 53 operable to receive the bushing 70 therein. A bushing aperture seal 54 about the bushing aperture 53 and operable to engage the conductor plates 52 a,52 b about the bushing aperture 53 is operable to maintain fluid-tight engagement there between to retain fluid within the fluid space 56.
Referring again to FIGS. 15 and 18, the conductor assembly 50 further comprises a fluid inlet 57 and a fluid outlet 58, in communication with the fluid space 56. Referring to FIG. 20, the fluid inlet 57 and outlet 58 are an element of one or both of the conductor plates 52 a,52 b. The conductor assembly 50 is operable such that fluid may be passed between the fluid inlet 57, the fluid space 56, and the fluid outlet 58 sufficient to provide efficient heat transfer from the conductor plates 52 a,52 b to the fluid as the conductor plates 52 a,52 b are heated during operation.
FIG. 21 is a schematic diagram of an engine-driven heat generation system 100, in accordance with an embodiment. The engine-driven heat generation system 100 provides heat to external applications via a working fluid supplied to a suitable external heat exchanger 126 as described below. The engine-driven heat generation system 100 comprises an internal combustion engine 110, a magnetic heater 9, such as, but not limited to, the embodiment of FIG. 18, and a fluid handling system 130. A drive coupling of the engine 110 drives or rotates the magnet assemblies 60 within the magnetic heater 9 which in turn heats the conductor plates 52 a,52 b and the working fluid flowing within the conductor assemblies 50.
The fluid handling system 130 comprises a working fluid handling system 120, an engine cooling system 112, and an exhaust system 129. The working fluid handling system 120 comprises a fluid reservoir 121, a manifold flow control 122, an exhaust heat exchanger 123, a coolant heat exchanger 124, and one or more circulating pumps 127, all in fluid communication operable to circulate the working fluid therein. The manifold flow control 122 is operable to direct the working fluid to the magnetic heater 9, the exhaust heat exchanger 123, and the coolant heat exchanger 124.
The heat generated by the magnetic heater 9 is transferred to the working fluid passing within the magnetic heater 9. The working fluid is collected in the fluid reservoir 121 and either directed again through the manifold flow control 122 or directed to an external heat exchanger 126 by way of an external manifold 125, or a combination thereof. The external manifold 125 is operable to provide one or more fluid take-offs to supply the heated working fluid and return cooled working fluid to/from one or more external heat exchangers 126.
The engine cooling system 112 comprises a coolant reservoir 114 for a coolant fluid in fluid communication with the engine 110 and the coolant heat exchanger 124. The coolant fluid circulates within the engine 110, wherein the heat from the structure of the engine 110 is transferred to the coolant fluid and subsequently transferred to the working fluid in the coolant heat exchanger 124. In this way, the heat from the engine 110 as well as the heat from the magnetic heater 9 is used to heat the working fluid.
The engine 110 produces hot exhaust gas as a product of combustion which is directed external to the engine 110 by an exhaust manifold 128. The exhaust system 129 comprises the exhaust heat exchanger 123 which is in fluid communication with the exhaust manifold 128 and is operable to transfer the heat from the exhaust of the engine 110 to the working fluid. In this way, the heat from the exhaust as well as the heat from the magnetic heater 9 is used to heat the working fluid.
The engine-driven heat generation system 100, therefore, utilizes the heat of the structure and the heat from the exhaust of the engine 110 to augment the heat from the magnetic heater 9 to efficiently provide a heated working fluid for use in external applications.
It is appreciated that a variety of configurations of an engine-driven heat generation system may be utilized, depending on engineering design preferences and constraints. FIG. 22 is a schematic diagram of another engine-driven heat generation system 200, in accordance with another embodiment. The engine-driven heat generation system 200 comprises an internal combustion engine 110, a magnetic heater 9, such as, but not limited to, the embodiment of FIG. 18, and a fluid handling system 230. The configuration and function is substantially similar to the embodiment of FIG. 21, but this embodiment comprises an engine 110 having two exhaust manifolds 128 a,128 b, two exhaust heat exchangers 123 a,123 b in fluid communication with respective exhaust manifolds 128 a, 128 b, and separate external manifolds, a supply manifold 125 a and a return manifold 125 b.
The applications for utilizing the heat generated by the engine-driven heat generation system 100,200 are vast. The working fluid is heated to a predetermined temperature suitable for a particular purpose. It is anticipated that most any application that utilizes the transfer of heat via a heat exchanger supplied by a heated working fluid would be suitable for use with the engine-driven heat generation system 100,200.
In an embodiment, the heated working fluid is passed through a heat exchanger that is part of a forced-air ventilation system to provide heated air to a building. In another embodiment, the working fluid is passed through hoses that are laid out on the ground and covered with a covering so as to heat the ground, such as to thaw out frozen ground for excavation. In yet another application, the working fluid is passed through a heat exchanger of a hot water supply system that is submerged in a tank of water so as to heat the water for use. These are but a few of the vast number of applications suitable for use with the engine-driven heat generation system 100,200.
The engine-driven heat generation system 100,200 realizes significantly improved efficiencies over conventional magnetic heaters by the utilization of the heat captured from the engine exhaust and the heat captured from the engine cooling system that are added to the heat generated by the magnetic heater.
FIGS. 23, 24 and 25 are partially exploded and assembled perspective views, respectively, of a split-conductor magnetic heater assembly 302 comprising a split-conductor magnetic heater 304 and a frame 312, in accordance with an embodiment. The frame 312 is operable to support various elements of the split-conductor magnetic heater 304 as well as providing a platform for ancillary components of a larger system. The split-conductor magnetic heater 304 comprises a magnet unit 62 and a first half-conductor unit 352 a and a second half-conductor unit 352 b in opposing relationship to each other. The first and second half-conductor units 352 a,b are operable to move laterally into and out of magnet assembly spaces 160 defined by the magnet unit 62 and thus, moving the first and second half-conductor units 352 a,b substantially into and out of magnetic engagement with the magnet unit 62, as will be explained below.
In the embodiment of FIG. 23, the magnet unit 62 comprises a first, second, third, and fourth magnet assembly 60 a-d of substantially the same configuration as provided by the embodiment of the magnet assembly 60 a of FIG. 19, though it is understood that any magnet assembly embodiment previously presented is suitable for the particular purpose. The magnet assemblies 60 a-d are carried and driven in rotation by a drive shaft 18 which itself is supported by a pair of pillow blocks 72, and held together as an assembly by a plurality of bushings 70, collars 71, and the pillow blocks 72 (one shown), substantially similar to the embodiment of FIG. 18, though it is understood that other support and retention means are suitable for the particular purpose. The magnet assemblies 60 a-d are spaced apart from each other a predetermined distance defining magnet assembly spaces 160, as previously presented and as will be explained further below. The magnet assemblies 60 a-d are coupled to the shaft 18 and rotate relative to the first and second half-conductor units 352 a,b when the shaft 18 is rotated. It is understood that in other embodiments, the magnet unit 62 comprises one or more magnet assemblies suitable for a particular purpose and complementary to the first and second half-conductor units 352 a,b.
The first and second half-conductor units 352 a,b together define a first, second and third conductor assembly 350 a-c each of which comprise a pair of two half-conductor assemblies: a pair of first half-conductor assemblies 350 a 1, 350 a 2, a pair of second half-conductor assemblies 350 b 1, 350 b 2, and a pair of third half-conductor assemblies 350 c 1, 350 c 2, respectively. The first half-conductor unit 352 a comprises one half-conductor assembly of each pair of half-conductor assemblies coupled together in spaced-apart, parallel arrangement and the second half-conductor unit 352 b comprises the other half-conductor assembly of each pair of half-conductor assemblies coupled together in spaced-apart, parallel arrangement. The first half-conductor unit 352 a, therefore, comprises the first half-conductor assembly 350 a 1, the second half-conductor assembly 350 b 1, and the third half-conductor assembly 350 c 1, and the second half-conductor unit 352 b comprises the first half-conductor assembly 350 a 2, the second half-conductor assembly 350 b 2, and the third half-conductor assembly 350 c 2. It is understood that in other embodiments, the first and second half-conductor units 352 a,b comprise one or more half-conductor assemblies suitable for a particular purpose and complementary to the magnet unit 62. The half-conductor assemblies 350 a 1,a2,b1,b2,c1,c2 comprise internal and external fluid handling means substantially similar to that described for the embodiment of FIG. 20.
The first and second half-conductor units 352 a,b are operable to translate transversely with respect to and on opposite sides of the axis of the drive shaft 18 between a first, disengaged position as shown in FIG. 24 and a second engaged position as shown in FIG. 25. The first and second half-conductor units 352 a,b are operable such that when translated towards the drive shaft 18, the corresponding pairs of half-conductor assemblies of each of the first, second and third conductor assemblies 350 a-c translate substantially co-planar towards each other until substantially adjacent each other in edge-to-edge orientation with each half-conductor assembly translating at least partially into the space between respective magnet assemblies 60 a-d.
The first and second half-conductor units 352 a,b comprise a means for translating respective half-conductor assemblies into and out of the space between corresponding magnet assemblies. In the embodiment of FIG. 23, the first and second half-conductor units 352 a,b comprise a plurality of slotted wheels 326: four wheels 326 on an upper side 332 of the first and second half-conductor units 352 a,b wherein the wheels' axes of rotation are substantially coplanar; and four wheels 326 on the lower side 333 of the first and second half-conductor units 352 a,b wherein the wheels' axes of rotation are substantially coplanar.
Two pairs of parallel tracks, upper tracks 238 a and lower tracks 328 b, are provided on the frame 312 and are operable to accept and guide the wheels 326 on the upper side 332 and the lower side 333 of the first and second half-conductor units 352 a,b, respectively. The tracks 328 a,b are substantially parallel with respect to each other and substantially perpendicular to the orientation of the axis of the drive shaft 18. The upper tracks 238 a are positioned on one side of the axis of the drive shaft 18 and the lower tracks 328 b are positioned on the opposite side of the axis of the drive shaft 18. The axis of rotation of the wheels 326 is substantially parallel with the axis of rotation of the drive shaft 18. The wheels 326 of the first and second half-conductor units 352 a,b are slidingly received onto opposite ends of the upper and lower tracks 328 a,b and are operable to translate along a portion of the length of the tracks 328, such that the first and second half-conductor units 352 a,b may translate substantially perpendicular to the axis of rotation of the drive shaft 18.
The split-conductor magnetic heater assembly 302 further comprises a drive means suitable for driving the first and second half-conductor units 352 a,b along the upper and lower tracks 328 a,b. The drive means shown in FIG. 23 comprises a motor 320, a screw drive shaft 322, and screw drive engagement element 324. The screw drive shaft 322 comprises a first shaft end 323 a having threads of a first direction and a second shaft end 323 b having threads of an opposite second direction. The screw drive shaft 322 is positioned parallel to the tracks 328 and perpendicular to the orientation of the axis of the drive shaft 18, such that the first and second shaft halves 323 a,b are on opposite sides of the axis of the drive shaft 18.
The motor 320 is operable to rotate the screw drive shaft 322 in a clockwise and counter-clockwise direction. Each screw-drive engagement element 324 is coupled to one of the first and second half-conductor units 352 a,b and engaged with one of the first and second shaft halves 323 a,b. The screw drive shaft 322 is threadably engaged with the screw-drive engagement elements 324 and operable such that when the screw-drive shaft 322 is rotated in a first direction, the first and second half-conductor units 352 a,b are driven towards each other and towards the drive shaft 18, and when rotated in a second, opposite direction, the first and second half-conductor units 352 a,b are driven away from each other and away from the drive shaft 18.
It is appreciated that one skilled in the art will recognize many other means for translating the first and second half-conductor units 352 a,b. Such other means include, but are not limited to, pulleys, gears, linear actuators, pneumatic and hydraulic cylinders, among many others. It is also understood that the first and second half-conductor units 352 a,b may be driven independently of each other by providing two drive means.
The length of the upper and lower tracks 328 a,b and thus the distance of travel of the first and second half-conductor units 352 a,b is predetermined to cover a range of travel such that at a first position, referred to as the disengaged position, the first and second half-conductor units 352 a,b are positioned away from the magnet assembly 60 as shown in FIG. 24, wherein they are substantially not magnetically engaged therewith, to a second, engaged position, wherein the first and second half-conductor units 352 a,b are interleaved with the magnet assembly 60, as shown in FIG. 25, where they are substantially magnetically engaged therewith.
The first, second, and third conductor assemblies 350 a-c, and the first, second, third, and fourth magnet assemblies 60 a-d are spaced apart a predetermined distance defining conductor plate spaces 150 and magnet assembly spaces 160, respectively, such that in the engaged position, each of the first, second, and third conductor assemblies 350 a-c are positioned in alternating, interleaved arrangement within the magnet assembly spaces 160 between the first, second, third, and fourth magnet assemblies 60 a-d. Each of the half-conductor assemblies 350 a 1,a2,b1,b2,c1,c2 further comprise a half-circular aperture 331 so as to accommodate the drive shaft 18 and/or bushings therein and not interfere therewith when the first and second half-conductor units 352 a,b are in the engaged position.
Magnetic engagement is defined as a conductor assembly at least partially under the influence of a magnetic field produced by a magnet assembly resulting when the conductor assembly and magnet assembly are at least partially in facing relationship. As discussed previously, the rotation of the magnet assembly adjacent the conductor assembly causes an eddy current to be set up in the conductor assembly due to the changing magnetic field produced by the movement of the magnets of the rotating magnet assembly. The current in the conductor assembly moves in such a way as to produce heat in the conductor assembly. The faster the magnet assembly is rotated, the stronger the currents induced in the conductor assembly and therefore the greater the heating of the conductor assembly.
The position of the first and second half-conductor units 352 a,b relative to the magnet unit 62 will determine the amount of heating of the first and second half-conductor units 352 a,b, from a minimum in the disengaged position to a maximum in the engaged position. As the first and second half-conductor units 352 a,b are translated over the range from the disengaged position to the engaged position, the amount of magnetic engagement with the magnet assemblies 60 a-d is increased, increasing the heating of the half conductor assemblies 350 a 1,a2,b1,b2,c1,c2 and thus the fluid passing therein. By selectively positioning the first and second half-conductor units 352 a,b along the upper and lower tracks 328 a,b, the heating of the first and second half-conductor units 352 a,b, and therefore the heat output of the split-conductor magnetic heater 304, can be controlled independently from the speed of rotation of the drive shaft 18.
In other embodiments of the magnetic heater, the first and second half-conductor units 352 a,b translate independently of each other, driven by separate drive means, providing various options for controlling heat output, such as, but not limited to, magnetically engaging or partially magnetically engaging one of the first and second half-conductor units 352 a,b.
In yet other embodiments, each of the first conductor assembly 350 a, second conductor assembly 350 b 1, and third conductor assembly 350 c, translate independently of each other, driven by separate drive means, providing various options for controlling heat output, such as, but not limited to, magnetically engaging or partially magnetically engaging one or more of the first, second and third conductor assembly 350 a, 350 b, 350 c.
In yet other embodiments, each of the half-conductor assemblies 350 a 1,a2,b1,b2,c1,c2, translate independently of each other, driven by separate drive means, providing various options for controlling heat output, such as, but not limited to, magnetically engaging or partially magnetically engaging one or more of the half-conductor assemblies 350 a 1,a2,b1,b2,c1,c2.
In yet other embodiments, the magnetic heater comprises one or more conductor assemblies that are not limited to pairs of half-conductor assemblies. In an embodiment, each of the first conductor assembly 350 a, second conductor assembly 350 b 1, and third conductor assembly 350 c, comprises one conductor assembly having a slot extending through an edge to beyond the center of the conductor assembly so as to allow the passing of the drive shaft therein when the conductor assembly is translated between a disengaged and engaged position.
FIG. 26 is a perspective view of a conductor assembly 450 comprising a slot 452, in accordance with an embodiment. The slot 452 extends through an edge to beyond the center of the conductor assembly 450 so as to allow the passing of the drive shaft therein when the conductor assembly is translated between a disengaged and engaged position.
It can be appreciated by those skilled in the art that the feature of translating half-conductor units, conductor assemblies, and half-conductor assemblies can be extended to other magnetic heater embodiments that do not necessarily have working fluid traversing within the conductor, such as, but not limited to, the embodiments of FIGS. 1, 6, 7 and 10, wherein the conductors are conductive members 14 in the form of solid plates.
FIGS. 27, 28, and 29 are perspective front and side views, respectively, of an engine-driven heat generation system 1230, in accordance with an embodiment. Referring again to FIG. 22, FIG. 22 is a schematic diagram of an embodiment of an engine-driven heat generation system 200 that is substantially similar to the engine-driven heat generation system 1230 of FIGS. 26, 27 and 28. The engine-driven heat generation system 1230 provides heat to external applications via a working fluid supplied to a suitable external heat exchanger 126 as previously described. The engine-driven heat generation system 1230 comprises an internal combustion engine 110, a split-conductor magnetic heater 304, such as, but not limited to, the embodiment of FIG. 23, and a fluid handling system 230. A drive coupling (not shown) of the engine 110 drives or rotates the drive shaft 18 and therefore the magnet unit 62 within the split-conductor magnetic heater 304 which in turn heats the first and second half-conductor units 352 a,b when magnetically engaged. In FIGS. 26, 27 and 28, the first and second half-conductor units 352 a,b are in the non-engaged position for clarity. When magnetically engaged in the engaged position, the first and second half-conductor units 352 a,b are heated, which in turn, heats the working fluid flowing therein.
The position of the first and second half-conductor units 352 a,b relative to the magnet unit 62 will determine the amount of heating of the working fluid inside of the half conductor assemblies 350 a 1,a2,b1,b2,c1,c2, from a minimum in the disengaged position to a maximum in the engaged position. As the first and second half-conductor units 352 a,b are translated from the disengaged position to the engaged position, the amount of magnetic engagement with the magnet unit 62 is increased, increasing the heating of the working fluid. By selectively positioning the first and second half-conductor units 352 a,b along the upper and lower tracks 328 a,b, the heating of the first and second half-conductor units 352 a,b, and therefore the heat output of the split-conductor magnetic heater 304 via the working fluid, can be controlled independent of the speed of rotation of the drive shaft 18.
The fluid handling system 230 comprises a working fluid handling system 220, an engine cooling system 112, and an exhaust system 229. The working fluid handling system 220 comprises a fluid reservoir 121, a manifold flow control 122, a pair of exhaust heat exchangers 123 a,b, a coolant heat exchanger 124, and one or more circulating pumps (not shown), all in fluid communication operable to circulate the working fluid therein. The manifold flow control 122 is operable to direct the working fluid to the half conductor assemblies 350 a 1,a2,b1,b2,c1,c2 of the split-conductor magnetic heater 304, among other components. The fluid reservoir 121 further comprises a supply coupling 155 and return coupling 153 for coupling in fluid communication with a remote heat exchanger (not shown).
The heat generated by the split-conductor magnetic heater 304 is transferred to the working fluid passing within the first and second half-conductor units 352 a,b. The first and second half-conductor units 352 a,b are coupled to the fluid reservoir 121 and manifold flow control 122 via flexible hoses 362 that are operable to accommodate for the movement of the first and second half-conductor units 352 a,b. The external manifold (not shown) is operable to provide one or more fluid take-offs to supply the heated working fluid to one or more external heat exchangers (not shown) previously described in reference to FIG. 22, and return cooled working fluid to the fluid reservoir 121.
The engine cooling system 112 comprises a coolant reservoir 114 for a coolant fluid in fluid communication with the engine 110 and the coolant heat exchanger 124. The manifold flow control 122 is also operable to direct the working fluid to the coolant heat exchanger 124. The coolant fluid circulates within the engine 110, wherein the heat from the structure of the engine 110 is transferred to the coolant fluid and subsequently transferred to the working fluid in the coolant heat exchanger 124. The coolant heat exchanger 124 is coupled to the manifold flow control 122 and the fluid reservoir 121. In this way, the heat from the engine 110 as well as the heat from the split-conductor magnetic heater 304 is used to heat the working fluid.
The engine 110 produces hot exhaust gas as a product of combustion which is directed external to the engine 110 by an exhaust manifold 128 (not shown in FIGS. 26-28). The exhaust system 229 comprises a pair of exhaust heat exchangers 123 a,b which are in fluid communication with the exhaust manifold 128 and are operable to transfer the heat from the exhaust of the engine 110 to the working fluid. The manifold flow control 122 is also operable to direct the working fluid to the exhaust heat exchangers 123 a,b which in turn directs the working fluid to the fluid reservoir 121. In this way, the heat from the exhaust, heat from the engine coolant, as well as the heat from the split-conductor magnetic heater 304 is used to heat the working fluid.
It is appreciated that a variety of configurations of an engine-driven heat generation system may be utilized, depending on engineering design preferences and constraints.
The feature of being able to translate the first and second half-conductor units 352 a,b into and out of magnetic engagement with the magnet assembly 60 provides a number of significant advantages. One advantage is in terms of drive performance at start up. Where the conductor assemblies are not translatable with respect to the magnet assemblies, at all times, but particularly at engine startup, the conductor assemblies are magnetically engaged with the magnet assemblies, that is, the magnet assemblies are magnetically attracted to the conductor assemblies. The engine at startup must therefore overcome the magnetic attraction between the conductor assembly and the magnet assemblies that occurs in the rest state, referred to as startup torque, requiring a larger engine torque to overcome the startup torque. Where the first and second half-conductor units 352 a,b are disengaged from the magnet assembly 60 at startup, as provided in accordance with the embodiments and as shown in FIG. 26, there is no magnetic torque for the engine to overcome at startup and therefore, a smaller engine with a lower torque may be used.
As discussed previously, the rotation of the magnet assembly adjacent the conductor assembly causes an eddy current to be set up in the conductor assembly due to the changing magnetic field produced by the movement of the magnets of the rotating magnet assembly. In accordance with Lenz's law, the current in the conductor assembly moves in such a way as to create a magnetic field opposing the changing magnetic field produced by the movement of the magnets, resulting in producing heat in the conductor assembly, but also producing a resistance to rotation, referred herein as magnetic torque, against which the drive means rotating the magnet assembly must work against (this discussion neglects the magnetic attraction of the conductor assembly to the magnet assembly experienced whether the magnet assembly is rotating or not). The faster the magnet assembly is rotated, the stronger the currents induced in the conductor assembly and therefore the stronger the magnetic torque which must be overcome.
The magnetic torque is an important consideration when specifying the drive means for rotating a particular magnet assembly having a predetermined magnetic field strength to a predetermined rotation speed. Wherein the magnet assemblies is coupled directly to the engine drive shaft and that the conductor assemblies are always magnetically engaged with and not translatable with respect to the magnet assemblies, the drive means must be able to produce sufficient torque to overcome the magnetic torque from rest to the desired rotation speed. An efficient configuration would provide a drive means capable of producing slightly more torque than what is required for the range of rotation speed. This is not easy to achieve for many drive means.
To explain further by way of example, an internal combustion engine of a given size may have a torque versus rotation speed curve that does not match the magnetic torque versus rotation speed curve for the magnetic heater. One of the engine or magnetic torques may have a greater slope of the torque versus rotation speed curve and/or the slope is not linear. A particular engine may have a preferred speed at which it operates efficiently and safely, for example, 2400 RPM (revolutions per minute). Assume that the magnet assembly is directly coupled to the engine drive shaft and that the conductor assemblies are always magnetically engaged with and not translatable with respect to the magnet assemblies. As the engine speed increases to a certain rotation speed for a particular engine/magnetic heater configuration, a speed that is below the preferred speed of 2400 RPM, say 1200 RPM, the magnetic torque becomes the same as the engine torque, at which point the engine will stall.
One way to overcome the stall condition is to provide a clutch on the drive shaft between the engine and the magnet assembly, the clutch operable to engage and start the rotation of the magnet assembly after the engine attains a rotation speed above 1200 RPM so as to prevent the magnet torque from ever being the same or greater than the engine torque and thus prevent the engine from stalling. The clutch could be provided that engages the magnet assembly at the preferred rotation speed, 2400 RPM in this example, but a clutch capable of handling higher speeds and greater engine torques are large, heavy and expensive. The use of a clutch that engages the magnet assembly below the preferred rotation speed is likely to cause a mismatch of engine torque to magnetic torque at the preferred engine speed of 2400 RPM due to the mismatched torque versus rotation speed curves, and thus the system will be less efficient as the engine will be producing excess torque.
Another way to overcome the stall condition is to provide an engine that supplies engine torque that is always greater than the magnetic torque over the range up to the preferred rotation speed. Again, it is likely that there will be a greater mismatch of engine torque to magnetic torque at the preferred engine speed of 2400 RPM and thus the system will be less efficient.
Another way to overcome the stall condition as well as the inefficient operation at the preferred rotation speed is to provide a magnetic heater comprising a movable conductive assembly and having a magnetic torque optimally matched to the engine torque at the preferred rotation speed of the engine, and magnetically engaging the conductor assembly with the magnet assembly at a rotation speed greater than any rotation speed that would produce a magnetic torque equal to or greater than the engine torque that would cause the engine to stall, in accordance with an embodiment of a method. In the above example, the conductor assembly would engage the magnet assembly at a rotation speed above 1200 RPM sufficient to prevent the rotation speed from falling below the rotation speed required to maintain an engine torque greater than the magnetic torque. At the lower rotation speeds, the conductor assembly would be in the disengaged position wherein there is no magnetic engagement between the conductor assembly and the magnet assembly. At a predetermined rotation speed above which the engine torque is always greater than the magnetic torque, the conductor assembly is brought into magnetic engagement with the magnet assembly.
In accordance with embodiments, a split-conductor magnetic heater 304 of the embodiment of FIG. 23 is operable to provide a magnetic torque that is optimized for efficient operation of a chosen engine, that is, a magnetic torque less than but closely approaching the engine torque at the preferred operating speed of the engine. The engine is started and brought up to the preferred speed with the first and second half-conductor units 352 a,b in the disengaged position. The first and second half-conductor units 352 a,b are then translated to the engaged position. At shut-down, the first and second half-conductor units 352 a,b are translated to the disengaged position, and the engine is shut down.
Further, by virtue of the ability of translating the first and second half-conductor units 352 a,b into and out of magnetic engagement with the magnet unit 62, the heat output can be varied without changing the speed of the engine 110. Therefore the engine 110 can be driven at its optimal speed and the heat output of the split-conductor magnetic heater 304 can be controlled by the drive means translating the first and second half-conductor units 352 a,b into a predetermined amount of magnetic engagement with the magnet unit 62.
FIGS. 30, 31 and 32 are partially exploded and two assembled perspective views, respectively, of a transverse-moving magnet magnetic heater assembly 402 comprising a transverse-moving magnet magnetic heater 404 and a frame 312, in accordance with an embodiment. The frame 312 is operable to support various elements of the transverse-moving magnet magnetic heater 404 as well as providing a platform for ancillary components of a larger system. The transverse-moving magnet magnetic heater 404 comprises a conductor plate assembly 354 and a first half-magnet unit 162 a and a second half-magnet unit 162 b in opposing relationship to each other. The first and second half-magnet units 162 a,b are operable to move laterally into and out of conductor plate spaces 150 defined by the conductor plate assembly 354 and thus, moving the first and second half-magnet units 162 a,b substantially into and out of magnetic engagement with the conductor plate assembly 354, as will be explained below.
In the embodiment of FIGS. 30-32, the conductor plate assembly 354 comprises a first, second, third, and fourth conductor plates 350 a-d. The conductor plates 350 a-d are substantially similar to conductive member 14 of the embodiment of FIGS. 3 and 6 and, similarly, comprises an electrically conductive material suitable for the particular purpose. In other embodiments, the conductor plates 350 a-d may be a part of an air handling system such as shown in FIGS. 14A-B as a blower fan 134 comprising a plurality of fan blades 198 coupled to the conductive member 14.
The conductor plates 350 a-d are carried and driven in rotation by a drive shaft 18 which itself is supported by a pair of pillow blocks 72 (one shown), and held together as an assembly by a plurality of bushings 70, collars 71, and the pillow blocks 72, substantially similar to the embodiment of FIG. 18, though it is understood that other support and retention means are suitable for the particular purpose. The conductor plates 350 a-d are spaced apart from each other a predetermined distance defining conductor plate spaces 150 therebetween, as will be explained further below. The conductor plates 350 a-d are coupled to the drive shaft 18 and rotate relative to the first and second half-magnet units 162 a,b when the drive shaft 18 is rotated. It is understood that in other embodiments, the conductor plate assembly 354 comprises one or more conductor plates 350 suitable for a particular purpose and complementary to the first and second half-magnet units 162 a,b.
The first and second half-magnet units 162 a,b together define a first, second and third magnet assembly 160 a-c each of which comprise a pair of two half-magnet assemblies: the first magnet assembly 160 a comprising a pair of first half-magnet assemblies 160 a 1, 160 a 2; the second magnet assembly 160 b comprising a pair of second half-magnet assemblies 160 b 1, 160 b 2; and the third magnet assembly 160 c comprising a pair of third half-magnet assemblies 160 c 1, 160 c 2, respectively. The first half-magnet unit 162 a comprises the first half-magnet assembly 160 a 1, the second half-magnet assembly 160 b 1, and the third half-magnet assembly 160 c 1 coupled together in spaced-apart, parallel arrangement. The second half-magnet unit 162 b comprises the first half-magnet assembly 160 a 2, the second half-magnet assembly 160 b 2, and the third half-magnet assembly 160 c 2 coupled together in spaced-apart, parallel arrangement. It is understood that in other embodiments, the first and second half-magnet units 162 a,b comprise one or more half-magnet assemblies suitable for a particular purpose and complementary to the conductor plate assembly 354.
Each of the half-magnet assemblies 160 a 1,a2,b1,b2,c1,c2 comprises a frame 22 and one or more magnets 12. The magnets 12 are coupled to and arranged in a planar, generally semi-circular, spaced-apart, orientation on the frame 22. The magnets 12 each have a first magnet surface 13 in a substantially planar relationship, referred herein as the first magnet plane 21, substantially as shown in FIG. 1.
The first and second half-magnet units 162 a,b are operable to translate transversely with respect to and on opposite sides of the axis of the drive shaft 18 between a first, disengaged position as shown in FIG. 31 and a second engaged position as shown in FIG. 32. The first and second half-magnet units 162 a,b are operable such that when translated towards the drive shaft 18, the corresponding pairs of half-magnet assemblies of each of the first, second and third magnet assemblies 160 a-c translate substantially co-planar towards each other until substantially adjacent each other in edge-to-edge orientation with each half-magnet assembly translating at least partially into the conductor plate spaces 150 between respective conductor plates 350 a-d.
The first and second half-magnet units 162 a,b comprise a means for translating respective half-magnet assemblies 160 a 1,a2,b1,b2,c1,c2 into and out of the space between corresponding conductor plates. In the embodiment of FIG. 30, the first and second half-magnet units 162 a,b comprise a plurality of wheels 326: four wheels 326 on an upper side 332 of the first and second half-magnet units 162 a,b wherein the wheels' axes of rotation are substantially coplanar; and four wheels 326 on the lower side 333 of the first and second half-magnet units 162 a,b wherein the wheels' axes of rotation are substantially coplanar.
Two pairs of parallel tracks, upper tracks 328 a and lower tracks 328 b, are provided on the frame 312 and are operable to accept and guide the wheels 326 on the upper side 332 and the lower side 333 of the first and second half-magnet units 162 a,b, respectively. The tracks 328 a,b are substantially parallel with respect to each other and substantially perpendicular to the orientation of the axis of the drive shaft 18. The upper tracks 328 a are positioned on one side of the drive shaft 18 and the lower tracks 328 b are positioned on the opposite side of the drive shaft 18. The axis of rotation of the wheels 326 is substantially parallel with the axis of rotation of the drive shaft 18. The wheels 326 of the first and second half-magnet units 162 a,b are slidingly received onto opposite ends of the upper and lower tracks 328 a,b and are operable to translate along a portion of the length of the tracks 328, such that the first and second half-magnet units 162 a,b may translate substantially perpendicular to the axis of rotation of the drive shaft 18.
The transverse-moving magnet magnetic heater assembly 402 further comprises a drive means suitable for driving the first and second half-magnet units 162 a,b along the upper and lower tracks 328 a,b. The drive means shown in FIG. 30 comprises a motor 320, a screw drive shaft 322, and screw-drive engagement element 324. The screw drive shaft 322 comprises a first shaft end 323 a having threads of a first direction and a second shaft end 323 b having threads of an opposite second direction. The screw drive shaft 322 is positioned parallel to the tracks 328 and perpendicular to the orientation of the axis of the drive shaft 18, such that the first and second shaft halves 323 a,b are on opposite sides of the axis of the drive shaft 18.
The motor 320 is operable to rotate the screw drive shaft 322 in a clockwise and counter-clockwise direction. Each screw-drive engagement element 324 is coupled to one of the first and second half-magnet units 162 a,b and engaged with one of the first and second shaft halves 323 a,b. The screw-drive shaft 322 is threadably engaged with the screw-drive engagement elements 324 and operable such that when the screw-drive shaft 322 is rotated in a first direction, the first and second half-magnet units 162 a,b are driven towards each other and towards the drive shaft 18, and when rotated in a second, opposite direction, the first and second half-magnet units 162 a,b are driven away from each other and away from the drive shaft 18.
It is appreciated that many other means for translating the first and second half-magnet units 162 a,b. Such other means include, but are not limited to, pulleys, gears, linear actuators, pneumatic and hydraulic cylinders, among many others. It is also understood that the first and second half-magnet units 162 a,b may be driven independently of each other by providing two drive means.
The length of the upper and lower tracks 328 a,b and thus the distance of travel of the first and second half-magnet units 162 a,b is predetermined to cover a range of travel such that at a first position, referred to as the disengaged position, the first and second half-magnet units 162 a,b are positioned away from the conductor plate assembly 354 as shown in FIG. 31, wherein they are substantially not magnetically engaged therewith, to a second, engaged position, wherein the first and second half-magnet units 162 a,b are interleaved with the conductor plate assembly 354, as shown in FIG. 32, where they are substantially magnetically engaged therewith.
The first, second, and third magnet assemblies 160 a-c, and the first, second, third, and fourth conductor plates 350 a-d are spaced apart a predetermined distance defining magnet assembly spaces 160 and conductor plate spaces 150, respectively, such that in the engaged position, each of the first, second, and third magnet assemblies 160 a-c are positioned in alternating, interleaved arrangement within the conductor plate spaces 150 between the first, second, third, and fourth conductor plates 350 a-d. Each of the half-magnet assemblies 160 a 1,a2,b1,b2,c1,c2 further comprise a half-circular aperture 331 so as to accommodate the drive shaft 18 and/or bushings therein and not interfere therewith when the first and second half-magnet units 162 a,b are in the engaged position.
Magnetic engagement is defined as a conductor assembly at least partially under the influence of a magnetic field produced by a magnet assembly resulting when the conductor assembly and magnet assembly are at least partially in facing relationship. As discussed previously, the rotation of the conductor plates adjacent the magnet assembly causes an eddy current to be set up in the conductor plates due to the changing magnetic field produced by the rotation of the conductor plates relative to the magnet assembly. The current in the conductor plates moves in such a way as to produce heat in the conductor plates. The faster the conductor plates are rotated, the stronger the currents induced in the conductor plates and therefore the greater the heating of the conductor plates.
The position of the first and second half-magnet units 162 a,b relative to the conductor plate assembly 354 will determine the amount of heating of the conductor plates, from a minimum in the disengaged position to a maximum in the engaged position. As the first and second half-magnet units 162 a,b are translated over the range from the disengaged position to the engaged position, the amount of magnetic engagement of the conductor plates with the magnet assemblies 160 a-d is increased, increasing the heating of the conductor plates 350 a-d and thus the fluid passing adjacent therewith. By selectively positioning the first and second half-magnet units 162 a,b along the upper and lower tracks 328 a,b, the heating of the conductor plates 350 a-d, and therefore the heat output of the transverse-moving magnet magnetic heater 404, can be controlled independently from the speed of rotation of the drive shaft 18.
In accordance with other embodiments of the magnetic heater, the first and second half-magnet units 162 a,b translate independently of each other, driven by separate drive means, providing various options for controlling heat output, such as, but not limited to, magnetically engaging or partially magnetically engaging one of the first and second half-magnet units 162 a,b with the conductor plates 350 a-d.
In accordance with yet other embodiments, each of the first magnet assembly 160 a, second magnet assembly 160 b, and third magnet assembly 160 c, translate independently of each other, driven by separate drive means, providing various options for controlling heat output, such as, but not limited to, magnetically engaging or partially magnetically engaging one or more of the first, second, third and fourth conductor plates 350 a, 350 b, 350 c, 350 d.
In yet other embodiments, each of the half-magnet assemblies 160 a 1,a2,b1,b2,c1,c2, translate independently of each other, driven by separate drive means, providing various options for controlling heat output, such as, but not limited to, magnetically engaging or partially magnetically engaging one or more of the half-magnet assemblies 160 a 1,a2,b1,b2,c1,c2.
It is appreciated that, as with the embodiment of the conductor assembly 450 of FIG. 26, in yet other embodiments, the magnetic heater comprises one or more magnet assemblies having a slot extending through an edge to beyond the center of the magnet assembly so as to allow the passing of the drive shaft therein when the magnet assembly is translated between a disengaged and engaged position.
It is appreciated that the feature of translating half-magnet units, magnet assemblies, and half-magnet assemblies can be extended to other magnetic heater embodiments, so as to move the magnets from engagement to disengagement with the conductor plates to control heat output. As discussed previously, the rotation of the conductor plates 350 a-d adjacent the magnet assemblies 160 a 1,a2,b1,b2,c1,c2 causes an eddy current to be set up in the conductor plates 350 a-d due to the changing magnetic field produced by the movement of the conductor plates 350 a-d of the rotating conductor plate assembly 354. In accordance with Lenz's law, the current in the conductor plates 350 a-d moves in such a way as to create a magnetic field opposing the changing magnetic field produced by the movement of the conductor plates 350 a-d relative to the stationary magnet assemblies 160 a 1,a2,b1,b2,c1,c2, resulting in producing heat in the conductor plates 350 a-d. Also as previously discussed, the heat of the conductor plates 350 a-d may be used to heat a working fluid that is driven with a suitable fluid handling system.
Substantially similar to the split-conductor magnetic heater assembly 302 of FIGS. 23, 24 and 25 comprising a split-conductor magnetic heater 304, the feature of being able to translate the first and second half-magnet units 162 a,b into and out of magnetic engagement with the conductor plates 350 a-d provides a number of significant advantages as described previously, such as, but not limited to, control of heat output and reduced startup torque requirements.
FIGS. 33, 34, and 35 are perspective, front, and side views, respectively, of an engine-driven heat generation system 1330, in accordance with an embodiment. Referring again to FIG. 22, FIG. 22 is a schematic diagram of an embodiment of an engine-driven heat generation system 200 that is substantially similar to the engine-driven heat generation system 1330 of FIGS. 33, 34, and 35. The engine-driven heat generation system 1330 provides heat to external applications via a secondary working fluid that exchanges heat from the transverse-moving magnet magnetic heater 404 and heat generated by an engine 110 via heat exchangers associated with an engine cooling system 112 and an exhaust system 229. The heat generated by the transverse-moving magnet magnetic heater 404 is transferred to the secondary working fluid passing within the conductor plate assembly 354. The secondary working fluid is driven through the engine-driven heat generation system 1330 by a secondary fluid handling system (not shown for clarity) such as the blower fan 134 of the embodiment of FIG. 14A.
The engine-driven heat generation system 1330 comprises an internal combustion engine 110, a transverse-moving magnet magnetic heater 404, such as, but not limited to, the embodiment of FIG. 31, and a fluid handling system 230. A drive coupling (not shown) of the engine 110 drives or rotates the drive shaft 18 and therefore the conductor plate assembly 354 within the split-magnet magnetic heater 404 which in turn heats the conductor plate assembly 354 when magnetically engaged. In FIGS. 33, 34, and 35, the first and second half-magnet units 60 a,b are in the non-magnetically engaged position for clarity. When magnetically engaged in the magnetically engaged position, the conductor plate assembly 354 is heated, which in turn, heats a secondary working fluid adjacent the conductor plates 350 a-d. At least a portion of the heat generated by the engine 110 is transferred to the secondary working fluid via the exhaust heat exchanger 123 a and the engine coolant heat exchanger 124.
The position of the first and second half-magnet units 60 a,b relative to the conductor plate assembly 354 will determine the amount of heating of the secondary working fluid by the transverse-moving magnet magnetic heater 404, from a minimum in the magnetically disengaged position to a maximum in the magnetically engaged position. As the first and second half-magnet units 60 a,b are translated from the magnetically disengaged position to the magnetically engaged position, the amount of magnetic engagement with the conductor plate assembly 354 is increased, increasing the heating of the secondary working fluid. By selectively positioning the first and second half-magnet units 60 a,b along the upper and lower tracks 328 a,b, the heating of the conductor plate assembly 354, and therefore the heat output of the split-magnet magnetic heater 404 via the secondary working fluid can be controlled independent of the speed of rotation of the drive shaft 18.
The fluid handling system 220 comprises an engine cooling system 112, and an exhaust system 229. The working fluid handling system 220 comprises a fluid reservoir 121, a manifold flow control 122, a pair of exhaust heat exchangers 123 a,b, a coolant heat exchanger 124, and one or more circulating pumps (not shown), all in fluid communication operable to circulate the working fluid therein. The manifold flow control 122 is operable to direct the working fluid through the engine cooling system 112 and exhaust system 229.
The engine cooling system 112 comprises a coolant reservoir 114 for a coolant fluid in fluid communication with the engine 110 and the coolant heat exchanger 124. The manifold flow control 122 is operable to direct the working fluid to the coolant heat exchanger 124. The coolant fluid circulates within the engine 110, wherein the heat from the structure of the engine 110 is transferred to the coolant fluid and subsequently transferred to the secondary working fluid in the coolant heat exchanger 124. The coolant heat exchanger 124 is coupled to the manifold flow control 122 and the fluid reservoir 121. In this way, the heat from the engine 110 as well as the heat from the transverse-moving magnet magnetic heater 404 is used to heat the secondary working fluid.
The engine 110 produces hot exhaust gas as a product of combustion which is directed external to the engine 110 by an exhaust manifold 128 (not shown in FIGS. 33-35). The exhaust system 229 comprises a pair of exhaust heat exchangers 123 a,b which are in fluid communication with the exhaust manifold 128 and are operable to transfer the heat from the exhaust of the engine 110 to the working fluid. The manifold flow control 122 is also operable to direct the working fluid to the exhaust heat exchangers 123 a,b which in turn directs the working fluid to the fluid reservoir 121. In this way, the heat from the exhaust, heat from the engine coolant, as well as the heat from the transverse-moving magnet magnetic heater 404 is used to heat the secondary working fluid.
It is appreciated that a variety of configurations of an engine-driven heat generation system may be utilized, depending on engineering design preferences and constraints.
It is anticipated that many mechanical apparatus may be operable to move the magnets into and out of engagement with the conductor plates. The embodiment of lateral movement along a linear track as shown in FIGS. 30-35 is but one example. Mechanical linkages and/or pivots may also be used in combination with motors and linear actuators, for example, to move the magnets into and out of engagement with the conductor plates in a pivoting, lateral, and/or other translational movement, by way of examples.
FIG. 36 is an exploded view of a magnet unit 262 comprising a plurality of pivotal magnet assemblies 260, in accordance with an embodiment. Each pivotal magnet assembly 260 comprises an arm 266 having an arm first end 261 and an arm second end 263. The pivotal magnet assembly 260 further comprises one or more magnets coupled to the arm second end 263. The pivotal magnet assembly 260 further comprises a pivot element 265 between the arm first end 261 and the arm second end 263 operable to receive a pivot pin 269 therein. The magnet unit 262 of the embodiment of FIG. 36 comprises a first, second and third magnet assembly 262 a-c. The first, second and third pivotal magnet assemblies 262 a-c are operable to pivot about a pivot axis X. In accordance with an embodiment, the first, second and third pivotal magnet assemblies 262 a-c are fixed to the pivot pin 269 that passes through each of the pivot elements 265 and operable such that the first, second and third magnet assemblies 262 a-c rotate simultaneously about the pivot axis P when the pivot pin is rotated. In accordance with another embodiment, each of the first, second and third pivotal magnet assemblies 262 a-c pivot independently about the pivot axis P, driven independently by an actuator (not shown).
FIGS. 37 and 38 are perspective views of a pivoting-magnet magnetic heater assembly 502 comprising a pivoting-magnet magnetic heater 504 and a frame 312, in a magnetically disengaged and magnetically engaged configuration, respectively, in accordance with an embodiment. The frame 312 is operable to support various elements of the pivoting-magnet magnetic heater 504 as well as providing a platform for ancillary components of a larger system. The pivoting-magnet magnetic heater 504 comprises a conductor plate assembly 554 and at least one magnet unit 262.
In the embodiment of FIGS. 37 and 38, the conductor plate assembly 454 comprises a first, second, third, and fourth conductor plates 450 a-d. The conductor plates 350 a-d are coaxial and spaced apart from each other a predetermined distance defining conductor plate spaces 150, as will be explained further below. The conductor plates 450 a-d are coupled to the drive shaft 18 by a plurality of spokes 470 and rotate relative to the magnet unit 262 when the drive shaft 18 is rotated. It is understood that in other embodiments, the conductor plate assembly 454 comprises one or more conductor plates 450 suitable for a particular purpose and complementary to the number of pivotal magnet assemblies 260 in the magnet unit 262. By way of example, wherein there is one conductor plate 350, there may be one or two pivotal magnet assemblies 260 on either side of the conductor plate 350.
The conductor plates 450 a-d are coupled to a drive shaft 18 by a plurality of spokes 470. The conductor plates 450 a-d define an annular passage 493 between the spokes 470 such that air may enter the annular passage 493 from a substantially axial direction and driven substantially radially outwardly from the conductor plate spaces 150 driven by fins 472 carried and driven in rotation by the drive shaft 18.
The magnet unit 262 is operable to pivotally move a first end 261 of one or more of the pivotal magnet assemblies 260 into and out of a corresponding conductor plate space 150 between and beside the conductor plates 450 a-d defined by the conductor plate assembly 454 and thus, moving the magnets 12 substantially into and out of magnetic engagement with the conductor plate assembly 454, as will be explained below.
The magnet unit 262 is operable to translate the pivotal magnet assemblies 266 a-c in a pivoting motion transversely with respect to the axis of the drive shaft 18 between a first, disengaged position as shown in FIG. 37 and a second engaged position as shown in FIG. 38. The pivotal magnet assemblies 266 a-c are operable such that when translated towards the drive shaft 18, the corresponding magnets 12 translate at least partially into respective conductor plate spaces 150 between and adjacent to respective conductor plates 450 a-d.
The pivoting-magnet magnetic heater assembly 502 further comprises a drive means suitable for driving the pivotal magnet assemblies 266 a-c into and out of engagement with the conductor plates 350 a-d. In the embodiment of FIGS. 38 and 39, pivoting-magnet magnetic heater assembly 502 further comprises a linear actuator 267 operable to engage the arm first end 261 of one or more of the pivotal magnet assemblies 266 a-c. The pivotal magnet assemblies 266 a-c are pivotally coupled to the frame 312 about a common pivot axis P.
The distance of travel of the magnet assemblies 263 a-c is predetermined to cover a range of travel such that at a first position, referred to as the disengaged position, the magnet assemblies 263 a-c are positioned away from the conductor plates 450 a-d as shown in FIG. 37, wherein they are substantially not magnetically engaged therewith, to a second, engaged position, wherein the magnet assemblies 263 a-c are interleaved with the conductor plate assembly 454, as shown in FIG. 38, where they are substantially magnetically engaged therewith.
Movement of the linear actuator 267 from an extended position to a retracted position provides movement of the magnets 12 from a disengaged position to an engaged position with the conductor plates 450 a-d, and visa versa. The degree of extension of the linear actuator 267 may be controlled such that the degree of movement, and thus, engagement of the magnets 12 with the conductor plates 450 a-d and therefore the level of heat output of the magnetic heater 502 may be controlled.
In yet other embodiments, each of the first pivotal magnet assembly 260 a, second pivotal magnet assembly 260 b, and third pivotal magnet assembly 260 c, move independently of each other, driven by separate drive means, providing various options for controlling heat output, such as, but not limited to, magnetically engaging or partially magnetically engaging one or more of the first, second, third and fourth conductor plates 450 a, 450 b, 450 c, 450 d.
In yet other embodiments, the magnetic heater comprises a plurality of magnet units 262.
The drive means shown in FIGS. 37-38 comprises a linear actuator 267. It is appreciated that other drive means for translating the magnet assemblies 260 a-c may be used. Such other means include, but are not limited to, levers, pulleys, gears, motors, linear actuators, pneumatic and hydraulic cylinders, among many others, and in combination, as well as operable to be manually manipulated. It is also understood that each magnet assembly 260 a-c may be driven independently of each other.
Although specific embodiments have been illustrated and described herein for purposes of description of the preferred embodiment, it will be appreciated by those of ordinary skill in the art that a wide variety of alternate and/or equivalent implementations calculated to achieve the same purposes may be substituted for the specific embodiments shown and described without departing from the scope of the present invention. Those with skill in the art will readily appreciate that the present invention may be implemented in a very wide variety of embodiments. This application is intended to cover any adaptations or variations of the embodiments discussed herein.
Persons skilled in the art will recognize that many modifications and variations are possible in the details, materials, and arrangements of the parts and actions which have been described and illustrated in order to explain the nature of this invention and that such modifications and variations do not depart from the spirit and scope of the teachings and appended claims contained.

Claims

1. A magnetic heater, comprising:

a drive shaft defining a drive shaft axis and operable to rotate with respect to the drive shaft axis, the drive shaft defining a drive shaft first side and a drive shaft second side opposite the drive shaft first side;

a conductor plate unit comprising at least one conductor plate, the conductor plate comprises an electrically conductive material operable to enable inductive heating within the conductor plate when exposed to a time-varying magnetic flux;

at least one magnet unit comprising at least one magnet assembly, the magnet assembly being operable to provide time-varying magnetic flux to the conductor plate when the conductor plate moves relative to the magnet assembly, the magnet assembly comprises at least one magnet, wherein the magnet assembly is operable to dispose the magnet in close proximity to the conductor plate; and

drive means operable for translating the magnet assembly transversely with respect to the drive shaft axis between a magnetically disengaged position wherein the magnet is out of opposing spaced apart facing relationship with the conductor plate and a magnetically engaged position wherein the magnet is at least partially in opposing spaced apart facing relationship with the conductor plate,

the conductor plate being coupled to the drive shaft such that the conductor plate rotates relative to the magnet assembly when the drive shaft is caused to rotate.

2. The magnetic heater of claim 1, comprising a first magnet unit adjacent the drive shaft first side and a second magnet unit adjacent the drive shaft second side, wherein the first magnet unit and the second magnet unit are operable to translate towards and away from each other transversely with respect to the drive shaft axis.

3. The magnetic heater of claim 1, wherein the conductor plate unit comprises a plurality of conductor plates being parallel and spaced apart a predetermined distance from each other defining conductor plate spaces therebetween,

wherein the magnet unit comprises a plurality of magnet assemblies being parallel and spaced apart a predetermined distance from each other, the magnet unit operable such that in the magnetically engaged position each of the plurality of magnet assemblies are positioned in alternating interleaved arrangement placing the magnet at least partially within the conductor plate space between each of the plurality of conductor plates.

4. The magnetic heater of claim 1, further comprising two upper tracks and two lower tracks, the upper tracks and lower tracks being substantially parallel with respect to each other and substantially perpendicular to the drive shaft axis defined by the drive shaft, the upper tracks being located adjacent the drive shaft first side and the lower tracks being located adjacent the drive shaft second side,

the magnet unit further comprising an upper side and a lower side opposite the upper side, and a plurality of wheels pivotally coupled to the upper side and a plurality of wheels pivotally coupled to the lower side, the upper and lower tracks operable to receive and guide the wheels in translation along a portion of a length of the upper and lower tracks such that the magnet unit may translate substantially perpendicular to the drive shaft axis defined by the drive shaft.

5. The magnetic heater of claim 1, further comprising a pivot actuator,

wherein the magnet assembly comprises an arm having an arm first end and an arm second end opposite the arm first end, the at least one magnet being coupled to the arm second end, the magnet assembly further comprising a pivot element between the arm first end and the arm second end operable to facilitate pivoting motion of the arm in a first direction and a second direction opposite the first direction,

the pivot actuator operable to pivot the arm between the magnetically disengaged position with the magnet being out of opposing spaced apart facing relationship with the conductor plate and the magnetically engaged position with the magnet translating at least partially in opposing spaced apart facing relationship with the conductor plate.

6. The magnetic heater of claim 3, further comprising a pivot actuator,

wherein each of the plurality of magnet assemblies comprises an arm having an arm first end and an arm second end opposite the arm first end, the at least one magnet being coupled to the arm second end, the magnet assembly further comprising a pivot element between the arm first end and the arm second end operable to facilitate pivoting motion of the arm in a first direction and a second direction opposite the first direction,

the pivot actuator is operable to pivot each of the arms between the magnetically disengaged position with the plurality of magnet assemblies being out of opposing spaced apart facing relationship with the conductor plate and the magnetically engaged position wherein each of the plurality of magnet assemblies are positioned in alternating interleaved arrangement translating the magnet at least partially within the conductor plate space between each of the plurality of conductor plates.

7. The magnetic heater of claim 6, wherein the magnet unit further comprises a pivot shaft defining a pivot axis, wherein the plurality of magnet assemblies are coupled to the pivot shaft via the pivot element and operable such that the plurality of magnet assemblies pivot simultaneously about the pivot axis when the pivot shaft is rotated.

8. The magnetic heater of claim 7, wherein the pivot actuator comprises a linear actuator having a fixed end and an extendable end opposite the fixed end, the extendable end being coupled to the arm, wherein movement of the extendable end from an extended position to a retracted position rotates the arm moving of the magnet between the magnetically disengaged position and magnetically engaged position.

9. The magnetic heater of claim 6, wherein the pivot actuator is operable to independently pivot each of the plurality of magnet assemblies.

10. The magnetic heater of claim 6, wherein the conductor plate comprises a plurality of spokes radiating from about a center of the conductor plate, the conductor plate being coupled to the drive shaft by the plurality of spokes.

11. The magnetic heater of claim 10, further comprising a fluid driver element operable for moving a working fluid through the annular passage and through the conductor plate spaces.

12. The magnetic heater of claim 11, wherein the fluid driver element comprises at least one fin projecting from the drive shaft between the conductor plates and adjacent the spokes, the fins driven in rotation by the drive shaft and operable to move air in through the annular passage from a substantially axial direction and substantially radially outwardly from the conductor plate spaces.

13. An engine-driven heat generation system comprising:

an internal combustion engine having a drive shaft defining an axis of rotation;

a magnetic heater comprising:

the conductor plate being coupled to the drive shaft such that the conductor plate rotates relative to the magnet assembly when the drive shaft is caused to rotate; and

a fluid handling system, the drive shaft of the engine operable to rotate the conductor plates within the magnetic heater which in turn heats the conductor plates which in turn heats a secondary working fluid flowing about the conductor plates, the fluid handling system comprising:

a fluid reservoir;

an exhaust heat exchanger in fluid communication with the fluid reservoir; and

a coolant heat exchanger in fluid communication with the fluid reservoir, wherein the heat from the exhaust of the engine is transferred to the working fluid in the exhaust heat exchanger, the heat from the coolant heat exchanger is transferred to the working fluid in the coolant heat exchanger, the heat generated by the magnetic heater is transferred to the secondary working fluid passing within the magnetic heater, and the heat generated by the exhaust heat exchanger and the coolant heat exchanger is transferred to the secondary working fluid.

14. The magnetic heater of claim 13, comprising a first magnet unit adjacent the drive shaft first side and a second magnet unit adjacent the drive shaft second side, wherein the first magnet unit and the second magnet unit are operable to translate towards and away from each other transversely with respect to the drive shaft axis.

15. The magnetic heater of claim 13, wherein the conductor plate unit comprises a plurality of conductor plates being parallel and spaced apart a predetermined distance from each other defining conductor plate spaces therebetween,

16. The magnetic heater of claim 13, further comprising two upper tracks and two lower tracks, the upper tracks and lower tracks being substantially parallel with respect to each other and substantially perpendicular to the drive shaft axis defined by the drive shaft, the upper tracks being located adjacent the drive shaft first side and the lower tracks being located adjacent the drive shaft second side,

17. The magnetic heater of claim 13, further comprising a pivot actuator,

18. The magnetic heater of claim 15, further comprising a pivot actuator,

19. The magnetic heater of claim 18, wherein the magnet unit further comprises a pivot shaft defining a pivot axis, wherein the plurality of magnet assemblies are coupled to the pivot shaft via the pivot element and operable such that the plurality of magnet assemblies pivot simultaneously about the pivot axis when the pivot shaft is rotated.

20. The magnetic heater of claim 19, wherein the pivot actuator comprises a linear actuator having a fixed end and an extendable end opposite the fixed end, the extendable end being coupled to the arm, wherein movement of the extendable end from an extended position to a retracted position rotates the arm moving of the magnet between the magnetically disengaged position and magnetically engaged position.

21. The magnetic heater of claim 18, wherein the pivot actuator is operable to independently pivot each of the plurality of magnet assemblies.

22. The magnetic heater of claim 18, wherein the conductor plate comprises a plurality of spokes radiating from about a center of the conductor plate, the conductor plate being coupled to the drive shaft by the plurality of spokes.

23. The magnetic heater of claim 22, further comprising a fluid driver element operable for moving a working fluid through the annular passage and through the conductor plate spaces.

24. The magnetic heater of claim 23, wherein the fluid driver element comprises at least one fin projecting from the drive shaft between the conductor plates and adjacent the spokes, the fins driven in rotation by the drive shaft and operable to move air in through the annular passage from a substantially axial direction and substantially radially outwardly from the conductor plate spaces.