Classifications

• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
  • H02P9/00—Arrangements for controlling electric generators for the purpose of obtaining a desired output
  • H02P9/48—Arrangements for obtaining a constant output value at varying speed of the generator, e.g. on vehicle
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K16/00—Machines with more than one rotor or stator
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K19/00—Synchronous motors or generators
  • H02K19/16—Synchronous generators
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K21/00—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets
  • H02K21/12—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K21/00—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets
  • H02K21/12—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets
  • H02K21/24—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K3/00—Details of windings
  • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
  • H02K3/28—Layout of windings or of connections between windings
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
  • H02P9/00—Arrangements for controlling electric generators for the purpose of obtaining a desired output
  • H02P9/02—Details of the control

Definitions

• the present invention relates to the field of generators, and more particularly, it relates to a generator having polyphasic multiple coils in staged staggered arrays
• Conventional electric motors employ magnetic forces to produce either rotational or linear motion
• Electric motors operate on the principle that when a conductor, which carries a current, is located m the magnetic field, a magnetic force is exerted upon the conductor resulting in movement
• Conventional generators operate through the movement of magnetic fields thereby producing a current in a conductor situated within the magnetic fields
• conventional generator technologies have focused mainly on modifying electric motor designs, for example, by reversing the operation of an electric motor
• Applicant also is aware of United States Patent No 4,535,263 which issued August 13, 1985 to Avery for Electric D C Motors with a Plurality of Units, Each Including a Permanent Magnet Field Device and a Wound Armature for Producing Poles
• Avery discloses an electric motor having spaced stators enclosing respective rotors on a common shaft wherein circumferential, spaced permanent magnets are mounted on the rotors and the stator windings are angularly offset with respect to adjacent stators slots so that cogging that occurs as the magnets pass a stator slot are out of phase and thus substantially cancelled out.
• the "sweet spot" for many typical systems is about 1800rpm At this speed the generator can efficiently process kinetic energy into electricity, but at speeds outside this optimal range these systems cannot adapt and therefore either the energy collection system (i e , turbine) or signal processing circuitry must compensate
• the methods for compensation are many, and may simply be the turning of turbine blades away from the wind (furling or pitching) to slow the rotor, or gearing mechanisms to compensate when wind speeds are below the generators optimal operating range
• CFPI Closed Flux Path Induction
• PMCG Poly-Phasic Multi-Coil Generator
• Magnets have a diffuse magnetic field that permeates their immediate surroundings
• the flux lines that leave one pole MUST return to the opposite pole
• the effective magnetic field induced by a flux line depends on the path that it follows If it must cover a large distance through a medium of low magnetic permeability (air) it will be a relatively weak field If the flux line can pass through a material of high magnetic permeability (ferromagnetic materials) a stronger field is produced and less leakage will occur
• a small button magnet can easily pick up a paperclip if it is held close to it but, if held at a distance equal to the paperclips length there will be little effect because the permeability of air is very low If a paperclip is placed between the magnet and another paperclip, both paperclips may be picked up
• the first paper clip acts as a path of high permeability for the magnet effectively increasing the strength of the magnetic field at a distance
• Flux leakage is defined as the undesirable magnetic field That is, the magnetic field that is not focused on the desired object (the induction coil in a generator) Flux leakage is problematic for generators because it results in less magnetic field strength where it is desired, at the induction coil poles, and it generates unwanted effects such as eddy currents that reduce the systems efficiency
• the pins or other electrical contacts may be disposed around the casing in a manner that allows the user or manufacture to select the operating voltage of the motor or generator by connecting adjacent layers in a selected angular orientation with respect to each other An orientation may be selected, such as to allow the operator to determine the resultant voltage being created, if it is acting as a generator, or the appropriate input voltage, if it is acting as a motor For example, the same machine may run at 120 volts, 240 volts or 480 volts
• the PPMCG "Preprocessing" power electronics is a key element to the PPMCG system It allows the significant advantage of creating the desired output signal m raw form rather than creating an inadequate signal and then trying to fix it with conventional "post-processing" electronics
• the PPMCG generator stages are monitored by the "Pre-Signal" Processing circuit, which allows the device to harmonize output voltage and system resistance with grid requirements, simultaneously through adding and removing independent generator stages While the staging system offers a course control, the electronics system offers the fine control required to ensure grid tolerances are met and seamless integration is achieved
• Various mechanisms can be employed to ensure smooth fine control as stages are added or removed from the system One such mechanism would be a pulse wave modulator that pulses in and out the stages while maintaining the desire generator operation
• the current from each stage of the system is monitored by the pre-signal processing circuit that determines what system configuration is most beneficial based upon readily available information When the turbine (prime-mover) reaches adequate momentum the pre-signal processing circuit will engage the first stage Each stage is monitored and additional stages are added, or removed, by the control system depending on availability of the energy source and the current operating condition of existing engaged stages
• gearboxes allow the generator to function at low wind speeds but when wind speeds are low the system can least afford to waste precious wind energy
• the PPMCG Technology is well suited to a 'direct- coupled' configuration that forgoes the gearbox and the attendant losses that impede performance
• the PPMCG does not function through mechanical gearing but by applying resistance to the rotor to maintain appropriate speeds, effectively acting as its own gearbox
• the required resistance at the rotor will be determined by the system electronics and will be created by engaging the appropriate number of complete generator stages
• the rotor speed is controlled (up to a predetermined threshold) by the resistance created through the process of creating electrical power, unlike a mechanical system that sheds valuable energy to control the rotor rotation
• the PPMCG technology's multi-pole stator field will allow slow speed operation such that the system could function effectively without a conventional gearbox that impedes overall system performance
• each coil is induced 18 times (assuming 18 coils per stator) Therefore regardless of if there were 1 coil or 100 coils on the stator, each coil would still produce electricity at the same frequency as all other coils on the same stator
• a consistent output signal is created for all coils on each stator
• the mechanical configuration determines that the output signal is a synchronous 3 phase signal
• variable speed generators work by rectifying the variable AC output of the generator to DC and then inverting it back to grid synchronized AC This method requires the use of high power silicon (expensive) and losses are incurred in the processes of transforming and inverting the output current (i e AC to DC to AC)
• the PPMCG technology shifts with the input source, capturing more energy at a wider range and reducing the need for mechanical interference and the wasted energy that results Adding, or dropping, stages as input energy and load vanes, the self-adapting unit reduces need for complex, expensive gearboxes and power controls
• a fault is defined here as a short circuit
• the output current of synchronous generators increases substantially, because the impedance is reduced
• the large current can damage equipment and should therefore be reduced as soon as possible by removing the faulted component from the system, thus cancelling the low impedance current path
• the large current is also a clear indicator that a short circuit exists
• the fault current is undesirable because it can lead to equipment damage while on the other hand it is an essential indicator to distinguish between faulted and normal situations
• PPMCG employs a unique and beneficial fault control mechanism
• an internal failure occurs in a PM generator
• the failed winding will continue to draw energy until the generator is stopped
• This may represent a long enough duration to incur further damage to electrical and mechanical components It could also mean a safety hazard for individuals working m the vicinity
• the induction generator is safely shut down by de-excitation within a few milliseconds preventing hazardous situations and potential damage to the unit
• the system In either scyna ⁇ o, the system must be completely shut down until it can be repaired causing unwanted downtime at potentially very inopportune times when power is needed most
• the PPMCG system will create the correct sinusoidal sine wave as a raw signal directly from the field coils
• the sine wave created by the system can be manipulated through a unique design attribute that allows, through internal geometry, shaping of the waveform created by the generator This is of particular relevance as the sine wave for most conventional systems required considerable conditioning in order for it to be adequately synched with grid systems These systems must typically function as less desirable "asynchronous" machines
• the disclosed generator will also prove to offer significant value to conventional non-renewable systems. For example, many conventional systems having one state of efficient operation will utilize far more fuel than is required to meet the power needs of the consumer With the disclosed generator system, the generator will re-configure itself so as to be the right sized generator to meet only the current needs of the consumer thus preserving fuel as power requirements are lower than the rated speed for a conventional system.
• the polyphasic multi-coil generator includes a d ⁇ veshaft, at least first, second, and third rotors rigidly mounted on the d ⁇ veshaft so as to simultaneously synchronously rotate with rotation of the d ⁇ veshaft, and at least one stator sandwiched between the first and second rotors
• the stator has an aperture through which the d ⁇ veshaft is rotatably journalled
• a stator array on the stator has a radially spaced-apart array of electrically conductive coils mounted to the stator in a first angular orientation about the d ⁇ veshaft
• the stator array is radially spaced apart about the d ⁇ veshaft and may, without intending to be limiting be equally radially spaced apart
• the rotors and the stator lie m substantially parallel planes
• the first, second, and third rotors have, respectively, first, second, and third rotor arrays
• the first rotor array has a first radially
• the angular offset is such that, as the d ⁇ veshaft and the rotors are rotated in a direction of rotation of the rotors so as to rotate relative to the stator, an attractive magnetic force of the magnets of the first rotor array attracts the magnets of the first rotor array towards corresponding next adjacent coils in the stator array which lie in the direction of rotation of the rotors so as to substantially balance with and provide a withdrawing force applied to the magnets of the second rotor array to draw the magnets of the second rotor array away from corresponding past adjacent coils in the stator array as the magnets of the second rotor array are withdrawn in the direction of rotation of the rotors away from the past adjacent coils Similarly, as the driveshaft and the rotors are rotated in the direction of rotation of the rotors, an attractive magnetic force of the magnets of the second rotor array attracts the magnets of the second rotor array towards corresponding next adjacent coils in the stator array which he in the
• a further stator is mounted on the d ⁇ veshaft, so that the d ⁇ veshaft is rotatably journalled through a d ⁇ veshaft aperture in the further stator
• a further stator array is mounted on the further stator
• the further stator array has an angular orientation about the drive shaft which, while not intending to be limiting, may be substantially the same angular orientation as the first angular orientation of the stator array of the first stator
• a third rotor is mounted on the driveshaft so as to simultaneously synchronously rotate with rotation of the first and second rotors
• a third rotor array is mounted on the third rotor
• the third rotor array has a third equally radially spaced apart array of magnets radially spaced around the driveshaft at a third angular orientation relative to the driveshaft
• the third angular orientation is angularly offset for example, by the angular offset of the first and second rotor arrays so that the third rotor array is offset relative to the
• the sequentially angularly staggered first, second and third rotors, the first stator and the further stators may be referred to as together forming a first generator stage
• a plurality of such stages, that is, substantially the same as the first generator stage, may be mounted on the driveshaft Further stages may or may not be aligned with the first stage depending upon the desired application
• the magnets in the rotor arrays may be pairs of magnets, each pair of magnets may advantageously be arranged with one magnet of the pair radially inner relative to the driveshaft and the other magnet of the pair radially outer relative to the driveshaft
• This arrangement of the magnets and depending on the relative position of the corresponding coils on the corresponding stator, provides either radial flux rotors or axial flux rotors
• each pair of magnets may be aligned along a common radial axis, that is, one common axis for each pair of magnets, where each radial axis extends radially outwardly of the d ⁇ veshaft, and each coil in the stator array may be aligned so that the each coil is wrapped substantially symmetrically around corresponding radial axes
• the magnetic flux of the pair of magnets is orthogonally end-coupled, that is, coupled at ninety degrees to the corresponding coil as each pair of magnets are rotated past the corresponding coil
• the first rotor array is at least in part co- planar with the corresponding stator array as the first rotor array is rotated past the stator array
• the second rotor array is at least in part co-planar with the corresponding stator array as the second rotor is rotated past the stator array
• the third rotor array is at least in part co-planar with the corresponding stator array as the third rotor is rotated past the stator array
• the rotors may include rotor plates wherein the rotor arrays are mounted to the rotor plates, and wherein the rotor plates are mounted orthogonally onto the d ⁇ veshaft
• the stators may include stator plates and the stator arrays are mounted to the stator plates, and wherein the stator plates are orthogonal to the drive shaft
• the rotors may be mounted on the d ⁇ veshaft by mounting means which may include clutches mounted between each of the first and second rotors and the d ⁇ veshaft
• the d ⁇ veshaft includes means for selectively engaging each clutch in sequence along the d ⁇ veshaft by selective longitudinal translation of the d ⁇ veshaft by selective translation means
• the clutches may be centrifugal clutches adapted for mating engagement with the d ⁇ veshaft when the d ⁇ veshaft is longitudinally translated by the selective translation means into a first position for mating engagement with, firstly, a first clutch for example, although not necessarily, on the first rotor and, secondly sequentially into a second position for mating engagement with also a second clutch for example on the second rotor and so on to sequentially add load to the d ⁇ veshaft, for example during start-up
• some or all of the rotors may have clutches between the rotors and the dnves
• the mounting means may be a rigid mounting mounted between the third rotor, each of the first and second rotors and the d ⁇ veshaft
• the electrical windings on the rotor arrays m successive stages may be selectively electrically energized, that is, between open and closed circuits for selective windings wherein rotational resistance for rotating the d ⁇ veshaft is reduced when the circuits are open and increased when the circuits are closed
• Staging of the closing of the circuits for successive stator arrays that is, in successive stages, provides for the selective gradual loading of the generator
• control electronics which activate and deactivate individual coils, the output of the generator can be varied from zero to the nominal power rating
• the generator can produce a variable power output at a fixed frequency
• the control electronics could also be used to vary the voltage of the generator output By connecting coils in series or parallel the voltage can be varied instantaneously
• the PPMCG output can be modified to accommodate constantly changing source energy "or" constantly changing energy consumption For example, when energy demand is low at night, the PPMCG system will simply disengage un-necessary stages This will be particularly advantageous to Hydro systems that are challenged to adapt to changing energy demands
• the PPMCG system varies stage engagement as required for optimal output
• the current PPMCG design divides the generator into 18 distinct 3 coil (three phase) stages bundled together in a single generator
• the three coils, one from each of the three stators in a three stator system, may be connected to each other in series or parallel depending upon the desired application
• the PPMCG's unique staged internal configuration and pre-processing electronics will allow the system to serve as its own electronic gearbox (with 18 stages for example) offering greater control over the induction process and thus offering a better quality power output
• a PWM pulse wave modulator
• the generator sections are monitored by the "Pre-Signal" Processing circuit, which allows the device to harmonize output voltage and system resistance with grid requirements, simultaneously through adding and removing independent generator stages
• the current from each stage of the system is monitored by a pre-signal processing circuit that determines what system configuration is most beneficial based upon readily available information
• the turbine primary-mover
• the pre-signal processing circuit will engage the first stage
• Each stage is monitored and additional stages are added, or removed, by the control system depending on availability of the energy source and the current operating condition of existing engaged stages The result of this process is greater overall energy output due to capturing more of the potential energy of the wind or other transient energy source
• the PPMCG utilizes a completely closed magnetic field path
• the disclosed generator system is divided into pairs of magnets arranged in a shape that is similar to two opposing horseshoes with two coil cores in the middle to complete the circuit thus directly inducing magnetic flux into either end of an isolated electromagnet with a North-Pole field orientation on one end, and a South-Pole field orientation on the other
• This salient-pole-to-salient-pole configuration creates opportunities for increased electrical current due to a more direct induction process where flux is allowed to move freely though the coil cores and m a completed magnetic field path
• the geometry of this arrangement isolates the induction process in such a way as to increase the field density at the induction coil poles while at the same time greatly reducing undesired flux leakage
• a coil would just have to be wrapped around the backing plates for the permanent magnets creating a permanent magnet augmented with an electromagnet
• Such a design could provide an even more powerful PPMCG also providing even more control over the output of the PPMCG, since the hybrid coils could be used as a fine control of the magnetic field and thus the output of the PPMCG
• the PPMCG pre-processing algorithmic microprocessor will use a semiconductor switching system to match source with load to engage, or disengage, electrical circuits for each of the induction coils of a three armature/three stator system
• Appropriate conditioning electronics (i e filters) between the semiconductor switching system and the grid will ensure seamless and trouble-free grid integration
• the system will monitor relevant conditions such as load, prime -mover status and the state of the current collective of engaged stages to determine exactly when it is optimal to engage or disengage the next generator stage
• the power electronics are not exposed to the collective and significant implications of a fault current representing the entire generator output due to the isolation of independent coils throughout the system
• Dividing the output current into smaller manageable sections withm the PPMCG System significantly reduces the negative impact of faults in the stator windings Far less current is created by each three-coil sub-system, or staged-element, and therefore negative system fault impacts are localized and minimized
• the generator will have 18 X 3 or 54 independent 3 phase sub-stages (162 coils divided into 3 phase sub-stages) Each of which will be managed with a simple semiconductor switching mechanism to isolate faults
• the microprocessor may be designed to assess the status of each three-coil stage prior to engaging it, and if in fact the stage is faulted, the system will automatically skip this stage element allowing the generator to continue operation where conventional systems would require shut down and immediate repair This segmenting of generator sections offers many advantages in controlling the system as well as
• Control over the shape of the output sine wave created by the generator is another unique opportunity that is offered by the PPMCG design
• the induction process can be manipulated m such as way as to form the desired waveform as a raw output signal
• the magnetic field strength that passes through the coil cores will be relative to the air gap between the magnetic influence and the induction coil poles Therefore, by controlling the shaping the poles, the desired sinusoidal waveform can be produced as the raw unprocessed output
• the result of this design attribute is a better quality raw output signal with reduced requirements for expensive power conditioning equipment
• Figure Ia is, in partially cut away perspective view, one embodiment of the polyphasic multi-coil generator showing a single stator sandwiched between opposed facing rotors,
• Figure 1 is, m front perspective view, a further embodiment of the polyphasic multi-coil generator according to the present invention illustrating by way of example nine rotor and stator pairs wherein the nine pairs are grouped into three stages having three rotor and stator pairs withm each stage, the radially spaced arrays of magnets on each successive rotor within a single stage staggered so as to be angularly offset with respect to each other,
• Figure 2 is, in front perspective exploded view, the generator of Figure 1
• Figure 3 is the generator of Figure 2 m rear perspective exploded view
• Figure 4 is a partially exploded view of the generator of Figure 1 illustrating the grouping of the rotor and stator pairs into three pairs per stage,
• Figure 4a is, in front elevation view, the generator of Figure 1 with the front rotor plate removed so as to show the radially spaced apart magnet and coil arrangement
• Figure 5 is, in perspective view, the generator of Figure 1 within a housing
• Figure 6 is a sectional view along line 6-6 in Figure 1 ,
• Figure 7 is, in front perspective exploded view a single rotor and stator pair of the generator of Figure 1 ,
• Figure 8 is the rotor and stator pair of Figure 7 in rear perspective exploded view
• Figure 9 is, in cross sectional view, an alternative embodiment of a single rotor and stator pair illustrating the use of a centrifugal clutch between the rotor and the d ⁇ veshaft,
• Figure 9a is a cross sectional view through an exploded front perspective view of the rotor and stator pair of Figure 9,
• Figure 10 is, in partially cut away front elevation view, an alternative embodiment of the present invention illustrating an alternative radially spaced apart arrangement of rotor and stator arrays
• Figure 11a is in side elevation a further alternative embodiment of the generator according to the present invention wherein the stator coils are parallel to the d ⁇ veshaft on a single stage,
• Figure 1 Ib is in side elevation two stages according to the design of Figure l la,
• Figure 1 Ic is, m side elevation, three stages of a further alternative embodiment wherein the stator coils are inclined relative to the d ⁇ veshaft,
• Figure 12 is, in front elevation view, an alternate embodiment of the generator of Figure 1 with the front rotor plate removed so as to show a non-symmetrical arrangement of coil cores to magnets where three or more phases can be accomplished with only one stator,
• Figure 13 is, on front elevation view, one embodiment representing a single stage comprised of two magnets and two field coils,
• Figure 14 is, in front perspective view, a single rotor of the generator of Figure 16,
• Figure 15 is, in front perspective view, a single stator of the generator of Figure 16
• Figure 16 is, a partial cross sectional view of a front perspective of an alternate embodiment of the generator if Figure 1 utilizing double sided rotors and stators, and
• Figure 17 is, a front perspective view of a one embodiment of a single hybrid permanent magnet which will also act as an electromagnet
• the device is a generator polyphasic multiple coils in staged staggered arrays
• a single stage 10 of the polyphasic multi-coil generator according to the present invention includes a pair of rotors 12 and 14 lying in parallel planes and sandwiching there between so as to be interleaved in a plane parallel and lying between the planes of the rotors, a stator 16 Rotors 12 and 14 are rigidly mounted to a d ⁇ veshaft 18 so that when driveshaft 18 is rotated by a prime mover (not shown) for example in direction A, rotors 12 and 14 rotate simultaneously at the same rate about axis of rotation B
• Feet 32 are provided to mount stator 16 down onto a base or floor surface Rotors 12 and 14 each have a central hub 19 and mounted thereon extending in an equally radially spaced apart array around driveshaft 18 are pairs of magnets 22a and 22b Although only one pair of magnets, that is, only two separate magnets are illustrated, with a keeper shown between to increase flux, a single magnet
• Rotor 14 is a mirror image of rotor 12 Rotors 12 and 14 are mounted in opposed facing relation on opposite sides of stator 16
• the angular orientation of rotors 12 and 14 about d ⁇ veshaft 18 differs between the two rotors That is, the magnets 22 on rotor 14 are angularly offset about axis of rotation B relative to the magnets mounted on rotor 12
• each of the pairs of magnets on rotor 14 may be angularly offset by, for example, and offset angle ⁇ (better defined below) of five degrees or ten degrees or fifteen degrees relative to the angular orientation of the pairs of magnets on rotor 12
• offset angle ⁇ better defined below
• Further stages may be mounted onto d ⁇ veshaft 18 for example further opposed facing pairs of rotors 12 and 14 having a stator 16 interleaved there between
• further efficiency of the generator may be obtained by progressive angular offsetting of the magnets so as to angularly stagger each successive rotors' array of magnets relative to the angular orientation of the magnets on adjacent rotors
• the magnetic forces may be relatively seamlessly balanced so that at any point during rotation of d ⁇ veshaft 18, the attractive force of the magnet approaching the next adjacent cores in the direction of rotation balances the force required to push or draw the magnet pairs on other rotors away from that core thus reducing the force required to rotate d ⁇ veshaft 18
• FIG. 1-9 A further embodiment of the invention is illustrated in Figures 1-9, again wherein similar characters of reference denote corresponding parts in each view
• nine banks of rotors 34 each have radially spaced apart arrays of magnet pairs 36a and 36b wherein the arrays are angularly displaced or staggered relative to adjacent arrays on adjacent rotors
• each magnet pair 36a and 36b in the equally radially spaced array of magnet pairs 36a and 36b, radially spaced about axis of rotation B are angularly offset by the same offset angle ⁇ , for example, five degrees, ten degrees or fifteen degrees, between adjacent rotors
• the successive banks of rotors are cumulatively staggered by the same angular displacement between each successive rotor so as to achieve a more seamlessly magnetically balanced rotation of the rotors relative to the stators 38 and m particular relative to the coils 40 and cores 42 mounted on stators 38
• Magnets 36a and 36b are mounted onto a carrier plate 44
• the carrier plate 44 for each rotor 34 is rigidly mounted onto d ⁇ veshaft 18
• Coils 40 and their corresponding cores 42 are mounted onto a stator plate 48
• Stator plate 48 is rigidly mounted to housing 56, which itself may be mounted down onto a base or floor by means of rigid supports (not shown)
• a small motor 54 which is in addition to the prime mover (not shown), may be employed to engage additional stages or banks having further progressively angularly displaced or staggered stages or banks of magnet pairs in radially spaced array on successive rotors
• motor 54 may selectively drive a shifter rod so as to sequentially engage centrifugal clutch mechanisms on each rotor as described below
• a housing 56 may be provided to enclose stators 38 and the armatures or rotors 34 Housing 56 may be mounted on a supporting frame (not shown), and both may be made of non-magnetic and non-conductive materials to eliminate eddy currents
• a single stage 58 of the generator includes three stators 38 interleaved with three rotors 34
• the generator may include multiple stages 58 along the d ⁇ veshaft to reduce the magnetic drag by offsetting any resistances created within the generator
• Stators 38 may include a plurality of induction coils 40 made of electrically conducting materials, such as copper wire Each induction coil 40 may be wrapped around a highly ferromagnetic core such as a soft iron core 42 Alternatively, induction coils 40 may be air coils (that is, not wrapped around any core) for applications where less output current is required or where less mechanical force is available to be applied to rotors 38
• the stators are disk shaped
• the embodiment of Figure Ia includes eight induction coils 28 mounted equidistant and equally radially spaced apart from each other on a plate or disk made of non-magnetic and non-conductive materials
• stators 38 include sixteen induction coils 40 on each stator disk or plate 48 The number of induction coils 40 may vary depending on the application of the generator, and may be only limited by the physical space available on the stator plate
• the induction coils 40 may be configured such that a first set of induction coils 40 produce a first independent phase signal and a second set of induction coils 40 produce a second independent phase signal with opposing wave signals
• the induction coils 40 are alternately orientated such that an induction coil 40 producing the first independent phase signal is positioned in between induction coils 40 producing the second independent phase signal
• the two independent phases are exact reciprocals of each other wherein one independent phase may be inverted to combine the potential current of the two into one phase with a synchronous wave pattern
• each of the first set and second set of induction coils 40 have an equal number of induction coils 40 wrapped around their cores 42 in a first direction and an equal number of induction coils 40 wrapped around their cores 42 in an opposite second direction to align the currents of the two phases
• the stators 38 include sixteen, that is, two sets of eight induction coils 40 (alternate phases)
• each of the first set of eight induction coils 40 will produce a
• Rotors 34 may have magnets 36 of any magnetic materials such as neodymium magnets
• Rotors 34 each include an array of equally spaced apart pairs of magnets 36a and 36b which are mounted on rotor plates made of non-magnetic and non-conductive materials so as to discourage straying flux lines or eddy currents
• the rotor array of magnets (the "rotor array") includes eight "U"-shaped opposed facing pairs of magnets 36 on each rotor 34
• Each end of each "U"-shaped magnet 36, sixteen ends in all on the radially outer ring and sixteen on the inner ring, are paired to the corresponding sixteen coils as the ends of the magnets are rotated closely past the opposite ends of the coils
• the rotor arrays between successive rotors 34 in stage 58 are angularly offset about the axis of rotation B of the d ⁇ veshaft by an offset angle ⁇ of for example fifteen degrees It is understood that an offset of fifteen degrees is merely one preferred offset, but it may be any number of degrees of offset Offset angle ⁇ is seen best in Figure 4a as the angle between the radial axes 60 and 60' of magnets 36a and 36a' of successive rotors 34
• the magnets 36 travel towards induction coils 40 by attraction of the magnets to the cores 42 AC pulse is created in all the induction coils on the stators as the induction coils are designed to draw the magnetic flux from the magnets 36
• the opposing polarity of the magnets between each rotor and the angularly offset alignment of the rotor array relative to each other permits the magnets to be drawn away from one core and towards the next core
• the north, south (N,S) polarity configuration of the magnets on the first rotor 12 is drawn by the opposing south, north (S,N) polarity configuration of the magnets on is the second rotor 14, where the first rotor array is offset by fifteen degrees relative to the second rotor array such that the magnetic attraction between the magnets on the first rotor and the magnets on the
• the rotating magnetic fields created by the configuration of the magnets with alternating magnetic orientation between rotors and the alternating multi phase configuration of the induction coils create multiple reciprocal AC phase signals
• AC power may be harnessed directly from the induction coils without brushes
• the regulation and attenuation of these currents may be achieved by methods known m the art
• the magnets pass the induction coils they induce a current that alternates in direction
• Magnets may be configured such that for example an equal number of magnets influence the first set of induction coils by a N,S magnetic polarity as the number of magnets influencing the second set of induction coils by a S,N magnetic polarity
• the configuration of the rotors create an alternating current in each of the two phases of the single stage embodiment of Figure Ia
• the configuration of magnetic forces allow for a balancing of the resistances within the generator
• Clutch 62 is mounted within the hub of each of rotors 34
• Rotation of a clutch arm 64 once the clutch is engaged by the splines on the splmed portion 18b of d ⁇ veshaft 18 engaging matching splines within the arm hub 66, drives the arm against stops 68
• a linear actuator for example such as motor 54, actuates shifter rod 72 in direction D so as to engage splmed portion 18b with firstly, the splines within the arm hub 66
• the splmed portion is further translated so as to engage the splines 74a within the rotor hub 74
• Subsequent rotor/stator pairs or subsequent stages, such as stages 58, may be added, by further translation of the
• the rotor arrays may be appropriately angularly offset as described above Alternatively as seen in Figure l ie, the induction coils may be angled such that the rotor arrays are not perfectly aligned in parallel to each other As induction coils 40 and their corresponding cores 42 are on a slight angle, magnets (not shown) on rotors 78 on either side of the stator arrays 80 are preferably misaligned too as the magnetic influence from the magnets should induce each of the induction coils from both ends simultaneously for optimum function
• the misalignment of rotor arrays is increasingly smaller, becoming negligible as more stages are added As additional stages are added, the less of an angular offset exists between the subsequent rotor arrays with the stages Any number on of stages may be added to the d ⁇ veshaft and additional stages may be aligned or misaligned with other stages withm the generator, depending on the desired function
• the optimum number of stages may be determined by the degrees of offset of each stage relative to the previous stage
• the number of induction coils in the stator arrays need not depend on the corresponding number of magnets in the rotor arrays
• the stator arrays may include any number of induction coils and they may or may not be symmetrical in their placement about the stators
• the generator may be reconfigured allow the maximum current to be produced regardless of how much wind is driving the generator This may be accomplished by engaging a greater number of stages, such as stages 58 for example as the wind increases and decreasing the engagement of stages to reducing the number of engaged stages when the wind decreases
• the first stage of the generator may include air coils such that very little wind energy is required to start rotating the d ⁇ veshaft, and subsequent stages may include induction coils having iron cores such that greater currents may be generated when there is greater wind energy
• additional stages may increase is size and diameter so as to create greater physical resistance when greater wind energy is present but as well to create more electrical output from the system when input energy is high When wind energy is minimal, the generator may thus still allow for rotor 30 to rotate as it will engage only one, that is the first stage of the generator As the wind energy increases, the generator
• variable load generator is not only able to adapt to variable source energies, such as wind, but can be adapted to service specific power needs when source energy can be controlled
• source energy can be controlled
• a hydro powered generator that rather than turning off at night, and needing to warm up again to service greater power needs m the day, may simply vary its output to suit the night cycle and thus use less source energy to function during that time
• staging application mechanical with clutches, or electrical by engaging and disengaging coil array circuitry may be applied to existing generator designs that are appropriately constructed into short, stout sections so as to accommodate the staging application
• One embodiment would have a circuit designed to assess the relevant information about the device such as load information m order to determine and employ the optimal number of stages of a multi-sage generator apparatus
• the device could have a circuit designed to assess the relevant prime- mover information in order to determine and employ the optimal number of stages of the generator apparatus, or a circuit designed to assess the relevant prime-mover and load information in order to determine and employ the optimal number of stages of the generator or a circuit wherein each stage is monitored and when deemed appropriate, additional stages are added, or removed, by the control system, and where the engagement or disengagement of these multiple stages is determined by the availability of the energy source and/or the current operating condition of existing generator stages or independent coils as part of a stage
• the generator device can also have an apparatus comprising an algorithmic microprocessor connected to a high speed semiconductor switching system designed to match source with load through the engaging, or disengaging, electrical circuits It can utilizing a pulse wave modulator or similar device in order to offer fine control in smoothing out the transition of generator stages as they are added or removed electrically from the system
• the above apparatus incorporating appropriate conditioning electronics, such as filters, between the semiconductor switching system and the grid to ensure the signal is appropriate for grid integration
• the generator will have a system whereas the electronics of the system are capable of checking the integrity of individual coils or series of coils, that represent a single stage, prior to engagement of the stage being accomplished through the creation of a fault current by the system that checks to ensure the integrity of each stage prior to its engagement
• the system can have processing circuitry that where as a fault occurs in a coil winding, it is treated as an isolated fault by the processing circuitry
• the generator through various fault detection means and whereas said fault occurrence is isolated by the system and avoided by the system through leaving its circuit open and thus out of the collective output signal
• Figure 12 is, in front elevation view, an alternate embodiment of the generator of Figure 1 with the front rotor plate removed so as to show a non-symmetrical arrangement of coil cores to magnets where three or more phases can be accomplished with only one stator
• Figure 4a that has a symmetrical spacing of magnets and field coils
• this illustration shows that a variety of different sized coil cores 42 can be utilized and as well, the coil winding can be modified to accomplish different results with the induction process It can be seen in this illustration that coil windings 40 are larger than coil winding 40a It may be desirable to create less resistance to the rotation of the shaft in certain circumstances, and with select stages, such as during the generator's start up so as to reduce resistance
• the illustration of figure 12 shows that a full three phase system, or virtually any number of phases, can be accomplished with just one stator and armature assembly This can be seen as there are three different mechanical positions with respect to magnets and induction coils and that in this illustration, they are appropriately offset from each other thus they will create the desired three phase output
• a stage can represent a single coil or a multitude of coils as is determined by the desired output
• the coils may be connected in parallel or series thus creating as many phases in the output signal as is desired
• the staging may be accomplished with the coils of a single disk being of equidistant spacing in a radially spaced array, or, an apparatus where stages may be unsymmetrical in spacing as is seen in figure 12
• the generator can have a configuration of three stator arrays divided into numerous individual induction coils and where each stator array is offset mechanically in such a way as to create a three phase output signal Also at least one coil from each of the three stator arrays can be connected together either in series or in parallel so as to create a multitude of smaller independent induction stages each having a complete three phase sine -wave as appropriate for grid integration, and, where each of these stages creates the same output characteristics as all other stages as a result of identical mechanical geometry with respect to the relationship of magnetic influences to induction coils
• the generator can also have a configuration magnets and coils on a single disk offset in such as way as to create a balanced multiphase output, and where the stator may have more than one size of induction coil, or induction coil cores, being employed in one or more stages offering increased control over resistance and output such as is seen m figure 12
• Figure 13 is, on front elevation view, one embodiment representing a single stage comprised of two magnets and two induction coils
• This single induction element, or stage serves many unique purposes, most significantly it offers an isolated induction process that increases flux density and reduces unwanted flux leakage
• the inner magnet 36a and the outer magnet 36b will create a strong and focussed magnetic field that will induce in a completed path from North magnetic poles to South magnetic poles passing through both of the induction coils 40 and their cores 42 in such as way as to allow an isolated path for the flux
• Figure 13 illustrates how the relationship between stator and armature is "salient-pole to salient-pole" This characteristic of the design allows for manipulation of the physical characteristics of either the magnet end poles or the induction coil core end poles Through manipulating the shape of the ends of the poles, the sme-wave will take a different shape If the wave form created has sharp corners due to the abrupt approach of the magnets to the induction coils, then the end of the induction cores 42 may be shaved off as is shown in the illustration by the line pointed to by number 82 Additionally, if it is desirable to create a more gradual, smother induction process, and thus a more rounded sme-wave, a more curved shaping of the induction coil core 42 can be utilized as is shown by the line 82a
• the generator can be set up to mechanically manipulate the induction process and thus the output signal created as the magnets pass by the induction coils and manipulate the field strength that passes through the coil cores through changing the air gap between the magnetic influence and the induction coil poles at specific regions of these poles
• This can be as illustrated in Figure 13 where the relationship of magnet poles and induction coil poles is manipulated to create the desired output sme-wave shape and the modification of poles may be to the magnet's poles or the induction coil's pole's, or both, and where the shaping of the end of the poles is allowing a more gradual, less abrupt approach of the magnetic field thus smoothing out operation of the system whereby further reducing cogging torque, and creating a more sinusoidal wave-form shape as is desired for integration into most grid systems
• It can also allow the outer and or inner magnets to be adjusted so as to allow for and increased or decreased air gap so as to allow for greater control over the flux density impacting the induction coil and the characteristics of the induction process, particularly those that impact the
• Figures 14 to 16 illustrate the parts of yet another alternate design embodiment, focussed on reducing manufacturing costs by utilizing both sides of the stator plate 38 and armature carrier plate 44 to hold the induction coils and magnets in place It can be seen that with the exception of the armature assemblies at either end of the generator, this design employs both sides of both the stator and armature to house magnets and induction coils thus reducing manufacturing costs As well, this design will assist in balancing out the bending force on the armature and stator plates by offsetting the force on one side of the plate, with the force being created on the other side of the plate
• FIG. 16 illustrates a generator section with 4 stator arrays having removed a cross section of the upper right quadrant
• the induction coil cores 42 are mounted on the stator plates 38 and are tightly packed between the armature plates 44 Wires from each coil will pass through a hole in the stator plate 38 and may be housed in a channel on the outer edge of the plate Wires may come together at the controller mounting brackets 85 that will direct the wiring into the circuit box
• Figure 17 illustrates a hybrid magnetic device that may be employed in the generator
• the magnet in this design may be simply two magnets at either pole with an appropriate ferromagnetic material serving as the housing between the two and thus allowing the two magnets to act as one larger magnet
• This permanent magnet may be fitted with a coil in the middle so as to allow the magnet to function as well as an electromagnet
• the electromagnet may or may not utilize a bobbin 84 to hold the wire coil 83 in place
• An alternate design for this hybrid magnet might be encasing only one magnet in the housing material rather than two This can be done by simply encasing a permanent magnet in the middle of the housing material, in this illustration, underneath the wire coil 83
• This hybrid magnet can act as a permanent magnet with the potential for greater control in serving as an electromagnet as well
• this magnetic arrangement is particularly advantageous in a closed flux path environment Research shows that the collective flux density of the combined magnet and electromagnet is beyond simply adding up the two forces when applied in a closed path arrangement
• the magnetic device as in figure 17, comprises two smaller magnets that are situated at either pole with a ferromagnetic material between and wherein the polarities of these magnets are opposed, that is where one is facing outwardly North, and the other outwardly South, and where there is an appropriate ferromagnetic material serving as the housing between the two magnets thus allowing the two magnets effectively act as one larger magnet
• the magnetic apparatus above fitted with a coil of magnet wire in the middle, between the poles, so as to allow the magnet to function as well as an electromagnet when a current is applied to the coil and where the electromagnet may or may not utilize a bobbin 84 to hold the wire coil 83 in place
• the generator has two magnets, and two field coils, in a closed loop configuration thus allowing a completed path for magnetic flux
• a completed flux path where the magnets are in the shape of horseshoes and where the poles of both magnets are facing towards each other and where there are induction cores that when aligned with the poles of the magnets, will create a closed loop pathway for flux through both magnets, and both coils
• an armature disk having a multitude of radially inner and outer magnetic influences that along with the stator's induction coils create a multitude of closed flux path induction stages withm a single armature and stator assembly
• the armature having an inner and outer magnetic assembly in a non-symmetrical fashion so as to allow for a multitude of phases to be created from a single armature interacting with a single stator array and where the desired force balancing effect is still accomplished as is done with three armatures or stators offset to balance out forces
• the generator one embodiment, will function as its own gearbox where the generator that is of itself and electronic gearbox and that as well offers a convenient and integrated electrical breaking system
• This configuration will have a method of controlling the rotational speed of the rotor m such a way as to avoid shedding energy wherein the generator itself through a process of increasing or decreasing the number of independent coils engaged within the system allows the system to function as an efficient gearbox system controlling the rotational speed of the turbine without conventional shedding techniques
• the generator can add resistance to the rotation of the rotor through the process of induction thereby slowing the rotor speed as additional stages are engaged as well as removing resistance to the rotation of the rotor through the process of electrically removing stages from the system
• the generator can also allow for a direct-coupled (single cog) connection to the prime-mover rotor as a result of multiple stator poles and the resistance control system provided by the engagement and disengagement of a multitude of generator stages
• the generator can also comprise of a unique staged internal generator that is combined
• the generator can use a flywheel effect where there are any number of induction coils that are employed when at the same time other induction coils (with open circuits) are not employed, and where the rotor contains one or more armature plates rotating about the stators regardless of how many stages, or coils in the system, have closed circuits and are thus engaged, where the mass of the balanced stages of the armature disks rotate and serve to function as a flywheel that will stabilize the system from sudden and undesirable changes in rotational speed thus smoothing out the operation of the system and where said flywheel will store kinetic energy and will offer a mechanism for moderation of the rotational speed of the turbine thus smoothing out sudden changes in source energy and load
• the generator can set up to be capable of selecting various combinations for coils to create various output voltages where the pms or other electrical contacts may be disposed around the casing in a manner that allows the selection of various operating voltages for application when the apparatus is operating as either a motor or generator accomplished by connecting adjacent terminal layers m a selected orientation with respect to each other and where the orientation of coil contacts may be selected, such as to allow the operator to determine the resultant voltage being created if it is acting as a generator, or the appropriate input voltage, if it is acting as a motor (for example, the machine may run at 120 volts, 240 volts or 480 volts or offer an output of 120 volts, 240 volts, or 480 volts)
• the generator can also have a Parallel-series coil arrangement
• the output voltage is directly proportional to generator rpm Therefore a generator designed to work at variable speeds must overcome the varying voltage output that results
• the generator dynamically controls the arrangement of the coils so that at low speed (low voltage output) the coils are in series, therefore their voltages are summed to obtain the target voltage
• the coils are connected in two series banks, the banks are connected in parallel
• the coils are connected into four series banks and the banks are connected in parallel Etc Until at max operating speed (max voltage output from each coil) all the coils are connected m parallel
• an individual coil will be attaining a voltage equal to the low speed voltage of all the coils in series
• the theoretical desired output is 1000V
• the generator in the preferred embodiment, is capable of functioning as a high output variable input motor divided mto independent motor stages
• This motor configuration is comprised of a multitude of stages where some stages may function as a motor while others are left disengaged and inactive
• any number of stages may function as a generator while any number of alternate stages may function as a motor thus allowing the system to modify its state from a motor to a generator quickly and with ease with certain applications it may be advisable to have some stages acting as a motor while other stages at the same time, act as a generator
• the generator has the benefit of the closed flux path induction process apparatus that allows for greater flexibility and choice in the selection of materials to be used in the construction of the generator system
• the generator can have a multitude of isolated induction processes thereby allowing greater choice in the materials that can be used to create the generator system allowing lighter non metallic materials to be used for housings and other parts thereby reducing the system weight
• the unique disclosed generator offers a multi-stage power generation system designed to match generator resistance to source energy through electronically adding, or dropping, generator stages as input energy and load vary
• a single stage can be just one coil or for three phase output, three coils, one from each array in a three stator array arrangement for example Additional benefits for the proposed generator systems are numerous and include reduced mechanical energy loss and a reduced requirement for conventional signal processing electronics

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• Engineering & Computer Science (AREA)
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• Permanent Magnet Type Synchronous Machine (AREA)
• Permanent Field Magnets Of Synchronous Machinery (AREA)
• Iron Core Of Rotating Electric Machines (AREA)
• Connection Of Motors, Electrical Generators, Mechanical Devices, And The Like (AREA)
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