Axle-Less Pat.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention is directed towards an electric rotating engine or assembly in the form of a motor, generator or combination of both, depending upon the specific embodiments applied. An important feature of the various preferred embodiments of the present invention is the ability to expand the overall configuration of the motor and/or generator in terms of varying the radius or diameter particularly based on the fact that the electric rotating assembly of the present invention is absent a central axle or rotary shaft commonly found in prior art motor/generator assemblies. Therefore, the term “axle-less” is meant to include the electric rotating assembly of the present invention being without a centrally disposed rotary shaft or axle which is normally disposed, in the aforementioned prior art devises, to support and/or be connected to an innermost component, typically a stator or rotor structure.

To the contrary, the present invention comprises one “commonly shared” stator assembly having an annular configuration which may or may not include a central opening and disposed, structured, configured and dimensioned in cooperation with at least one but in certain embodiments, a plurality of rotor assemblies mounted exteriorly of the annularly configured stator assembly and in concentrically surrounding relation thereto. The absence of a central axle or shaft, which renders the electric rotating assembly of the present invention “axle-less”, allows the aforementioned variance in the dimension of the radius and/or diameter so as to accommodate an almost infinite number of practical applications depending upon the operating characteristics of the motor or generator, incorporating the structural design of the present invention, which are intended or desired. Therefore, the present invention represents a different interaction between the one or more annularly configured rotor assemblies and a centrally disposed concentrically surrounded stator assembly operatively positioned common to the one or more rotor assemblies. Such different interaction and overall structural configuration was determined after hours of experimental, laboratory work.

In conventional motors incorporating a stator structure typically including spaced apart substantially opposed stator segments respectively comprising a south (S) and a north (N)polarity, wherein the stator segments are disposed in spaced apart, substantially opposing relation to one another generally at a 180 degree spacing, the armature or rotor assembly associated therewith travels within an enclosed magnetic field from a repelling pole to an attracting pole. Forces or impulses are directed to the armature at approximate spacings of 180 degrees rotation. This, of course, corresponds to the location of the N and S stator segments, as set forth above.

In the axle-less motors/generators of the present invention a stator assembly is provided with a plurality of conductive segments disposed about the periphery and cooperatively defining a plurality of N-S poles in adjacent position to one another. This serves to achieve a “repulsion-attraction” force on the one or more rotor assemblies in relatively short sequences. These are hereinafter termed “throw out” sequences extending along the continuous, annularly configured length assumed by the plurality of conductive segments which define the stator assembly in the motors/generators of the present invention. Therefore, the circumferential size of the stator assembly and accompanying, cooperatively disposed one or more rotor assemblies determines the amount of conductive segments or stator portions which may be arranged on the interior of the moving rotor assembly or assemblies. This in turn affects the operative performance of the motor/generators which allows a variance in torque, speed or other operating characteristics. More specifically the short repulsion-attraction “throw out” sequences are provided in proportion to the aforementioned circumference and diameter of the stator assembly. Based on the above, the torque of the various embodiments could be regulated by regulating the number of interacting fields (increasing or decreasing the number of conductive segments) provided on the one or more rotor assemblies and the single stator assembly. In addition, increasing the area of the interacting magnetic field (flux) preferably by increasing the longitudinal dimension will in effect increase the speed or RPM of the one or more rotor assemblies.

The various preferred embodiments of the present invention are shown in the accompanying figures.

First, with reference to the preferred embodiment of FIGS. 1 through 5, the present invention is directed to an axle-less rotary motor having a housing which includes a top cover 20a secured by one or more bolts or like connectors 15 to the remainder of the housing. The housing, as will be more clear based on the description provided hereinafter, may comprise a part of a support structure. The lower portion of the housing or base portion 20 is also secured by appropriately positioned connector members 15 and is disposed in spaced apart relation to the top cover 20a. With primary reference to FIGS. 2 through 5, the interior and operative components of the motor assembly comprises a single stator assembly generally indicated as 9 including an inner, annular support structure 20 which may be also considered a part of the housing and the support structure. The stator assembly 9 comprises the stator core 23 having mounted thereon a plurality of conductive segments each of which are defined by stator field windings 24 mounted on and supported by a stator core or yoke 23.

A single rotor assembly comprises an outer rotor core or yoke 10 supported or interconnected to an outer ring structure 11. The single rotor assembly comprises a plurality of spaced apart but immediately adjacent conductive segments, which in the embodiment of FIGS. 1 through 5, are defined by the conductive material core or yoke 10 having windings 12 mounted thereon as shown. The segments are arranged in a continuous annular configuration or array such that the entire rotor assembly is defined by an annular configuration. The annular configuration of the rotor assembly of this embodiment further defines a central opening or open portion as at 100, sufficiently dimensioned and configured to be disposed in operative, surrounding and concentric relation to the single stator assembly 9. In such an operative disposition as shown in FIGS. 3, 4 and 5, an air gap 102 is defined there between. Further, relating to the air gap structure and with specific reference to FIG. 5, the transverse dimension or width of the air gap 102 may vary between the points 36 and 37 and 36a and 37a, but is consistent along its length.

FIG. 2 is an exploded view of the various components of the preferred embodiment of FIGS. 1 through 5 and includes the top cover 20a of the main supporting structure, being a part of the housing and including an insert seat or groove 21a designed to house a mounting means in the form of an axial bearing 21b. Similarly the bottom cover or portion of the housing which also defines a part of the support structure as at 20 includes the annular groove 21a designed to receive the bearing 21. It is further emphasized that a variety of bearing structures could be substituted as a mounting means including superconductor magnetic field levitation. It should be readily apparent, therefore, the stator 9 is fixedly secured to the housing or more specifically to the support portion 20 of the housing and is surrounded by the movably mounted rotor assembly by being positioned within the central opening 100. The rotational movement of the rotor assembly is accomplished due to the precise placement of the annularly disposed axial bearings 21 and 21b as explained. The outer ring structure 11 is inwardly fixed or otherwise secured to the axial bearing lower flange 14 in which the groove 21a is formed. The outer ring 11 is preferably formed from an insulating material such as a ceramic material or the like but with strength enough to carry on take off power.

FIG. 3 represents an isometric view in partial cutaway and section showing the interaction and respective, cooperative positioning of the various components of this embodiment of the present invention in their assembled form. As shown, commutators 13 are mounted on the rotor assembly and are engaged by oppositely disposed spaced apart brush assemblies 22. Interconnection of the commutator sections 13 with various conductive segments defined by the core 10 and the windings 12 may be made by any applicable connection such as by conductive wiring being placed within the outer ring structure 11. As clearly shown in FIG. 3 and as referred to above, bearing structures 21 are designed to be positioned as shown to accomplish the moveable attachment or mounting of the one rotary assembly on the housing such as on the lower supporting structure 20 so as to accomplish rotation thereof relative to the stator assembly generally indicated as 9.

As shown in FIG. 4, the outer ring structure 11 is rotatably supported by the upper and lower axial bearings 21b and 21 through the outer ring structure flanges 14 and 14a having the insert seat grooves 21a to engage respectively each of the axial bearings as shown.

FIG. 5 is a top view of the armature core 10, relative to the two stator portions 9′ and 9″ defining the single stator assembly 9 as shown in FIG. 2. The core portions 23 of stator portions 9′ and 9″ are shown, for purposes of clarity, without the stator field windings and structural support. The motor armature assembly shown in FIG. 5 based on the inclusion of twelve conductive segments disposed continuously along the annular, continuous length of the one rotor assembly and eight conductive segments formed in spaced apart relation (four segments each in the stator portion 9′ and 9″) formed in the single stator assembly. The number of conductive segments in the rotor and stator assemblies could, of course, vary depending upon the intended or desired operative characteristics of the resulting motor, incorporating all the important features of this embodiment.

FIG. 5 also schematically demonstrates that the rotor assembly core 10 throws a repulsive force along the rotational path indicated by segment 30 as the same poles N–N are disposed adjacent to one another. A simultaneous attraction occurs along the path segment 31 by the positioning of the conductive segments of opposite polarity N-S. This same interaction occurs at 180 degree spacings along the path segments 30a and 31a by the various conductive segments of the core 10 of the single rotor assembly engaging the static portion 9″. Therefore, a double simultaneous repulsion reaction takes effect, causing the travel of the armature to the closest opposite magnetic field of the stator assembly. However, in order to avoid any “drag” which would have a tendency to slow the rotation of the rotor assembly, current is interrupted and/or regulated such that the end-poles are canceled or switched to S-poles along the path segment 31 in order to avoid attraction between unlike poles. A similar action occurs along path segment 31a in order to avoid the aforementioned drag which would inherently occur if the N-pole were to be maintained as the rotor 10 travels in adjacent relation to the S-pole of the stator as at 9′ and 9″.

In order to increase or affect the attraction stage to the more distant point of the attracting pole of the stator assembly or at points 37 and 37a, as shown in FIG. 5, the spacing or transverse dimension of the air gap 101 has been increased to the starting point of the attracting stator poles 36 and 36a thereby reducing the electromotive force (EMF). The transverse dimension of the air gap 102 is gradually decreased to its minimum possible dimension at the end of this stage or path of rotation which will serve to increase the EMF at points 37 and 37a. Accordingly, dual complete interaction cycles of repulsion-attraction at both sides of the circumference at stages 34 and 34a is accomplished. Following the direction of travel indicated by directional arrow 33 and 33a of the rotor assembly, from the path segment 30, where it is electro magnetized to assume an N polarity, when armature field travels 180 degrees to a position or path segment 30a where the polarity inverts due to the action of the brush and commutator assembly 22 and 13, respectively.

Yet another preferred embodiment is shown in FIGS. 6 through 8. FIG. 6 is an isometric view of an assembled dual rotor assembly motor having a common centrally disposed and concentrically surrounded stator assembly. Of particular importance and features of the embodiments of FIGS. 6 through 8 is the specifically elongated dimension of the primary stator core portion 46 and windings 47 so as to extend along the entire transverse dimension or rotary path of travel of each of the plurality of the rotor assemblies. In this embodiment, the aforementioned plurality of rotor assemblies comprises a first rotor assembly (motor armature) generally indicated as 105 and second rotor assembly (generator armature) generally indicated as 106. These first and second rotor assemblies respectively define the armature or rotor assembly of a motor and generator structure but may be either momentarily or fixedly interconnected to one another so as to rotate together in surrounding, concentric relation about the common stator assembly 109, as described in greater detail hereinafter. The stator assembly 109 includes a common primary stator core portion 46 and plurality of conductive segments each including an elongated winding 47 formed thereon. Combined first and second rotary segments 105 and 106 may also be considered a dual armature system.

A third rotary assembly 108 defines the rotor assembly of a motor and is movably mounted on the housing or support portion 42 as well as being rotational relative to both the stator 109 and the first and second rotary assemblies 105 and 106 previously referred to as the dual motor generator armatures. In order to accomplish relative movement between the rotor assemblies 105, 106 and the third rotor assembly 108, a bearing assembly 31c is common to both and is mounted on the support structure flange 14a as shown.

With reference to both FIGS. 7 and 8 an upper frame cover 42a is attached to the main frame structure 42 through one or more connecting bolts 15 or the like which may vary in number. The common elongated primary stator core portion 46, which is operatively positioned relative to each of the plurality of rotor assemblies 105, 106 and 108 is supported to the main frame structure by the more elongated connecting bolts 15b.

The first rotor assembly or motor armature assembly 105 comprises the core 10a and field windings 12a defining each of the plurality of adjacently positioned conductive segments. The electrical excitement of this field by commutators 43 located at the lower section of the outer ring structure 11a are fed current by the upper brush assembly 41 by an applicable electrical connection as set forth above. The generator armature assembly defined by the second rotor assembly 106 comprises the spider generator armature core 44 and an interior insulating member or shield 45 adhered to the spider armature core 44. The insulation shield 45 is provided in order to prevent the generator coil 40 from being short circuited by contact with the conductive material core 44. The first rotor assembly or motor armature 105 will cause the rotation of the generator armature defined by the second rotor assembly 106 since they have a common supporting structure 11a in order to define an interconnection therebetween the connection is not necessarily fixed but may be engaged momentarily by changing the structural configuration of the common support structure 11a. An induced voltage is produced in the rotating generator coil 40 when interacting with the flux or magnetic field created by the stator assembly 109.

It should, of course, be recognized that this structure could effectively be reversed by changing the position of the components and inducing a voltage in the static portion 109.

FIG. 9 is a sectional view in partial cutaway showing another embodiment somewhat similar to the embodiment of FIGS. 6 through 8 but including a plurality of rotor assemblies 120, 122, 124 and 126. In this embodiment the plurality of rotor assemblies are cooperatively positioned in surrounding relation to a “common stator assembly”. The common stator assembly, in this particular embodiment, is defined by a common supporting yoke 48 designed to support a plurality of stator portions 23a, 23b, 23c and 23d. Each of these stator portions 23a through 23d are associated with individual windings 24. This common stator assembly includes a longitudinal dimension similar to that of the embodiment of FIG. 7, in terms of the yoke 48 being sufficiently elongated to extend transversely along the entire rotary path of all four of the rotary assemblies of the embodiment of FIG. 9, wherein the stator portions each generate a magnetic field in operative relation to one of the rotor assemblies 120-126. Further, while four rotor assemblies 120, 122, 124 and 126 are shown, the actual number of rotor assemblies could, of course, vary. Further, each of the rotor assemblies are designed to be movably mounted on a support structure 20a and 20b and are also designed to be moveable relative to one another by the additionally provided bearing assemblies 21c as shown at different speeds and/or in different directions. Accordingly, the operative characteristics of each of the rotor assemblies 120, 122, 124 and 126 may vary in terms of operating characteristics specifically including speed (RPM), relative direction of travel (clockwise and counter-clockwise) and torque.

Another feature of the present invention is the angular orientation of the windings 12 and associated core 10 of the various conductive segments of each of the rotor assemblies 120-126 and the cooperative, parallel but angular orientation of the individual and correspondingly positioned stator portions 23a through 23d and their associated windings 24. The common supporting yoke 48 is fixedly attached by conventional bolts or like connectors 15b to the support or housing 20 as indicated above. A plurality of commutator assemblies 13 and cooperative electrically interconnecting brush assemblies 22 may also be provided as shown in order to provide current to the plurality of windings 12 on each of the rotary assemblies 120, 122, 124 and 126. In order to diminish the height of the assembled array of stacked rotor assemblies 120 through 126 certain ones of the conductive segments defined by core 10 and windings 12, as well as their cooperatively positioned core and field windings on the correspondingly positioned stator structures 23a through 23d, are arranged at a common angular orientation. More specifically, the two segments are substantially parallel and the air gap 101′ there between has a predetermined transverse dimension as shown throughout the entire rotary path of the respective rotor assemblies 120 through 126. In addition, the rotor assembly 120 has its core 10 and windings 12 arranged generally at a 45 degree angle from a reference orientation or normally upright orientation as represented by the core 10 and windings 12 of the rotor assembly 122. The rotor assembly 124 has its core 10 and windings 12 arranged at an angle of 135 degrees relative to the zero reference angle or upright orientation of the core 10 and windings 12 of the second rotor assembly 122. In addition, the rotor assembly 126 has its core 10 and windings 12 arranged at a 45 degree angle similar to the 45 degree angular orientation of the first rotor assembly 120. This angular orientation may more specifically be referred to as the “interaction plane angle” (IPA) in that the correspondingly positioned stator portions 23d, 23c and 23b as well as their associated windings 24 are all arranged at this same angular orientation to assume the aforementioned parallel orientation and thereby define the IPA.

FIG. 9A represents the imaginary vertical plane of interaction in its cross sectional profile and the reference angles are basically to be used as a guideline locator for the IPA set forth above with specific explanation of the angular orientation of the various cores and associated windings 10 and 12, respectively, of the first, third and fourth rotor assemblies. FIGS. 9B and 9C are schematic representations of similar reference and comparative representations. In particular, FIG. 9C is a schematic representation of the circular or annular path of travel of the various rotor assemblies 120, 122, 124 and 126 as indicated. With reference to FIG. 9C, the IPA of the armature-stator 11e-23a, being at zero degrees, would form a cylindrical section in relation to the complete motor assembly during its rotary path of travel. Armature-stator 11d-23d oriented at a 45 degree IPA would form a positive 45 degree truncated cone generated in the positive or upper part of X-Y plane. The armature-stator 11c-23c located at 135 degree IPA takes the configuration of a negative 45 degree truncated cone located below or in the negative part of the X-Y plane. Also as set forth above, the advantage of this multiple application and use of the various IPA angles of zero degrees (upright), 45 degrees and 135 degrees would be to drastically reduce the overall height of the assembled structure incorporating multi-level rotor assemblies having a plurality of rotor assemblies arranged in a stacked array, wherein the rotor assemblies may be armatures for motors or generators.

FIG. 10 is directed to an axle-less generator TYPE I structure wherein induced voltage is generated in the outer rotary assembly or what would be equivalent to the rotor (generator armature) assembly 106 in the embodiment of FIG. 7. For purposes of clarity, the structure of FIG. 10 shows the common continuously elongated stator primary stator portion 46 without the common elongated windings 47 and introducing, in the primary stator portion core 46, the secondary stator portion 46a at the generator armature level only. In other words, the inner stator field structure includes main or primary stator portions 46 and additional or inserted secondary stator portions 46a in order to increase the number of conductive segments and thereby affecting the operative characteristics of the formed generator armature by having a plurality of conductive segments now defined by both the primary stator portions 46 and the secondary or supplementary stator rotor portions 46a arranged in a continuous annular configuration. Therefore, the stator-field structure is enclosed in a 360 degree array at the generator armature level only.

FIG. 11 represents yet another embodiment of the present invention which may be referred to as a TYPE II axle-less/generator, wherein induced voltage is generated in the static structure through the conductors 40a. The conductors 43a are surrounded by the spider generator static armature core 44a which attached to the main frame or support structure 42 in a fixed manor. FIG. 11 further discloses the elongated outer ring structure 11a supporting the rotary field structure core 49, which is a continuous field fed by slip ring and brush assemblies. Such brush assemblies are connected to run from the inner main frame 42, similar to the embodiment of FIG. 7, and the brush assemblies 41 and 22 therein, to make contact with the continuous slip rings (not shown for purposes of clarity) in order to keep the outer rotary field structure constantly energized. While not clearly shown, the inner static portion main frame structure 42 is supporting the spider generator static armature core 44a and its generating coil 40a and also supports armature core 44a and its generating coil 40a and also supports the inner stators which are disposed to cooperatively interact with the outer motor armatures and brush assemblies to feed the motor armatures. As pointed out above, this system is the inverse of the operatively oriented structure of the embodiment of FIG. 10.

In the embodiment of FIG. 12 an operative segment or portion of a TYPE III axle-less generator is shown and is defined as an assisting system applicable for use in cooperation with TYPE I or TYPE II axle-less generator as described above. This assisting system as shown in FIG. 12 is used to decrease the load to the prime mover. In the structure of FIG. 12 a strip sequence of a fractional dual axle-less motor/generator armature (similar to FIG. 7) is provided. More specifically, a duplicate segment of the motor armature 50 is inserted into the generator spider armature along side the spider armature core 44. This structure includes an elongated outer ring structure 11a supporting the upper motor armature core 10a and its field windings 12a as well as the spider generator rotary armature core 44 and its generating coil 40. Along path segment 30 in FIG. 12, the motor armature or rotor assembly has been energized to assume an N polarity facing the elongated stator which maintains a steady N polarity. The duplicate segment of the motor armature 50 inserted into the generator armature core 44 (without physically or structurally interrupting the generator coil 40) will be energized to an N polarity simultaneously at and along the path segment or stage 30. A greater EMF will then be produced, creating a greater attraction at stage 31 to the stator, which is now in an S polarity following the rotation segment 33a and thereby decreasing the load of the motor armature assembly 10a, 12a.

This system could also be applied to the axle-less generator TYPE II, inserting the duplicate segments 50 into the inner spider generator static armature core 44a to interact with the outer rotating structure field 49 or vice versa. This could be accomplished by inserting the motor armature duplicate segments 50 in sections of the rotary structure fields 49 and extending the inner static motor stators, into the spider generator static armature core 44a to interact with the indicated duplicate segments of motor armature 50. This insertion improves considerably the output performance of the motor armature which serves to produce rotating force to the dual motor/generator system.

In operation, one embodiment of the electric rotating assembly of the present invention is shown in FIG. 13 wherein an exterior view represents a first power takeoff generally indicated as 200 including a takeoff shaft 202 and a connecting driven gear 204. The first power takeoff assembly 200 is connected in driven relation by means of a ring gear 206 which is driven by one of a plurality of rotor assemblies of the type shown in the embodiment of FIG. 9. The actual inter connection between the driving ring gear 206 and the rotor assembly (see FIG. 9) to which it is attached is not shown for purposes of clarity but may take any applicable connection.

In addition, FIG. 13 shows a second power takeoff generally indicated as 210 and including a power take off shaft 212 and a driven gear 214 shown in a partial cutaway view. The driven gear 214 of the second power takeoff 210 is drivingly connected to an exterior periphery driven ring gear 216. The ring gear 216 is connected directly to one of the other of plurality of rotor assemblies of the type shown in the embodiment of FIG. 9. It is also important to note that directional arrows 220 and 222 are clearly indicative that the driving ring gear 206 and the driving ring gear 216 each being connected to a different rotor assembly of the type shown in the embodiment of FIG. 9 are rotating in opposite directions and are drivingly engaging so as to provide positive energy or work force to the respective power takeoff assemblies 200 and 210. As set forth above, the power takeoff assemblies 200 and 210 may, of course, be driven at different speeds since, as pointed out throughout description of the various embodiments of the present invention, the relatively movable rotor assemblies of the type shown in the embodiment of FIG. 9 may operate at different speeds (RPM).

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