Us10211702 PDF

US010211702B2
(12) United States Patent (10) Patent No.: US 10 ,211,702 B2

Jahshan (45) Date of Patent: * Feb . 19 , 2019
( 54 ) ELECTRIC MOTORGENERATOR WITH
INTEGRATED DIFFERENTIAL
(58 ) CPC
Field .of.....Classification Search
.. B60K 2006 /4825 ; B60L 2220 / 50 : B60L
15 / 20 ; HO2K 21 / 12
(71) Applicant: Axiflux Holdings Pty Ltd , Southbank , See application file for complete search history .
Victoria (AU ) ( 56 ) References Cited
( 72 ) Inventor: David Elias Jahshan , Fawkner (AU ) U . S . PATENT DOCUMENTS
(73 ) Assignee: Axiflux Holdings Pty Ltd , Southbank 5 ,419 ,406 A 5/ 1995 Kawamoto et al.
(AU ) 2003 /0189388 A 10 /2003 Hashimoto
(Continued )
( * ) Notice : Subject to any disclaimer, the term of this
patent is extended or adjusted under 35 FOREIGN PATENT DOCUMENTS
U .S . C . 154 (b ) by 0 days.
TW 201107635 3 / 2001
This patent is subject to a terminal dis WO WO 2012 / 167316 12 /2012
claimer .
(21 ) Appl. No.: 15 /297 ,082 OTHER PUBLICATIONS
(22 ) Filed : Oct. 18, 2016 International Search Report dated Feb . 18 , 2014 for PCT/AU2013/
001438 .
(65 ) Prior Publication Data Primary Examiner — Karen Masih
US 2017 /0085153 A1 Mar. 23 , 2017 (74 ) Attorney , Agent, or Firm — Jones Day
(57) ABSTRACT
Related U .S . Application Data An electricalmachine comprising: at least one stator, at least
one module , the at least one module comprising at least one
(63 ) Continuation of application No. 14 /651, 106 , filed as electromagnetic coil and at least one switch , the at least one
application No . PCT/ AU2013 /001438 on Dec. 9 , module being attached to the at least one stator; at least one
2013 , now Pat. No. 9,509 , 198 . rotor with a plurality of magnets attached to the at least one
( Continued ) rotor, an integrated electrical differential coupled to at least
one of the rotors , the at least one integrated electrical
(51) Int. Ci. differential permitting the at least one rotor to output at least
HO2P 25 /00 ( 2006 .01) two rotational outputs to corresponding shafts, wherein the
HO2K 7 /116 ( 2006 .01 ) at least two rotational outputs are able to move the shafts at
(Continued ) different rotational velocities to one another. The electrical
(52 ) U .S . CI. machine is configured to fit into a housing , and that can be
CPC .......... HO2K 7 / 116 ( 2013.01) ; B60L 1/003 retrofitted into a conventional vehicle by replacing the
(2013. 01 ); B60L 3/ 0061 (2013 .01); mechanical differential.
(Continued ) 20 Claims, 29 Drawing Sheets
42 A
- 47
40-7 - - - - - - - -- - - - - - - -- - - - - - - - - - - - - - - -- -
COMMUNICATION -
TRANCEIVER -
40 44
MICROCONTROLLER
-
SENSOR -
454 -
- - - - - - - - - -
COIL COIL -
DRIVER -
- -- - - - -- - - - - - - -
41
HIGH VOLTAGE DC -DC

INPUT CONVERTER
48
US 10 ,Page
211 ,2702 B2
Related U .S . Application Data 1/ 12 ( 2013 .01); HO2K 3 /04 ( 2013 .01); HO2K
11/21 ( 2016 .01 ) ; HO2K 11/33 ( 2016 .01 ) ;
(60 ) Provisional application No.61/735,379, filed on Dec . HO2K 16 / 00 ( 2013 .01) ; HO2K 21/ 24
10 , 2012 ( 2013 .01); H02P 3 / 12 (2013 .01); HO2P 3/ 14
( 2013 .01) ; HO2P 3 / 22 ( 2013 .01); HO2P 3 / 24
(51) Int . Cl. ( 2013 .01); H02P 6 / 14 ( 2013 .01); H02P 6 /24
HO2K 16 /00 ( 2006 .01) ( 2013.01); HO2P 23/00 ( 2013 .01); BOOK 6 /405
HO2P 6 / 14 ( 2016 .01 ) ( 2013 .01) ; B60K 6 / 52 ( 2013 .01) ; B60K
HO2P 3 / 14 ( 2006 .01) 2006 / 4808 ( 2013.01); BOOL 2200 / 36
HO2P 3 /12 ( 2006 .01) ( 2013 .01); B60L 2210 /12 (2013 .01 ); BOOL
HOPP 6 /24 ( 2006 .01) 2210 /40 ( 2013 .01) ; BOOL 2220 / 14 ( 2013 . 01 );
HO2P 23 /00 ( 2016 .01 ) B6OL 2220 / 50 ( 2013.01); BOOL 2240 / 12
HO2K 21/ 24 ( 2006 .01) ( 2013.01); BOOL 2240 /26 ( 2013 .01); BOOL
HO2K 1/ 12 ( 2006 .01 ) 2240 /36 (2013 .01) ; B60L 2240 /421 ( 2013 .01);
HO2K 3 /04 (2006 .01) BOOL 2240 /423 ( 2013 .01) ; BOOL 2240 /425
B60L 1 /00 ( 2006 .01 ) ( 2013.01); B60L 2240 /427 (2013 .01) ; B6OL
BOOL 3 /00 ( 2006 .01 ) 2240 /429 ( 2013 .01) ; BOOL 2240 /486
BOOL 7 /14 (2006 .01) ( 2013 .01 ) ; B6OL 2250 / 16 (2013 .01 ) ; BOOL
BOOL 8 / 00 (2006 .01) 2250/ 26 (2013 .01); BOOL 2260/ 28 ( 2013.01) ;
B60L 11 /00 (2006 .01) BOOL 2270 / 145 ( 2013 .01); B60Y 2304 /076
BOOL 11/ 14 (2006 .01) ( 2013 .01); HO2K 2213 /06 ( 2013 .01); HO2K
BOOL 11 / 18 ( 2006 .01 ) 2213 /09 (2013 .01); HO2K 2213/ 12 (2013.01);
B60L 15 /00 (2006 .01) HO2P 2207/ 03 ( 2013.01); YO2T 10 /626
B60L 15 /02 ( 2006 .01) (2013.01 ); YO2T 10 /6265 (2013 .01 ); YO2T
B60L 15 /20 ( 2006 .01 ) 10 /641 ( 2013 .01); YO2T 10 /643 (2013 . 01 );
HO2K 11 /21 (2016 .01) YO2T 10 / 70 ( 2013 .01) ; YO2T 10 /7022
HO2K 11 /33 ( 2016 .01 ) (2013 .01); YO2T 10 / 7061 (2013 .01 ); YO2T
HO2P 3 /22 (2006 .01) 10 / 7077 (2013 . 01 ); YO2T 10 / 7083 ( 2013 .01 ) ;
HO2P 3 /24 ( 2006 .01) YO2T 10 /7233 (2013.01); YO2T 10 /7241
BOOK 6 /405 ( 2007 . 10 ) ( 2013.01); YO2T 10 /7275 (2013.01); YO2T
BOOK 6 /52 (2007. 10 ) 90 / 34 (2013 .01)
B60K 6 /48 (2007 . 10 )
(52 ) U . S . CI. (56 ) References Cited
CPC ............... BOOL 3/ 0084 ( 2013.01); B60L 7 / 14 U . S . PATENT DOCUMENTS
(2013.01) ; B60L 8 /003 ( 2013 .01 ) ; B60L 8 /006
( 2013 .01 ); BOOL 11 /005 ( 2013 .01 ) ; BOOL 2004/0263112 Al 12 /2004 Morgante et al.
11/ 14 ( 2013 .01); B60L 11/ 1803 ( 2013.01); 2010 / 0012402 AL 1/2010 Vargas
B60L 11/ 1857 ( 2013.01); B60L 11/ 1864 2011 /0218070 AL 9 / 2011 Mack et al.
( 2013 .01 ); B60L 11/ 1877 (2013 .01); B6OL 2013 / 0274051 A1 * 10 / 2013 Kalmbach ............. F16H 57/031
11/ 1887 (2013 .01) ; B60L 15 / 007 ( 2013 .01 ); 475 / 150
B60L 15 /025 ( 2013 .01); B60L 15 /2009 2015 /0295455 Al 10 /2015 Nemoto
(2013.01); B60L 15 /2054 (2013 .01 ); HO2K * cited by examiner
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COMMUNICATION
TRANCEIVER
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US 10 ,211,702 B2
ELECTRIC MOTOR /GENERATOR WITH used , for example , in hybrid electric vehicles (HEV ) and
INTEGRATED DIFFERENTIAL electric vehicles (EV ) are interior permanent magnet syn
chronous machines. In common with other synchronous
CROSS REFERENCE designs, these may suffer from conduction and magnetic
5 losses and heat generation during high power operation .
This application is a continuation of U .S . application Ser. Rotor cooling is more difficult than with brushless direct
No. 14/651, 106 , filed Jun . 10 , 2015 , which is the National current motors and peak point efficiency is generally lower.
Phase application of International Application No . PCT/ Generally speaking , induction machines are more difficult to
AU2013/ 001438 , filed Dec. 9 , 2013 , which designates the control, the control laws being more complex and less
United States and was published in English , and claims 10 amenable to modelling. Achieving stability over a suitable
priority to U . S . Provisional Application No. 61 /735 ,379 torque - speed range and controlling temperature is more
filed Dec . 10 , 2012 . In addition , this application is related to difficult than with brushless direct-current motors. Induction
Australian Provisional Application No. 2011902310 , filed machines and switched -reluctance machines have been used
Jun . 10 , 2011 , and International Patent Application No . for many years , but require modification to provide suitable
PCT/AU2012/000655 , filed Jun . 8, 2012 Each of these 15 optimal performance in , for example , HEV and EV appli
applications, in their entirety , are incorporated herein by cations.
reference .
Current state of the art electric vehicle drive trains consist
FIELD of an electric battery or generator connected to control
20 electronics, the control electronics modulate the voltage to
This disclosure relates generally electric motors /genera - the required frequency to drive the electric motor, the output
tors adapted for various applications as well as to related of the electric motor is coupled to the input of a gear set with
methods and/ or system . Certain embodiments of the present an integrated differential and the output is connected to the
disclosure relate to electric motors / generators which are : 1 ) vehicles half shaft . There is a need for designs that fit the
reversible, 2 ) able to efficiently produce high torque in 25 same size envelope as the differential housing in an existing
portions of the power and /or RPM range , 3 ) able to effi - petrol powered vehicle and mounted in the existing location
ciently produced power in portions of the power and /or as the existing differential where the output can be directly
RPM range , 4 ) able to efficiently produce high torque coupled to the wheel using the vehicles existing half shafts .
substantially throughout the whole of a defined extended This would permit the use of electric drive trains inside
power and/or RPM range, 5 ) able to efficiently produce 30 existing vehicles frames without redesign and retooling of
power substantially throughout the whole of a defined the existing vehicle subframe and half shafts .
extended power and / or RPM range , 6 ) are compact, 7 ) are There is a need for improved systems, devices and meth
modular, 8 ) have an integrated differential or 9 ) combina - ods directed to electric motors / generators . The present dis
tions thereof. Certain embodiments are able to be employed , closure is directed to overcome and/or ameliorate at least
for example , as direct-drive wheel motors , mills and /or 35 one of the disadvantages of the prior art as will become
regenerative braking . apparent from the discussion herein .
BACKGROUND SUMMARY
The use of electric motors /generators in a number of 40 This summary is meant to be exemplary of certain
application areas is known. For example, in electric vehicles embodiments . Devices , methods of use , methods of manu
and / or industrial equipment. Traditional electric motors / facture and /or systems are disclosed in the specification .
generators typically work reasonable well at particular Some embodiments may not be disclosed in this summary
speeds and power requirements. However, as the speed or but are disclosed in other examples or other portions of this
power output is varied the efficiency of these traditional 45 disclosure .
motors / generators drops . To ensure that the device keeps Certain embodiments are directed to an electrical machine
operating at high efficiency most devices are often run at comprising at least one stator ; at least one module , the at
higher speeds even when less would suffice , wasting energy, least one module comprising at least one electromagnetic
or are coupled to expensive and heavy transmission systems coil and at least one switch , the at least one module being
which require ongoing maintenance and greatly increase the 50 attached to the at least one stator, at least one rotor with a
number ofmoving parts increasing the risk of failure . plurality of magnets attached to the at least one rotor, the at
Modifying existing motor drive systems such that they are least one rotor has an integrated differential, the at least one
capable of Variable Speed Drive (VSD ) can introduce differential permits the rotor to output at least two rotational
energy savings depending on the application . However, outputs, wherein the at least two rotational outputs are able
adding VDS to traditional motors is an expensive exercise . 55 to move at different rotational velocities to each other and
The power supply 's frequency has to be modified , requiring wherein the at least one module is in spaced relation to the
high current switching, which use large and expensive plurality of the magnets ; and the at least one rotor being in
electronic switches . Further once the speed of the motor is a rotational relationship with the at least one stator, wherein
adjusted the motor may no longer be operating at its peak the quantity and configuration of the at least one module in
efficiency therefore the energy savings of running the motor 60 the electrical machine is determined based in part on one or
slower may be offset by running the motor in a region that more operating parameters ; wherein the at least one module
is less efficient. is capable of being independently controlled ; and wherein
Various configurations of traction electric motors are the at least one module is capable of being reconfigured
known . However, for many applications such motors tend to based at least in part on one or more of the following: at least
have excessive weight and bulk . Also known is the use of 65 one operating parameter during operation , at least one
disk - shaped wheel motors, located at or within a wheel, and performance parameter during operation , or combinations
driving directly. At present, the majority of traction motors thereof.
US 10 ,211, 702 B2
Certain embodiments are directed to an electrical machine parameter during operation , and at least one performance
comprising: at least one stator; at least one module , the at parameter during operation . Certain aspects are directed to
least one module comprising at least one electromagnetic the electric machine , wherein the electrical machine is
coil and at least one switch , the at least one module being configured to fit into a housing and that can be located in
attached to the at least one stator; at least one rotor with a 5 substantially that same position where a differential would
plurality ofmagnets attached to the at least one rotor, the at otherwise be located in a vehicle or other machine. Certain
least one rotor has an integrated differential, the at least one aspects are directed to the electric machine, wherein the
differential permits the rotor to output at least two rotational electrical machine is configured to fit into a housing and that
outputs, wherein the at least two rotational outputs are able can be retrofitted into a conventional vehicle by replacing
to move at different rotational velocities to each other and 10 the differential.
wherein the at least one module is in spaced relation to the Certain embodiments are directed to an electricalmachine
plurality of the magnets ; and the at least one rotor being in
a rotational relationship with the at least one stator. comprising: a plurality of stators ; a plurality of modules
Certain embodiments are directed to an electrical machine comprising at least one electromagnetic coil and at least one
comprising : at least one stator, at least one module , the
one module the atat 1515 switch
Swi and being attached to at least one of the plurality of
least one module comprising at least one electromagnetic stators ; a plurality of rotors with a plurality of magnets
coil and at least one switch , the at least one module being attached to at least one of the plurality of rotors, the plurality
attached to the at least one stator; at least one rotor with a of rotors are able to move independently to one another to
plurality of magnets attached to the at least one rotor, produce a differential output that permits the electric
wherein the at least one module is in spaced relation to the 20 machine to output at least two rotational outputs to corre
plurality ofthe magnets ; an integrated differential coupled to sponding shafts , wherein the at least two rotational outputs
at least one of the at least one rotors , the at least one are able to move the shafts at different rotational velocity ' s
integrated differential permitting the at least one rotor to relative to one another, and the plurality of modules are in
output at least two rotational outputs to corresponding spaced relation to the plurality of the magnets ; and the
shafts , wherein the at least two rotational outputs are able to 25 plurality of rotors being in a rotational relationship with the
move the shafts at different rotational velocities relative to plurality of stators ; wherein the quantity and configuration
one another , and the at least one rotor being in a rotational of the plurality of modules in the electrical machine is
relationship with the at least one stator ; wherein the quantity determined based in part on one or more operating param
and configuration of the at least one module in the electrical e ters ; wherein the plurality ofmodules are capable of being
machine is determined based in part on one or more oper - 30 independently controlled , and wherein the plurality of mod
ating parameters; wherein the at least onemodule is capable ules are capable of being reconfigured based at least in part
of being independently controlled ; and wherein the at least on one or more of the following: at least one operating
one module is capable of being reconfigured based at least parameter during operation , and at least one performance
in part on one or more of the following : at least one parameter during operation ; and wherein the electrical
operating parameter during operation , at least one perfor- 35 machine is configured to fit into a housing and that can be
mance parameter during operation , and combinations located in substantially that same position where a differ
thereof. Certain aspects are directed to the electric machine , ential would otherwise be located in a vehicle or other
wherein the electrical machine is configured to fit into a machine .
housing and that can be retrofitted into a conventional Certain embodiments are directed to an electrical machine
vehicle by replacing the differential. Certain aspects are 40 comprising : at least one stator ; at least one module , the at
directed to the electric machine, wherein the electrical least one module comprising at least one electromagnetic
machine is configured to fit into a housing and that can be coil and at least one switch , the at least one module being
located in substantially that same position where a differ - attached to the at least one stator ; at least one platter or rotor
ential would otherwise be located in a vehicle or other with a plurality ofmagnets attached to the at least one platter
machine . Also disclosed are methods of using and manu - 45 or rotor , wherein the at least onemodule is in spaced relation
facturing the embodiments disclosed herein . to the plurality of the magnets ; an integrated differential
Certain embodiments are directed to an electrical machine coupled to at least one of the at least one platters or rotors ,
comprising: a plurality of stators ; a plurality of modules the at least one integrated differential permitting the at least
comprising at least one electromagnetic coil and at least one one platter or rotor to output at least two rotational outputs
switch and being attached to at least one of the plurality of 50 to corresponding shafts , wherein the at least two rotational
stators ; a plurality of rotors with a plurality of magnets outputs are able to move the shafts at different rotational
attached to at least one of the plurality of rotors , the plurality velocities relative to one another , and the at least one platter
of rotors are able to move independently to one another to or rotor being movement relationship with the at least one
produce a differential output that permits the electric stator, wherein the quantity and configuration of the at least
machine to output at least two rotational outputs to corre - 55 one module in the electrical machine is determined based in
sponding shafts , wherein the at least two rotational outputs part on one or more operating parameters ; wherein the at
are able to move the shafts at different rotational velocity ' s least one module is capable of being independently con
relative to one another, and the plurality of modules are in trolled ; and wherein the at least one module is capable of
spaced relation to the plurality of the magnets ; and the being reconfigured based at least in part on one or more of
plurality of rotors being in a rotational relationship with the 60 the following: at least one operating parameter during opera
plurality of stators ; wherein the quantity and configuration tion , at least one performance parameter during operation , or
of the plurality of modules in the electrical machine is combinations thereof.
determined based in part on one or more operating param - Certain embodiments are directed to a modular, more
eters ; wherein the plurality ofmodules are capable of being flexible , more adaptable electric motor.
independently controlled , and wherein the plurality ofmod- 65 Certain embodiments are directed to an electric motor
ules are capable of being reconfigured based at least in part fitted to an electric car that increases the battery life 10 % ,
on one or more of the following at least one operating 20 % , 30 % , 40 % , 50 % , 60 % , 70 % or more.
US 10 ,211, 702 B2
Certain embodiments are directed to electricalmotors that In certain embodiments, existing internal combustion
are smaller and/or lighter than similar competing electric vehicles may be converted to hybrid drives by attaching the
motors in the same class . Because of its small size and at least one rotor to at least one crown wheel that is driven
sufficient power to weightratio it opens a plethora of options by at least one drive shaft . The crown wheel could alterna
in terms of where to mount the motor. For example , in a 5 tively be machined as part of the magnetic rotor. During
vehicle an electric motor with the same, substantial the internal combustion operation the drive shaft turns the
same, similar or sufficient power and wheel as a existing crown wheel. During electric drive the drive shaft is disen
internal combustion motor and drive train could be gaged and the vehicle is propelled by the coils . The coils can
designed , and yet the electric motor will fit the existing size also be driven at the same time, or substantially same time,
envelope, or substantially the existing size envelope, as the 10 as the drive shaft to increase acceleration performance .
differential housing in an existing petrol powered vehicle In certain embodiments , a typical arrangement of brush
and can be mounted in the existing location , or substantial less , axial-flux electric motor comprises one or more rotors
the same location , as the existing differential. In other words, in the form of circular plates (these may be substantial flat,
certain disclosed embodiments permit the replacement or disk -shaped ) rotationally supported on a differential, which
substitution of a combustion motor and drive train for 15 may consist of an epicyclic gear train , that permits two
powering the vehicle with a small light direct drive electric outputs to rotate at different speeds, the rotor having a
motor that has similar or improved power outputs to the circular array of high energy permanentmagnets embedded
combustion motor and yet can be placed where the existing around its periphery with alternating polarity , the axes of the
differential is located . The output can be directly coupled to magnets being parallel to the shaft ; one ormore stators in the
the wheel using the vehicles existing half shafts . This 20 form of circular plates fixed parallel to the rotors and
permits the use of electric drive trains inside existing separated by a small air gap , each the stator having a circular
vehicles frames without redesign and retooling of the exist - array of electromagnetic coils embedded around its periph
ing vehicle subframe and half shafts . ery on the same centre diameter as the magnets ; sensing
Certain embodiments may be used to extend an existing ways ( or means) to detect absolute position and rotational
internal combustion vehicle production line by adding an 25 speed of the rotors, and a control system which , in response
additional electric motor variant to the assembly line. For to inputs from the sensing ways ( or means) and power and
example at the junction point of the production line where rotational direction commands, energises the magnetic coils
different chassis are diverted to different engine size lines , an to attract and repel the magnets for the purpose of generating
additional line could be added where instead of installing a rotary motion . One advantage of certain configurations are
differential the technology disclosed herein is installed in the 30 its high power and / or torque density , the magnitude of
existing location using the existing mounting points . A wire torque generated being proportional to the strength of the
may then be run from the battery pack to the power supply. magnetic flux generated by the coils , the strength of the
To retrofit a vehicle the drive train consisting of the magnetic flux of the permanent magnets , the effective diam
internal combustion engine, transmission , differential can be eter of the coil and magnet arrays and the gap between them .
removed from the vehicle and replaced by the electric motor 35 At the same time, the use of electronic commutation to
onto the existing mounting points as the existing differential.control the current flows to individual stator coils confers
The half shafts may then be connected , and wires from a high energy efficiency over a wide power and RPM range ,
battery pack that could be fitted to the previous location of resulting in essentially flat efficiency curves .
the internal combustion engine and transmission . Certain embodiments of the present disclosure are
A comparison between certain embodiments of the pres - 40 directed to configurations of brushless, axial- flux , direct
ent disclosure extending an existing internal combustion current electric motors which have one or more of the
engine production line against other state of the art electric following characteristics : high power and /or torque densi
drive trains where the chassis ' body would require modifi - ties ; which combines rapid acceleration with an extended
cation could result in estimated savings of 100s of millions RPM range ; which has low weight and / or compact form ,
of US dollars . 45 making it suitable for a variety of applications; which
A comparison between the certain embodiments of the employs complex controlmechanisms (or means ) to obtain
present disclosure and other state of the art electric drive high efficiency throughout the desired range of operational
trains not including the batteries could reduce the weight of parameters ; which has minimal cooling requirements ; which
the drive train by 100 % , 25 % , 35 % , 50 % , 60 % , 75 % or is robust and mechanically and electrically reliable ; which is
more . For example , the GM Holden EV Commodore pre - 50 capable of being manufactured through the assembly of
production vehicle 's drive train not including the battery standard components in a range of configurations suitable
weighs in close to 100 kg . Certain embodiments of the for employment in vehicles from automobiles to heavy
present disclosure would save approximately 60 kg. Certain trucks and machinery ; able to optimise driving and regen
embodiments would only introduce one directly swappable erative efficiency throughout a range of highly variable
part to the drive train assembly line ( the motor), while the 55 driving and generating conditions and which may be manu
exiting EV Commodore preproduction vehicle would intro - factured at a competitive cost.
duce at least 9 . According to certain embodiments, a brushless, axial flux ,
A comparison between the certain embodiments of the direct- current electric motor comprises: one or more disc
present disclosure and Tesla 's current electric motor indi- shaped stators around the periphery ofwhich a circular array
cates that certain embodiments have double the power to 60 of equally -spaced ( or substantially equally spaced ) electro
weight ratio . Substantial further weight savings are made as magnetic coils may be embedded ; one or more disc - shaped
there is no , or less requirement for the motor controller and rotors around the periphery of which a circular array of
gearbox. Certain embodiments have a power to weight ratio equally -spaced (or substantially equally spaced) magnets
that is 25 % , 50 % , 100 % , 125 % , 150 /0 , 200 % , 250 % , or may be embedded , the array having the same, or substan
300 % greater than a brushless permanent magnet three 65 tially the same centre diameter as that of the electromagnetic
phase electricalmachine with a substantially similar size and coils and the magnets having alternating pole orientation ;
weight. the rotors being rotationally supported parallel (or substan
US 10 ,211,702 B2
21 -
tially parallel) to the stators with an air gap between them . the differential can fit the size of envelope of existing
The central parts ofthe stators may be cut away to permit the differentials in a conventional combustion engine driven
passage therethrough of a differential, which may consist of vehicle .
an epicyclic gear train , that permits two outputs from the Certain embodiments are directed to an electrical
rotor to rotate at different speeds, supporting the rotors and 5 machine, wherein the electrical machine is a compact direct
the circuit boards are supported from the stators concentri drive electric motor that generate sufficient or improved
cally with the shaft, the circuit boards may incorporate propulsion of a wheeled vehicle and the electric motor and
solid -state switches which may be activated by command the differential can be installed in line with a drive axial
signals from a control system to power the electromagnetic while providing adequate clearance from a road without
coils to cause the rotors to rotate . In certain embodiments, 10 wheeled
substantial modification to an existing suspension of the
vehicle.
one or more sensor may be provided to generate signals Certain embodiments are directed to an electrical
relating to the absolute and instantaneous positions of the machine, wherein the electrical machine is a compact direct
rotors . In certain embodiments, one or more sensormay be drive electric motor that generate sufficient propulsion of a
provided to generate signals relating to the substantially 15 wheeled vehicle and the electric motor and the differential
absolute and/ or substantially instantaneous positions of the can be installed in line with one or more drive axels while
rotors. In certain embodiments, the permanent magnets are providing adequate clearance from a road without substan
sufficiently powerful and may be of the rare earth type and tial modification to an existing suspension of the wheeled
the electromagnetic coils are of a form generating high vehicle .
levels of magnetic flux , but having low magnetic reluctance 20 Certain embodiments are directed to an electrical
permitting rapid switching or reversal of polarity . In certain machine, wherein the electrical machine is a compact direct
embodiments , the permanent magnets may be sufficiently drive electric motor that generate sufficient propulsion of a
powerful and/or may be of the rare earth type wherein the wheeled vehicle and the electric motor and the differential
one or more of the electromagnetic coils are of a form can be installed in line with one ormore drive axels without
generating sufficiently high levels of magnetic flux . In 25 lower , or substantially lowering, the clearance from a road
certain embodiments , permanent magnets and /or electro - and without substantial modification to an existing suspen
magnetic coils of conventional form are optionally sion of the wheeled vehicle .
employed in electric motors for lower cost applications or Certain embodiments are directed to an electrical
those required to meet different operational parameters . machine , wherein the at least one stator is a substantial
Electrical currentmay be supplied to the solid - state switches 30 portion of the stators contained in the electrical machine .
via the structure of the stators , thereby permitting a heavy Certain embodiments are directed to an electrical machine ,
current flow to the solid -state switches with minimal losses, wherein the at least one stator is all of the stators contained
and the embedding of the electromagnetic coils in the stators in the electrical machine .
permits efficient conductive cooling . In certain embodi Certain embodiments are directed to an electrical
ments, electrical current may be supplied to the solid - state 35 machine , wherein the at least one module is a substantial
switches via the structure of the stators, thereby permitting portion of the modules contained in the electrical machine .
a suitably heavy current flow to one or more of the solid Certain embodiments are directed to an electrical machine,
state switches with suitably minimal losses, and the embed wherein the at least one module is all of the modules
ding of the electromagnetic coils in the stators permits contained in the electrical machine .
suitable efficient conductive cooling. The positioning of the 40 Certain embodiments are directed to an electrical
switches immediately adjacent the electromagnetic coils machine , wherein the at least one electromagnetic coil is a
provides conduction paths of low resistance with minimal substantial portion of the electromagnetic coils contained in
losses. In certain embodiments , the positioning of the the electricalmachine. Certain embodiments are directed to
switches adjacent (or substantially adjacent) one or more of an electrical machine, wherein the at least one electromag
the electromagnetic coils provides conduction paths of suit- 45 netic coil is all of the electromagnetic coil contained in the
ably low resistance with suitably minimal losses . In certain electrical machine.
embodiments, the positioning of the switches above the Certain embodiments are directed to an electrical
rotor reduces the external circumference of the motor to machine , wherein the at least one switch is a substantial
ensure a small packaging fit while maintaining a suitably portion of the switches contained in the electrical machine .
low resistance with suitably minimal losses. In certain 50 Certain embodiments are directed to an electrical machine,
embodiments, the combination of one or more of the fea - wherein the at least one switch is all of the switches
tures provides an electric motor of high power density contained in the electrical machine.
and/ or one able to operate efficiently over an extended RPM Certain embodiments are directed to an electrical
range . In certain embodiments, the control system of the machine, wherein the at least one rotor is a substantial
direct current electric motor may be made to be continuously 55 portion of the rotors contained in the electrical machine.
adaptive , utilising complex logic to determine the most certain embodiments are directed to an electrical machine ,
efficient mode of operation in relation to prevailing opera - wherein the at least one rotor is all of the rotors contained in
tional parameters . In certain embodiments , the control sys - the electrical machine .
tem of the direct current electrical machine may be suffi Certain embodiments are directed to an electrical
ciently continuously (or substantially continuously ) 60 machine , wherein the plurality of magnets is a substantial
adaptive , utilising logic to determine or estimate the appro - portion of the magnets contained in the electrical machine .
priately efficient mode of operation in relation to one or Certain embodiments are directed to an electrical machine,
more prevailing operational parameters . wherein the plurality of magnets is all of the magnets
Certain embodiments are directed to an electrical contained in the electrical machine .
machine, wherein the electrical machine is a compact direct 65 Certain embodiments are directed to an electrical
drive electric motor that generates sufficient or improved machine , wherein the plurality ofmagnetic induction loops
propulsion in a wheeled vehicle and the electric motor and is a substantial portion of the magnetic induction loops
US 10 ,211,702 B2
10
contained in the electrical machine . Certain embodiments FIG . 13 is a face view of a rotor of the electric motor of
are directed to an electricalmachine, wherein the plurality of FIG . 10 , according to certain embodiments .
magnetic induction loops is all of the magnetic induction FIG . 14 shows a schematic top view of a rotor platter and
loops contained in the electrical machine . coil configuration , according to certain embodiments.
Certain embodiments are directed to an electrical 5 FIG . 15 shows a perspective view of the configuration of
machine , wherein the plurality ofmagnetic reluctance pro FIG . 14 .
jections is a substantial portion of the magnetic reluctance FIG . 16 shows in side view an example of the magnetic
projections contained in the electrical machine. Certain field lines between two magnetic rotors and one coil platter,
embodiments are directed to an electrical machine , wherein without end caps, according to certain embodiments.
the plurality of magnetic induction loops is all of the 10 FIG . 17 shows in side view an example of the magnetic
magnetic induction loops contained in the electrical field lines between two magnetic rotors and one coil platter,
machine. with ferrous steel end caps , according to certain embodi
Certain embodiments are directed to an electrical ments .
machine , wherein the plurality of stators is a substantial
portion of the stators contained in the electrical machine . 15 between. 18twoshows
FIG an example of the magnetic field lines
magnetic rotors and one coil platter, with the
Certain embodiments are directed to an electrical machine,
wherein the plurality of stators is all of the stators contained top rotor consisting ofmagnets aligned in a Halbach array,
in the electricalmachine . according to certain embodiments .
Certain embodiments are directed to an electrical FIG . 19 shows an example of a H -bridge switch topology
machine, wherein the plurality ofmodules is a substantial 20 that may be used with certain embodiments .
portion of the modules contained in the electrical machine. FIG . 20 illustrates an exemplary Motor Control Unit
Certain embodiments are directed to an electrical machine , (MCU ), Coil Control Unit (CCU ) , coil driver controller
wherein the plurality of modules is all of the modules architecture , according to certain embodiments.
contained in the electrical machine . FIG . 21 illustrates a CCU 's architecture , according to
Certain embodiments are directed to an electrical 25 certain embodiments .
machine , wherein the plurality of rotors is a substantial FIG . 22 shows one or more individual MCUs and CCUS
portion of the rotors contained in the electrical machine . in a 1: 1 : 1 configuration , according to certain embodiments .
Certain embodiments are directed to an electrical machine , FIG . 23 shows switches controlled by one CCU , with the
wherein the plurality of rotors is all of the rotors contained one CCU being controlled by one or more MCU in a 1 :1:n
in the electrical machine . su configuration , according to certain embodiments .
BRIEF DESCRIPTION OF THE FIGURES FIG . 24 shows switches controlled by CCUs, with the
CCUs being controlled by one or more MCU in a 1 :m :n
These and other features, aspects, and advantages of the configuration , according to certain embodiments .
with 3535
present disclosure will become better understood with FIG . 25 shows an exemplary controller configurations,
regard to the following description , appended claims, and whereby switches are controlled directly by one or more
accompanying figures where : MCUs in a 1:n configuration
FIG . 1 is a schematic showing the geometric properties of FIG . 26 illustrates a CCU without the need for a master
a magnet shape placed in a circular array, according to controller, according to certain embodiments .
certain embodiments . 40 FIG . 27 shows a configuration where a single motor
FIG . 2 is a schematic showing the geometric properties of control unit is connected to a common communication bus ,
a circular magnet shape placed in a circular array, according which is connected to one or more of the coil control units ,
to certain embodiments . according to certain embodiments .
FIG . 3 is a side view of an electrical machine that is made FIG . 28 shows a configuration where multiple motor
up of two electrical machines that are back to back and share 45 control units are connected to a common communication
a common rotor shaft , according to certain embodiments. bus, which is connected to one more of the coil control units ,
FIG . 4 is a side view of the electricalmachine illustrated according to certain embodiments .
in FIG . 3 but these embodiments share a common magnet FIG . 29 illustrates a configuration wherein each coil
rotor. control unit is connected directly to some or all other coil
FIG . 5 is a graph that shows how the total magnet count 50 control units , according to certain embodiments .
decreases as the number of coil stages increases , according FIG . 30 illustrates a configuration wherein a central
to certain embodiments. communication bus (token ring ) is used , according to certain
FIG . 6 is a graph torque comparison , according to certain embodiments .
embodiments . FIG . 31 illustrates a configuration with three redundant
FIG . 7 is a graph comparing the power losses due to 55 communication buses, according to certain embodiments .
electrical resistance of certain embodiments. FIG . 32 is a longitudinal cross -sectional view through an
FIG . 8 illustrates a gap in the conductive region of the electric motor made in accordance with certain embodi
stator, according to certain embodiments . ments.
FIG . 9 is a partially cut -away view of the electromagnetic FIG . 33 is an exploded view of the electric motor in FIG .
coils , according to certain embodiments of the present 60 32 .
disclosure . FIG . 34 illustrates an isometric view of the circuit boards
FIG . 10 illustrates a cross section view of a rotor platter
illustrated in FIG . 32 mounted in an electrical machine,
configuration according to certain embodiments . according to certain embodiments .
FIG . 11 illustrates a cross section view of two rotor FIG . 35 is a face view of a rotor of the electric motor of
platters configuration according to certain embodiments. 65 FIG . 32 .
FIG . 12 illustrates a cross section view of a three rotor FIG . 36 is a schematic diagram of the electrical and
platters configuration according to certain embodiments . electronic systems of the electric motor of FIG . 32 .
US 10 ,211,702 B2
11 12
FIG . 37 illustrates the electricalmachine detailed in FIG .motors in the same class and yet have sufficient power
33 . Suitable applications include traction motors in vehicles output to replace the combustion motor that would otherwise
attached in place of the differential, according to certain be used to power the machine or vehicle . Because of its
embodiments. small size and sufficient power to weight ratio , the electric
FIG . 38 is a top view of a rear wheel drive vehicle 5 motors disclosed herein allow the sameor a similar machine
illustrating a location of the electricalmachine, according to or vehicle to be powered at the same, similar or substantial
certain embodiments. the same performance characteristics. For example , an elec
FIG . 39 is a top view of a front wheel drive vehicle tric motor with the same, substantial the same, similar or
illustrating a location of the electrical machine , according to sufficient power and wheel torque as an existing internal
certain embodiments 10 combustion engine and drive train is disclosed in certain
FIG . 40 is a top view of an all wheel drive vehicle embodiments herein and yet the electric motor will fit the
illustrating a location of the electricalmachine, according to existing size envelope , or substantially the existing size
certain embodiments envelope , as the differential housing in an existing petrol
FIG . 41 is a top view of a semi-trailer truck illustrating a powered vehicle and mounted in the existing location , or
location of the electrical machine, according to certain 15 substantial the same location, as the existing differential. In
embodiments . other words, certain disclosed embodiments permit the
FIG . 42 is an exploded view of an electric machine, replacement or substitution of a combustion motor for
according to certain embodiments. powering the vehicle with an small light direct drive electric
FIG . 43 illustrates an isometric view of the circuit boards motor that has similar power outputs to the combustion
illustrated in FIG . 42 . 20 motor and yet can be placed where the existing differential
FIG . 44 is an exploded view of the stator illustrated in is located . The output can be directly coupled to the wheel
FIG . 42. using the vehicles existing half shafts. This permits the use
FIG . 45 illustrate four ways of stacking electrical lami of electric drive trains inside existing vehicles frames with
nates , according to certain embodiments. out redesign and retooling of the existing vehicle subframe
FIG . 46 illustrate various coils using a variety of conduc - 25 and half shafts.
tor winding types , according to certain embodiments . Certain embodiments are directed to compact direct drive
FIG . 47 illustrates a thinner section of the coil thatmay be electric motors that generate sufficient or improved propul
included in certain embodiments . sion of the wheeled vehicle wherein the electric motor and
FIG . 48 illustrates a pair of cores connected at the bottom the differential can fit the size of envelope of existing
such that the connectors are both at the top , according to 30 differentials in a conventional combustion engine driven
certain embodiments. vehicle .
Certain embodiments are directed to compact direct drive
DESCRIPTION electric motors that generate sufficient or improved propul
sion of the wheeled vehicle wherein the electric motor and
The present disclosure will now be described in detail 35 the differential can be installed in line with the drive axial
with reference to one or more embodiments , examples of while providing adequate clearance from the road without
which are illustrated in the accompanying drawings . The substantial modification to the existing suspension of the
examples and embodiments are provided by way of expla - wheeled vehicle .
nation and are not to be taken as limiting to the scope of the Certain embodiments are directed to a compact direct
disclosure. Furthermore, features illustrated or described as 40 drive electricmotor that generate sufficient propulsion of the
part of one embodiment may be used by themselves to wheeled vehicle , wherein the electric motor and a differen
provide other embodiments and features illustrated or tial can be installed in line with one or more the drive axels
described as part of one embodimentmay be used with one while providing adequate clearance from the road without
or more other embodiments to provide a further embodi- substantial modification to an existing suspension of the
ments . It will be understood that the present disclosure will 45 wheeled vehicle .
cover these variations and embodiments as well as other Certain embodiments are directed to a compact direct
variations and/or modifications . It is also to be understood drive electric motor that generate sufficient propulsion of the
that one or more features of one embodiment may be wheeled vehicle , wherein the electric motor and a differen
combinable with one or more features of the other embodi- tial can be installed in line with one or more drive axels
ments. In addition , a single feature or combination of 50 without lower, or substantially lowering, the clearance from
features in certain embodiments may constitute additional the road and without substantial modification to an existing
embodiments . suspension of the wheeled vehicle .
The features disclosed in this specification (including Certain embodiments consist of a stator and a rotor which
accompanying claims, abstract, and drawings) may be may be contained in an enclosure . The rotor creates a
replaced by alternative features serving the same, equivalent 55 magnetic field in the vicinity of the stator , the stator creates
or similar purpose , unless expressly stated otherwise . Thus, a disturbance in the magnetic field forcing the rotor to move
unless expressly stated otherwise , each feature disclosed is to a position that minimizes the disturbance in the magnetic
one example of a generic series of equivalent or similar field . The rotor may consist of a series of permanentmagnets
features . attached to a differential. The stator may consist of a series
The subject headings used in the detailed description are 60 of coils, attached to an enclosure . The enclosure may house
included only for the ease of reference of the reader and bearings to ensure that the rotor can rotate to minimize the
should not be used to limit the subjectmatter found through disturbance in the magnetic field . Certain embodiments are
out the disclosure or the claims. The subjectheadings should directed to an electrical machine comprising : at least one
notbe used in construing the scope of the claims or the claim rotor, a plurality of magnets used in , or in contact with , the
limitations. 65 rotor, at least one stator and a plurality of coils used in , or
Certain embodiments are directed to electricalmotors that in contact with , the stator, wherein the configuration is
are smaller and/or lighter than similar competing electric contain , partially contained within and a enclosure ; and a
US 10,211,702 B2
13 14
control electronics provides individual control over each coil electricalmachine requires between 500 to 100 , 100 to 300 ,
and /or cluster of coils generating the disturbances . In certain 50 to 100 , 150 to 250 , 300 to 250 , 225 to 175 , 150 to 75 , 75
embodiments, the control electronics provides individual to 50 , 50 to 25 , 20 to 10 , 15 to 5 , 2 to 5 times less the weight
control over one or more coils and /or one ormore cluster of heavier of wire as compared with a brushless permanent
coils generating the disturbances . In certain embodiments , 5 magnet three phase electrical machine with similar power.
the control electronics provides individual control over at In the example , above as there is 10 times less wire , the
least 40 % , 50 % , 60 % , 70 % 80 % , 90 % , 95 % or 100 % of the
volume of iron core required to wrap the wire around is
coils or at least 40 % , 50 % , 60 % , 70 % 80 % , 90 % , 95 % ordecreased . Subsequently the entire unit can fit into a sub
100 % of the duster of coils generating the disturbances . stantially smaller enclosure further reducing the mass of
Certain embodiments are directed to an electrical machine 10
that provides significant size , weight reduction , price reduc materials . High currents still need to be transferred from the
devices power input to the coils . If the body of the electrical
tion , or combinations thereof, while increasing the electrical machine is constructed from a good conductor such as
machine ' s power output, efficiency, reliability , maintainabil
ity or combinations thereof. Also disclosed are methods of aluminium , the body can be used as the conductor, further
using the electrical machine , methods ofmanufacturing the 15 reducing the mass of materials used . In this example , the
electricalmachine and /or systems that incorporate the elec exemplary electrical machine disclosed herein reduces the
trical machine. weight of a 300 kw electricalmachine from many hundreds
Certain embodiments are directed to adaptive magnetic of kilograms to about 34 kilograms. Certain embodiments
flux arrays wherein the device , methods, and /or systems disclosed herein provide an electrical machine that may
permit real time, or substantially real time, software recon- 20 produce substantially the same power output of a traditional
figurable electrical motor/ generator. The disclosed devices, electrical machine but with a weight that is reduced by at
methods and/ or systemsmay be used as both a motor and a least 95 % , 90 % , 85 % , 80 % , 70 % , 60 % , 50 % , 40 % , 30 % , or
generator may also be referred to as an electrical machine . 20 % . Certain embodiments disclosed herein provide an
One advantage of certain embodiments is the ability of those electrical machine that may produce substantially the same
embodiments to reconfigure itself in real time, or substan - 25 power output of a traditional electrical machine but with a
tially real time, this permits the machine , method and/ or weight that is reduced by between 95 % to 20 % , 90 % to 70 % ,
system to find its optimal settings across very wide operating 85 % to 60 % , 90 % to 50 % , 80 % to 40 % , 70 % to 50 % , 60 %
speeds and /or loads . Such flexibility results in energy sav - to 30 % , 50 % to 20 % , 40 % to 20 % or 30 % to 20 % .
ings across a plethora of industries . Other advantages of Another advantage of certain embodiments is the ability
certain embodiments disclosed herein are : reduce cost by 30 to independently control each coil, when less torque is
reducing the amount of copper in the windings ; the amount required or available , sections of the electricalmachine may
of electrical steel; the size of the package required to house be powered down. In certain embodiments the ability to
it or combinations thereof. independently control one or more coils , when less torque is
For example, the weight of the copper windings in an required or available, then sections of the electricalmachine
electrical machine is proportional to the size of current, 35 may be powered down . Certain embodiments are directed to
greater the current the heavier the wire . This relationship is an electrical machine with the ability to independently
quadratic , not linear. Certain embodiments effectively divide control one ormore coils. Certain embodiments are directed
and conquer this relationship . In certain embodiments each to an electrical machine with the ability to independently
(or one or more ) independent coil handles relatively small control one or more coils . Certain embodiment are directed
amounts of current. By using numerous small coils, the 40 to an electrical machine with the ability to independently
overall current through each coil ( or one or more ) remains control at least 70 % , 80 % , 90 % , 95 % , 98 % or 100 % of one
low , but the total current for the whole system scales or more coils in a plurality of coils . Certain embodiment are
linearly, along with the quantity of material and /or the cost directed to an electricalmachine with between 10 to 100, 20
of the electrical machine. By overcoming this quadratic to 50 , 50 to 200 , 20 to 60 , 30 to 80 , or 30 to 60 coils wherein
relationship much larger electrical machines may be built at 45 the electricalmachine is configured to independently control
more affordable prices . at least 70 % , 80 % , 90 % , 95 % , 98 % or 100 % of the coils .
For example , a traditional 3 phase 300 kw electrical Because certain disclosed embodiments have numerous
machine operating off a 415 v supply requires a current coils , substantially finer control over optimising the effi
through each phase of the coil of 240 amps. In one exem - ciency of the machine is available .
plary embodiment, the windings are distributed across 34 50 Traditional electrical machines control their peak effi
coils, the current per coils is 21 amps . To have the same, ciency by varying the timing of the switching between
substantially the same, or similar, resistive power loss phases of their coils. As the timing is traditionally set at
through the two configurations, the traditional electrical assembly or installation either by the brushes or the fre
machine requires about 10 times the weight ofwire . Certain quency of the drive circuit, variations of velocity and power
embodiments are directed to an electrical machine wherein 55 reduces the peak efficiency of the electrical machine .
the resistive power loss is substantially the same as the Another advantage of certain embodiments is that they may
resistive power loss of a traditional electrical machine but be configured to continuously optimize the timing of the
the electrical machine requires at least 500 , 400 , 300 , 250 , coils , this can provide efficiency savings of up to , for
200, 150 , 100 , 75 , 50 , 25, 20 , 10, 5 or 2 times less weight example , 40 % when summed over the entire operating
of wire . Certain embodiments are directed to an electrical 60 region of a comparatively powered electrical machine. Cer
machine that uses substantially less copper wherein the tain embodiments may be configured to optimize the timing
resistive power loss is substantially the same as the resistive of a plurality of coils substantially continuously , sufficiently
power loss of a similarmachine with fewer coils . The copper continuously, continuously , non -continuously , or intermedi
saved is proportional to the number of coils on the embodi- ately . In certain embodiments the ability to optimize the
ment contains compared to the number of coils contained in 65 timing of a plurality of coils substantially continuously ,
a comparable machine dn . The potential savings are up to dn sufficiently continuously, continuously, non - continuously , or
divided by cn times the copper. In certain embodiments, the intermediately provides an efficiency savings of up to 10 % ,
US 10 ,211, 702 B2
15 16
15 % , 20 % , 25 % , 30 % , 35 % , 40 % , 45 % , 50 % or 60 % when wave output. A consequence of cylindrical magnets is
summed over the entire operating region of a comparatively reduced total magnet volume, now referring to FIG . 1 we
powered electrical machine . have: Volume of trapezoidalmagnet:
In an axial configuration , certain embodiments of the
present disclosure may reduce the total number of perma - 5
nent magnets by a minimum of 25 % . The total saving V trap
la + b )
cd ; d = magnet thickenss
percentage increases with the number of rotors required .
This may be achieved by the sharing of common rotors ,
making use of both sides of a rotors magnetic fields rather
than one . For example , in a two stator, 4 rotor motor, one 10 Volume of circular magnet V circ = Tºd ; Noting : 2r = C
rotor is eliminated for a saving of 25 % . For 6 stator, 12 rotor and given the ratio of a :b is sufficient such that the trap
motor , 5 rotors are eliminated for a saving of 41 % . In certain ezoidal perimeter does not Intersect the circular perimeter.
embodiments, the total number of permanentmagnets may Now referring to FIG . 2 we have : Volume saving per coil :
be reduced by a minimum of 10 % , 15 % , 20 % , 25 % , 30 % ,
35 % , 40 % , 45 % , 50 % , 55 % , 60 % or 70 % and still provide 15
comparable power output. Vsaving = Verop - Veire
Certain embodiments of the present disclosure may
accommodate magnets of various shapes . For example , the
shape may be a cylinder , cuboid , segmented , trapezoidal or
Vsaving =(* 2. )od -ulja
saving =
la + b )
1012Icd - -
2/ a
other suitable shapes . 20

For smooth torque a sinusoidal application of force may Alternatively:
be suitable. Through the use of the interleaved coil design of
certain disclosed embodiments it is possible to create a
smooth sinusoidal output using cylindrical magnets . A fur
ther consequence of the interleaved coil design is reduced 25 Varingen=(1- Vacing )x 100=(1- 2004 ))x100
magnet volume. Most axial flux motors use trapezoidal
magnets , which for a given diameter, or trapezoidal height, In certain embodiments, this saving can be substantial, for
occupy and require more magnetic volume. For a trapezoi example if we compare two 25 mm thick rotors, one
dal with long edge length 40 , short 15 and height 25 , vs . a containing a cylindricalmagnet of a diameter of 25 mm and
circular magnet of diameter 25 , a volumetric saving of 30 once containing a trapezoidalmagnet with a = 30 , b = 20 , c = 25
29. 24 % is achieved . Minimal saving occurs when the trap the material savings in the cylindrical magnet would be
ezoidal shape approaches a square , giving a minimum
reduction of approximately 21 % . Certain embodiments may 21 .46 % . In certain embodiments, the material savings in the
be configured in a circular array , or substantially circular magnets would be at least 10 % , 15 % , 20 % , 30 % , 40 % , 50 % ,
array , such that the electrical machine has one more setset of
of 3535 or
or 60 % . Inwould
certain embodiments , thematerial savings in the
magnets than coils , the coils can be powered in such a magnets be between 10 % to 60 % , 15 % to 25 % , 15 %
to 40 % , 20 % to 60 % , 20 % to 35 % , 30 % to 60 % or 35 % to
sequence that the torque generated by the electrical machine
is sufficiently smooth . Ensuring that there is little variation 55 % In certain embodiments , the savingsmay be calculated
in torque during start up ensures smooth acceleration at low as follows:
speeds. For example , an embodiment that comprises a 17 40
coil circular array has about 30 times less variation in torque
N25
through a rotation than a 3 phase equivalent. Certain
embodiments comprising a plurality of coils in at least one
circular array has 50 , 40 , 35 , 30 25 , 20 , 15 , 10 or 5 , times
Varvinges ={1- 2630720))x100=(1–126)x100
Vsaving % 2030 + 20 )
x 100 = 11
725
100 )
x 100
:: Vsaving % = 21.46(% )
less variation in torque through a rotation than a 3 phase 45
equivalent.
Magnet Volume Reduction In regards to peak power, more power may be transferred
In regards to efficiency the ideal switching waveform in a square wave than in a sine wave . The effective power
inside a coil is a sine wave . The sine wave has only one thatmay be imparted into the coil by a sine wave is 1 divide
frequency component, the fundamental frequency, ensuring 50 by a square root of 2 (approximately 2/3) while the effective
that higher frequency harmonics may notbe contained in the power of a square wave is 1 . In terms of the effectiveness of
signal. An ideal square wave may be made up of the the mechanical energy that can be converted by a square
fundamental frequency ( the frequency of the square wave ) wave vs . a sine wave is dependent at least in part on the
plus an infinite sequence of higher frequency harmonics design of the coils and the magnets.
contained in its Fourier series. There are a number of 55 Magnets Saving Through Shared Platter Stacks
drawbacks in terms of high frequency harmonics . High In certain embodiments, the device may be extended to
frequency signals tend to travel along the outer edge of the provide more power by connecting two motors back to back
conductor known as the skin effect. The higher the fre - as illustrated in FIG . 3 . A weight and /or cost saving may be
quency the closer to the skin the signal travels. The resis - achieved by sharing of rotors as illustrated in FIG . 4 . In this
tance of a wire is proportional to the cross sectional area 60 example, the total number ofmagnets is reduced by sharing
where the electrons are travelling . The resistance of the wire the inner rotors, segments 1 and 2 , combining them into one
is therefore proportional to the frequency through that wire . rotor, segment 3 . Further, only the outer platters, segments
Further high frequency signals tend to radiate away from the 4 and 5 require back irons to contain the magnetic field
device causing interference to other devices . These radiated inside the device , as opposed to the unshared configuration
effects need to be contained and filtered to pass CE , FCC , 65 which requires all rotors to be shielded (a total of 4 plates ).
C - tick and other compliance standards . Circular magnets Typically, the back irons are heavy and thus there is a
coupled with the interleaved coil design create a nice sine substantial weight saving through sharing inner rotors . Fur
US 10 ,211,702 B2
17 18
ther the device is more compact, saving the mass of the angular position over a range of 0 to 360 degrees . Because
associated materials. In other words : Total number of mag the 17 phase electrical machine configuration effectively has
nets (unshared ): more phases than the other electricalmachine configurations
n totalunshared =nplattersXm ; m = number of magnets per
it has a more constant producible torque and a much
platter smoother torque without any smart software control or
otherwise controlling the electrical machine. In certain
Total number of magnets (shared centre rotor platter): applications the achievable torque may be even smoother
with the aid of software algorithms and feedback control.
Although the peak instantaneous torque producible of the
nunshared 10 other motor configurations is larger than that of the 17 phase
n total , = Munshared (Munshared – 1))xm
2
electrical machine , the power being delivered is approxi
mately the same, the power from the other motor types is
Left Figure: applied largely in short bursts making it harder to control.
n total =4x17 ; Assuming 17 magnets per platter
One of the features of certain disclosed embodiments is
15 that there may be an offset between a coil and a pair of
magnets , i.e.: if there is n coils and n + 1 magnets , then the
M rotalunshared =68 magnets may not perfectly align with the coils . This ensures
Right Figure : that the electrical machine of these embodiments will be
able to turn on at least one coil to turn the machine, while
20 also having the effect of smoothing the torque applied to the
machine. Because there is an offset between coils and
Motelshared = (4- (1 -1))x17 magnets , it has the effect of making the motor into an n
phase motor. In a traditional electric motor, when less power
n totalshared
is required , the amount of power applied in each rotation to
25 the motor is reduced . This reduces the produced torque
FIG . 5 is a graph that illustrates the reduction in the number non -linearly . In certain disclosed embodiments as one or
of magnets when common magnetic rotors are shared more coils (or each coil ) are able to be digitally controlled ,
between multiple stators . This example is based on rotors coils that produce less optimal instantaneous torque onto
with 18 magnets , but the general trends hold true for a range their corresponding magnet may be turned off . This causes
of embodiments. The x axis illustrates the number of stators, 30 a non - linear reduction in torque with respect to reduction in
and the Y axis indicates the number ofmagnets . A compari power.
son is made between a configuration sharing common inter - FIG . 7 illustrates the non - linear increase in heat generated
nal rotor platters 6 , to a configuration without shared rotor due to resistive losses as power is increased in different
platters 7 . It illustrates that there are significant saving in the electrical machines with different number of phases, with
number ofmagnets required , and thus cost, space and weight 35 comparative power between the electrical machines Certain
savings , when the platters are shared . This saving tends embodiments of a 17 phase machine 11 are compared to a
linearly towards almost 50° % or more platters are used . three phase 12 machines with substantially identical input
Torque Smoothing power. The x axis is a comparative axis of the percentage of
A traditional motor with only a single phase supply is only power and the y axis is the power loss through resistive
able to apply peak power to the shaft twice per rotation . A 40 heating . This demonstrates the superior power handling
basic comparison between motor configurations may be capability of the certain embodiments disclosed herein , if
used by assuming the resulting rotational torque is propor - the power to the coils is linearly adjusted from 0 to 100 %
tional to the sine of the angular difference of the coils to the which is possible due to direct microprocessor control.
permanent magnets (ta sin ( F )) Having more phases for power divides the current supplied
In this exemplary embodiment it is assume that for the 45 between each of the phases substantially equally and as such
number of phases in a motor, the power applied is constant. the power loss due to resistive heating is non - linearly
As the numbers of phases in the motor are increased , the reduced by the factor of the number of phases , as power loss
power is distributed and applied more evenly . For a three is typically equal to the current squared times the resistance
phase motor, it provides maximum power and torque to the of its conductor. This means that to deliver the same power
shaft 6 times per rotation . Its maximum instantaneous power 50 as other motor types certain embodiments may be much
is less than the single phase motor. Since certain embodi- smaller and/ or lighter than existing motor types and/ or be
ments of the present disclosure may have at least 17 to 1024 capable of handling higher power requirements and outputs .
independently controllable phases . Certain embodiments Torque Smoothing Vs. Operating Frequency
may have between 17 to 1021 , 19 to 1181 , 29 to 109, 53 to Because torque applied at any instantaneous moment is a
127, 89 to 257 , 211 to 331, 199, to 577, 433 to 751 , 577 to 55 function of the angle of themotor platter, the apparent torque
1051, 613 to 757 , 619 to 919 , 773 to 857 , 787 1021 or 811 smoothing will vary with frequency , i. e.: as themotor speeds
to 1283 independently controllable phases . Certain embodi up , the variations in torque will become less obvious. Since
ments may have between 10 to 1050 , 20 to 40 , 30 to 50 , 50 certain embodiments may be operated with n phases, one or
to 1200 , 75 to 150 , 200 to 500 , 400 to 1200 , 600 to 900 or more coils (or each coil) may operate n times faster than it
700 to 1100 . This distributes power more evenly throughout 60 would on a single phase motor. The torque may be further
a single rotation and results in smooth torque being applied smoothed by using digital algorithms to limit the maximum
to a load. power applied to a coil in the optimal position . This may
A simple comparison of maximum producible instanta - have the effectofslightly reducing themaximum torque, but
neous torque throughout a motors rotation is presented in would substantial smooth the torque output FIG . 6 shows a
FIG . 6 . This graph demonstrates the relative torque on the y 65 graph that demonstrates the superior torque smoothing of
axis a similarly rated single phase 8 , three phase 9 and 17 certain digital axial flux motor embodiment compared to
phase electrical machine 10 . The x axis indicates the motors some standard motor types. One of the advantages of the
US 10 ,211,702 B2
19 20
motors in these embodiments is that it can individually other ball , pin or conical bearings ; interference between
control power to each coil ( or one or more coils ), allowing shaft and assembly with low friction surface ; the shaft may
it to maintain suitably high output powers and / or torques be of sufficient diameter and / or stiffness such that bending
while keeping its n phase torque smoothing characteristics . due to magnetic forces between rotor platters does not occur
These embodiments have the ability to change on the fly , for 5 or is sufficiently reduced . In certain embodiments , the mate
lower rpm ' s where torque smoothing is more important, the rials that may be used for shafts and / or spacers include
motor may intelligently apply a smoothing profile , or a metals ( such as steel, aluminum ), polymers or other suitable
profile for suitable maximum torque and / or output power as materials . Torque transmission : In certain embodiments ,
it is required , or at higher rpm ' s. once torque is induced in the rotor it may be transmitted
Rotor 10 either mechanically through direct fixture to a shaft, via
Exemplary embodiments of the present disclosure may magnetic couple to an externalmagnetic platter,mechanical
consist of one or more rotors . One of their purposes is to coupling to a shaft ( egg . via a clutch ), other suitable means
create a magnetic field in the vicinity of the electromagnets, or combinations thereof. In certain embodiments, it is pos
such that the stator coils induce torque in the rotor. Magnets sible for the shaft to be removed entirely ( or partially ) and
may be secured within the rotor via multiple methods. For 15 replaced with a spacer, or multiple spacers, to separate two
example by gluing ; clamping (between two or more rotor or more rotor platters. In these configurations the assembly
layers ) and /or interference fit (with the surrounding hole ); may be located within the enclosure through the use of
mechanically fixing (for example , bolted , threaded or other magnetic suspension . Alternatively, in certain embodiments ,
suitable ways ); welding (when applicable to chosen magnet an annular bearing supporting the inner or outer radial edge
and / or rotor material) ; sintering; other effective means or 20 of the rotors (or a substantially portion of the rotors ) may be
combinations thereof. used . These configurations may or may not use a centre
The rotor may be constructed from a number of materials. spacer to separate rotors axially , depending on the number of
Construction materials chosen for the rotor may vary bearings used .
depending on the application of the motor, as well as the Magnets
chosen magnetic field strength between the rotors . In certain 25 Certain embodiments of the electrical machine disclosed
embodiments , the chosen material will typically be of suf- herein may incorporate different types and/ or shapes of
ficient Young 's Modulus ( stiffness) to prevent unacceptable magnets . One of the purposes of the magnets is to induce a
deformation or substantial deformation due to the axial magnetic field , through which suspended electromagnetic
magnetic forces between two separate rotor platters . Mate coils can pass (thus inducing kinetic forces on the coils/
rials used may include (but are not limited to ): aluminium ; 30 rotors ). Applicable types of magnets include , for example :
polymers, such as HDPE (High density polyethylene); fibre rare earth magnets including but not limited to Neodymium ,
reinforced polymers , such as carbon fibre or fibreglass ;other Neodymium -boron, Samarium -cobalt alloys or combina
suitable materials or combinations thereof. tions thereof; various types of superconducting magnets ;
Magnetic Rotors : In certain embodiments , the need for standard and / or permanentmagnets made of materials such
separate magnets (which are then attached to the rotors ) may 35 as but not limited to Alnico , Bismano , Cunife , Ferico ,
be eliminated (or reduced ) through the use of sintering to Heusler, Metglas, and other magnetic alloys or combinations
bond separate magnets and the mechanical casing into thereof electromagnets , such as wire coils , thatmay induce
substantially one structure . A finishing surface may then be an electromagnetic field , magnetic fields resulting from
applied ( for example, nickel , epoxy ) to increase mechanical materials with encoded quantum spin effects; induction
strength and/or durability . 40 magnets , in which ferrous material exposed to a perpendicu
Reluctance configuration : In certain embodiments , it is lar, or substantially perpendicular, electromagnetic field may
possible for the magnets to be replaced in whole or in part be subject to a force pulling it towards the center of the
with a ferrous annular ring or disk and/ or with a series of electromagnetic field , other suitable magnets ; or combina
partial depth radial slots creating a series of protruding fins . tions thereof.
When a fin is within the vicinity of the magnetic field of the 45 In certain embodiments ,magnet shapes that could be used
stator that fin may rotate and align itself with that field , but not limited to are : cylinders ; cuboids ( suitable 3D
resulting in a reluctance motor configuration . Inductance shapes ); segmented , where the magnet is made up of in
configuration : In certain embodiments, by replacing one or whole or in part a cluster of smaller magnets; Trapezoidal;
more , a substantial portion of , or all of the magnets in the solid or hollow (e . g . toroidal shape or hollow cylinder );
rotors with coils , the stator coils magnetic fields will induce 50 Groups, either of the substantial the samepolarity or oppos
magnetic fields in the rotor coils. In certain embodiments by ing; angular and/ or radially offset repetition of above
wiring the rotor coils to their symmetric or offset equivalent arrangements ; other suitable shapes for a particular appli
coils (with respect to the rotor ), opposing magnetic fields cation ; or combinations thereof. The thickness of magnets
may be induced , resulting in rotational forces . Material may be either equal to or not be equal to the stator mount/
Reduction : for certain applications it may be advantageous 55 platter thickness . The thickness of coils may be variable to
to reduce the rotational inertia of the rotor and/ or shaft suit the application . In certain embodiments , the number of
assembly . To this end the rotor discs may have their shape magnets and coils may or may not be set such that: the
changed to remove excess material which is not necessary to number of coils never is the same as the number ofmagnets ,
the mechanical structure of the disk . to ensure one or more , a substantially plurality or all the
Shaft and Spacers: In certain embodiments , the rotor 60 magnets and coils never completely align ; if number of coils
assembly may be located within or partial within the motor is equal to number ofmagnets, the magnet or coil position
enclosure through the use of a shaft. This shaft may have a is geometrically offset to substantially prevent, prevent, or
non - uniform diameter such that translational movement of reduce their concentric alignment or combinations thereof.
the rotor magnet platters in the rotational axis of the shaft is In certain embodiments , the magnets and / or coils may be
reduced , substantially prevented or prevented . The transla - 65 aligned such that: magnets may suitably axially aligned with
tional forces may be absorbed from the shaft into the casing . coils or vice - versa , such as in an axial flux configuration ;
Methods include (but not limited to ): axial thrust bearings or magnets are suitably axially misaligned with coils or vice
US 10 ,211,702 B2
21 22
versa up to 20 , 25 , 30 , 35 , 40, 45 , 50 , 55 , 60 , or 65 degrees; enhance magnetic field proportional to the number of loops
aligned , or substantially aligned , with the platter ; substan - of the ribbon . The magnetic field may reach its maximum
tially perpendicular, or perpendicular, to platter other suit- magnitude at the centre of the coil with a sine distribution on
able configurations perpendicular or combinations thereof. either side . Combinations of the various constructions dis
Stator 5 closed herein are also contemplated . The coils may be
Certain embodiments of the disclosed electricalmachines constructed in one or more of the following shapes: round/
may incorporate one or more stators which may be used to cylindrical, square /cuboid , trapezoidal, solid or hollow (air
locate the electric coils . The stator may be incorporated gap )/ annular, and other suitable shapes .
directly into the casing, independent or a combination in certain embodiments, the electromagnetic coils may be
thereof. As such the materials chosen for the stator follow 10 wound , bent and / or otherwise constructed from one or more
the same convention outlined in the ‘Material' section of the pieces of a conducting material, or a sufficiently conducting
casing description or disclosed elsewhere herein . The cho - material. The coils may be 3D printed or otherwise made .
sen material may be highly (or suitably ) conductive both The conductor may be 3D printed along with a core ( if 2
electrically and/or thermally. In certain embodiments, the material (or more) 3D printing is used ). The conductor may
one or more stators may be used as electrical conductor 15 be 3D printed and the core added in a separate process . 3D
(power delivery ), as heat sinks ( from the electronics and printing refers to selective laser sintering, selective electron
coils to casing ), as well as mechanically supporting the coils beam melting and/ or other selective deposition techniques.
and electronics or combinations thereof. In certain embodi- In certain embodiments , coils may be affixed to the stator
ments, the one or more stators may allow transmission of by: a glue/bonding agent, clamping, mechanically , welded ,
communication signals , either digital or analog , superim - 20 3D printed directly with the stator plate , or combinations
posed on the power layer, on its own layer, or combinations thereof.
thereof. Thus, layers in the stator may be electrically insu In certain embodiments, the conductor of the coil may be
lated from each other, if they are used for electrical con - composed of copper, aluminum , carbon structures such as
duction purposes . In certain embodiments ,methods of insu - graphene or other suitable conductive material.
lation may include : oxide layers on metallic surfaces ; using 25 In certain embodiments , the ferrous material may be
insulating materials between layers such as plastics or other constructed out of electrical steel, amorphous metal or other
appropriate materials, or combinations thereof. In certain high magnetic permeability material.
embodiments , gaps may be included in the one or more Coils and/or Magnet Positions
stators to reduce material required and/ or the weight. When In certain embodiments, coils and/ or magnets may be
the stator is constructed out of conductive material gaps may 30 arranged / varied in many different physical configurations. In
be added to eliminate eddy currents from forming around the certain embodiments, an axial flux configuration may be
coil. For example as shown in FIG . 8 a gap 14 in the used comprising: at least one, two ormultiple rotor platters
conductive stator 15 is introduced in the stator near the ofmagnets creating an alternating magnetic field parallel, or
location of the mounting hole for the magnetic coil 16 substantially parallel, to the axel ; and a plurality of coils
breaking the conduction path of the eddy current 17 induced 35 between magnetic fields.
when a current flows through the magnetic coil. In certain FIGS . 10 , 11 and 12 exemplify a number of different
embodiments, the gaps are located such that two concentric configurations of the electrical machine. FIG . 10 illustrates
annular rings are not formed radially on either side of the a cross section view of a rotor platter configuration accord
ring formed by the coils . ing to certain embodiments. The platter 18 has a differential
Coils 40 carrier 19 and a plurality of alternating pole orientation
Certain embodiments of the disclosed electrical machines magnets 20 and 21 in this exemplary embodiment 18
may incorporate different types and/ or shapes of inductive magnets are present) and coils 22 (in this exemplary
coils , the purpose of which is to by use of electric current, embodiment 23 coils are present). Themagnets are arranged
induce and/ or alter an existing electromagnetic field , creat in a substantial concentric configuration arrangement near
ing a force which causes the rotor of the motor to turn . In 45 the outer edge of the platter. FIG . 11 is similar to FIG . 10 ,
certain embodiments , the coils may be constructed of suf- but has two rotor, element 8 which create a more concen
ficient materials to handle both the heat and the electric trated magnetic field across the coils, 22 . Also shown is a
current requirements of the motor, the coils may be con - spacer 63 between the two platters . FIG . 12 is similar to FIG .
structed so as to lower the electrical resistance to ensure 10 in a triple rotor platter configuration . This configuration
there is minimal power loss due to resistive heating ; the coil 50 permits more power to be added by adding appending extra
may be constructed such that they produce a magnetic field coil platters .
sufficiently large enough to create sufficient force or com FIG . 13 shows a top down view of the rotor platter 18 in
binations thereof. One exemplary coil is shown in FIG . 9 . the configurations illustrated in FIGS . 10 to 12 . Shown are
In certain embodiments , coilsmay be constructed as an air the 18 alternating polarity cylindrical magnets 20 and 21,
core , the conductive material is wrapped or rolled in such a 55 distributed radially on the rotor platter 18 . Also shown is the
way that there is an air gap in the middle of the coil ; solid location of the differential carrier 19 .
core , there is no (or suitably little ) air gap in the middle of Certain embodiments of the disclosed electrical machines
the coil. In certain embodiments , the core may either be may be configured in a substantially circular array (radially
made of the conductive materialused or be a non - conductive aligned ) wherein : a plurality magnets and a plurality of coils
material, either ferrous or nonferrous . Ferrousmaterials with 60 may be axially perpendicular ( or substantially perpendicu
a high magnetic permeability increase the magnitude of the lar) to at least one rotor shaft ' s primary axis . In these
magnetic field for a given current before the magnetic embodiments , the magnetic properties of a normal axially
material saturates . In certain embodiments , the coil may be aligned stator motor are present with the added benefits of
interleaved , the coil is made from conductive ribbon and /or fine grained adaptive magnetic flux control. FIG . 14 shows
sheet. The ribbon is coiled from the centre core to the outside 65 a schematic top view of a rotor platter 23 wherein the
while interleaving layers of insulated ferrous materials . The magnets 24 and 25 are axially perpendicular (or substan
ferrous material acts as an insulator and as a core material to tially perpendicular ) to the rotor 's differential carrier 10 and
US 10 ,211,702 B2
21 -
23 24
are at least partially within the platter, according to certain In certain embodiments , the enclosure may or may not be
embodiments . Also shown are a plurality of coils 22 that are electrically conductive . In certain embodiments , power and
also axially perpendicular ( or substantially perpendicular) to signal lines may route placements but the casing itself is not
the rotor ’s differential carrier 10 and are configured concen - used as a conductor. In certain embodiments , the casing
trically around the outer radius of the platter embodiments . 5 itself may be used as a conductor . In certain embodiments ,
The stator 26 can be seen holding coils 22 radially around portions of the enclosure may be electrically conductive ,
the magnets . A clearance gap 27 can be seen between the typically with conductive parts separated by insulating lay
magnets and the coils. FIG . 15 shows a perspective view of e rs. Such configurations allow power to be supplied directly
the configuration of FIG . 14 . (or indirectly ) to the electronics through the casing. In
Certain embodiments of the disclosed electricalmachines 10 certain embodiments , conductive mount points may be
may be configured in a substantially circular array ( radially attached directly ( or indirectly ) to the outside and /or inside
aligned ) wherein : a plurality magnets and a plurality of coils of the casing. In certain embodiments , portions of the casing
may axially perpendicular (or substantially perpendicular ) to may be used as conductors , for example , signal transmis
at least one rotor shaft' s primary axis . Such embodiments sion . Nonconductive sections may be used to isolate con
have the magnetic properties of a normal axially aligned 15 ductive sections to allow multiple signal ‘lines ' through the
statormotor, with the added benefits of fine grained adaptive casing . In certain embodiments, power configuration and /or
magnetic flux control. electronic communication and/ or other signals may be mul
End Caps tiplexed onto the power lines at a higher frequency by means
Magnetic fields that are not constrained may couple onto of a suitable technology such as Direct Sequence Spread
conductive surfaces and induce eddy currents which may 20 Spectrum (DSSS ). The present disclosure also contemplated
create magnetic fields opposing the motion of the magnets . combinations the enclosure configurations discussed herein .
For example, FIG . 16 is a side cross -sectional magnetic field In certain embodiments, one or more circuit boards may be
diagram of a linear array of evenly distributed magnets , replaced with conductive /tracks/pads routed and/or etched
where consecutive magnets 20 have their north pole facing directly into the device casing . In certain embodiments , at
up , and the rest of the magnets 21 have their north pole 25 least a substantial portion of the circuit boards may be
facing down, with electromagnetic coils in the middle induc - replaced with conductive/ tracks/pads routed and / or etched
ing a magnetic field north 28 and south 29 . FIG . 16 illus- directly into the device casing.
trates the external radiating magnetic field 30 without any In certain embodiments, one of the purposes of the casing
shielding . FIG . 17 illustrates the reduction in radiated elec - may be to extract heat from the electronics ( for example , the
tromagnetic energy in the scenario described in FIG . 16 with 30 coils ). It is useful if this heat is transferred to the environ
ferrous shielding plates 31 added . In certain embodiments, a ment surrounding the casing as efficiently as possible . In
Halbach array arrangement may be used instead of the certain embodiments, methods of cooling thatmay be imple
ferrous shielding FIG . 18 illustrates the reduction in radiated mented include one or more of the following active cooling
electromagnetic energy in the application described in FIG . (forced air flow ) ; active cooling ( force liquid flow ); active
16 with a Halbach array arrangement of magnets used on the 35 cooling ( refrigeration ); passive cooling (heat pipe /pump
top platter. The Halbach array arrangement may use smaller transfer ); passive cooling (convective heat fins , ribs ); pas
magnets 32 , and opposite polarity magnets 33. The smaller sive cooling ( convection holes ); active or passive cooling
magnet is positioned between the two larger magnets with a (convection channels ); chambered ( sealed static fluid with
magnetic field substantially perpendicular to those of the high thermal conductivity to concentrate and /or direct heat
bigger magnets . The smaller magnet bends the magnetic 40 flow ); and entire enclosure sealed with non - electrically
field lines from the first large magnet to the next large conductive fluid .
magnet and reduces the distance to which the flux loops past In certain embodiments, circuit boards (and their attached
the end of the plate 33 . This has close to the same effect of electronics ) may be mounted such that they do not move
adding a ferrous shield to the system , and may dramatically when subject to external or internal forces ( linear or angular
reduce the external electromagnetic energy ; this has the 45 accelerations of the motor) or vibrations. In certain embodi
effect of saving the weight of the ferrous shielding plates that ments , circuit boards ( and their attached electronics ) may be
would otherwise be used in this application . Ferrous shield - mounted such that they do not substantially move when
ing 31 is used on the bottom layer of magnets for compari - subject to external and / or internal forces ( linear or angular
son . accelerations of the motor ) or vibrations. In certain embodi
Enclosure 50 ments , circuit boards ( and their attached electronics) may be
The enclosures discussed herein serve numerous pur - mounted such that they are sufficiently stable when subject
poses. In certain embodiments , it may be designed to cover to external and/ or internal forces (linear or angular accel
or enclose ( partially , substantially or fully ) the moving parts erations of the motor ) or vibrations . In certain embodiments ,
and circuit boards, it can also hold one ormore coils in place , circuit boards (and their attached electronics ) may be
the electronics in place , provides a source of heat sinking 55 mounted using one or more of the following methods:
away from the coils and / or electronics , it can support the specifically shaped cavities in the casing such that circuit
bearings and/ or absorb axial forces on the shaft, it may be boards can slot in with a transition or interference fit;
used as a conductor to shunt electrical power to and / or from modular inserts ; circuit boards sandwiched between two
the electronics , or combinations thereof. The enclosure may casing components; mechanically fastened or clipped ;
be constructed from materials (or combinations ofmaterials ) 60 glued , or otherwise permanently joined .
which are sufficiently strong to resist (or substantially resist ) For applications that are not as mechanically constrained
deformation due to loads applied from the half shafts. this represents a more flexible electrical and mechanical
Additionally, in certain embodiments , it is desirable for the solution . In certain embodiments, electronic components
casing to sufficiently resist thermal fluctuations resulting in (and / or circuit boards ) may be attached to modular inserts
part from the electronics current draw . Example materials 65 that may be slot/snap /or be otherwise attached to the primary
that match these properties include, but are not limited to : casing externally, without the need to disassemble other
aluminium , polymers or other suitable materials . inserts and /or the primary casing . In certain embodiments,
US 10 ,211 ,702 B2
21 -
25 26
electronic components (and /or circuit boards ) may be con - mechanical relays . In certain embodiments , the one or more
figured as a modular insert that may be attached to the switches may be used to drive the electromagnetic coils and
primary casing externally, without the need to disassemble may be implemented in different ways and may be com
other inserts and /or the primary casing . prised totally or partially from one or more of the following
In certain embodiments , the electrical machine may 5 configurations/ devices : single switch ; an H - bridge ( full
include one or more of the following : at least one electrical bridge ); a Half bridge ; a Half bridge with a high and a low
bus, at least one optical bus, at least one radio frequency side switching ; bilateral switch configurations, single phase
channel and a bus consisting of one or more digital and /or voltage source inverter, half bridge voltage source inverter,
analogue communication channels . For example, when mul- AC chopper regulation and other various one, two , three
tiple microcontrollers are used , inter communication 10 phase and multiphase configurations .
between microprocessors typically may occur over a bus . The switches may be obtained without their plastic pack
This bus may be mounted and constructed in one or more of aging and embedded directly into the one or more coils .
the following ways : for electrical conductor ( groove cut for Switches may be integrated into the body of the one or more
circuit board , or other form of conductor to mount); for coils , either after or during the construction process of the
optical conductor ( cut directly into casing , with reflective 15 one or more coils. In certain embodiments referencing FIG .
coatings applied to cut surfaces, and / or inserted into groove 19 where the high side switches 35 and 36 , the transistors
in casing); other suitable methods for mounting the conduc may be biased to the high side of the coils. When using
tor . In certain embodiments , when an optical bus is in use , Positive Field Effect Transistor (PFET ) or Positive Negative
optical transceivers on one or more microcontroller may be Positive (PNP ) Bi Junction Transistors (BJTs ), a negative
mounted to interface with the bus. Thus the microcontroller 20 voltage is applied in reference to their positive input and the
positionsmay be tangentially arrayed around the optical bus. control pin may turn on the gates. PNP BJTs and PFETs are
In certain embodiments, where optical or radio frequency generally more expensive than Negative Positive Negative
transceivers are used , the bus may be the voids within the (NPN ) BJTS, Negative FETs and IGBTs. These devices
enclosure. would turn on if the voltage at their controlling terminal is
In certain embodiments , another function of the casing 25 greater than the voltage at their negative terminal by a few
may be to protect one or more internal components from volts. In certain embodiments , to achieve this one or more of
external damage . It may be desirable that the seams of the the following may be used : a charge pump; an isolated
casing be waterproof. Itmay also be desirable that the casing DC -DC converter, a separate power supply ; and other volt
be covered in , and /or made partially of, vibration /impact age boost methods may be used . It is possible to vary the
absorbing coating ( e . g . elastomer polymers ). In certain 30 current flowing through the coil by use of pulse width
applications, the casing may be an optional mounting point modulation . In certain embodiments , the switches may be
for master power cutoff switch . turned on and off at a high frequency, and by controlling the
In certain embodiments , one or more power and/or con duty cycle (the time the switch is on compared to the time
trol signals may pass through the enclosure . In certain the switch is off) the amount of current flowing through the
embodiments , at least a substantial portion of the power 35 coil is controlled by this duty cycle . If the switches are just
and /or control signals may pass through the enclosure . on (100 % duty cycle ), then the maximum current flows
Mounts can be provided for these connections using one or through the coil . If the switches are off (0 % duty cycle ), then
more of the following: lugs /clips, bolts , rings / sockets no current will flow through the coil. If the switches are on
clamps, weld points, and other suitable ways for mounting . half the time and off half the time the current could be 50 %
Also for external control and / or information mounts one or 40 of the full current but may depend if the inductance of the
more of the following may be used : switch mounts , calibra - coil at the switching frequency is too high or too low . In
tion mounts ( variable , quasi fixed controls ), and embedded certain embodiments , when the direction of current through
displays (LCD , or other ). For Microcontroller Bus Interfaces the coil does not need to be reversed , a single switch can be
one or more of the following may be used : galvanically used between the voltage source , the coil and the ground .
isolated connections (optical, radio , magnetic ), USB , Serial, 45 This reduced the component count by three switches . In a
other digital and analogue connections , and other suitable single phase AC configuration the voltage can be half
ways or structures . In certain embodiments , for mechanical rectified to create a positive rail and a negative rail . The two
outputs when applicable , the differential carrier may pass rails can then be switched through the coil to ground
through the casing via one or more of the following ways : effectively changing the direction of the current. This
optionally , a bearing seal, variable diameters , unsealed pass 50 reduces the number of switches required by two. In certain
through hole (exposed inner assembly ) and other ways of three phase star configurations , the phase with the nearest
sealing shaft passthrough point. In certain embodiments, the ideal voltage may be switched so that power can flow from
enclosure may also have mounting points for magnetic that phase to ground . In certain delta three phase configu
coupling platters . rations, two switches may be required on either end of the
Switch Architecture 55 coil to each phase , in this configuration current can be
In certain embodiments, one or more electronically con - selected to flow from one or more phases to one or more
trolled switches may be used to control the size and direction other phases .
of the current through the coils. These switches may bemade Control
up of discrete components (e . g., transistors and/or other In certain embodiments , one or more control mechanics
silicon switch technology ) including one or more of the 60 may be used with respect to the driving operation of one or
following: IGBT's or other similar technology ; FET 's or more electronic components. The one or more control
other Channel/Field effect transistor based device (MOS- mechanics may be implemented either at a hardware or
FETS etc ); BJT 's or other hi- polar transistor based device ; software level, or both . In certain embodiments, the number
ECP or other emitter coupled transistor device ; digital of coils activated at a particular instance may be varied from
switches such as transistors; silicon carbide transistors; 65 0 to the totalnumber of coils . The choice of this numbermay
diamond switches ; Triacs; Diodes ; SCRs ; other suitable be based at least in part upon the currently active control
electronically controlled switching technology ; and electro scheme. This decision may be made at the Main Control
US 10 ,211,702 B2
27 28
Unit (MCU ), Coil Control Unit (CCU ) and/ or an external and used in either hardware and/ or software as outlined in
level. In certain embodiments ,motors may be configured to the control sections . In certain embodiments , feedback may
operate in the clockwise , counter clockwise , or both direc - be collected local to one or more devices or remotely and
tions . In certain embodiments , in order to produce motion , used in either hardware and /or software as discussed herein .
coils may be switched on and off at specific instants. These 5 In certain embodiments , feedback may be measured and / or
instances may be determined by one or more of the follow - obtained in one or more of the following ways: instanta
ing: neous voltage across a coil via an ADC , or otherwise , at any
A . Stored sequences including : observed ( obtained via time or substantially any time; current through a coil or
sensor feedback ); streamed ( obtained via external devices ); power supply , by either contactless (hall effect) or contact
precomputed (stored within the motor electronics) ; 10 currentmeasurement; back EMF measurement, may be done
B . Computed sequences including: sequential based acti- while coil is not in a powered state ; angular position ,
vation ( coils are toggled sequentially in a rotary fashion with obtained by a sensor as discussed herein ; magnetic field
alternating polarity ) ; Optimal force activation ( coils are strength or angle ; temperature ; and vibrations via acceler
activated when their individual feedback data indicates an o meters or otherwise . In certain embodiments , angular posi
optimal force will be applied to the rotor ); optimal efficiency 15 tions of the rotor may be obtained by measuring one or more
activation (coils are activated in a manner to maintain target of the following : absolute angle or position : relative angle or
operating motor dynamics whilst minimizing power con - position ; and velocity . In certain embodiments, readings
sumption ); and random based activation (coils are activated may be achieved through the use of sensors such as one or
randomly ); pattern based sequence (coils are sequenced in a more of the following: Hall effect and /or other magnetic
predetermined pattern ); feedback frequency based (Coils are 20 sense technology, such as GMR, AMR ; rotary and/or
activated based on a driving analogue frequency signal); and quadrature encoder, optical or otherwise ; position / velocity
C . Other suitable driving sequence which achieves desir detection sensors such as laser/optical trackers currently
able motor performance . used in computer mice ; and cameras in combination with
In certain embodiments , feedback may be used to gener - Software processing.
ate and /or choose optimal driver routines/patterns to adapt 25 Controller Architecture
the device to changing conditions such as but not limited to : In certain embodiments, axial flux electrical machines
changing temperature or other temporary forces/ stress ' that may comprise : coil driving controllers , coil control units
may alter motor operational performance ; a depleted battery (CCU ' s ) and /or motor control units (MCU ' s ). In certain
changing voltage supply ; an increase in demand on a gen - embodiments , the layout of the controllers may be varied ,
erator or formechanical output in an application ; change in 30 while maintaining control of each coil individually .). In
parameters of the device caused by damage and/ or general certain embodiments, the layout of the controllers may be
wear and tear; or combinations thereof. varied , while maintaining control of one or more coils
In certain embodiments , certain electricalmachine param - individually . In certain embodiments , the layout of the
eters may be calibrated using sensor feedback or other ways controllers may be varied , while maintaining control of at
of tuning . For example , the use of machine learning tech - 35 least a substantial number of the coils individually . In certain
niques , and/ or other automated tuning, operating internally, embodiments , the layout of the controllers may be varied ,
externally or combinations thereof may be used . while maintaining control of at least 50 % ,60 % , 70 % , 800 % ,
In certain embodiments, the active control scheme can 900 % , 95 % , 98 % , 99 % or 100 % individually. The control
utilize several techniques to reduce power consumption lers drive ‘ switches ' as described in this disclosure , allowing
and/ or better optimize power consumptions . For example , 40 control of the coils, as described in this disclosure . FIG . 20
one or more of the following may be used : dynamic reduc - illustrates one exemplary relationship between an exemplary
tion of active coil count ( lower power per torque ); dynamic Motor ControlUnit (MCU ) 37 , Coil Control Unit (CCU ) 38
reduction of active coil power percentage ( smoother torque); the communications buses 39 , 40 that are available to them .
back EMF reproduction /elimination optimization ; and pulse One or more MCU ' s may be communicating with one of
width modulation of the coil driving signal to allow preci- 45 more CCU ' s. Also illustrated is the coil driver architecture ,
sion control on power applied to coils . according to certain embodiments , which includes a one or
In certain embodiments, feedback monitoring may be more coil drivers 41 for one or more coils 22 . The signalling
used to detect faults and automatically power off faulting between CCU ' s , MCU ' s 47 and coil drivers 42 may be
devices . For example , one or more of the following coil galvanically isolated . FIG . 21 illustrates a CCU architecture,
current overflow protection /detection ; over -voltage/Over 50 according to certain embodiments .
power protection ; overheating protection , and velocity over - A Microcontroller 43 may be used to control the device ;
spin protection . In certain embodiments , arbitrated master it incorporates an Analogue to digital converter ( ADC ) with
mechanismsmay be used such as master controllers may be an external interface 44 for collecting data from sensors 45 .
nonsingular, with the resulting control signal arbitrated Communications transceiver 46 is connected to themicro
using a 3 way votingmechanism to ensure redundancy of the 55 controllers serial bus 47 allowing it to receive commands
master controller. In certain embodiments, an external signal and exchange data with a MCU . The microcontroller con
maybe applied to bypass one or more single controllers with trols a coil driver 41 by use of a digital bus and /or PWM
the purpose of shutting down, restarting, or reconfiguring the signals. The coil driver takes a high voltage input 48 and
one or more controllers. controls the supply of that to the coil 22. Themicrocontroller
Feedback 60 and other peripheral low power devices may be supplied by
In certain embodiments, feedback may be useful for a high efficiency DC to DC converter 49 . Galvanic isolation
optimal operation under one or more conditions, but may be is optional at several points 42 . In certain embodiments , the
only cost effective for incorporation into certain devices . number of controllers used may be varied depending on
When feedback is not required , a standard open loop control specific needs of the application . FIG . 22 shows a 1 : 1 : 1
may be used . Feedback may be utilized by the controllers, 65 configuration such that one individual Motor Control Unit
either by CCUs or MCUs or both . In certain embodiments , (MCU ) 37 communicates with one Coil Control Units
feedback may be collected local to each device or remotely (CCU ) 38 , which in turn controls for each switch and or
US 10 ,211,702 B2
29 30
switch driver 41 in a 1 : 1 : 1 configuration . ( for example as ration wherein a central communication bus ( token ring ) 51
shown in FIG . 22 ) ;many switches controlled by one or more is used for communication between CCUS 38 . In both FIGS.
CCU ' s, in a 1 :n ( for example as shown in FIG . 23 ) or m : n 29 and 30 a MCU is not required .
configuration (for example as shown in FIGS. 24 and 25 ) ; In certain embodiments, power systems for supplying the
motor Control Unit (MCU ) may control CCU ' s, giving 5 digital logic and /or other devices in the CCU ' s and/ or the
velocity and/ or other commands ; and MCU ' s may directly MCU ' s may need to convert a higher or lower voltage to the
control one or more coils, bypassing the need for CCU 's operating voltage of the devices used , and can take one or
In certain embodiments , the controllers may be imple more of the following the topologies : DC -DC converters ,
mented through multiple ways, examples include one or switching such as buck or boost; linear regulation or other
more of the following: utilization of software and/ or hard - 10 wise ; transformers ; resistive supply (by division ); and opti
ware features in an embedded system such as a microcon cal power transfer. In certain embodiments, power may be
troller ormicroprocessor, the use of an FPGA , CPLD , ASIC supplied to the control units , CCU 's, MCU 's, an overall
or other VLSI or programmable logic device ; an analog motor and /or another device . Such implementations may
system , such as the use of classical electrical feedback include one or more of the following : using the same (or
topologies to create basic control loops, and combinations 15 substantially the same) supply the switches use , such as
thereof. when switches are mounted to a motor casing; from RF /EM
FIG . 26 illustrates a certain embodiment, in which there ‘waste ' or ' background ' energy harvesting ; via BM induc
is multiple microprocessor configurations , the master con - tion / generation , such as in the application of a generator,
trolling processor may be, for example , a CCU 38 . In certain batteries , either per CCU /MCU device and /or otherwise ,
embodiments , CCU ' s may act independently, without the 20 rechargeable or non -rechargeable; solar, wind , hydro , fuel
need for a master controller. In certain embodiments, CCU ' S
cell and/ or other forms of renewable energy sources; and
may act independently , without the need for a master con mains supply , single phase , three phase at a variety of
troller wherein synchronous behavior may be achieved different voltages .
through the use of common sensors, or sensors with pre - In certain embodiments , power supplies for switches
dictable and consistent readings related to the electrical 25 and /or CCU 's /MMU ' s may also have power control over
machines behavior. In certain embodiments , where the rides, as a safety feature , allowing power to be turned off to
motors speed and/ or power is uniform ( or substantially one or more CCUs or coils . This can be implemented via
uniform ), and the only input to the system is that the power suitable switching topology , for example , as discussed
is on or off, a common communication bus may not be herein .
required . 30 In certain embodiments, communications between a
Certain embodiments are directed to an MCU 's (Motor MMU and an external controller , MMU and internal CCU
control unit ) in a standard master slave configuration where and /or other devices may be galvanically isolated by using
a single motor control unit is connected to a common one or more of the following methods: optical (IR or other
communication bus, which is connected to one or more coil spectrums) over a physicalmedium as a light guide like fiber
control units . Certain embodiments are directed to an 35 or shaped plastic , through space /air or otherwise ; radio
MCU ' s (Motor control unit ) in a standard master slave Frequency of suitable spectrums, physical layer technology ,
configuration where a single motor control unit is connected and/or encoding method , such as Direct Sequence Spread
to a common communication bus, which is connected to at Spectrum (DSSS ), O - QPSK or otherwise ; conductive , via
least 70 % , 80 % , 90 % , 95 % , 98 % , 99 % or 100 % of the coil wires and /or other electrically conductive material, and
control units. FIG . 27 shows a configuration where a single 40 isolated via the use of a galvanically isolating technology
motor control unit (MCU ) 37 is connected to a common such as : RF isolation IC ' s, transformers , capacitive , optical
communication bus 47 , which is connected to each of the isolation IC 's , or combinations thereof.
coil control units (CCU ) 38 . Certain embodiments are FIG . 31 illustrates a configuration with three redundant
directed to redundant master slave configuration where communication buses 52 . In certain embodiments, the com
multiple masters arbitrate to come to an accepted value. For 45 munication layers may have 2 , 3 , 4 , 5 , 6 , 7 , 8 , 9 , 10 or more
example 2 , 3 , 4 , 5 , 6 , 7 , 8 , 9 , or 10 MCU 's may calculate redundant layers.
commands to the CCU ' s, but only one MCU ' s commands In certain embodiments, communications inside the devices
are used by means of an arbitration method. In this way in between controllers/drivers/MCU ' s 37 and/or CCU 's 38
the event of failure the failed MCU will be ‘ outvoted ' and and /or to external devices, (e .g . vehicle control unit to
their commands discarded , possibly even being powered off 50 MCU ) may involve one or more of the following technolo
by the other MCU ' s . Other embodiments may include gies and/ or communications protocols in combination with
redundant MCU ' s in case of failure , which only actively one or more of the physical layer implementations disclosed
send commands when another MCU has failed FIG . 28 herein : single ended , serial and /or parallel ( for example
shows a configuration where 3 motor control units (MCU ) UART, SPI, or 12C ), differential signalling. ( for example
37 are connected to a common communication bus 47 , 55 CAN bus or RS485 protocols ), optical point to point and/ or
which is connected to each of the coil control units (CCU ) optical bus and RF communications.
38 . In certain embodiments , it is possible to have configu - With reference to FIG . 32 , FIG . 33 and FIG . 42 , two
rations wherein one or more of the coil control units are not embodiments are illustrated of a brushless , axial flux, direct
in communication with the plurality ofmotor control units . current electric motor with integrated differential 53 com
In certain embodiment, one or more of the CCU ' s may act 60 prises one or more disc - shaped stators 54 . The stator may be
together as a group , sharing sensor data and /or providing constructed out of a non conductive material, for example ,
common output . In such embodiments , communication may nylon 12, fibreglass composite , Kevlar composite , other
occur via a common bus or direct peer to peer. In such suitable materials , or combinations thereofmay also be used
embodiments, a motor control unit may not be required to prevent ( substantially prevent, sufficiently prevent or
FIG . 29 illustrates a configuration wherein no central com - 65 reduce the generation of an electrical eddy current around
munication bus is present and communication from each one of more of the electromagnetic coils . An alternative
CCU 38 is point to point 50 . FIG . 30 illustrates a configu - embodiment is ( illustrated in FIG . 8 ) may be constructed
US 10 ,211,702 B2
31 32
from a conductive material such as aluminium with slots 14 tially equally -spaced ), powerful permanentmagnets 20 , the
extending more or less radially inwards from each aperture array may have the same, or substantially the same, centre
accommodating a the electromagnetic coil . In certain diameter as that of the electromagnetic coils and themagnets
embodiments, the elements may be made from a light may have alternating pole orientation . In certain embodi
material of suitable mechanical strength and/ or conductivity, 5 ments , (not shown ), the centre diameters of the arrays of
such as an aluminium or magnesium alloy , and the external permanent magnets and electromagnetic coils may be made
surfaces may be finned or ribbed to provide greater heat unequal but such that themagnetic fields of the magnets and
dissipation surface area . Alternatively in certain embodi- coils intersect . In certain embodiments (not shown ), the
ments the ring may have a cavity or other suitable passage poles of the permanentmagnets in the array may have like
for coolant in or around the stator and/ or in close proximity 10 orientation . In certain embodiments , not shown ), the per
to the stator. In certain embodiments, the ring may accom manent magnets in the array may be made in groups, the
modate the distribution of coolant directly onto the coils polar orientation of the magnets being common in each
and/ or cores Other suitable heat dissipation mechanisms or group while the polar orientation of adjacent groupsmay be
methods may be used . opposed . In certain embodiments , ( not shown ), the perma
Around the periphery of the stators is embedded a circular 15 nent magnets in the array may be made in groups, the polar
array of equally - spaced , or substantially equally spaced , orientation of the magnets being common in one or more of
electromagnetic coils 22 , heat from the coils may be con - the groups while the polar orientation of adjacent groups
ducted out to the exterior surface of the annular conductive may be opposed . In certain embodiments, (not shown ), the
elements by means of a channel inside the coil . Conductive permanent magnets may be arranged in groups of unequal
elements 55 connect to Coil Control Units 38 . The Coil 20 numbers, the polar orientation of the magnets in a group
Control Units consist of one or more stacked circuit boards being common . In certain embodiments, (not shown ), the
56 . These stacked circuit boards may be parallel, substan - permanent magnets pass through the whole of the axial
tially parallel and/or other suitable configurations. In certain depth of the rotors and may be orientated parallel, or
embodiments, ( not shown ), the circuit boards may be par substantially parallel, to the rotational axis, but with their
tially , or wholly, replaced by a system of internal conductors . 25 centre distances randomly displaced (displaced inwardly or
In certain embodiments , the circuit boards may be supported outwardly in a radial sense ) up to half their radial depth . In
by the solder tags of solid -state switches 57 being soldered certain embodiments , the displaced (displaced inwardly or
to them , the switches, in turn , being fixed (as described outwardly in a radial sense ) may be up to 0 . 1 , 0 .2 , 0 .3 , 0 .4 ,
elsewhere herein ) to a heat sink elements 58 . In certain 0 . 5 , 0 .6 , 0 . 7 , 0 .8 or 0 . 9 of their radial depth . In certain
embodiments , (not shown ) the circuit boards are supported 30 embodiments , (not shown ), the permanent magnets in an
from the stators by a suitable structure , including conductive array pass through the whole of the axial depth of the rotor
brackets , insulating brackets, pillars, struts or combinations and may be displaced in common from being parallel ( or
thereof. On the PCB there can be four solid state switches substantially parallel) with the rotational axis by a deflection
such as IGBTs in a H -Bridge configuration . The IGBTs , in in various senses of between zero and 30 degrees. In certain
certain embodiments , may be connected to a heat sink with 35 embodiments , the deflection in various senses of may be
an electrically insulating, thermally conductive layer such as between zero and 30 degrees, zero to 20 degrees, zero to 40
Mica , aluminium oxide , aluminium nitride or other suitable degrees, 5 to 40 degrees, 5 to 30 degrees, 5 to 10 degrees,
insulation to isolate the various voltages ( not shown ) which 10 to 30 degrees , 20 to 35 degrees or other suitable ranges .
then slides into a cooling ring. The heat sink 58 can be In certain embodiments, (not shown ), the permanent mag
retained in the cooling ring by screws or a springs or cam 40 nets in an array pass only partly through the axial depth of
locks (not shown .) The cooling ring contains one or more a rotor, their inner ends optionally abutting a back iron of
cooling channels 74 ; the coolant enters the cooling ring suitable magnetically permeable material embedded in the
through an inlet and exists through an outlet. A set of rotor. In certain embodiments , (not shown ), the permanent
connectors made out of a conductivematerial such as copper magnets and the electromagnetic coils may be arranged in
that permits the connector 59 to connect to the power rails . 45 possible combination of the embodiments disclosed herein .
The power rails comprising of a first annular conductive The rotors are bolted 75 , splined or otherwise fixed to a
element 60 and second annular conductive element 61 , the differential carrier 19 parallel (or substantially parallel) to
conductive elements may be separated by an electrically the stators with an air gap between the electromagnetic coils
insulating layer 62 . In certain embodiments, the insulating and the permanent magnets , suitable spacers 63 being posi
layer may be made from a mechanically tough material 50 tioned on the differential carrier to maintain ( or partially
having a high dielectric value, such as Acetal. Other suitable maintain ) the rotors in correct (or suitable ) axial separation .
materials may also be used . In certain embodiments, (not In certain embodiments, the differential carrier is coupled to
shown) the stators may be electrically separated by hard three or more bevelled gears . Two of the bevelled gears 64 ,
anodising of their surfaces with care taken to ensure that the 65 , that are axially aligned with the rotor are splined to
anodising extends substantially , or sufficiently, to their 55 accommodate complementary splining of two half shafts.
edges, the anodising being employed alternatively and /or in The remaining bevelled gears 66 are mounted perpendicular,
addition to the insulating layer . or near perpendicular, to the axially aligned gears transfer
During assembly and / or maintenance a single Coil Con - the rotational energy to or from the rotors to two or more
trol Unit can be removed by detaching the conductors from shafts, while permitting the two shafts to rotate at different
the coils, disengaging the retaining mechanisms and sliding 60 angular velocities. The outer ends of the differential carrier
the Coil Control Unit in or out thereby removing or install - is rotationally supported in suitable bearing 67 carried in the
ing the CCU from the device , two examples are depicted in bearing support 68 or the casing 69 of the electric motor. The
FIGS. 34 and 43 . position of the bearing can be adjusted through the use of a
With reference to FIG . 32 , FIG . 33 and FIG . 42 again , the screw collar 70 or by the use of spacers to ensure correct
electric motor may further comprise one or more disc - 65 alignment. The casing may comprise of a clamshell or a
shaped rotors 18 around the periphery of which may be radial enclosure 71, 72 . The enclosure is sealingly closed by
embedded in a circular array of equally -spaced (or substan - a bearing housing 68 which accommodates suitable thrust or
US 10 ,211,702 B2
33 34
deep groove bearing 67 and a suitable sealant (or sealing be bonded into place and/ or potted with , for example, a
means ) ( not shown ) which rotationally support the differ - high -strength , high -temperature epoxy resin , the arrange
ential carrier, substantially prevent or sufficiently prevent the ment permitting efficient ( or suitably efficient) conductive
egress of lubricant or the ingress of contaminants. To pro cooling . The stators may be made sufficiently strong and /or
vide a flux return path , annular back irons 31 of a suitable 5 rigid to resist magnetic forces generated during operation
magnetically permeable materialmay be provided on one or and/ or when the rotors are at rest . In certain applications ,
more faces (or each face ) of a the rotor not facing a the where the electric motor may be employed as a direct -drive
stator, the back irons covering the annular zone occupied by automotive wheel motor , itmay be mounted to the existing
the magnets . In alternative embodiments (not shown ) in the mounting points of a differential of a vehicle by suitable
rotors having a face not immediately adjacent the stator, the 10 fastenings engaging attachment bolt apertures 77 .
back irons may be deleted and the magnets take the form of In certain applications , where the electric motor may be
suitable Halbach arrays . Electronics housing 73 is formed on employed as a direct- drive automotive wheel motor, the
or fixed to a suitably located part of the housing and contains centre diameters of the arrays of permanent magnets and
control circuit board 37 . The solid - state switches are acti- arrays of electromagnetic coils fall in the range 15 to 60
vated by command signals from a control system not 15 centimeters , the number of the coils being odd and the
shown ) to power the electromagnetic coils and thereby cause number of the magnets being one more than the number of
the rotors to rotate . Suitable sensors (not shown) are pro - coils . Other suitable ranges may also be used . In certain
vided to generate signals that are transmitted to the control embodiments , 24 magnets may be employed . In certain
system to provide data as to the absolute and instantaneous embodiments , 48 magnets may be employed . In certain
positions of the rotors . In certain embodiments , one or more 20 other embodiments employing similar operating principles,
suitable sensors (not shown) may be provided to generate the numbers of the permanent magnets and the electromag
signals that may be transmitted to the control system to netic coils may optionally be doubled , tripled or quadrupled
provide data as to the absolute , substantially absolute, or and the coils powered as required to generate a desired
sufficiently absolute and/or instantaneous, substantially torque and RPM . In certain applications, the number of the
instantaneous , suitably instantaneous, relative, or substan - 25 permanent magnets and the number of electromagnetic coils
tially relative positions of one or more of the rotors, or any may 1 , 2 , 3 , 4 , 5 , 6 , 8 , 10 , 12 , 14 , 20 or more and the coils
combination thereof. In certain embodiments, the sensors powered as required to generate a desired torque and RPM .
take the form of one or more optical sensors and/ or one or Similarly , in other alternative embodiments , the permanent
more Hall - effect sensors . In certain embodiments, (not magnets and the electromagnetic coils may optionally be
shown ), rotor position may be determined by reference to 30 made in equal numbers . Similarly , in other alternative
the back EMF generated in undriven coils. In certain embodiments, the permanent magnets and the electromag
embodiments , the permanent magnets may take the form of netic coils may optionally be made in equal numbers , but
powerful, or sufficiently powerful, rare earth -type magnets with locational asymmetry to prevent magnetic stasis at
and may be secure in position within the axial depth of the start-up. In certain applications, the greater centre diameter
rotors by, for example , bonding , by suitable mechanical 35 of the arrays of permanent magnets and electromagnetic
fastenings or, as depicted in the Figure in the central the coils, the greater the torque able to be generated . The
rotor, by imprisonment between two parts clamped together. arrangement of the electric motor permits many combina
In certain embodiments , ( not shown ) which may be tions to be created from specially designed components ,
employed in lower cost applications and/ or those required to standard components, or combinations thereof — from a
meet different operational parameters , the magnets take a 40 single rotor and stator combination to combinations employ
conventional form . The body parts of the rotors are made ing at least 10 rotors. In certain applications the number of
sufficiently strong and/ or rigid to suitably resist magnetic rotors may be at least 5 , 10 , 15 , 20 or 25 . The combinations
forces generated during operation and / or when the rotors are employing larger numbers of rotors and stators may be used
at rest. The rotor body parts are optionally made solid and /or in large devices or machines , such as heavy trucks and
partially hollow with radial ribbing 76 to reduce rotating 45 earthmoving equipment.
mass and /or confer stiffness . In certain embodiments, the solid state switches employed
In certain embodiments , the electromagnetic coils can be to provide electronic commutation may be insulated - gate
made in the form described in relation to FIG . 9 and generate bipolar transistors ( IGBT ) which may be capable of han
suitably higher magnetic flux levels while having suitably dling the supply voltages required by the electric motor.
lower magnetic reluctance permitting rapid switching and /or 50 Although both p - type (P -FET) and n -type (N - FET) field
reversal of magnetic polarity . In certain embodiments, (not effect transistors may be suitable for the application , in the
shown ), coils of conventional, wire -wound or ribbon - certain embodiments, IGBTs may be employed in an
wound , bobbin construction may be employed , with an air H -bridge arrangement with powering of the high side of
core and /or core made from a suitable magnetically perme- each (or one or more ) of the IGBT by an integrated circuit
able material. In certain aspects , the coil configuration may 55 incorporating a charge pump. In the certain embodiments ,
necessarily be a compromise between maximisation of cur - IGBTs may be employed in an H -bridge arrangement with
rent flow and minimisation of inductance effects and/ or powering of the high side of one or more of the IGBT by, for
losses due to at least in part hysteresis . Electrical current example , an integrated circuit incorporating a charge pump.
may be supplied to the solid - state switches via the annular The positioning of the IGBTs within close proximity to the
conductive elements 60 and 61, thereby permitting a heavy 60 electromagnetic coils may provide short, efficient conduc
current flow to the solid - state switches. A plurality of tion paths of low resistance . Other positioning may also be
suitable lugs ( depicted as 78 in FIGS. 33 and 42 ) may be used such as substantially adjacent, suitably adjacent or in
provided around the peripheries of the annular conductive communication with . The type of the IGBTs employed may
elements for the attachment of electrical conductors . A high provide large tabs intended as heat sinks, but which may be
power fuse may be attached at this point to protect the 65 also electrically conductive . The tabs may be therefore fixed
machine from short circuits . The electromagnetic coils may directly, or indirectly, to the fingers of annular conductive
be embedded within the axial depth of the stators and may elements 4 , thereby providing the IGBTs with an efficient
US 10,211,702 B2
35 36
electrical current supply path with low resistance , making shown ) the copper foil part of the electromagnetic coils may
efficient use of space and /or providing an efficient thermal be made by computer -controlled deposition and electron
conduction path out to the finned or ribbed exterior surfaces beam welding or sintering following which , pre -cut pieces
of the annular conductive elements. of the grain -oriented silicon steel may be slid into the
DC to DC isolated converters and high voltage step - down 5 apertures between the turns of copper foil. For example ,
regulator circuit boards may be mounted to the circuit copper foil having a thickness of 0 .2 millimeters and a
boards. Independent power supplies may be employed to maximum effective width of 25 millimeters is able to carry
prevent, or substantially prevent, the existence of a closed the desired maximum current of 90 Amperes . Other suitable
conductive loop , thereby preventing ( substantially prevent foil configurations may also be used . With a thickness of
ing or sufficiently preventing ) induced current from 10 0 .23 millimeters , the volume of the grain - oriented silicon
adversely affecting electronic functions. Similarly , to pre - steel within the electromagnetic coil is sufficient to allow
vent, substantially prevent, or sufficiently prevent induced generation of the necessary magnetic flux strength . The
current from interfering with command and feedback sig - thicknesses of the copper foil and the grain -oriented silicon
nals, inner and/ or outer circuits may be galvanically isolated steel may be intended as substantially only indicative and, in
In some embodiments , the galvanic isolation is achieved 15 alternative embodiments , thicker or thinner materials are
through the use of infra -red transmitting circuit and receiv - optionally employed . In certain embodiments electromag
ing circuit , with one such pair provided for each Coil netic coils of conventional wire -wound or ribbon -wound ,
Control Unit. In the certain embodiments , control signals bobbin construction may be employed , with an air core or
from microcontrollers on the Coil Control Unit on the core made from a suitable magnetically permeable material.
insides of the stators may be galvanically isolated using 20 In alternative embodiments , the core may be wound with
electromagnetic (RF ) isolation structures or techniques . In interleaved layers of graphene and amorphous metals . In
alternative embodiments (not shown), the galvanic isolation another alternative embodiment, the electromagnetic coils
may be achieved through the use of optical, capacitance , may be made with high -temperature superconducting wind
induction , electromagnetic , acoustic , mechanical structures ings. The coils may be made with an air core and/or liquid
or techniques or combinations thereof adapted for the pur- 25 nitrogen cooling techniques or means may be employed to
pose . maintain a suitable operating temperature . In alternative
With additional reference to FIG . 9 , in the certain embodi- embodiments , the core may be edge wound from thin foil
ments, a current of 40 Amperes at between 300 and 450 maximising packing density .
Volts may be required to be supplied to the electromagnetic With additional reference to FIG . 13 , in certain embodi
coils to achieve maximum power output from the electric 30 ments , powerful (or sufficiently powerful) permanent mag
motor . In the certain embodiments , electromagnetic coils 22 nets 20 , 21 of circular cross- sectional shape may be embed
may be wound up from two separate strips of copper foil ded in the thickness of rotor disc 8 as described herein .
79 -82 , etc and 83 - 86 , etc around a suitable magnetically Suitable slots 76 may be provided in the rotor disc to reduce
permeable core of square cross -sectional shape. The turn of the rotating mass and thereby the angular momentum of the
the copper foil windings may be interleaved with rectangles 35 rotors and to permit an axial flow of air within the electric
of grain -oriented silicon steel 87 - 90 , etc specially cut to motor casing. With additional reference to FIG . 35 , in
shape. The steel is often supplied coated with an insulating certain embodiments, powerful permanent magnets 20, 21
compound but, when cut, uninsulated edges are exposed to may be made more or less trapezoidal in shape and abutting
the copper foil windings . In practice , in certain applications, each other with alternating pole orientation . In certain imple
this has only a minimal effectupon coil function as , because 40 mentations, one ormore of the magnets may be abutting . In
of the lower resistance of the copper foil, the proportion of certain applications, the magnets may be made more or less
total current passing through the steel plates is also minimal. trapezoidal in shape and abutting , substantially abutting ,
The inner ends of the copper foil windings are connected to each other with alternating pole orientation . In these
insulated conductors 91 which are led out via the gap embodiments , the radially inner edges of the permanent
between the two the copper foil windings and via suitably 45 magnets may be shaped to engage (or communicate with a
located apertures in the appropriate the steel plates and, complementary shape formed in the outer edge of the rotor
together with the outer ends 92 of the copper foil windings, disc, the side edges of the magnets may be shaped to engage
are extended as required to make the necessary connections (or communicate with complementary shaping of adjacent
between the coils and the IGBTs. The electromagnetic coils the magnets in an array and the magnets may be retained in
may be bonded into place in the stators with , and potted 50 place on the rotor disc by a circumferential restraining band
with , for example , a high strength , and high temperature (not shown) of a high - strength metal material. The central
epoxy resin adhesive. The electromagnetic coils may be bore 93 of the rotor disc is splined to accommodate comple
wound with copper foil to reduce inductance effects and mentary splining of the differential carrier. In certain
thereby, to increase the maximum rate of polarity switching . embodiments (not shown), the powerful permanent magnets
In certain embodiments , a maximum switching rate of 400 55 may be shaped approximately trapezoidal, but with the axis
Hz being achieved . In certain embodiments, a maximum of one or more inclined to a radial passing through it by an
switching rate of 100 Hz, 200 Hz, 400 H , 500 HZ , 600 Hz angle ofbetween 2 .5 and 20 degrees. Other ranges of angles
or 800 Hz may be achieved . In certain embodiments (not may also be used , for example , an angle of between 2 .5 to
shown ) to meet different operational parameters, higher or 5 degrees, 5 to 25 degrees , 5 to 10 degrees or 15 to 20
lower switching rates may be achieved . By also reducing 60 degrees .
back EMF, the voltage required to operate the electric motor In certain embodiments (not shown ), individual small
at a given speed may be reduced . In certain embodiments circuit boards containing power electronics , including the
( not shown ), the electromagnetic coils may be made by H -bridge , microcontroller and galvanic isolation means may
computer -controlled deposition of copper and a suitable be placed on the stator disc adjacent one or more of the
ferromagnetic material to create a facsimile of these embodi- 65 electromagnetic coils. The circuit boards are positioned
ments of the coils , the built - up assembly then being given radially outside of the coils , but occupy minimal space and
permanent form by sintering . In certain embodiments (not do not substantially inhibit conductive cooling of the coils .
US 10 ,211,702 B2
37 38
The reduced conductor length between the power electronics n : 1. In certain embodiments of the operating method of the
and the power input reduces losses due to resistive heating . electric motor,minimum power is maintained by powering
A ring of clear polymer material serves as a light tube to one or more of the electromagnetic coils only once per
relay control signals to the microcontrollers . In certain rotation of the rotor such that each the coil attracts only one
embodiments (not shown ), the IGBTs may be made inte - 5 the magnet in the peripheral array of magnets . The electric
grally with the copper of the electromagnetic coils . motor is thereby electromechanically geared , in effect, by a
With reference to FIG . 36 , reflective optical position ratio of 1: 1. Various sequences or combinations of the coil
sensor 95 and Hall -effect sensor 96 provide rotor position powerings and de-powerings may be employed to achieve a
related signals to microprocessor -based control unit 97. The nominated electromechanical gearing.
control unit optionally takes the form of a microcontroller 10 In certain embodiments (not shown), to reduce cogging
and /or programmable logic device and /or programmable effects and/ or to maximise efficiency , the back EMF of an
gate array and /or other custom -built unit. From the interior unpowered coil is recorded at a representative range of
100 of the electric motor, the control unit transmits data via
galvanic isolation transmitter 98 to galvanic isolation speeds using the analogue -to - digital converter in the micro
receiver 102 on the exterior 101 of the electric motor and 15 controller. During operation , the electromagnetic coils in an
thence to microcontroller unit 105 . Similarly, microcon array that are normally un -powered may be powered to a
troller unit 105 transmits data to control unit 97 via galvanic level at which the magnetic flux generated equals, or sub
isolation transmitter 103 and galvanic isolation receiver 99 . stantially equals, the back EMF effect of the coil , thereby
Separate bi- directional galvanic isolation means may be neutralizing the magnetic interaction between the un -pow
required for each the stator. From microcontroller unit 95 , 20 ered coils and the permanent magnets . The mechanism is
data is transmitted to and from a master control unit via also used in regenerative braking permitting the wave to be
conductors 94 . Microcontroller unit 95 optionally takes the analysed and then switched into the correct power planes.
form of a microcontroller and /or programmable logic device The characteristics of the back EMF of the coils may be
and/ or other purpose - built logic device . Control unit 97 further analysed during run time for a specific velocity ,
communicates with switch drivers 110 , 112 via galvanic 25 power requirement and operating temperature , and an opti
isolation unit 111. The galvanic isolation units optionally mal or near optimal wave generated using pulse -width
employ one or more of the operating principles described modulation to , as far as is possible , maximise the efficiency
herein and one the galvanic isolation unit is provided for one of the electric motor. In the certain embodiments , such
or more of the stators . Electrical current is supplied to analysis may be performed automatically, substantially auto
H -bridge arrangement of IGBTs via conductors 113 , 114 and 30 matically , on a continuous basis , on a discontinuous basis or
IGBTs 115 , 116 , 117 , 119 are controlled by the switch other suitable intervals . Pre - computed or partially pre -com
drivers . Electromagnetic coil 118 is connected to the puted waveform patterns may be stored in a look - up table
H - bridge such that current flow reversal via switching and may be recalled when specific velocity, power require
reverses the magnetic polarity of the coil. Electrical current ment, operating temperature and , optionally, back EMF, or
is supplied to DC to DC down - converter 107 via conductors 35 combinations of these , is detected . The look -up tables are
106 and the down -converter supplies current to isolated DC optionally optimised through the use ofmeta -heuristic algo
to DC down -converter (switching ) 108 and isolated DC to rithms, evolutionary algorithms, traditional, deterministic
DC down - converter (logic ) 109. The down -converter algorithms, other suitable optimisation techniques or com
(switching) supplies electrical current to galvanic isolation binations thereof. In certain embodiments, adaptive control
unit 111, the switch drivers and the IGBTs and the down- 40 may be implemented by performing optimisation at run time
converter (logic ) supplies electrical current to control unit through the use of an incorporated support vector machine,
97 . through the use of neural network technology, through the
Control unit 97 permits arbitrary switching of one or more use of fuzzy logic technology , through the use of other
of the electromagnetic coil independently of the other the suitable application ofmachine learning technology , through
coils. Using pulse -width modulation , excitation waveforms 45 the use of suitable adaptive control techniques or through
can be generated and used to drive the coil. A wide variety combinations thereof.
of coil drive profiles can be employed for the real- time In certain embodiments (not shown ), a supply of clean
maximisation of efficiency and power output over a wide cooling air may be supplied to the interior of the motor
range of RPM and operating temperatures . In certain casing as required to maintain the stators at a predetermined
embodiments of the operating method of the electric motor, 50 temperature . The cooling air may be exhausted via a suitable
maximum power may be maintained by simultaneously valve which maintains a predetermined minimum pressure
powering the electromagnetic coils except one, the magnetic within the casing to prevent, or substantially reduce , ingress
polarity of the powered coils being alternating . The un - of contaminants . The supply of cooling air is optionally
powered coil is then re -powered with opposite magnetic cooled in a refrigerated heat exchanger before being sup
polarity such that it opposes the magnetic polarity of the 55 plied to the electric motor casing . In another certain embodi
preceding the coil (proceeding in the sense of the direction ments (not shown ), a flow of liquefied refrigerant may be
of rotation of the rotors ) while the next coil ( next in the same supplied to galleries formed in the casing walls and /or
rotational sense ) is de-powered . The process is continued stators of the electric motor and may be allowed to boil off
with each successive coil being de -powered and then re - as it takes up heat from the casing. Vapour formed by the
powered with opposite polarity to complete a movement of 60 cooling process may be drawn off, compressed and cooled
the one or more permanent magnets from one the coil to the in suitable heat exchange configuration or means to re
next . Thus, for a complete rotation of the rotors , the number liquefy it . In these embodiments, the liquefied refrigerant is
of the coil de -powerings and re -powerings (with opposite optionally a conventional refrigerant or, where high -tem
polarity ) in the coil array is given by the square of the total perature superconducting coils are employed , liquid nitro
number of the coils in the array . Where the number of 65 gen . In certain embodiment (not shown ), a flow of a suitable
powered the coils in an array is n , the electric motor is liquid coolant may be circulated through galleries formed in
thereby electromechanically geared , in effect, by a ratio of the casing walls and/ or stators of the electric motor, heat
US 10 ,211,702 B2
39 40
taken up by the coolant subsequently being dissipated via combination of the above. With reference to FIG . 47 , a
suitable air -cooled heat -exchange configuration or means. thinner section of copper 135 may be included in certain
In certain embodiments (not shown), the electric motor embodiments where in the event of a short through the coil
may be employed as an electrical generator and one or more the coil may fuse open preventing large eddy currents that
of the operating principles may be employed to maximise 5 introduce unnecessary drag resulting in excessive heat
electric power generation efficiency during rapidly varying reducing the risk of fire and/ or improving overall robustness
generating conditions. Such variable generating conditions of the system .
may be, for example , those experienced during regenerative With reference to FIG . 48 in certain embodiments , to
braking. facilitate the routing of the wires , two coils are wired side by
In certain embodiments (not shown ), where the electric 10 side providing opposing magnetic fields providing a return
motor is employed as a propulsion unit for an electric path to a single set of electronics .
vehicle, it optionally drives a wheel via a rigid or articulated In a certain exemplary embodiment, 46 32 mm by 7 .5 mm
shaft, it optionally drives a wheel via one or more chains or trapezoidal cores are arranged in a 27 mm stator. Each core
belts , it is optionally fixed centrally to a vehicle and drives is constructed out of 0 .23 mm electrical steel, with small
wheels to either side via articulated shafts , or it optionally 15 locking features ensuring that the upper and lower retaining
generates a flow of pressurised hydraulic fluid to power a plates fabricated out of carbon fibre hold the cores in place .
hydraulic motor driving one or more wheels . The carbon fibre is attached to a 290 mm outer ring where
With reference to FIG . 44 , the stator comprising of an the torque is transferred to a set of mounting holes in a
upper retaining plate 138 , an outer ring 140 , an inner ring similar location of that of a standard differential. Each core
141 and a lower retaining plate 139 . A series of ferromag - 20 is surrounded with a 0 . 5 mmx3 mm edge wound coil , which
netic cores 55 thatmay be constructed using laminated grain is attached to the core using a thermally conductive adhe
oriented silicon steel and a conductor such as copper wound sive. These cores are glued into the lower retaining plate
around the outside 22 are sandwiched between the upper and ensuring no leaking between the core and the retaining plate .
lower retaining plates . Cut- outs for the cores 144 ensure that 0 . 5 mm air gap is maintained between the ends of the
the air gap between the rotor and cores are kept to a 25 cores and a platter of 48 trapezoidal magnets of 32 mm by
minimum . Torque is transferred via the upper and lower 7 mm , with a thickness of 8 mm . The motor consists of 4
retaining rings to the outer ring which is used to transfer the stators interleaved between 5 rotors , with the end rotors
torque . The resultant cavities between the cores may then be having a ferrous end plate to contain the magnetic field .
filled with coolant via inlets 142 around the periphery of the Conductors and ducts for coolant are attached between the
upper retaining plate to the outlets 143 which are offset by 30 stators and arriving at the end where it is connected to drive
one coil on the lower retaining plate . Coolant may circulate electronics . The rotors are attached to a differential carrier
around the core on its way through the stator . Constrictions and the entire device is housed in an enclosure with thrust
on the wall of the inner and outer ring ensure that coolant bearing at either end . Each coil control unit is connected to
circles around the coils . Coolant distribution manifolds (not 8 coils , one output from the H -bridge connected to a coil in
shown ) may be placed above the stator and below the stator 35 the top stator, in series with a coil in the second stator , in
to supply and collect coolant from a coolanthose . In certain series with a coil in the third stator, in series with a coil in
embodiments , where multiple stators are stacked together, the bottom stator. At the bottom the coil is connected to an
connecting hoses from the outlets of the previous stator to adjacent coil that heads exits at the top of the bottom stator.
the inlet of the next stator may be used . In certain embodi- This coil is attached to the coil on the third stator , which is
ments, the void between coils may be filled with thermally 40 attached to the coil in the second stator, which is ultimately
conductive resin or ceramics to ensure effective cooling to connected to the coil in the top stator which is connected to
the outer ring . In certain embodiments , fins may be added to the second connection of the H -bridge .
the outer ring to maximise the thermal conduction path to a In the afore mentioned embodiment, each stator magnet
coolant ring in the outer core . pair is able to produce approximately 750 Nm of torque at
FIG . 45 illustrates a top view of four different exemplary 45 75 Amps RMS. The 4 stators therefore provide a maximum
core configurations, with the magnetic field heading into the torque of around 3000 Nm , enough to propel a full sized
page , certain embodiments may consist of a rectangular core family Sudan without the need for gearing. The direct liquid
with the laminates along the short edge 126 , of a rectangular cooling may provide continuous cooling at around 50 Amps
core with the laminates along the long edge 127 , of a per mm squared . In certain applications , this embodiment
trapazoidal core with the laminates along the edge 128 , of a 50 may be rated to operate continuously at this torque . At 400
square trapezoidal core made up of a series of trapezoidal volts this embodiment may reach a top speed of approxi
laminates along the long edge 129 . Cores may also be made mately 1500 RPM which is roughly equivalent to 150 km /h
using a concertina of laminates, for example , U shapes, I when driving a standard sedan sized tyre. The total length of
shapes, E shapes, T shapes , with laminates along both the this embodiment is 283 mm and diameter is 290 mm of a
long and the edge . Cores may further be made by casting or 55 size that can fit into the differential mounting area of a GM
sintering powdered metals or from solid ferrous material. In Holden Commodore . The weight is approximately 52 kg
certain embodiments , laminated electrical steels do provide including the control electronics and differential.
an advantage in terms of its very high permeability and low Method of Design and Manufacture of Certain Exemplary
eddy current losses. The cores may have notches cut out orEmbodiments
holes or other features cut to assist in the stacking and 60 The following examples are included to be illustrative of
assembly of the cores and in retaining them within the stator. the variety of devices that may be designed and/ or manu
As shown in FIG . 46 , certain embodiments may have factures using certain disclosed embodiments. By using the
cores with coils of conductors wrapped around the periphery approaches disclosed herein , it is contemplated that a large
of the core . The copper may be over a bobbin 130 , be number of devices may be designed and constructed using
standard round wire directly around a core 131 , rectangular 65 the technology disclosed herein .
wire around a core 132 , rectangular wire edge wound around A . In this exemplary method ofmanufacture , one or more
a core 133, or foil wrapped around a core 134 , or a design requirements are supplied . For example , these
US 10 ,211, 702 B2
41 42
requirements may including: size of the device , weight of build the device. The next step is to modify software to
the device , the maximum power of the device , the voltage it control 17 coils and to switch to generation mode on
needs to operate off or generate , the peak current draw or breaking.
supply (controls the maximum power ), the number of con C . In this exemplary manufacture a specifications is set
nections to the power supply (DC , single phase , three 5 forth that specifies 3MW , weight is not a consideration ,
phase ), the range of angular velocities which the device will needs to fit into a diameter less than 2000 mm , rotation up
run at , the amount of torque that needs to be delivered , the Ampsto 120 RPM , output voltage should be 3000 volts RMS 650
maximum torque the shaft needs to be absorbed , or combi tion further at 50 Hz to match mains , three phase . The specifica
nations thereof. It is to be understood that other features may specifies high voltage at low speed , specifies
be used in designing and manufacturing the device . 10 iron core , lots of windings, low current to optimise effi
This information may then be processed in the following ciency. Three phase source therefore specifies three outputs.
way : First a suitable module is selected such that it is module This indicates to select iron core 4000 v, 10 A three phase
capable of handling the voltage required and has enough is 30 kw. Run at 3000 volts ,max current of 10 A , peak power
. This also indicates a minimum of 100 coils.
contacts and switches, (for example, two for single phase 15 Furthermore, to maximise angular velocity over the coils to
and DC , three for three phase delta , four for three phase maximise voltage generation , a large diameter platter is well
star). The power rating of each module is then divided into suited for this application . Since torque smoothness is not of
the maximum power required . The maximum size of the as much concern , but harmonics in large blades can be of
motor is then taken into consideration to decide the number concern , this example indicates one more magnet than coil
of coils that can fit into a circular arrangement; this becomes 20 per platter.
the size of the platter . The number of platters is the number Based on this information , the next step is to calculate the
of coils per platter divided into the total number of coils . number of magnets that can be arranged in a circle of
This number of coils is then checked against the maximum diameter of 2000 mm , find that up to 104 can fit. Since the
angular velocity ensuring that the inductance of the coil in number of coils is typically prime to minimise harmonics ,
the module is not such that it cannot switch at that desired 25 101 works in this example .
frequency. If it is too high , the diameter can be reduced to This results in a final configuration of, 1 stator platters of
result in less number of coils per platter, resulting in lower 101 coils , and 2 platters of 102 magnets .
frequency of operation . This provides the design informa The next step is to design and manufacture platter stator
tion that may then be used to construct the device . for coils accommodating 101 coils . Design and manufacture
B . In this exemplary method ofmanufacture, onee or or more
more 3030 magnetic platters accommodating 102 coils . Design and
specifications are provided . In this example , the device to be manufacture enclosure and bearing supports to hold the
device together. Assemble the coils into stator platters ,
built specifies a motor 300 kw as light as possible , preferably magnets into rotor platters and put it together. Modify the
under 30 kgs, needs to fit into a diameter less than 400 mm , software to control 101 coils and to synchronise to the grid
as much torque as possible , needs to accelerate smoothlyY 35 and ensure voltage is maintained at 3000V RMS.
from stationary, top angular velocity 3000 RPM , 120 volts D . In this exemplary example the specification specifies
DC , peak current 1500 Amps . The device further specifies IGW , weight not a problem , size not a problem , rotation up
high torque , and small size , and iron core , high power to 300 RPM , output voltage should be 3000 volts RMS
magnets . The DC source results in two inputs . 333333 Amps at 50 Hz primary driver of mains frequency,
The next step is to selected iron core 330 v, 90 A single 40 three phase . There are notmany constraints in this specifi
phase module which runs at 120 volts, max current of 90 A , cation so it is possible to vary several parameters. However ,
peak power is 10 kw . This information indicates a minimum this example uses the process outlined in example C .
of 30 coils. To get maximum torque smoothing, this speci- Another factor is to ensure that diameter is big enough for
fication would indicate one more magnet than coil per a shaft that is strong enough to not shear when IGW of
platter, Therefore , calculating the number of magnets that 45 rotational power is being put into the shaft . This example
can be arranged in a circle of diameter of 400 mm , and find may use 512 stacks of 101 coils, total modules 5221.
that up to 19 can fit . The magnets selected in this example E . In this exemplary example the specification specifies 2
are an even number so that they have alternating fields Kw , max diameter 400 mm , rotation up to 300 RPM , input
around the platter, with one less to make it even , i.e ., 18 voltage single phase 230 V AC 50 hz, price constraint
magnets . 50 Choose small modules, air core , 1 amps max per coil . Total
Next the number of coils is selected . In certain applica - per coil 230 w , require about 10 , pick 17 to ensure that the
tions as in this one , the number of coils is often a prime dead points in the single phase do not affect the overall
number to minimise harmonics , here 17 works, repetition power output . To minimise cost combine switches and
every 34 rotations, harmonic at maximum angular velocity processor onto single circuit board and arrange coils around
1 .5 Hz. The maximum frequency of switching coils at 55 stator.
maximum angular velocity is 50 rotations per second times Applications
17 coils, divided by two to take into account positive and Certain embodiments may be used to convert electrical to
negative switch equals 425 Hz. mechanical energy. In certain embodiments , where the elec
This results in a final configuration of 2 stator platters of tric motor is employed as a propulsion unit for an electric
17 coils , total 34 coils total of 320 kw (as one coil per platter 60 vehicle the motor may be mounted directly into a vehicle to
is off at any point in time), and 3 platters of 18 magnets. the same or somewhat similar mounting point as a standard
Based on this design a device may be built with a platter vehicle differential. FIG . 37 illustrates an exemplary elec
stator for coils accommodating 17 coils. The next step is to tricalmachine that may be used in traction applications.
design and manufacture magnetic platter accommodating 18 In certain embodiments the electrical machine may be
coils and to design and manufacture an enclosure and 65 used to drive a rear wheel drive electric vehicle . FIG . 38 is
bearing supports to hold the device together. Next assemble a top down illustration of an example of such an installation .
the coils into stator platters , magnets into rotor platters and The electric motor 53 is mounted at the rear of the vehicle
US 10 ,211,702 B2
21 -
43 44
in the same or similar location as the differential. The equal numbers, butpreferably with locational asymmetry to
standard half shafts 121 are connected from the motor to the prevent or reduce magnetic stasis at start-up. In certain
rear wheels 120 . High voltage , high current conductors and applications, the greater centre diameter of the arrays of
control cables can be run along drive shaft tunnel the same magnets and the electromagnetic coils, the greater the torque
path previously occupied by the drive shaft from the battery 5 able to be generated . The arrangement of the electric motor
122 that may be located in the location previously occupied permits many combinations to be created from standard
by the internal combustion engine and transmission . components — from a single rotor and stator combination to
In certain embodiments the electrical machine may be combinations employing at least 10 rotors . The combina
used to drive a front wheel drive electric vehicle. FIG . 39 is tions employing larger numbers of rotors and stators may be
a top down illustration of an example of such an installation . 10 used in large machines , such as heavy trucks and earthmov
The electric motor 53 is mounted at the front of the vehicle ing equipment. Other applications may be regenerative
in the same or similar location as the differential. The braking and/ or power generation .
standard half shafts 121 are connected from the motor to the Adding a capacitor to the module , and configuring the
front wheels 125 . High voltage , high current conductors and switches and the coil in either a buck , boost or a buck and
control cables connect the battery 122 thatmay be located in 15 boost configuration , the device may be driven by software to
the location previously occupied by the internal combustion generate a specific dc voltage to charge batteries .
engine and transmission . In certain embodiments , the torque required to turn the
In certain embodiments the electrical machine may be electrical machine depends on the number of coils generat
used to drive an all-wheel drive electric vehicle . FIG . 40 is ing . The torque required to turn the machine maybe in
a top down illustration of such an installation . Two electric 20 substantially real time ( or real time) increased and/ or
motors 53 are mounted at the front and rear of the vehicle in decreased .
the same or similar location as the differential. The standard
half shafts 121 are connected from the motor to the front and Example 1A . 1
rear wheels 120 . High voltage , high current conductors and
control cables can be run along drive shaft tunnel the same 25 An electrical machine comprising : at least one stator ; at
path previously occupied by the drive shaft from the battery least onemodule , the at least one module comprising at least
122 thatmay be located in the location previously occupied one electromagnetic coil and at least one switch , the at least
by the internal combustion engine and transmission . one module being attached to the at least one stator, at least
In certain embodiments the electrical machine may be one rotor with a plurality of magnets attached to the at least
used to drive a semi trailer truck . FIG . 41 is a top down 30 one rotor, wherein the at least one rotor has an integrated
illustration of such an installation . Two electric motors 53 differential, the at least one differential permits the rotor to
are mounted at the rear of the vehicle in the same or similar output at least two rotational outputs , wherein the at least
location as the differential. The standard half shafts 121 are two rotational outputs are able to move at different rotational
connected from the motor to the two pairs of rear wheels velocities to each other, wherein the at least one module is
120 . High voltage , high current cables run along the same 35 in spaced relation to the plurality of the magnets ; and the at
path previously occupied by the drive shaft from the battery least one rotor being in a rotational relationship with the at
located in the location previously occupied by the petrol least one stator, wherein the quantity and configuration of
tanks. These batteries can be made detachable and can be the at least one module in the electrical machine is deter
lifted on and off the truck using a forklift for rapid recharg - mined based in part on one or more operating parameters ;
ing of a truck . 40 wherein the at least one module is capable of being inde
In an alternative embodiment (not shown ), where the pendently controlled ; and
electric motor is employed as a propulsion unit for an wherein the at least one module is capable of being recon
electric vehicle , it optionally drives a wheel via a rigid or figured based at least in part on one or more of the following :
articulated shaft, it optionally drives a wheel via one or more at least one operating parameter during operation , at least
chains or belts , it is optionally fixed centrally to a vehicle 45 one performance parameter during operation , or combina
and drives wheels to either side via articulated shafts , or it tions thereof.
optionally generates a flow of pressurised hydraulic fluid to
power a hydraulic motor driving one or more wheels . Example 1A .4
Furthermore in certain applications, vehicles having elec
tronic control of braking and/or acceleration, opportunities 50 An electrical machine comprising at least one stator ; at
exist for computer control of vehicle dynamics , including least one module , the at least onemodule comprising at least
one or more of the following : one electromagnetic coil and at least one switch , the at least
Active cruise control, in which a vehicle maintains a pre one module being attached to the at least one stator , at least
determined distance from a vehicle ahead ; one platter or rotor with a plurality of magnets attached to
Collision avoidance , where a vehicle brakes automatically to 55 the at least one platter or rotor, wherein the at least one rotor
avoid a collision ; has an integrated differential, the at least one differential
Emergency brake assistance , in which a vehicle senses an permits the rotor to output at least two rotational outputs ,
emergency stop and applies maximum effective braking ; wherein the at least two rotational outputs are able to move
Active software differentials, where individual wheel speed at different rotational velocities to each other , wherein the at
is adjusted in response to other inputs ; 60 least one module is in spaced relation to the plurality of the
Active brake bias, where individual wheel brake effort is magnets ; and the at least one platter or rotor being move
adjusted in real time to maintain vehicle stability ; ment relationship with the at least one stator , wherein the
Brake steer, where individualwheel brake bias is adjusted to quantity and configuration of the at least onemodule in the
assist steering ; and sources of electric current, for traction electrical machine is determined based in part on one or
applications, in sustained or intermittent. 65 more operating parameters ; wherein the at least one module
Similarly , in other alternative embodiments, the magnets is capable of being independently controlled ; and wherein
and the electromagnetic coils may optionally be made in the at least one module is capable of being reconfigured
US 10 ,211, 702 B2
45 46
based at least in part on one ormore of the following : at least the at least one rotors, the at least one integrated differential
one operating parameter during operation , at least one permitting the at least rotor to output at least two rotational
performance parameter during operation , or combinations outputs to corresponding shafts, wherein the at least two
thereof. rotational outputs are able to move the shafts at different
5 rotational velocities to one another wherein the at least one
Example 1A .5 module is in spaced relation to the plurality of the magnets ;
and the at least one rotor being in a rotational relationship
with the at least one stator .
An electrical machine comprising: at least one stator; at
least one module , the at least one module comprising at least Example 1A . 9
one electromagnetic coil and at least one switch , the at least 10
one module being attached to the at least one stator, at least An electrical machine comprising: at least one stator; at
one platter or rotor with a plurality of magnetic induction least one module , the at least one module comprising at least
loops , attached to the at least one platter or rotor, wherein the one electromagnetic coil and at least one switch, the at least
at least one platter or rotor has an integrated differential, the one module being attached to the at least one stator , at least
at least one differential permits the rotor to output at least 15 one platter or rotor with a plurality of magnets attached to
two rotational outputs , wherein the at least two rotational the at least one platter or rotor, wherein the at least one rotor
outputs are able to move at different rotational velocities to has an integrated differential, the at least one differential
each other, wherein the at least one module is in spaced permits the rotor to output at least two rotational outputs , the
relation to the plurality of the magnetic induction loops ; and at least one rotor is attached to at least one crown wheel that
the at least one platter or rotor being movement relationship 20 is driven by at least one drive shaft, wherein the at least two
with the at least one stator, wherein the quantity and con - rotational outputs are able to move at different rotational
figuration of the at least one module in the electricalmachine velocities to each other, wherein the at least one module is
is determined based in part on one or more operating in spaced relation to the plurality of themagnets ; and the at
parameters ; least one platter or rotor being movement relationship with
wherein the at least one module is capable of being 25 the at least one stator.
independently controlled ; and
wherein the at least one module is capable of being Example 1A . 10
reconfigured based at least in part on one or more of the
following at least one operating parameter during operation , An electricalmachine comprising: at least one stator, at
at least one performance parameter during operation , or 30 least onemodule, the at least one module comprising at least
combinations thereof. one electromagnetic coil and at least one switch , the at least
one module being attached to the at least one stator, at least
Example 1A .6 one platter or rotor with a plurality of magnets attached to
the at least one platter or rotor , an integrated differential
An electrical machine comprising : at least one stator; at 35 coupled to at least one of the at least one platters or rotors,
least one module , the at least one module comprising at least the at least one integrated differential permitting the at least
one electromagnetic coil and at least one switch , the at least platter or rotor to output at least two rotational outputs to
one module being attached to the at least one stator, at least corresponding shafts , wherein the at least two rotational
one platter or rotor with a plurality ofmagnetic reluctance outputs are able to move the shafts at different rotational
projections attached to the at least one platter or rotor, an 40 velocities to one another, wherein the at least one module is
integrated differential coupled to at least one of the at least in spaced relation to the plurality of the magnets ; and the at
one platters or rotors, the at least one integrated differential least one platter or rotor being movement relationship with
permitting the at least one platter or rotor to output at least the at least one stator.
two rotational outputs to corresponding shafts, wherein the
at least two rotational outputs are able to move the shafts at 45 Example 1A .11
different rotational velocities to one another, wherein the at
least one module is in spaced relation of a plurality of An electrical machine comprising : at least one stator; at
magnetic reluctance projections; and the at least one platter least one module , the at least one module comprising at least
or rotor being movement relationship with the at least one one electromagnetic coil and at least one switch , the at least
stator, wherein the quantity and configuration of the at least 50 one module being attached to the at least one stator , at least
onemodule in the electrical machine is determined based in one platter or rotor with a plurality of magnetic reluctance
part on one or more operating parameters ; wherein the at projections attached to the at least one platter or rotor, an
least one module is capable of being independently con - integrated differential coupled to at least one of the at least
trolled ; and wherein the at least one module is capable of one platters or rotors, the at least one integrated differential
being reconfigured based at least in part on one or more of 55 permitting the at least platter or rotor to output at least two
the following: at least one operating parameter during opera rotational outputs to corresponding shafts , wherein the at
tion , at least one performance parameter during operation,or least two rotational outputs are able to move the shafts at
combinations thereof. different rotational velocities to one another, wherein the at
least one module is in spaced relation to the plurality of
Example 1A .7 60 magnetic reluctance projections, and the at least one platter
or rotor being movement relationship with the at least one
An electrical machine comprising at least one stator; at stator.
least onemodule , the at least one module comprising at least
one electromagnetic coil and at least one switch , the at least Example 1A .12
one module being attached to the at least one stator , at least 65
one rotor with a plurality of magnets attached to the at least An electrical machine comprising: at least one stator, at
one rotor, an integrated differential coupled to at least one of least one module, the at least one module comprising at least
US 10 ,211 ,702 B2
48
one electromagnetic coil and at least one switch , the at least parameter during operation , at least one performance param
one module being attached to the at least one stator, at least eter during operation , or combinations thereof.
one platter or rotor with a plurality of magnetic induction
loops attached to the at least one platter or rotor , an inte Example 2A .7
grated differential coupled to at least one of the at least one 5
platters or rotors, the at least one integrated differential 1A The electrical machine of one or more of the examples
.7 to 1A . 12 , wherein the quantity and configuration of the
permitting the at least platter or rotor to output at least two at least one module in the electrical machine is determined
rotational outputs to corresponding shafts , wherein the at based in part on one or more operating parameters; and
least two rotational outputs are able to move the shafts at wherein the at least one module is capable of being recon
different rotational velocities to one another, wherein the at figured based at least in part on one or more of the following :
least one module is in spaced relation to the plurality of at least one operating parameter during operation , at least
magnetic induction loops; and the at least one platter or rotor one performance parameter during operation , or combina
being movement relationship with the at least one stator. tions thereof.
Example 2 . 1 15 Example 3
A The electrical machine of one or more of the above A
The electrical machine of one or more of the examples examples , wherein the one or more operating parameters are
1A . 7 to 1A . 12 , wherein the quantity and configuration of the selected from one or more of the following: maximum
at least one module in the electrical machine is determined 20 angular velocity , average angular velocity , minimum angu
based in part on one or more operating parameters; wherein lar velocity, maximum power output, average power output,
the at least one module is capable of being independently minimum power output, maximum input voltage, average
controlled ; and wherein the at least one module is capable of input voltage, minimum input voltage , maximum generation
being reconfigured based at least in part on one or more of voltage , average generation voltage , minimum generation
the following : at least one operating parameter during opera - 2525 voltage ,peak input current, average input current, minimum
input current,maximum generation current, average genera
tion , at least one performance parameter during operation , or tion current, minimum generation current,maximum torque ,
combinations thereof. average torque, activation sequence , minimum torque,
Example 2A .2 torque smoothness, rate of acceleration , accuracy of hold
angle, minimising the variation of angular velocity, rate of
deceleration during breaking , diameter of the shaft, maxi
The electrical machine of one or more of the examples mum radius of the electrical machine, maximum length of
1A .7 to 1A . 12 , wherein the quantity and configuration of the the electrical machine, maximum depth of the electrical
at least one module in the electrical machine is determined machine , maximum height of the machine , maximum slide
based in part on one or more operating parameters . distance , minimum slide distance , maximum weight of the
35 machine , minimum weight of the machine, maximum resis
Example 2A .3 tive power loss, unit redundancy and overall price .
The electrical machine of one or more of the examples Example 4A .1
1A .7 to 1A . 12, wherein the at least onemodule is capable of 40 The electrical machine of one or more of the above A
being independently controlled . examples, wherein the at least one operating parameter
Example 2A .4 during operation may be selected from one or more of the
following: maximum angular velocity , average angular
The electrical machine of one or more of the examplesf 45 velocity
put,
, minimum angular velocity , maximum power out
average power output, minimum power output, maxi
1A .7 to 1A . 12 , wherein the at least one module is capable of mum input voltage
being reconfigured based at least in part on one or more of voltage , maximum , generation
average input voltage , minimum input
voltage, average generation
the following : at least one operating parameter during opera voltage , minimum generation voltage , shape and frequency
tion , at least one performance parameter during operation , or of generated voltage , peak input current , average input
combinations thereof. 50 current, minimum input current, maximum generation cur
rent, average generation current, minimum generation cur
Example 2A .5 rent, maximum torque , average torque, minimum torque ,
The electrical machine of one or more of the examples torque smoothness, activation sequence, rate of acceleration ,
order of accuracy ofhold angle , minimising the variation of
1A . 7 to 1A . 12 , wherein the quantity and configuration of the 55 angular velocity, rate of deceleration during breaking, diam
at least one module in the electrical machine is determined eter of the shaft , maximum radius of the electrical machine,
based in part on one or more operating parameters ; and maximum length of the electricalmachine , maximum depth
wherein the at least one module is capable of being inde of the electrical machine , maximum height of the machine ,
pendently controlled . maximum slide distance, minimum slide distance, maxi
60 mum weight of the machine, minimum weight of the
Example 2A .6 machine, maximum resistive power loss, unit redundancy
and overall price .
The electrical machine of one or more of the examples
1A .7 to 1A . 12 , wherein the at least one module is capable of Example 4A .2
being independently controlled ; and wherein the at least one 65
module is capable ofbeing reconfigured based at least in part The electrical machine of one or more of the above A
on one or more of the following: at least one operating examples, wherein the at least one performance parameter
US 10 ,211,702 B2
49 50
during operation may be selected from one or more of the electromagnetic coils is the same number as the number of
following: maximum angular velocity, maximum power magnetic in the plurality ofmagnets and the spaced relation
output, deviation from output voltage during generation , between the plurality of electromagnetic coils and the plu
maintaining a required generation voltage , torque smooth rality of magnets is geometrically offset to prevent concen
ness , rate of acceleration , accuracy of hold angle , minimis -- 55 tric alignment.
ing the variation of angular velocity , matching requested rate
of deceleration during breaking, minimising resistive power Example 9
loss, overall efficiency, power factor correction ,mechanical
harmonic cancelation , electrical harmonic cancelation , accu
racy of reproduced output voltage wave, and accuracy of 1010 examples
generated frequency. , wherein the number of coils in the at least one
electromagnetic coil is at least one less than the number of
Example 4A . 3 magnets in the plurality of magnets.
The electrical machine of one or more of the above A Example 10
examples, wherein one or more performance parameters 15
during operation may be selected from one or more of the A The electrical machine of one or more of the above A
following: maximum angular velocity, maximum power examples, wherein the plurality of electromagnetic coils are
output, deviation from output voltage during generation , arranged in an axially aligned arrangement with the plurality
maintaining a required generation voltage , torque smooth - of magnets .
ness, rate of acceleration , accuracy of hold angle , minimis
ing the variation of angular velocity, matching requested rate Example 11
of deceleration during breaking,minimising resistive power
loss, overall efficiency, power factor correction , mechanical A The electrical machine of one or more of the above A
harmonic cancelation , electrical harmonic cancelation , accu 25 examples, wherein the plurality of electromagnetic coils are
racy of reproduced output voltage wave, and accuracy of arranged in axially misaligned arrangement by at least 5 , 10 ,
generated frequency . 15 , 20 , 25 , 30 , 35, 40 , or 45 degrees with the plurality of
magnets .
Example 4A .4
Example 12
The electrical machine of one or more of the above A 30
examples, wherein the at least one module is capable of A The electricalmachine of one or more of the above A
being reconfigured based at least in part on one or more of examples , wherein the plurality of electromagnetic coils are
the following ; at least one operating parameter during opera
tion , wherein the at least one operating parameter during axially aligned with the at least one stator and the plurality
operation may be selected from one or more of the param m 35 of magnets are axially aligned with the at least one rotor.
eters listed in example 4A .3 ; at least one performance Example 13
parameter during operation , wherein the at least one perfor
mance parameter during operation may be selected from one
or more of the parameter listed in example 4A . 2 ; or com A The electrical machine of one or more of the above A
binations thereof. 40 examples , wherein the plurality of electromagnetic coils are
substantial perpendicular or perpendicular with the at least
Example 5 one stator and the plurality of magnets coils are substantial
perpendicular or perpendicular with the at least one rotor.
examples , wherein the at least one electromagnetic coil 45 Example 14
comprises a plurality of electromagnetic coils that are in a
substantially circular arrangement or an axial flux arrange A The electrical machine of one or more of the above A
ment. examples, further comprising an enclosure that is mechani
cally sufficient to suitably resist deformation from mechani
Example 6 50 cal forces when in operation .
A The electrical machine of one or more of the above A Example 15
examples , wherein the at least one electromagnetic coil and
the plurality of magnets are in an angular or a radially offset A The electrical machine of one or more of the above A
arrangement. 55 examples, further comprising an enclosure that is thermally
conductive.
Example 7
Example 16
examples , wherein the number of coils in the at least one 60 A The electrical machine of one or more of the above A
electromagnetic coil is not the same number as the number examples , further comprising an enclosure thatmay be used
of magnetic in the plurality magnets. as a conductor for one or more electronic switches.
Example 8 Example 17A .1
65
A The electrical machine of one or more of the above A The electrical machine of one or more of the above A
examples, wherein the number of coils in the plurality of examples, wherein the power to weight ratio ofthe electrical
US 10 ,211,702 B2
51 52
machine is at least 0 .01, 0 .1 , 0 .25 , 0 .5 , 1 , 2 , 3 , 3.4 4 , 4 .5 5 , at least one control system activates at least one switch
6 , 7 , 8 , 8 .4 9 , 10 11, 12 , 13 , 14 or 15 kilowatts per kilogram . which connects one ormore of the magnetic coils terminals
together to oppose motion .
Example 17A .2
Example 19A .5
The electrical machine of one or more of the above A
examples,wherein the power to weight ratio of the electrical The electrical machine of example 19A .1, wherein the
machine is at between 10 to 1 , 15 to 3 , 10 to 0 .5 , 9 to 4 , 5 electrical machine is configured to be in a holding configu
to 0 .01, 3 . 4 to 6 or 8 . 4 to 3 . 4 kilowatts per kilogram . ration or has the at least one mode command to hold , the at
10 least one control system activates at least one switch ener
Example 18A .1 gises one or more of the magnetic coils to attract and repel
magnets for the purpose of stopping motion .
The electrical machine of one or more of the above A Example 20A . 1
examples, wherein the power to weight ratio of the electrical
machine is 10 % , 25 % , 50 % , 100 % , 125 % , 150 % , 200 % , 15
250 % , 300 % , 500 % or 1000 % greater than a brushless examples , wherein the at least one control system in opera
permanent magnet three phase electrical machine with a tion is determining one or more appropriately efficient
substantially similar size and weight. modes of operation in relation to the at least one operating
Example 18A . 2 20 parameter on a substantially continuous basis during oper
ating periods.
The electrical machine of one or more of the above A Example 20A. 2
examples , wherein the power to weight ratio of the electrical
machine is between 10 % to 1000 % , 10 % to 25 / % , 10 % to 5 The electrical machine of one or more of the above A
100 % , 25 % to 50 % , 25 % to 150 % , 50 % to 250 % , 50 % to examples, wherein the at least one control system in opera
100 % , 100 % to 125 % , 100 % to 250 % , 125 % to 150 % , 150 % tion is determining one or more appropriately efficient
to 300 % , 200 % to 1000 % , 250 % to 500 % , 250 % to 1000 % modes of operation in relation to the at least one operating
or 500 % to 1000 % greater than a brushless permanent parameters, the at least one performance parameter or com
magnet three phase electrical machine with a substantially 30 binations thereof on a substantially continuous basis during
similar size and weight. operating periods.
Example 19A .1 Example 21A
The electrical machine of one or more of the above A 35 The electrical machine of one or more of the above A
examples, further comprising at least one sensor to detect examples , wherein the electrical machine is capable of being
operated efficiently over 50 % , 60 % , 70 % , 80 % , 90 % , 95 % ,
absolute or relative position of the at least one rotor, and at 98 % or 100 % of the RPM ranges of the electricalmachine .
least one control system which , in response to inputs from
the one ormore of the following : the at least one sensor , at Example 22A .1
least one power command , at least one mode command 40
comprising one or more of the following at least one drive , The electrical machine of one or more of the above A
generate, braking and hold command and at least one examples, wherein the electrical machine has a power den
rotational direction command. sity of about 100 , 500 , 1000, 2000 , 5000, 10000 or 20000
Example 194 .2 kw /meter cubed .
Example 22A .2
The electrical machine of example 19A .1 , wherein the at
least one control system is configured to be in a drive The electrical machine of one or more of the above
configuration or has the at least one drive mode command, examples, wherein the electricalmachine has a power den
the at least one control system activates at least one switch 50 sity of at least 100 , 500 , 1000 , 2000 , 5000 , 10000 , or 20000
which energies one or more of the magnetic coils to attract kw /meter cubed .
and repel the magnets for the purpose of generating motion .
Example 22A .3
Example 194 .3
55 The electrical machine of one or more of the above A
The electrical machine of example 19A .1, wherein the examples, wherein the electrical machine has a power den
electrical machine is configured to be in a generation con - sity of between 100 to 20 ,000, 100 to 200 , 100 to 500, 250
figuration or has at least one mode command to generate to 500 , 500 to 1000 , 500 to 2000 , 1000 to 10 , 000 , 1000 to
power, the at least one control system activates at least one 5000 , 2000 to 5000 , 5000 to 10 ,000 , 5000 to 15 , 000 , 10 ,000
switch which connects one or more coils to the external 60 to 30 ,000 or 10 ,000 to 20 ,000 kw /meter cubed .
power rails .
Example 23A .1
Example 194 .4
The electrical machine of example 19A . 1, wherein the 65 examples, wherein one or more of the at least one operating
electrical machine is configured to be in a braking configu - parameter of the electrical machine may be reconfigured in
ration or has the at least one mode command to brake, the substantially real time.
US 10 ,211, 702 B2
53 54
Example 23A . 2 Example 28A .2
The electrical machine of one or more of the above A The electrical machine of one or more of the above A
examples, wherein one ormore of the at least one operating examples , wherein the plurality of coils has between 1000 to
parameter, the at least one performance parameter or com - 5 30100, ,501000 to 100 , 500 to 100 , 500 to 20 , 100 to 5 , 100 , to
binations thereof of the electrical machine may be recon 15 to 5 or 10, 40to to5 , 15times
to 10 , 35 to 10 , 30 to 15 , 25 to 10 , 20 to 5 ,
less variation in torque through a
figured in substantially real time. rotation than a brushless permanent magnet three phase
Example 24A electricalmachine with comparable power output.
10
Example 29A .1
examples, wherein the at least one control system provides The electrical machine of one or more of the above A
individual control over at least 30 % , 40 % , 50 % , 60 % , 70 % examples, wherein the material savings in the magnets
80 % , 90 % , 95 % or 100 % of the plurality of coils. would be at least 10 % , 15 % , 20 % , 30 % , 40 % , 50 % or 60 %
of a brushless permanent magnet permanent magnet three
Example 25A phase electrical machine with comparable power output.
The electrical machine of one or more of the above A Example 29A .2
examples, wherein the at least one operating parameter of
the electricalmachine may be reconfigured in substantially . The electrical machine of one or more of the above A
real time and the optimal settings for performance deter - examples, wherein the material savings in the magnets
mined and implemented across 50 % , 60 % , 70 % , 80 % , 90 % , would be between 10 % to 60 % , 10 % to 30 % , 15 % to 30 % ,
95 % , 98 % or 100 % of one or more of the following: 20 % to 50 % , 30 % to 50 % , 40 % to 60 % or 50 % to 70 % of
operating speeds and loads. brushless permanent magnet three phase electrical machine
with comparable power output.
Example 26A .1
Example 30A .1
examples, wherein the timing of the plurality of coils may be The electrical machine of one or more of the above A
reconfigured in substantially real time in order to continu - 3 examples, wherein the material savings in the copper would
ously optimize the timing of the plurality of coils. be at least 10 % , 15 % , 20 % , 30 % , 40 % , 100 % , 200 % or
1000 % more than that of a similar brushless permanent
Example 26A .2 magnet 3 phase electrical machine with similar resistive
power loss per power output.
examples , wherein the timing of the at least one coilmay be Example 30A .2
reconfigured in substantially real time in order to continu
ously optimize the timing of the at least one of coil. The electrical machine of one or more of the above A
examples, wherein the material savings in the copper would
Example 27A .1 40 be between 10 % to 100 % , 15 % to 40 % , 20 % to 100 % , 20 %
to 200 % , 30 % 1000 % , 40 % to 150 % , 100 % to 200 % , 200 %
The electrical machine of one or more of the above A to 500 % , 200 % to 1000 % or 500 % to 1000 % more than that
examples , wherein the total number of permanent magnets of a similar brushless permanent magnet 3 phase electrical
may be reduced by a minimum of 10 % , 15 % , 20 % , 25 % , machine with similar resistive power loss per power output.
30 % , 35 % , 40 % , 45 % , 50 % , 55 % , 60 % or 70 % , and still 45
provide comparable power output to a brushless permanent Example 31A
magnet three phase electrical machine .
Example 27A.2 examples , wherein the stator can be manufactured out of
50 aluminium , steel, copper, polyethylene, acrylic , polymer
The electrical machine of one or more of the above A reinforced carbon fibre , polymer reinforced fiberglass, gra
examples, wherein the total number of permanent magnets phene, other metallic , plastic and /or composite materials or
may be reduced by a minimum of between 10 % to 70 % , combinations thereof, and the stator has suitable rigidity .
10 % to 25 % , 20 % to 50 % , 15 % to 35 % , 20 % to 55 % , 25 %
to 50 % , 30 % 0 to 60 % , 35 % to 50 % , 40 % to 60 % , 45 % to 55 Example 32A
70 % or 50 % to 70 % , and still provide comparable power
output to a brushless permanentmagnet three phase electri The electrical machine of one or more of the above A
cal machine. examples, wherein the rotor can be manufactured out of
aluminium , steel, copper , polyethylene , acrylic, polymer
Example 28A. 1 60 reinforced carbon fibre , polymer reinforced fiberglass , gra
phene, other metallic , plastic and / or composite materials or
The electrical machine of one or more of the above A combinations thereof and the rotor has suitable rigidity.
examples,wherein the plurality of coils has about 1000 , 500 ,
100 , 50 , 40 , 35 , 30 25 , 20 , 15 , 10 or 5 , times less variation Example 33A
in torque through a rotation than a brushless permanent 65
magnet three phase electrical machine with comparable The electrical machine of one or more of the above A
power output. examples, wherein the enclosure can be manufactured out of
US 10 ,211,702 B2
55 56
aluminium , steel, copper, polyethylene , acrylic , polymer magnets may be attached to one or more other magnets to
reinforced carbon fibre , polymer reinforced fiberglass, gra - create at least one rotor that may be connected to at least one
phene, other metallic , plastic and /or composite materials or shaft.
combinations thereof and the enclosure has suitable rigidity .
Example 41A
Example 34A
The electrical machine of one or more of the above A examples, wherein the physical location of the at least one
examples, wherein the magnetic field in the rotor or slider module in reference to the other modules and the at least one
can be produced through the use of rare earth or other 10 stator is hard coded into the control software.
conventional forms of permanent magnets.
Example 42A
Example 35A
The electrical machine of one or more of the above A15 examples , wherein the physical location of the at least one
examples, wherein the plurality magnetic field generators module in reference to one or more of the othermodules and
are one ormore of the following : loops or coils of a metallic the at least one stator is encoded by one or more sequences
material that induce a current in the loops to produce a of electrical connections that may be constructed using
magnetic field . switches , solder bridges, jumpers , connectors, cutting
printed circuit tracks , other suitable ways of making and
Example 36A breaking electrical connections , or combinations thereof.
The electrical machine of one or more of the above A Example 43A
examples, wherein the plurality magnetic field generators 25 The electrical machine of one or more of the above A
are strips of ferromagnetic material that redirect magnetic examples, wherein the physical location of the at least one
fields .
module in reference to one or more of the othermodules and
Example 37A .1 the at least one stator is detected by the location that the at
30 aleast one module is inserted into in the at least one stator by
series of electrical contacts , optical reflections, magnetic
The electrical machine of one or more of the above A forces or combinations thereof encoding the position of the
examples, wherein to save space , cost or both , the at least module .
one switches for the at least one module is fabricated on the
same circuit board . Example 44A
35
Example 37A .2 The electrical machine of one or more of the above A
The electrical machine of one or more of the above examples, that are one or more combinations of examples
41A , 42A and 43A .
examples , wherein , the at least one switch for the at least one
module is fabricated on the same circuit board . 40 Example 45A
Example 38A . 1 The electrical machine of one or more of the above A
examples, wherein the at least one electromagnetic coil is
The electrical machine of one or more of the above A arranged around the periphery of the at least one stator.
examples, wherein to save space , cost or both , at least one 45
electromagnetic coil of the at least one module is fabricated Example 46A
as a single unit .
Example 38A .2 examples , further comprising at least one shaft.
50
examples, wherein the at least one electromagnetic coil of
the at least one module is fabricated as a single unit . The electrical machine of one or more of the above A
examples, wherein the plurality of magnets are arranged
Example 39A 55 around the periphery of the at least one rotor and have
substantially the same centre diameter as that of one or more
The electrical machine of one or more of the above A of the at least one electromagnetic coil, a plurality of the at
examples , wherein the at least one module has an enclosure least one electromagnetic coils , or a substantial portion of
that may be attached to one or more other modules in order the plurality of the at least one electromagnetic coils .
to construct the at least one stator without having to have a 60
separate stator structure . Example 49A
Example 40A The electrical machine of one or more of the above A
examples, wherein the plurality of magnets are arranged
The electrical machine of one or more of the above A 65 around the periphery of the at least one rotor and have
examples, wherein one or more of the plurality of magnets substantially the same centre diameter as that of one ormore
have an enclosure around them such that one or more of the of the at least one electromagnetic coil, a plurality of the at
US 10 ,211, 702 B2
57 58
least one electromagnetic coils , or a substantial portion of computed during machine operation , the order ofmodules
the plurality of the at least one electromagnetic coils and two activating being determined by a sequence pattern .
or more of the magnets have alternating pole orientation .
Example 50A Example 55A .2
examples , wherein two or more of the magnets of the examples, wherein the module coil activation sequence is
plurality ofmagnets have alternating pole orientation . computed during machine operation and the order of the at
10in least one modules activating being determined by at least in
Example 51A part one or more sequence patterns.
The electrical machine of one or more of the above A Example 56A . 1
examples, wherein there is a gap between the at least one
stator and the at least one rotor. 15 The electrical machine of one or more of the above A
Example 52A .1 examples, wherein the module coil activation sequence is
computed during machine operation and the order of mod
ules activating being determined based at least in part on one
examples, wherein the relative weight of the at least one 3 or more optimal power usage scenarios.
electromagnetic coil is approximately equal to an inverse of
the total number of coils as compared to a single phase Example 57A . 2
electricalmachine with a substantially similar resistive loss .
Example 52A .2 The electrical machine of one or more of the above A
25 examples , wherein the module coil activation sequence is
predetermined and stored , and the sequence is sourced at
The electrical machine of one or more of the above A least in part from sensor feedback .
examples , wherein the electrical machine has (n ) coils and
a weight of approximately 1/(n - 1 ) to 1/(n + 1 ) relative to a Example 58A . 1
single phase motor with substantially the similar resistive 30,
loss .
predetermined and stored, the nature of the sequence being
The electrical machine of one or more of the above A sourced from precomputed data stored within the module .
examples, wherein one or more module coil activation
sequences are computed during operation of the electrical Example 58A.2
machine and the order of the at least one module activating
being sequentially based on its geometric position in a
module array . The electrical machine of one or more of the above A
40 examples , wherein the module coil activation sequence is
Example 53A . 2 predetermined and stored , and the nature of the sequence
being sourced at least in part from precomputed data stored
The electrical machine of one or more of the above A within the module .
examples, wherein the module coil activation sequence is
computed during machine operation the order of modules 45 Example 59A .1
activating being sequentially based on their geometric posi
tion in the module array . The electrical machine of one or more of the above A
50 predetermined and stored, the nature of the sequence being
The electrical machine of one or more of the above A sourced from external modules over a communications bus .
examples , wherein the one or more module coil activation
sequence is computed during electrical machine operation , Example 59A .2
the order of at least one module activating being based at
least in part on sensor feedback . 55 The electrical machine of one or more of the above A
predetermined and stored , and the nature of the sequence
being sourced from one or more externalmodules over one
The electrical machine of one or more of the above A or more communications busses.
examples , wherein the module coil activation sequence is 60
computed during machine operation , the order of modules
activating being based upon sensor feedback . Example 60A
Example 55A . 1 The electrical machine of one or more of the above
65 examples, wherein the module coil activation sequence is
The electrical machine of one or more of the above A determined based on one or more of the above A examples ,
examples, wherein the module coil activation sequence is sourced based on one ormore of the above examples or both .
US 10 ,211,702 B2
59 60
examples the total number of powered coils in the active examples, wherein one or more of the at least one modules
sequence can vary during operation from the total number of 5 may be individually removed , added , or replaced while the
coils, to none . machine is powered off.
The electrical machine of one or more of the above A 10 examples
, wherein one or more of the at least one opera
examples, wherein the total number of the at least one tional parameter used by individual modules are tuned
electromagnetic coils powered in the active sequence may
vary during operation from the total number of coils , to dynamically during operation of the electrical machine ,
none . is based at least in part on sensor feedback .
Example 62A Example 71A
The electrical machine of one or more of the above A examples , wherein one or more of the at least one opera
examples, wherein the number of the at least one electro - 20 tional parameter used by individual modules are tuned
magnetic coils active may or may not be based upon sensor dynamically during operation of the electricalmachine, and
feedback . the tuning methods used may ormay not involve the use of
machine learning algorithms.
Example 63A 25
Example 72A
examples , wherein the control of the electricalmachine is examples , wherein the machines control system permits the
centralised on at least one control module .
motor to operate in both the clockwise and countclockwise
direction with respect to the rotational axis of the primary
Example 64A output or input.
examples, wherein the control of the electrical machine is
distributed to one or more of the modules with one or more 35 The electrical machine of one or more of the above A
modules acting independently . examples, wherein one or more of the at least one modules
further comprises one or more safety systems implemented
Example 65A in hardware , software , or both to allow automatic power
cut-off with respect to the coil, in the event of a feedback
40 based event.
examples, wherein the control of the electrical machine is Example 74A
arbitrated between two or more designated modules.
Example 66A 45 examples, wherein one or more of the at least one modules
further comprises one or more external power safety cut-off
The electrical machine of one or more of the above A control inputs on one or more of the modules . The inputs
examples, wherein one or more modules may be individu taking the form of tactile switches or digital touch panels or
communications buses, the cut offs being designed such that
ally removed , added , or replaced during operation of the 5050 they
machine, without substantially affecting the operational state bypass the primary controller in each module .
of the machine. Example 75A
Example 67A The electrical machine of one or more of the above A
55 examples, wherein one or more of the at least one modules
The electrical machine of example 66A , wherein 1 , 2 , 3 , further comprises one or more external power safety cut-off
4 , 5 , 6 , 7 , 8 , 9 or 10 modules may be individually removed . control inputs on one or more of themodules and the inputs
added , or replaced during operation of the machine, without may be one ormore of the following : tactile switches, digital
substantially affecting the operational state of the machine. 60 touch panels, communications buses, or combinations
thereof, wherein the cut offs are designed such that they
bypass the primary controller in one or more of the at least
Example 68A one module .
The electrical machine of example 66A , wherein 1, 2 , 3 , Example 76A
4 , 5 , 6 , 7 , 8 , 9 or 10 modules may be individually removed , 65
added , or replaced during operation of the machine , without The electrical machine of one or more of the above A
substantially affecting the operational state of the machine. examples, wherein the at least one module further comprises
US 10 ,211, 702 B2
at least one sensor for detecting the back EMF from the one or more sensors for detecting one or more of the
modules coil in order to reduce cogging effects to improve following: the magnitude , the angle and the direction of at
efficiency , and the back - EMF of an unpowered coil is least one magnetic field .
recorded at a representative range of speeds using the
analogue- to -digital converter in at least one coil control unit 5 Example 85A
during operation; the unpowered coil is then powered to a
voltage that substantially negates the back -EMF thereby The electrical machine of one or more of the above A
neutralizing the magnetic interaction between the un -pow examples , wherein the at least one module further comprises
ered coil and the magnets ; and optional this procedure may one or more sensors for detecting accelerations , for the
be repeat for one or more coils in the array in order to reduce 10 purpose of vibration detection .
cogging effects.
Example 86A
Example 77A
Any of the above A examples implemented in hardware, 15 more
A method of use that uses the electricalmachine of one or
of the above A examples or combinations of the
software , or combinations thereof. features disclosed herein .
20
examples,wherein the at least onemodule further comprises of Athesystem
above
that uses the electrical machine of one or more
A examples or combinations of the features
one or more sensors for detecting the voltage across the at disclosed herein .
least one module ' s coil.
25
The electrical machine of one or more of the above A A module that incorporates the features of one or more of
examples, wherein the at least one module further comprises the above A examples or combinations of the module
features disclosed herein .
one ormore sensors for detecting the current flowing across 30 Teat
the at least one module' s coil.
Example 89A
Example 80A
A control systems for an electricalmachine that incorpo
The electrical machine of one or more of the above A 35 rates the features of one or more of the above A examples or
examples, wherein the at least one module further comprises combinations of the control features disclosed herein .
one or more sensors for detecting the back EMF from the at
least one module ’s coil . Example 90A
Example 81A * A control systems for a module that incorporates the
features of one or more of the above A examples or com
The electrical machine of one or more of the above A binations of the control features disclosed herein .
examples, wherein the at least onemodule further comprises
one or more sensors for detecting the absolute or relative Example 91A
position of the machine' s the at least one rotor in relation to 45
the at least one module ' s position .
Example 82A examples, wherein at least one adaptive control is imple
mented by performing optimisation during machine opera
The electrical machine of one or more of the above A 50 tion through the use of one or more of the following: at least
examples, wherein the at least one module further comprises one support vector machine, neural network algorithm , a
one or more sensors for detecting the velocity of the fuzzy logic algorithm , of machine learning algorithms and
machines the at least one rotor in relation to the at least one through the use of other suitable adaptive control tech
module ’s position . niques.
55
examples , wherein the at least one module further comprises examples , wherein the at least one stator is a substantial
one or more sensors for detecting the thermal temperature 60 portion of the stators contained in the electrical machine.
around the at least one module or other surfaces within the
electrical machine. Example 93A
Example 84A
65 The electrical machine of one or more of the above A
The electrical machine of one or more of the above A examples , wherein the at least one stator is all of the stators
examples, wherein the at least one module further comprises contained in the electrical machine .
US 10 ,211, 702 B2
63 64
examples, wherein the at least one module is a substantial examples, wherein the plurality ofmagnetic induction loops
portion of the modules contained in the electrical machine. 5 is all of the magnetic induction loops contained in the
Example 95A electrical machine.
Example 106A
examples, wherein the at least one module is all of the 10 The
modules contained in the electrical machine. examples, wherein the plurality of magnetic reluctance
Example 96A projections is a substantial portion of the magnetic reluc
tance projections contained in the electrical machine .
The electrical machine of one or more of the above A 15 Example 107A
examples , wherein the at least one electromagnetic coil is a
substantial portion of the electromagnetic coils contained in
the electrical machine . The electrical machine of one or more of the above A
examples, wherein the plurality ofmagnetic induction loops
Example 97A 20 is all of the magnetic induction loops contained in the
electrical machine .
examples , wherein the at least one electromagnetic coil is all Example 109A
of the electromagnetic coil contained in the electrical
machine . 25 The electrical machine of one or more of the above A
examples, wherein the plurality of stators is a substantial
Example 98A portion of the stators contained in the electrical machine.
examples , wherein the at least one switch is a substantial 302
portion of the switches contained in the electrical machine. The electrical machine of one or more of the above A
examples, wherein the plurality of stators is all of the stators
Example 99A contained in the electrical machine .
The electrical machine of one or more of the above A , Example 111A
examples , wherein the at least one switch is all of the
switches contained in the electrical machine. The electrical machine of one or more of the above A
examples, wherein the plurality of modules is a substantial
Example 100A portion of the modules contained in the electrical machine.
40
Example 112A
examples, wherein the at least one rotor is a substantial
portion of the rotors contained in the electrical machine . The electrical machine of one or more of the above A
examples, wherein the plurality of modules is all of the
Example 101A 45
modules contained in the electrical machine.
examples , wherein the at least one rotor is all of the rotors
contained in the electrical machine . The electrical machine of one or more of the above A
examples, wherein the plurality of rotors is a substantial
Example 102A 50 portion of the rotors contained in the electrical machine .
examples, wherein the plurality of magnets is a substantial
portion of the magnets contained in the electricalmachine . The electrical machine of one or more of the above A
55 examples, wherein the plurality of rotors is all of the rotors
Example 103A contained in the electrical machine .
The electrical machine of one or more of the above A Example 1B
examples, wherein the plurality of magnets is all of the
magnets contained in the electrical machine . 60 An electrical machine comprising: at least one stator, at
least one module, the at least one module comprising at least
Example 104A one electromagnetic coil and at least one switch , the at least
one module being attached to the at least one stator; at least
The electrical machine of one or more of the above A one rotor with a plurality ofmagnets attached to the at least
examples , wherein the plurality of magnetic induction loops 65 one rotor, wherein the at least one module is in spaced
is a substantial portion of the magnetic induction loops relation to the plurality of the magnets ; an integrated dif
contained in the electrical machine . ferential coupled to at least one of the at least one rotors, the
US 10 ,211,702 B2
65 66
at least one integrated differential permitting the at least one plurality ofmodules are capable of being reconfigured based
rotor to output at least two rotational outputs to correspond at least in part on one or more of the following: at least one
ing shafts , wherein the at least two rotational outputs are operating parameter during operation , and at least one
performance parameter during
performance parameter
able to move the shafts at different rotational velocities 5 electrical operation ;; and
during operation and wherein
whe the
relative to one another , and the at least one rotor being in a 5 can machine is configured to fit into a housing and that
e be located
rotational relationship with the at least one stator , wherein in substantially that same position where a
the quantity and configuration of the at least one module in differential would otherwise be located in a vehicle or other
the electrical machine is determined based in part on one or machine .
more operating parameters ; wherein the at least one module Example 4B
is capable of being independently controlled ; wherein the at 10
least one module is capable of being reconfigured based at An electrical machine comprising : a plurality of stators ; a
least in part on one or more of the following: at least one plurality ofmodules comprising at least one electromagnetic
operating parameter during operation , at least one perfor - coil and at least one switch and being attached to at least one
mance parameter during operation , and combinations of the plurality of stators; a plurality of rotors with a plurality
thereof; and wherein the electrical machine is configured to 15 ofmagnets attached to at least one of the plurality of rotors,
fit into a housing and that can be retrofitted into a conven the plurality of rotors are able to move independently to one
tional vehicle by replacing the differential. another to produce a differential output that permits the
electric machine to output at least two rotational outputs to
Example 2B corresponding shafts , wherein the at least two rotational
20 outputs are able to move the shafts at different rotational
An electrical machine comprising : at least one stator; at velocity ' s relative to one another, and the plurality of
least one module , the at least onemodule comprising at least modules are in spaced relation to the plurality of the mag
one electromagnetic coil and at least one switch , the at least nets; and the plurality of rotors being in a rotational rela
one module being attached to the at least one stator; at least tionship with the plurality of stators ; wherein the quantity
one rotor with a plurality ofmagnets attached to the at least 25 and configuration of the plurality of modules in the electrical
one rotor, wherein the at least one module is in spaced machine is determined based in part on one or more oper
relation to the plurality of the magnets ; an integrated dif ating parameters ; wherein the plurality of modules are
ferential coupled to at least one of the at least one rotors , the
capable of being independently controlled , and wherein the
at least one integrated differentialpermitting the at least one plurality ofmodules are capable of being reconfigured based
rotor to output at least two rotational outputs to correspond - 30 operating part
at least in on one or more of the following: at least one
parameter during operation , and at least one
ing shafts, wherein the at least two rotational outputs are performance parameter during operation ; and wherein the
able to move the shafts at different rotational velocities electrical machine is configured to fit into a housing and that
relative to one another, and the at least one rotor being in a can be retrofitted into a conventional vehicle by replacing
rotational relationship with the at least one stator ; wherein the differential.
the quantity and configuration of the at least one module in 35
the electricalmachine is determined based in part on one or Example 5B
more operating parameters ; wherein the at least one module
is capable of being independently controlled ; wherein the at An electrical machine comprising : a plurality of stators ; a
least one module is capable of being reconfigured based at plurality ofmodules comprising at least one electromagnetic
least in part on one or more of the following: at least one 40 coil and at least one switch and being attached to at least one
operating parameter during operation , at least one perfor of the plurality of stators ; a plurality of rotors with a plurality
mance parameter during operation , and combinations ofmagnets attached to at least one of the plurality of rotors ,
thereof, and wherein the electrical machine is configured to the plurality of rotors are able to move independently to one
another to produce a differential output that permits the
fit into a housing and that can be located in substantially that
electric machine to output at least two rotational outputs to
same position where a differential would otherwise be 45 corresponding
located in a vehicle or other machine . shafts, wherein the at least two rotational
outputs are able to move the shafts at different rotational
Example 3B velocity 's relative to one another, and the plurality of
modules are in spaced relation to the plurality of the mag
nets ; and the plurality of rotors being in a rotational rela
An electricalmachine comprising : a plurality of stators; a 50 tionship with the plurality of stators ; wherein the quantity
plurality ofmodules comprising at least one electromagnetic and configuration of the plurality ofmodules in the electrical
coil and at least one switch and being attached to at least one machine is determined based in part on one or more oper
of the plurality ofstators ; a plurality ofrotors with a plurality ating parameters ; wherein the plurality of modules are
of magnets attached to at least one of the plurality of rotors, capable of being independently controlled , and wherein the
the plurality ofrotors are able to move independently to one 55 plurality of modules are capable ofbeing reconfigured based
another to produce a differential output that permits the at least in part on one or more of the following : at least one
electric machine to output at least two rotational outputs to operating parameter during operation , and at least one
corresponding shafts , wherein the at least two rotational performance parameter during operation ; and wherein the
outputs are able to move the shafts at different rotational electricalmachine is configured to fit into a housing and that
velocity 's relative to one another, and the plurality of 60 can be located in substantially that same position where a
modules are in spaced relation to the plurality of the mag - differential would otherwise be located in a vehicle or other
nets; and the plurality of rotors being in a rotational rela - machine .
tionship with the plurality of stators; wherein the quantity
and configuration of the plurality of modules in the electrical Example 6B
machine is determined based in part on one or more oper- 65
ating parameters ; wherein the plurality of modules are An electrical machine comprising: at least one stator, at
capable of being independently controlled , and wherein the least onemodule, the at least onemodule comprising at least
US 10 ,211,702 B2
68
one electromagnetic coil and at least one switch , the at least machine is at between 10 to 1 , 15 to 3 , 10 to 0 .5 , 9 to 4 , 5
one module being attached to the at least one stator; at least to 0 .01, 3 .4 to 6 or 8 .4 to 3 .4 kilowatts per kilogram .
one platter or rotor with a plurality ofmagnets attached to
the at least one platter or rotor, wherein the at least one
module is in spaced relation to the plurality of the magnets ; 5
Example 10B
an integrated differential coupled to at least one of the at The electrical machine of one or more of the above B
least one platters or rotors , the at least one integrated examples, further comprising at least one sensor to detect
differential permitting the at least one platter or rotor to absolute or relative position of the at least one rotor, and at
output at least two rotational outputs to corresponding
shafts , wherein the at least two rotational outputs are able to , least one control system which , in response to inputs from
move the shafts at different rotational velocities relative to the one or more of the following: the at least one sensor, at
one another , and the at least one platter or rotor being least one power command , at least one mode command
movement relationship with the at least one stator, wherein comor
comprising one or more of the following at least one drive ,
the quantity and configuration of the at least one module in generate , braking and hold command and at least one
the electricalmachine is determined based in part on one or rotational direction command .
more operating parameters; wherein the at least onemodule 15
is capable of being independently controlled ; and wherein Example 11B
the at least one module is capable of being reconfigured
based at least in part on one or more of the following : at least The electrical machine of example 10B , wherein the at
one operating parameter during operation , at least one least one control system is configured to be in a drive
performance parameter during operation , or combinations 20
thereof. configuration or has the at least one drive mode command ,
the at least one control system activates at least one switch
Example 7B which energies one or more of the magnetic coils to attract
The electrical machine of one or more of the above B 35
examples , wherein the at least one operating parameter Example 12B
during operation may be selected from one or more of the
following: maximum angular velocity , average angular The electrical machine of example 10B , wherein the
velocity , minimum angular velocity , maximum power out - electrical machine is configured to be in a generation con
put, average power output, minimum power output, maxi- figuration or has at least one mode command to generate
mum input voltage , average input voltage , minimum input power, the at least one control system activates at least one
voltage , maximum generation voltage , average generation switch which connects one or more coils to the external
voltage, minimum generation voltage , shape and frequency power rails.
of generated voltage , peak input current, average input
current, minimum input current, maximum generation cur Example 13B
rent, average generation current, minimum generation cur- 35
rent, maximum torque , average torque , minimum torque , The electrical machine of example 10B , wherein the
torque smoothness , activation sequence , rate of acceleration , electrical machine is configured to be in a braking configu
order of accuracy of hold angle , minimising the variation of ration or has the at least one mode command to brake, the
angular velocity , rate of deceleration during breaking , diam - at least one control system activates at least one switch
eter of the shaft, maximum radius of the electrical machine , 40 which connects one or more of the magnetic coils terminals
maximum length of the electrical machine,maximum depth together to oppose motion .
of the electricalmachine , maximum height of the machine ,
maximum slide distance , minimum slide distance , maxi Example 14B
mum weight of the machine, minimum weight of the
machine , maximum resistive power loss and unit redun- 45 The electrical machine of example 10B , wherein the
dancy and overall price. electrical machine is configured to be in a holding configu
Example 8B
ration or has the at least one mode command to hold , the at
least one control system activates at least one switch ener
gises one or more of the magnetic coils to attract and repel
The electrical machine of one or more of the above B 50 magnets for the purpose of stopping motion .
examples, wherein the at least one performance parameter
during operation may be selected from one or more of the Example 15B
following: maximum angular velocity , maximum power
output , deviation from output voltage during generation , The electrical machine of one or more of the above B
maintaining a required generation voltage , torque smooth - 55 examples, wherein the at least one control system in opera
ness, rate of acceleration , accuracy of hold angle, minimis - tion is determining one or more appropriately efficient
ing the variation ofangular velocity ,matching requested rate modes of operation in relation to the at least one operating
of deceleration during breaking, minimising resistive power parameters, the at least one performance parameter or com
loss, overall efficiency, power factor correction , mechanical binations thereof on a substantially continuous basis during
harmonic cancelation , electrical harmonic cancelation , accu - 60 operating periods.
racy of reproduced output voltage wave and accuracy of
generated frequency. Example 16B
Example 9B The electrical machine of one or more of the above B
65 examples , wherein the electricalmachine has a power den
The electrical machine of one or more of the above B sity of between 100 to 20 ,000 , 100 to 200 , 100 to 500 , 250
examples, wherein the power to weight ratio of the electrical to 500 , 500 to 1000 , 500 to 2000, 1000 to 10 ,000 , 1000 to
US 10 ,211,702 B2
69 70
5000 , 2000 to 5000 , 5000 to 10 ,000 , 5000 to 15 ,000, 10 ,000 being reconfigured based at least in part on one or more of
to 20 ,000 or 10 ,000 to 30 ,000 kw /meter cubed . the following: atleast one operating parameter during opera
tion , wherein the at least one operating parameter during
Example 17B operation may be selected from one or more of the param
5 eters listed in example 7B ; at least one performance param
The electrical machine of one or more of the above B eter during operation , wherein the at least one performance
examples , wherein one or more of the at least one operating parameter during operation may be selected from one or
parameter, the at least one performance parameter or com more of the parameter listed in example 8B ; or combinations
binations thereof of the electrical machine may be recon thereof.
figured in substantially real time. 10
Example 26B
Example 18B
The electrical machine of one or more of the above B
The electrical machine of one or more of the above B examples, wherein the electrical machine is a compact direct
examples, wherein the at least one control system provides drive electric motor that generates sufficient or improved
individual control over at least 30 % , 40 % , 50 % , 60 % , 70 % propulsion in a wheeled vehicle and the electric motor and
80 % , 90 % , 95 % or 100 % of the plurality of coils . the differential can fit the size of envelope of existing
differentials in a conventional combustion engine driven
Example 19B 20
vehicle .
The electrical machine of one or more of the above B Example 27B
computed during machine operation the order of modules The electrical machine of one or more of the above B
activating being sequentially based on their geometric posi- os . examples, wherein the electrical machine is a compact direct
tion in the module array . 25 drive electric motor that generate sufficient or improved
propulsion of a wheeled vehicle and the electric motor and
Example 20B the differential can be installed in line with a drive axial
while providing adequate clearance from a road without
The electrical machine of one or more of the above B substantial modification to an existing suspension of the
examples, wherein the module coil activation sequence is » wheeled vehicle .
computed during machine operation , the order of modules
activating being based upon sensor feedback . Example 28B
Example 21B The electrical machine of one or more of the above B
35 examples , wherein the electricalmachine is a compact direct
The electrical machine of one or more of the above B drive electric motor that generate sufficient propulsion of a
examples, wherein the module coil activation sequence is wheeled vehicle and the electric motor and the differential
computed during machine operation and the order of the at can be installed in line with one or more drive axels while
least one modules activating being determined by at least in providing adequate clearance from a road without substan
part one or more sequence patterns. 40 tial modification to an existing suspension of the wheeled
vehicle .
Example 22B
Example 29B
The electrical machine of one or more of the above
examples, wherein the total number of the at least one 45 The electrical machine of one or more of the above B
electromagnetic coils powered in the active sequence may examples, wherein the electrical machine is a compact direct
vary during operation from the total number of coils , to drive electric motor that generate sufficient propulsion of a
none . wheeled vehicle and the electric motor and the differential
can be installed in line with one or more drive axels without
Example 23B 50 lower, or substantially lowering, the clearance from a road
and without substantial modification to an existing suspen
The electrical machine of one or more of the above B sion of the wheeled vehicle .
examples, wherein the control of the electrical machine is Example 1C
55
Example 24B An electrical machine comprising: at least one stator; at
least one module , wherein a substantial portion of the
The electrical machine of one or more of the above modules comprise at least one electromagnetic coil and at
examples, wherein one or more modules may be individu - least one switch , the at least one module being attached to
ally removed , added , or replaced during operation of the 60 the at least one stator; at least one rotor with a plurality of
machine , without substantially affecting the operational state magnets attached to the at least one rotor, wherein the at
of the machine. least one module is in spaced relation to the plurality of the
magnets ; an integrated differential coupled to at least one of
Example 25B the at least one rotors, the at least one integrated differential
65 permitting the at least one rotor to output at least two
The electrical machine of one or more of the above B rotational outputs to corresponding shafts , wherein the at
examples, wherein the at least one module is capable of least two rotational outputs are able to move the shafts at
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different rotational velocities relative to one another, and the controlled , and wherein the substantial portion of the mod
at least one rotor being in a rotational relationship with the ules are capable of being reconfigured based at least in part
at least one stator; wherein the quantity and configuration of
on one or more of the following: at least one operating
the substantial portion of the modules in the electrical parameter during operation , and at least one performance
machine is determined based in part on one or more oper - 5 parameter during operation , and wherein the electrical
ating parameters ; wherein the substantial portion ofmodules machine is configured to fit into a housing and that can be
are capable of being independently controlled ; located in substantially that same position where a differ
wherein the substantial portion of modules are capable of ential would otherwise be located in a vehicle or other
being reconfigured based at least in part on one or more of machine .
the following ; at least one operating parameter during opera - 10
tion , at least one performance parameter during operation , Example 4C
and combinations thereof; and wherein the electrical
machine is configured to fit into a housing and that can be An electrical machine comprising : a plurality of stators ; a
retrofitted into a conventional vehicle by replacing the plurality of modules, wherein a substantial portion of the
differential. 15 modules comprise at least one electromagnetic coil and at
least one switch and being attached to at least one of the
Example 2C plurality of stators ; a plurality of rotors with a plurality of
magnets attached to at least one of the plurality of rotors , the
An electrical machine comprising : at least one stator; at plurality of rotors are able to move independently to one
least one module , wherein a substantial portion of the 20 another to produce a differential output that permits the
modules comprise at least one electromagnetic coil and at electric machine to output at least two rotational outputs to
least one switch , the at least one module being attached to corresponding shafts, wherein the at least two rotational
the at least one stator; at least one rotor with a plurality of outputs are able to move the shafts at different rotational
magnets attached to the at least one rotor, wherein the at velocity ' s relative to one another, and the plurality of
least one module is in spaced relation to the plurality of the 25 modules are in spaced relation to the plurality of the mag
magnets ; an integrated differential coupled to at least one of nets ; and the plurality of rotors being in a rotational rela
the at least one rotors, the at least one integrated differential tionship with the plurality of stators ; wherein the quantity
permitting the at least one rotor to output at least two and configuration of the substantial portion of the modules
rotational outputs to corresponding shafts, wherein the at in the electricalmachine are determined based in part on one
least two rotational outputs are able to move the shafts at 30 or more operating parameters ; wherein the substantial por
different rotational velocities relative to one another, and the tion of the modules are capable of being independently
at least one rotor being in a rotational relationship with the controlled , and wherein the substantial portion of the mod
at least one stator; wherein the quantity and configuration of u les are capable of being reconfigured based at least in part
the substantial portion of modules in the electrical machine on one or more of the following : at least one operating
are determined based in part on one or more operating 35 parameter during operation , and at least one performance
parameters ; wherein the substantial portion of the modules parameter during operation ; and wherein the electrical
are capable of being independently controlled ; wherein the machine is configured to fit into a housing and that can be
substantial portion of modules are capable of being recon - retrofitted into a conventional vehicle by replacing the
figured based at least in part on one ormore of the following: differential.
at least one operating parameter during operation , at least 40
one performance parameter during operation , and combina Example 5C
tions thereof; and wherein the electrical machine is config
ured to fit into a housing and that can be located in An electricalmachine comprising: a plurality of stators; a
substantially that same position where a differential would plurality of modules, wherein a substantial portion of the
otherwise be located in a vehicle or other machine . 45 modules comprise at least one electromagnetic coil and at
least one switch and being attached to at least one of the
Example 3C plurality of stators ; a plurality of rotors with a plurality of
magnets attached to at least one of the plurality of rotors, the
An electricalmachine comprising: a plurality of stators ; a plurality of rotors are able to move independently to one
plurality of modules , wherein a substantial portion of the 50 another to produce a differential output that permits the
modules comprise at least one electromagnetic coil and at electric machine to output at least two rotational outputs to
least one switch and being attached to at least one of the corresponding shafts , wherein the at least two rotational
plurality of stators ; a plurality of rotors with a plurality of outputs are able to move the shafts at different rotational
magnets attached to at least one of the plurality of rotors, the velocity 's relative to one another, and the plurality of
plurality of rotors are able to move independently to one 55 modules are in spaced relation to the plurality of the mag
another to produce a differential output that permits the nets ; and the plurality of rotors being in a rotational rela
electric machine to output at least two rotational outputs to tionship with the plurality of stators ; wherein the quantity
corresponding shafts, wherein the at least two rotational and configuration of the substantial portion of the modules
outputs are able to move the shafts at different rotational in the electrical machine is determined based in part on one
velocity ' s relative to one another, and the plurality of 60 or more operating parameters ; wherein the substantial por
modules are in spaced relation to the plurality of the mag - tion of the modules are capable of being independently
nets; and the plurality of rotors being in a rotational rela - controlled , and wherein the substantial portion of the mod
tionship with the plurality of stators ; wherein the quantity ules are capable of being reconfigured based at least in part
and configuration of the substantial portion of the modules on one or more of the following: at least one operating
in the electrical machine are determined based in part on one 65 parameter during operation , and at least one performance
or more operating parameters ; wherein the substantial por - parameter during operation ; and wherein the electrical
tion of the modules are capable of being independently machine is configured to fit into a housing and that can be
US 10 ,211,702 B2
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located in substantially that same position where a differ- ness, rate of acceleration , accuracy of hold angle, minimis
ential would otherwise be located in a vehicle or other ing the variation of angular velocity, matching requested rate
machine . of deceleration during breaking, minimising resistive power
loss, overall efficiency, power factor correction , mechanical
Example 6C 5 harmonic cancelation , electricalharmonic cancelation , accu
racy of reproduced output voltage wave , and accuracy of
An electrical machine comprising: at least one stator ; at generated frequency .
least one module , wherein a substantial portion of the
modules comprise at least one electromagnetic coil and at Example 9C
least one switch , the at least one module being attached to 10
the at least one stator ; at least one platter or rotor with a The electrical machine of one or more of the above C
plurality of magnets attached to the at least one platter or examples , wherein the power to weight ratio of the electrical
rotor, wherein the at least one module is in spaced relation machine is at between 10 to 1 , 15 to 3 , 10 to 0 .5 , 9 to 4 , 5
to the plurality of the magnets; an integrated differential to 0 .01 , 3 . 4 to 6 or 8 .4 to 3 .4 kilowatts per kilogram .
coupled to at least one of the at least one platters or rotors , 15
the at least one integrated differential permitting the at least Example 10C
one platter or rotor to output at least two rotational outputs
to corresponding shafts , wherein the at least two rotational The electrical machine of one or more of the above C
outputs are able to move the shafts at different rotational
velocities relative to one another, and the at least one platter 20 absolute or, further
examples
relative
comprising at least one sensor to detect
position of the at least one rotor; and at
or rotor being movement relationship with the at least one least one control system which , in response to inputs from
stator, the one or more of the following : the at least one sensor, at
wherein the quantity and configuration of the substantial least one power command , at least one mode command
portion of the modules in the electrical machine are deter comprising one or more of the following : at least one drive ,
mined based in part on one or more operating parameters; 25 generate , braking and hold command and at least one
wherein the substantial portion of themodules are capable of rotational direction command .
being independently controlled ; and wherein the substantial
portion of the modules are capable of being reconfigured Example 11C
based atleast in part on one or more of the following: atleast
one operating parameter during operation, at least one 30 The electrical machine of example 10C , wherein the at
performance parameter during operation, or combinations least one control system is configured to be in a drive
thereof. configuration or has the at least one drive mode command,
Example 7C the at least one control system activates at least one switch
which energies one or more of the magnetic coils to attract
and repel themagnets for the purpose of generating motion .
The electrical machine of one or more of the above C
examples, wherein the at least one operating parameter Example 120
during operation may be selected from one or more of the
following: maximum angular velocity , average angular The electrical machine of example 10C , wherein the
velocity , minimum angular velocity , maximum power out - 40 electrical machine is configured to be in a generation con
put, average power output, minimum power output, maxi figuration or has at least one mode command to generate
mum input voltage , average input voltage, minimum input power, the at least one control system activates at least one
voltage , maximum generation voltage, average generation switch which connects one or more coils to the external
voltage, minimum generation voltage, shape and frequency power rails.
of generated voltage, peak input current, average input 45
current, minimum input current, maximum generation cur Example 13C
rent, average generation current, minimum generation cur
rent, maximum torque , average torque, minimum torque , The electrical machine of example 10C , wherein the
torque smoothness , activation sequence, rate of acceleration , electrical machine is configured to be in a braking configu
order of accuracy of hold angle , minimising the variation of 50 ration or has the at least one mode command to brake , the
angular velocity , rate of deceleration during breaking, diam - at least one control system activates at least one switch
eter of the shaft, maximum radius of the electricalmachine, which connects one ormore of the magnetic coils terminals
maximum length of the electrical machine, maximum depth together to oppose motion .
of the electrical machine, maximum height of the machine,
maximum slide distance, minimum slide distance, maxi- 55 Example 14C
mum weight of the machine , minimum weight of the
machine, maximum resistive power loss , and unit redun The electrical machine of example 10C , wherein the
dancy and overall price . electrical machine is configured to be in a holding configu
ration or has the at least one mode command to hold , the at
Example 8C 60 least one control system activates at least one switch ener
gises one or more of the magnetic coils to attract and repel
The electrical machine of one or more of the above C magnets for the purpose of stopping motion .
examples , wherein the at least one performance parameter
during operation may be selected from one or more of the Example 15C
following: maximum angular velocity, maximum power 65
output, deviation from output voltage during generation , The electrical machine of one or more of the above C
maintaining a required generation voltage, torque smooth examples, wherein the at least one control system in opera
US 10 ,211,702 B2
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tion is determining one or more appropriately efficient Example 24C
modes of operation in relation to the at least one operating
parameters , the at least one performance parameter or com The electrical machine of one or more of the above C
binations thereof on a substantially continuous basis during 5 examples , wherein one or more modules may be individu
ally removed , added , or replaced during operation of the
operating periods. machine , without substantially affecting the operational state
Example 16C of the machine.
Example 25C
examples , wherein the electrical machine has a power den - 10 The electrical machine of one or more of the above C
sity of between 100 to 20 ,000 , 100 to 200, 100 to 500 , 250 examples, wherein the substantial portion of themodules are
to 500 , 500 to 1000 , 500 to 2000 , 1000 to 10 , 000 , 1000 to capable of being reconfigured based at least in part on one
5000 , 2000 to 5000 , 5000 to 10 ,000 , 5000 to 15 ,000 , 10 ,000 or more of the following : at least one operating parameter
to 30 ,000 or 10 ,000 to 20,000 kw /meter cubed . during operation , wherein the at least one operating param
15 eter during operation may be selected from one or more of
Example 17C the parameters listed in example 2C ; at least one perfor
mance parameter during operation , wherein the at least one
The electrical machine of one or more of the above C performance parameter during operation may be selected
from one or more of the parameter listed in example 3C ; or
examples, wherein one ormore of the at least one operating 30 combinations thereof
parameter, the at least one performance parameter or com
binations thereof of the electrical machine may be recon Example 26C
figured in substantially real time .
Example 18C 25 examples, wherein the electrical machine is a compact direct
drive electric motor that generates sufficient or improved
The electrical machine of one or more of the above C propulsion in a wheeled vehicle and the electric motor and
examples, wherein the at least one control system provides the differential can fit the size of envelope of existing
individual control over at least 30 % , 40 % , 50 % ,60 % , 70 % differentials in a conventional combustion engine driven
vehicle .
80 % , 90 % , 95 % or 100 % of the plurality of coils. 30
Example 19C Example 27C
The electrical machine of one or more of the above C examples , wherein the electrical machine is a compact direct
examples, wherein the module coil activation sequence is 35 drive electric motor that generate sufficient or improved
computed during machine operation the order of modules propulsion of a wheeled vehicle and the electric motor and
activating being sequentially based on their geometric posi the differential can be installed in line with a drive axial
tion in the module array . while providing adequate clearance from a road without
Example 20C 40 wheeled vehicle .
The electrical machine of one or more of the above C Example 28C
computed during machine operation , the order of modules The electrical machine of one or more of the above C
activating being based upon sensor feedback . 45 examples,wherein the electricalmachine is a compact direct
drive electric motor that generate sufficient propulsion of a
Example 210 wheeled vehicle and the electric motor and the differential
can be installed in line with one or more drive axels while
The electrical machine of one or more of the above C providing adequate clearance from a road without substan
examples, wherein the module coil activation sequence is 50 tial modification to an existing suspension of the wheeled
computed during machine operation and the order of the at vehicle .
least one modules activating being determined by at least in
part one or more sequence patterns. Example 290
Example 22C 55 The electrical machine of one or more of the above C
examples, wherein the electrical machine is a compact direct
The electrical machine of one or more of the above C drive electric motor that generate sufficient propulsion of a
examples, wherein the total number of the at least one wheeled vehicle and the electric motor and the differential
electromagnetic coils powered in the active sequence may can be installed in line with one or more drive axels without
vary during operation from the total number of coils , to 60 lower, or substantially lowering, the clearance from a road
none . and without substantial modification to an existing suspen
sion of the wheeled vehicle .
Example 23C
Example 1D
The electrical machine of one or more of the above C 65
examples, wherein the control of the electrical machine is An electrical machine comprising : at least one stator, at
centralised on at least one control module. least one module , each module comprising at least one
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electromagnetic coil and at least one switch , the at least one the magnets ; and the plurality of rotors being in a rotational
module being attached to the at least one stator, at least one relationship with the plurality of stators ; wherein the quan
rotor with a plurality of magnets attached to the at least one tity and configuration of each module in the electrical
rotor, wherein the at least one module is in spaced relation machine is determined based in part on one or more oper
to the plurality of the magnets; an integrated differential 5 ating parameters ; wherein each module is capable of being
coupled to at least one of the at least one rotors, the at least independently controlled , and wherein each module is
one integrated differential permitting the at least one rotor to capable of being reconfigured based at least in part on one
output at least two rotational outputs to corresponding or more of the following: at least one operating parameter
shafts, wherein the at least two rotational outputs are able to during operation, and at least one performance parameter
move the shafts at different rotational velocities relative to 10 during operation and wherein the electrical machine is
one another , and the at least one rotor being in a rotational configured to fit into a housing and that can be located in
relationship with the at least one stator, wherein the quantity substantially that same position where a differential would
and configuration of each module in the electrical machine otherwise be located in a vehicle or other machine .
is determined based in part on one or more operating
parameters ; wherein each module is capable of being inde- 15 Example 4D
pendently controlled ;
wherein each module is capable of being reconfigured An electrical machine comprising : a plurality ofstators; a
based at least in part on one or more of the following ; at least
one operating parameter during operation , at least one plurality of modules, each module comprising at least one
performance parameter during operation , and combinations 2020 attached
electromagnetic coil and at least one switch and being
to at least one of the plurality of stators ; a plurality
thereof; and wherein the electrical machine is configured to of rotors with a plurality of magnets attached to at least one
fit into a housing and that can be retrofitted into a conven
tional vehicle by replacing the differential. of the plurality of rotors, the plurality of rotors are able to
move independently to one another to produce a differential
Example 2D 25 output that permits the electric machine to output at least two
rotational outputs to corresponding shafts , wherein the at
An electrical machine comprising: at least one stator, at least two rotational outputs are able to move the shafts at
least one module , each module comprising at least one different rotational velocity ' s relative to one another , and the
electromagnetic coil and at least one switch , the at least one plurality of modules are in spaced relation to the plurality of
module being attached to the at least one stator, at least one 30 the magnets ; and the plurality of rotors being in a rotational
rotor with a plurality ofmagnets attached to the at least one relationship with the plurality of stators ; wherein the quan
rotor, wherein the at least one module is in spaced relation tity and configuration of each module in the electrical
to the plurality of the magnets ; an integrated differential machine is determined based in part on one or more oper
coupled to at least one of the at least one rotors, the at least ating parameters ; wherein each module is capable of being
one integrated differential permitting the at least one rotor to 35 independently controlled , and wherein each module is
output at least two rotational outputs to corresponding capable of being reconfigured based at least in part on one
shafts , wherein the at least two rotational outputs are able to or more of the following: at least one operating parameter
move the shafts at different rotational velocities relative to during operation , and at least one performance parameter
one another, and the at least one rotor being in a rotational during operation ; and wherein the electrical machine is
relationship with the at least one stator, wherein the quantity 40 configured to fit into a housing and that can be retrofitted
and configuration of each one module in the electrical into a conventional vehicle by replacing the differential.
machine is determined based in part on one or more oper
ating parameters , wherein each module is capable of being Example 5D
independently controlled ;wherein each module is capable of
being reconfigured based at least in part on one or more of 45 An electrical machine comprising: a plurality of stators ; a
the following : at least one operating parameter during opera - plurality ofmodules , each module comprising at least one
tion , at least one performance parameter during operation , electromagnetic coil and at least one switch and being
and combinations thereof; and wherein the electrical attached to at least one of the plurality of stators ; a plurality
machine is configured to fit into a housing and that can be of rotors with a plurality of magnets attached to at least one
located in substantially that same position where a differ - 50 of the plurality of rotors , the plurality of rotors are able to
ential would otherwise be located in a vehicle or other move independently to one another to produce a differential
machine. output that permits the electric machine to output at least two
rotational outputs to corresponding shafts , wherein the at
Example 3D least two rotational outputs are able to move the shafts at
55 different rotational velocity ' s relative to one another, and the
An electrical machine comprising : a plurality of stators; a plurality of modules are in spaced relation to the plurality of
plurality of modules , each module comprising at least one the magnets; and the plurality of rotors being in a rotational
electromagnetic coil and at least one switch and being relationship with the plurality of stators ; wherein the quan
attached to at least one of the plurality of stators ; a plurality tity and configuration of each module in the electrical
of rotors with a plurality ofmagnets attached to at least one 60 machine is determined based in part on one or more oper
of the plurality of rotors , the plurality of rotors are able to ating parameters ; wherein each module is capable of being
move independently to one another to produce a differential independently controlled , and wherein each module is
output that permits the electric machine to output at least two capable of being reconfigured based at least in part on one
rotational outputs to corresponding shafts, wherein the at or more of the following: at least one operating parameter
least two rotational outputs are able to move the shafts at 65 during operation , and at least one performance parameter
different rotational velocity 's relative to one another, and the during operation ; and wherein the electrical machine is
plurality ofmodules are in spaced relation to the plurality of configured to fit into a housing and that can be located in
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substantially that same position where a differential would harmonic cancelation , electrical harmonic cancelation , accu
otherwise be located in a vehicle or other machine . racy of reproduced output voltage wave, and accuracy of
generated frequency.
Example 6D
Example 9D
An electrical machine comprising: at least one stator, at
least one module, each module comprising at least one The electrical machine of one or more of the above
electromagnetic coil and at least one switch , the at least one examples, wherein the power to weight ratio of the electrical
module being attached to the at least one stator, at least one machine is at between 10 to 1 , 15 to 3, 10 to 0 .5 , 9 to 4 , 5
platter or rotor with a plurality of magnets attached to the at 10 to 0 .01, 3 .4 to 6 or 8 .4 to 3 .4 kilowatts per kilogram .
least one platter or rotor, wherein the at least one module is
in spaced relation to the plurality of the magnets ; an inte Example 10D
grated differential coupled to at least one of the at least one
platters or rotors, the at least one integrated differential The electrical machine of one or more of the above D
permitting the at least one platter or rotor to output at least 15 examples, further comprising at least one sensor to detect
two rotational outputs to corresponding shafts , wherein the absolute or relative position of the at least one rotor ; and at
at least two rotational outputs are able to move the shafts at least one control system which , in response to inputs from
different rotational velocities relative to one another, and the the one or more of the following: the at least one sensor , at
at least one platter or rotor being movement relationship
with the at least one stator, wherein the quantity and con - 20 least one power command, at least one mode command
comprising one or more of the following at least one drive ,
figuration of each module in the electrical machine is generate , braking and hold command , and at least one
determined based in part on one or more operating param rotational direction command .
eters ; wherein each module is capable of being indepen
dently controlled ; and wherein each module is capable of Example 11D
being reconfigured based at least in part on one or more of 25
the following : at least one operating parameter during opera
tion , at least one performance parameter during operation , or leastTheoneelectrical
control
machine of example 10D , wherein the at
system is configured to be in a drive
combinations thereof. configuration or has the at least one drive mode command ,
Example 7D 30 the at least one control system activates at least one switch
which energies one or more of the magnetic coils to attract
The electrical machine of one or more of the above D and repel the magnets for the purpose of generating motion .
examples , wherein the at least one operating parameter
during operation may be selected from one or more of the Example 12D
following: maximum angular velocity , average angular 35
velocity, minimum angular velocity , maximum power out The electrical machine of example 10D , wherein the
put, average power output, minimum power output, maxi- electrical machine is configured to be in a generation con
mum input voltage , average input voltage , minimum input figuration or has at least one mode command to generate
voltage , maximum generation voltage , average generation power, the at least one control system activates at least one
voltage, minimum generation voltage , shape and frequency 40 switch which connects one or more coils to the external
of generated voltage , peak input current, average input power rails .
current, minimum input current, maximum generation cur
rent, average generation current, minimum generation cur Example 13D
rent, maximum torque , average torque , minimum torque ,
torque smoothness , activation sequence , rate of acceleration , 45 The electrical machine of example 10D wherein the
order of accuracy of hold angle , minimising the variation of electrical machine is configured to be in a braking configu
angular velocity , rate of deceleration during breaking, diam ration or has the at least one mode command to brake , the
eter of the shaft, maximum radius of the electrical machine ,
at least one control system activates at least one switch
maximum length of the electrical machine, maximum depth so which
of the electrical machine , maximum height of the machine, 50 togetherconnects
to
one or more of the magnetic coils terminals
oppose motion .
maximum slide distance , minimum slide distance , maxi
mum weight of the machine , minimum weight of the Example 14D
machine, maximum resistive power loss, and unit redun
dancy and overall price . 55. The electrical machine of example 10D , wherein the
Example 8D electrical machine is configured to be in a holding configu
ration or has the at least onemode command to hold , the at
The electrical machine of one or more of the above D least one control system activates at least one switch ener
examples, wherein the at least one performance parameter gises one or more of the magnetic coils to attract and repel
during operation may be selected from one or more of the 60 magnets for the purpose of stopping motion .
following: maximum angular velocity , maximum power
output , deviation from output voltage during generation , Example 15D
maintaining a required generation voltage , torque smooth
ness, rate of acceleration , accuracy of hold angle, minimis - The electrical machine of one or more of the above D
ing the variation of angular velocity , matching requested rate 65 examples, wherein the at least one control system in opera
of deceleration during breaking , minimising resistive power tion is determining one or more appropriately efficient
loss, overall efficiency , power factor correction , mechanical modes of operation in relation to the at least one operating
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parameters , the at least one performance parameter or com - ally removed , added , or replaced during operation of the
binations thereof on a substantially continuous basis during machine , without substantially affecting the operational state
operating periods. of the machine.
Example 16D Example 25D
The electrical machine of one or more of the above D The electrical machine of one or more of the above D
examples , wherein the electrical machine has a power den
sity of between 100 to 20 ,000 , 100 to 200, 100 to 500 , 250 examples , wherein each module is capable of being recon
to 500 , 500 to 1000 , 500 to 2000 , 1000 to 10 , 000 , 1000 to figured based atleast in part on one or more of the following :
5000, 2000 to 5000, 5000 to 10 , 000 , 5000 to 15 , 000 , 10 ,0000 at least one operating parameter during operation , wherein
to 30 ,000 or 10 ,000 to 20 , 000 kw /meter cubed . the at least one operating parameter during operation may be
selected from one or more of the parameters listed in
Example 17D example 7D , at least one performance parameter during
operation , wherein the at least one performance parameter
The electrical machine of one or more of the above D 15 during operation may be selected from one or more of the
examples, wherein one or more of the at least one operating parameter listed in example 8D ; or combinations thereof.
parameter, the at least one performance parameter or com
binations thereof of the electrical machine may be recon Example 26D
figured in substantially real time.
Example 18D 20 The electrical machine of one or more of the above D
examples, wherein the electricalmachine is a compact direct
The electrical machine of one or more of the above D drive electric motor that generates sufficient or improved
examples , wherein the at least one control system provides propulsion in a wheeled vehicle and the electric motor and
individual control over at least 30 % , 40 % , 50 % , 60 % , 70 % w the differential can fit the size of envelope of existing
80 % , 90 % , 95 % or 100 % of the plurality of coils. differentials in a conventional combustion engine driven
vehicle .
Example 19D
Example 27D
The electrical machine of one or more of the above D
examples, wherein the module coil activation sequence is 3030 The electrical machine of one or more of the above D
computed during machine operation the order of modules examples, wherein the electricalmachine is a compact direct
activating being sequentially based on their geometric posi drive electric motor that generate sufficient or improved
tion in the module array . propulsion of a wheeled vehicle and the electric motor and
the6 : 1differential can be installed in line with a drive axial
Example 20D 35 while providing adequate clearance from a road without
The electrical machine of one or more of the above D wheeled vehicle .
computed during machine operation , the order of modules Example 28D
activating being based upon sensor feedback .
The electrical machine of one or more of the above D
Example 21D examples,wherein the electricalmachine is a compact direct
The electrical machine of one or more of the above D wheeled vehicle and the electric motor and the differential
examples, wherein the module coil activation sequence is 45 can be installed in line with one or more drive axels while
computed during machine operation and the order of the at providing adequate clearance from a road without substan
least one modules activating being determined by at least in tial modification to an existing suspension of the wheeled
part one or more sequence patterns. vehicle .
Example 22D 50 Example 29D
The electrical machine of one or more of the above D The electrical machine of one or more of the above D
examples, wherein the total number of the at least one examples, wherein the electricalmachine is a compact direct
electromagnetic coils powered in the active sequence may drive electric motor that generate sufficient propulsion of a
vary during operation from the total number of coils, to 55 wheeled vehicle and the electric motor and the differential
none. can be installed in line with one or more drive axels without
lower, or substantially lowering, the clearance from a road
Example 23D and without substantial modification to an existing suspen
sion of the wheeled vehicle .
The electrical machine of one or more of the above D 60
examples, wherein the control of the electrical machine is Example 1E
An electricalmachine comprising : at least one stator; at
Example 24D least one module comprising at least one electromagnetic
65 coil and at least one switch , the at least one module being
The electrical machine of one or more of the above D attached to the at least one stator; at least one rotor with a
examples , wherein one or more modules may be individu plurality of magnets attached to the at least one rotor,
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wherein the at least one module is in spaced relation to the modules are in spaced relation to the plurality of the mag
plurality of themagnets ; an integrated differential coupled to nets; and the plurality of rotors being in a rotational rela
at least one of the at least one rotors , the at least one tionship with the plurality of stators ;
integrated differential permitting the at least one rotor to wherein the quantity and configuration of the substantial
output at least two rotational outputs to corresponding 5 portion of the modules in the electrical machine are deter
shafts , wherein the at least two rotational outputs are able to mined based in part on one or more operating parameters ;
move the shafts at different rotational velocities relative to wherein the substantial portion of the modules are capable
one another , and the at least one rotor being in a rotational ofbeing independently controlled , and wherein the substan
relationship with the at least one stator, tial portion of the modules are capable of being reconfigured
wherein the quantity and configuration of a substantial 10 based at least in part on one or more of the following : at least
portion of the modules in the electrical machine are deter - one operating parameter during operation , and at least one
mined based in part on one or more operating parameters ; performance parameter during operation ; and
wherein a substantial portion of the modules are capable of wherein the electrical machine is configured to fit into a
being independently controlled ; housing and that can be located in substantially that same
wherein a substantial portion of the modules is capable of 15 position where a differential would otherwise be located in
being reconfigured based at least in part on one or more of a vehicle or other machine .
the following : at least one operating parameter during opera
tion , at least one performance parameter during operation , Example 4E
and combinations thereof; and
wherein the electrical machine is configured to fit into a 20 An electrical machine comprising: a plurality of stators ; a
housing and that can be retrofitted into a conventional plurality of modules, each module comprising at least one
vehicle by replacing the differential. electromagnetic coil and at least one switch and being
attached to at least one of the plurality of stators ; a plurality
Example 2E of rotors with a plurality of magnets attached to at least one
25 of the plurality of rotors, the plurality of rotors are able to
An electricalmachine comprising : at least one stator ; at move independently to one another to produce a differential
least one module, each module comprising at least one output that permits the electric machine to output at least two
electromagnetic coil and at least one switch , the at least one rotational outputs to corresponding shafts , wherein the at
module being attached to the at least one stator, at least one least two rotational outputs are able to move the shafts at
rotor with a plurality of magnets attached to the at least one 30 different rotational velocity ' s relative to one another , and the
rotor, wherein the at least one module is in spaced relation plurality ofmodules are in spaced relation to the plurality of
to the plurality of the magnets ; an integrated differential the magnets ; and the plurality of rotors being in a rotational
coupled to at least one of the at least one rotors, the at least relationship with the plurality of stators ;
one integrated differential permitting the at least one rotor to wherein the quantity and configuration of each module in
output at least two rotational outputs to corresponding 35 the electrical machine is determined based in part on one or
shafts, more operating parameters ;
wherein the at least two rotational outputs are able to wherein each module is capable of being independently
move the shafts at different rotational velocities relative to controlled , and
one another, and the at least one rotor being in a rotational wherein each module is capable of being reconfigured
relationship with the at least one stator; 40 based at least in part on one or more of the following; at least
wherein the quantity and configuration of each one mod one operating parameter during operation, and at least one
ule in the electrical machine is determined based in part on performance parameter during operation ; and wherein the
one or more operating parameters ; wherein each module is electricalmachine is configured to fit into a housing and that
capable of being independently controlled ; can be retrofitted into a conventional vehicle by replacing
wherein each module is capable of being reconfigured 45 the differential.
based at least in part on one or more of the following at least
one operating parameter during operation , at least one Example 5E
performance parameter during operation , and combinations
thereof; and wherein the electrical machine is configured to An electrical machine comprising : a plurality of stators ; a
fit into a housing and that can be located in substantially that 50 plurality of modules, each module comprising at least one
same position where a differential would otherwise be electromagnetic coil and at least one switch and being
located in a vehicle or other machine . attached to at least one of the plurality of stators ; a plurality
of rotors with a plurality of magnets attached to at least one
Example 3E of the plurality of rotors, the plurality of rotors are able to
55 move independently to one another to produce a differential
An electrical machine comprising: a plurality of stators; a output that permits the electric machine to output at least two
plurality of modules, wherein a substantial portion of the rotational outputs to corresponding shafts , wherein the at
modules comprise at least one electromagnetic coil and at least two rotational outputs are able to move the shafts at
least one switch and are attached to at least one of the different rotational velocity 's relative to one another, and the
plurality of stators ; a plurality of rotors with a plurality of 60 plurality of modules are in spaced relation to the plurality of
magnets attached to at least one of the plurality of rotors , the the magnets , and the plurality of rotors being in a rotational
plurality of rotors are able to move independently to one relationship with the plurality of stators ;
another to produce a differential output that permits the wherein the quantity and configuration of each module in
electric machine to output at least two rotational outputs to the electrical machine is determined based in part on one or
corresponding shafts , wherein the at least two rotational 65 more operating parameters ;
outputs are able to move the shafts at different rotational wherein each module is capable of being independently
velocity 's relative to one another, and the plurality of controlled , and
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wherein each module is capable of being reconfigured following : maximum angular velocity, maximum power
based at least in part on one or more of the following at least output, deviation from output voltage during generation ,
one operating parameter during operation , and at least one maintaining a required generation voltage, torque smooth
performance parameter during operation ; and wherein the ness, rate of acceleration , accuracy of hold angle, minimis
electrical machine is configured to fit into a housing and that 5 ing the variation of angular velocity, matching requested rate
can be located in substantially that same position where a of deceleration during breaking , minimising resistive power
loss, overall efficiency, power factor correction , mechanical
differentialwould otherwise be located in a vehicle or other harmonic cancelation , electrical harmonic cancelation , accu
machine. racy of reproduced output voltage wave and accuracy of
Example 6E in generated frequency .
Example 9E
An electrical machine comprising: at least one stator, at
least one module, each module comprising at least one The electrical machine of one or more of the above E
electromagnetic coil and at least one switch , the at least one examples, wherein the power to weight ratio of the electrical
module being attached to the at least one stator, at least one 15 machine is at between 10 to 1 , 15 to 3 , 10 to 0 . 5 , 9 to 4 , 5
platter or rotor with a plurality of magnets attached to the at to 0 .01, 3 .4 to 6 or 8 . 4 to 3 .4 kilowatts per kilogram .
least one platter or rotor, wherein the at least one module is Example 10E
in spaced relation to the plurality of the magnets ; an inte
grated differential coupled to at least one of the at least one 20
platters or rotors, the at least one integrated differential1 20 The electrical machine of one or more of the above E
permitting the at least one platter or rotor to output at least examples , further comprising at least one sensor to detect
two rotational outputs to corresponding shafts , absolute or relative position of the at least one rotor , and at
wherein the at least two rotational outputs are able to least one control system which , in response to inputs from
move the shafts at different rotational velocities relative to the one or more of the following : the at least one sensor , at
one another, and the at least one platter or rotor being 25 least one power command, at least one mode command
comprising one ormore of the following at least one drive,
movement relationship with the at least one stator , generate , braking and hold command and at least one
wherein the quantity and configuration of each module in rotational direction command .
the electrical machine is determined based in part on one or
more operating parameters ; wherein each module is capable Example 11E
of being independently controlled ; and 30
wherein each module is capable of being reconfigured The electrical machine of example 10E , wherein the at
based at least in part on one or more of the following at least least one control system is configured to be in a drive
one operating parameter during operation , at least one configuration or has the at least one drive mode command ,
performance parameter during operation, or combinations the at least one control system activates at least one switch
thereof. 35 which energies one or more of the magnetic coils to attract
Example 7E
Example 12E
The electrical machine of one or more of the above E
examples, wherein the at least one operating parameter 40o electrical
The electrical machine of example 10E , wherein the
during operation may be selected from one or more of the figuration machine is configured to be in a generation con
following: maximum angular velocity , average angular power, the orat has at least one mode command to generate
least one control system activates at least one
velocity , minimum angular velocity , maximum power out
put, average power output, minimum power output, maxi us switch
power
which connects one or more coils to the external
rails .
mum input voltage , average input voltage , minimum input 45
voltage, maximum generation voltage, average generation Example 13E
voltage , minimum generation voltage , shape and frequency
of generated voltage , peak input current, average input The electrical machine of example 10E , wherein the
current, minimum input current, maximum generation cur - electrical machine is configured to be in a braking configu
rent, average generation current, minimum generation cur- 50 ration or has the at least one mode command to brake, the
rent, maximum torque , average torque , minimum torque , at least one control system activates at least one switch
torque smoothness, activation sequence , rate of acceleration , which connects one or more of the magnetic coils terminals
order of accuracy of hold angle , minimising the variation of together to oppose motion .
angular velocity , rate of deceleration during breaking, diam
eter of the shaft, maximum radius of the electricalmachine , 55 Example 14E
maximum length of the electrical machine, maximum depth
of the electrical machine,maximum height of the machine, The electrical machine of example 10E , wherein the
maximum slide distance , minimum slide distance , maxi- electrical machine is configured to be in a holding configu
mum weight of the machine , minimum weight of the ration or has the at least one mode command to hold , the at
machine, maximum resistive power loss , and unit redun - 60 least one control system activates at least one switch ener
dancy and overall price . gises one or more of the magnetic coils to attract and repel
magnets for the purpose of stopping motion .
Example 8E
Example 15E
The electrical machine of one or more of the above E 65
examples, wherein the at least one performance parameter The electrical machine of one or more of the above E
during operation may be selected from one or more of the examples, wherein the at least one control system in opera
US 10 ,211,702 B2
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tion is determining one or more appropriately efficient Example 24E
modes of operation in relation to the at least one operating
parameters , the at least one performance parameter or com The electrical machine of one or more of the above E
binations thereof on a substantially continuous basis during examples, wherein one or more modules may be individu
operating periods. 5 ally removed , added , or replaced during operation of the
machine, without substantially affecting the operational state
Example 16E of the machine.
The electrical machine of one or more of the above E Example 25E
examples, wherein the electricalmachine has a power den - 10
sity of between 100 to 20 ,000 , 100 to 200, 100 to 500 , 250 The electrical machine of one or more of the above E
to 500 , 500 to 1000 , 500 to 2000 , 1000 to 10 , 000 , 1000 to examples, wherein the substantial portion of the modules is
5000 , 2000 to 5000 , 5000 to 10,000 , 5000 to 15 ,000, 10,000 all of the modules contained in the electrical machine.
to 30 ,000 or 10 ,000 to 20,000 kw /meter cubed . 15
Example 17E Example 26E
The electrical machine of one or more of the above E The electrical machine of one or more of the above E
examples, wherein one or more of the at least one operating examples, wherein the electricalmachine is a compact direct
parameter, the at least one performance parameter or com 20 drive electric motor that generates sufficient or improved
binations thereof of the electrical machine may be recon propulsion in a wheeled vehicle and the electric motor and
figured in substantially real time . the differential can fit the size of envelope of existing
differentials in a conventional combustion engine driven
Example 18E 25. Vehicle.
The electrical machine of one or more of the above E Example 27E
examples, wherein the at least one control system provides
individual control over at least 30 % , 40 % , 50 % , 60 % , 70 % The electrical machine of one or more of the above E
80 % , 90 % , 95 % or 100 % of the plurality of coils. 30 examples , wherein the electricalmachine is a compact direct
drive electric motor that generate sufficient or improved
Example 19E propulsion of a wheeled vehicle and the electric motor and
the differential can be installed in line with a drive axial
The electrical machine of one or more of the above E while providing adequate clearance from a road without
examples , wherein the module coil activation sequence is 35 substantial modification to an existing suspension of the
computed during machine operation the order ofmodules wheeled vehicle.
activating being sequentially based on their geometric posi
tion in the module array . Example 28E
Example 20E The electrical machine of one or more of the above E
The electrical machine of one or more of the above E examples, wherein the electricalmachine is a compact direct
examples, wherein the module coil activation sequence is wheeled vehicle and the electric motor and the differential
computed during machine operation , the order of modules 45 can be installed in line with one or more drive axels while
activating being based upon sensor feedback . providing adequate clearance from a road without substan
Example 21E tial modification to an existing suspension of the wheeled
vehicle .
examples , wherein the module coil activation sequence is 50 Example 29E
computed during machine operation and the order of the at
least one modules activating being determined by at least in The electrical machine of one or more of the above E
part one or more sequence patterns. examples, wherein the electrical machine is a direct drive
electric motor that generate sufficient propulsion of a
Example 22E 55 wheeled vehicle and the electric motor and the differential
are be installed in line with one or more drive axels without
The electrical machine of one or more of the above E lower, or substantially lowering, the clearance from a road
examples , wherein the total number of the at least one and without substantial modification to an existing suspen
electromagnetic coils powered in the active sequence may
vary during operation from the total number of coils , to 60
none .
Example 30E .1
Example 23E
The electrical machine of one or more of the above E 65 examples, wherein the at least one electromagnetic coil is
examples , wherein the control of the electrical machine is made by wrapping one or more conductor materials around
centralised on at least one control module. a temporary fixture which is then removed .
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Example 30E .2 Example 32E .2
The electrical machine of one or more of the above E The electrical machine of one or more of the above E
examples , wherein the at least one electromagnetic coil examples, wherein the at least one electromagnetic coil is of
comprises the one or more conductor materials wrapped 5 a rectangular or a substantially rectangular prism shape .
around a bobbin .
Example 32E .3
Example 30E .3
The electrical machine of one or more of the above E 10 examples, wherein the at least one electromagnetic coil is of
examples, wherein the at least one electromagnetic coil a trapezoidal or a substantially trapezoidal prism shape.
comprises the one or more conductor materials wrapped Example 32E .4
around a core .
Example 31E .1 15 The electrical machine of one or more of the above E

examples, wherein the at least one electromagnetic coil is of
The electrical machine of of examples 30E .1, 30E . 2 and a oval or a substantially oval prism shape.
30E . 3 , wherein the one or more conductor materials of the Example 33E .1
at least one electromagnetic coilhave a circular or a partially 20
circular cross section . The electrical machine of one or more of the above E
Example 31 E .2 examples, wherein the at least one electromagnetic coil
surrounds or partially surrounds a cylindrical or a substan
25 tially cylindrical core.
The electrical machine of of examples 30E .1, 30E .2 and
30E . 3 , wherein the one ormore conductor materials of the Example 33E .2
at least one electromagnetic coil have a rectangular or a
partially rectangular cross section . The electrical machine of one or more of the above E
30 examples, wherein the at least one electromagnetic coil
Example 31E . 3 surrounds or partially surrounds a rectangular or a substan
tially rectangular prism core.
The electrical machine of examples 30E . 1, 30E .2 and
30E . 3, wherein the one or more conductor materials of the Example 33E .3
at least one electromagnetic coil have a rectangular or a 35
partially rectangular cross section bent along the long axis , The electrical machine of one or more of the above E
This creates what is commonly known as an edge wound examples, wherein the at least one electromagnetic coil
coil. surrounds or partially surrounds a trapezoidal or a substan
tially trapezoidal prism core.
Example 31 E .4 40
Example 34E .1
The electrical machine of examples 30E . 1, 30E .2 and
30E .3, wherein the one or more conductor materials of the example The electrical machine of one or more of the above E
at least one electromagnetic coil have an arbitrarily shaped 45 there is ,awherein
area of
along the at least one electromagnetic coil
reduced cross section that is capable of
cross section . fusing in an open circuit or a partially open circuit state in
Example 315 .5 the event of an amount of current that is beyond a prede
termined amount of current.
The electrical machine of examples 30E .1 , 30E .2 and 50 Example 34E .2
30E . 3 , wherein the one or more conductor materials of the
at least one electromagnetic coil have a combination of one The electrical machine of one or more of the above E
or more of the cross sections described in examples 315 . 1 , example , wherein along the at least one electromagnetic coil
31E . 2, 31E .3 and 31 E .4 . there are at least two , three or four areas of reduced cross
55 section that are capable of fusing in an open circuit or a
Example 31 E .6 partially open circuit state in the event of an amount of
current that is beyond a predetermined amount of current.
The electrical machine of examples 30E .1, 30E .2 and Example 34E .3
30E . 3, wherein the one or more conductor materials ofofthe
the 60
at least one electromagnetic coil is foil .
Example 32E . 1 example , wherein along the at least one electromagnetic coil
there are at least one, two or three areas of reduced cross
section per coil winding that are capable of fusing in an open
The electrical machine of one or more of the above E 65 circuit or a partially open circuit state in the event of an
examples , wherein the at least one electromagnetic coil is of amount of current that is beyond a predetermined amount of
a cylindrical or a substantially cylindrical shape . current.
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Example 35E . 1 Example 38E .4
The electrical machine of one or more of the above E The electricalmachine of example 37E , wherein the core
examples, wherein the one or more conductor materials is is made of a material with suitable magnetic permeability .
composed of copper or a copper alloy . 5
Example 38E .5
Example 35E .2
The electrical machine of example 37E , wherein the core
The electrical machine of one or more of the above E is made of a magnetic permeable material.
examples, wherein the one or more conductor materials is 10
composed of aluminium or an aluminium alloy. Example 39E
Example 35E .3
examples, wherein the at least one stator is a substantial
The electrical machine of one or more of the above E 155 portion
examples, wherein the one or more conductor materials is of the stators contained in the electrical machine.
composed of graphine, a graphine hybrid or another carbon Example 40E
based conductor.
Example 35E .4 The electrical machine of one or more of the above E
20 examples , wherein the at least one stator is all of the stators
The electrical machine of one or more of the above E contained in the electrical machine .
examples, wherein the one or more conductor materials is
composed of a suitably conductive material . Example 41E
25
Example 36E.1 The electrical machine of one or more of the above E
examples, wherein the at least one module is a substantial
The electrical machine of one or more of the above E portion of the modules contained in the electrical machine .
examples, wherein the one or more conductor materials is
directly cooled by the flow of a suitable coolant directly over30 Example 42E
or over a layer of electrically insulating material.
Example 36E.2 The electrical machine of one or more of the above E
examples, wherein the at least one module is all of the
The electrical machine of one or more of the above E , modules contained in the electrical machine.
examples, wherein the one or more conductor materials is Example 43E
within close proximity of a thermally conductive material
that is capable of dissipating heat to a nearby coolant
channel. The electrical machine of one or more of the above E
examples, wherein the at least one electromagnetic coil is a
Example 36E .3 40 substantial portion of the electromagnetic coils contained in
the electricalmachine .
examples, wherein the one or more conductor materials is Example 44E
within close proximity of the thermally conductive material
is capable of conducting heat to a surface where the heat is 45 The electrical machine of one or more of the above E
at least in part removed by convection and thermal radiation . examples,wherein the at least one electromagnetic coil is all
of the electromagnetic coil contained in the electrical
Example 37E machine .
The electrical machine of one or more of the above E 50 Example 45E
examples, wherein the at least one electromagnetic coil is
placed around a core . The electrical machine of one or more of the above E
Example 38E . 1 examples, wherein the at least one switch is a substantial
55 portion of the switches contained in the electrical machine .
The electrical machine of example 37E , wherein the core Example 46E
is made of laminated electrical steel.
Example 38E .2 The electrical machine of one or more of the above E
60 examples , wherein the at least one switch is all of the
The electrical machine of example 37E , wherein the core switches contained in the electrical machine.
is made of layers of amorphous metal. Example 47E
Example 38E .3
65 The electrical machine of one or more of the above E
The electrical machine of example 37E , wherein the core examples, wherein the at least one rotor is a substantial
is made of powdered metals. portion of the rotors contained in the electrical machine .
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Example 48E wherein the at least one module is capable of being
reconfigured based at least in part on one ormore of the
The electrical machine of one or more of the above E following: at least one operating parameter during
examples , wherein the at least one rotor is all of the rotors operation , at least one performance parameter during
contained in the electrical machine . operation , and combinations thereof.
Example 49E 2 . The electrical machine of claim 1 , wherein the at least
one operating parameter during operation may be selected
from one or more of the following : maximum angular
The electrical machine of one or more of the above E velocity , average angular velocity, minimum angular veloc
examples, wherein the plurality of magnets is a substantial 10 ity , maximum power output, average power output, mini
portion of the magnets contained in the electrical machine . mum power output , maximum input voltage, average input
Example 50E voltage , minimum input voltage , maximum generation volt
age , average generation voltage, minimum generation volt
The electrical machine of one or more of the above E 15 age , shape and frequency of generated voltage , peak input
examples, wherein the plurality of magnets is all of the current, average input current, minimum input current,
magnets contained in the electrical machine. maximum generation current, average generation current,
The present disclosure should be taken to include feasible minimum generation current, maximum torque , average
combinations of features described herein . torque, minimum torque, torque smoothness , activation
The combination of features described is such as to allow 20 sequence , rate of acceleration , order of accuracy of hold
the electric motor to operate efficiently over a wide power angle , minimising the variation of angular velocity , rate of
and RPM range and , where required , with high power and deceleration during breaking, diameter of the shaft , maxi
torque density . Additionally , it permits combinations of mum radius of the electrical machine , maximum length of
standard components to be assembled together to provide a the electrical machine , maximum depth of the electrical
range of electric motor configurations . 25 machine, maximum height of the machine , maximum slide
The exemplary approaches described may be carried out distance , minimum slide distance , maximum weight of the
using suitable combinations of software , firmware and hard - machine , minimum weight of the machine, maximum resis
ware and are not limited to particular combinations of such . tive power loss, and unit redundancy and overall price.
Computer program instructions for implementing the exem 3 . The electrical machine of claim 1 , wherein the at least
plary approaches described herein may be embodied on a 30 one performance parameter during operation may be
tangible, non -transitory , computer-readable storage selected from one or more of the following : maximum
medium , such as a magnetic disk or other magnetic memory , angular velocity , maximum power output, deviation from
an optical disk (e .g ., DVD ) or other optical memory, RAM , output voltage during generation , maintaining a required
ROM , or any other suitable memory such as Flash memory, generation voltage, torque smoothness, rate of acceleration ,
memory cards, etc . 35 accuracy of hold angle , minimising the variation of angular
Additionally , the disclosure has been described with ref- velocity, matching requested rate of deceleration during
erence to particular embodiments. However, it will be read breaking ,minimising resistive power loss , overall efficiency ,
ily apparent to those skilled in the art that it is possible to
power factor correction , mechanical harmonic cancelation ,
embody the disclosure in specific forms other than those of electrical harmonic cancelation , accuracy of reproduced
the embodiments described above . The embodiments are 40 output voltage wave and accuracy of generated frequency .
merely illustrative and should not be considered restrictive . 4 . The electrical machine of claim 1 , further comprising
The scope of the disclosure is given by the appended claims, at least one sensor to detect absolute or relative position of
rather than the preceding description , and variations and the at least one rotor; and at least one control system which ,
equivalents that fall within the range of the claims are in response to inputs from the one or more of the following :
intended to be embraced therein . 45 the at least one sensor, at least one power command , at least
The invention claimed is: one mode command comprising one or more of the follow
1. An electrical machine configured to fit into a housing ing : at least one drive , generate,braking and hold command,
and that can be retrofitted into a conventional vehicle by and at least one rotational direction command .
replacing the differential, the electrical machine comprising: 5 . The electrical machine of claim 4 , wherein the at least
at least one module , the at least one module comprising at 50 one control system is configured to be in a drive configu
least one electromagnetic coil and at least one switch , ration or has the at least one drive mode command, the at
the at least one module being attached to at least one least one control system activates the at least one switch
stator ; which energies one or more of the at least one electromag
at least one rotor with a plurality ofmagnets attached to netic coils to attract and repel one or more of the plurality of
the at least one rotor, wherein the at least one module 55 magnets for the purpose of generating motion .
is in spaced relation to the plurality of the magnets ; 6 . The electrical machine of claim 4 , wherein the electri
an differential coupled to at least one of the at least one cal machine is configured to be in a generation configuration
rotors , the at least one differential permitting the at least or has at least onemode command to generate power, the at
one rotor to output at least two rotational outputs to least one control system activates the at least one switch
corresponding shafts , wherein the at least two rota - 60 which connects one or more of the at least one electromag
tional outputs are able to move the shafts at different n etic coils to the external power rails .
rotational velocities relative to one another, and 7. The electrical machine of claim 4 , wherein the electri
wherein the quantity and configuration of the at least one cal machine is configured to be in a braking configuration or
module in the electricalmachine is determined based in has the at least one mode command to brake, the at least one
part on one or more operating parameters ; 65 control system activates at least one switch which connects
wherein the at least one module is capable of being one or more of the magnetic coils terminals together to
independently controlled ; oppose motion .
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8. The electrical machine of claim 4 , wherein the electri- generates sufficient or improved propulsion in a wheeled
calmachine is configured to be in a holding configuration or vehicle and the electric motor and the differential can fit the
has the at least one mode command to hold , the at least one size of envelope of existing differentials in a conventional
control system activates at least one switch which energises combustion engine driven vehicle .
one or more of the electromagnetic coils attract and repel 55 and19that
. An electrical machine configured to fit into a housing
can be located in substantially that same position
one or more of the plurality of magnets for the purpose of
stopping motion . where a differential would otherwise be located in a vehicle
9 . The electricalmachine of claim 1 , wherein the at least or other machine , the electrical machine comprising:
one control system in operation is determining one or more at least one module, the at least one module comprising at
appropriately efficientmodes of operation in relation to the 10 least one electromagnetic coil and at least one switch ,
at least one operating parameters , the at least one perfor the at least one module being attached to at least one
mance parameter or combinations thereof on a substantially stator ;
continuous basis during operating periods. at least one rotor with a plurality ofmagnets attached to
10 . The electrical machine of claim 1, wherein one or the at least one rotor, wherein the at least one module
more of the at least one operating parameter, the at least one 15 is in spaced relation to the plurality of the magnets;
performance parameter or combinations thereof of the elec an differential coupled to at least one of the at least one
trical machine may be reconfigured in substantially real rotors, the at least one differential permitting the at least
time. one rotor to output at least two rotational outputs to
11 . The electricalmachine of claim 1, wherein the module corresponding shafts , wherein the at least two rota
coil activation sequence is computed during machine opera - 20 tional outputs are able to move the shafts at different
tion the order ofmodules activating being sequentially based rotational velocities relative to one another, and
on their geometric position in the module array . wherein the quantity and configuration of the at least one
module in the electricalmachine is determined based in
12 . The electrical machine of claim 1 ,wherein themodule part on one or more operating parameters ;
coil activation sequence is computed during machine opera
tion , the order of modules activating being based upon 25 25 wherein the at least one module is capable of being
sensor feedback . independently controlled ;
13 . The electrical machine of claim 1 , wherein the module wherein the at least one module is capable of being
coil activation sequence is computed during machine opera reconfigured based at least in part on one ormore of the
tion and the order of the at least one modules activating following: at least one operating parameter during
being determined by at least in part one or more sequence 30 operation , at least one performance parameter during
patterns. operation , and combinations thereof.
14 . The electrical machine of claim 1 , wherein the total 20 . An electrical machine comprising :
number of the at least one electromagnetic coils powered in at least one module , the at least one module comprising at
the active sequence may vary during operation from the total least one electromagnetic coil and at least one switch ,
number of coils, to none . 35 the at least one module being attached to at least one
15 . The electricalmachine of claim 1, wherein the control stator ;
of the electrical machine is centralised on at least one control at least one platter or rotor with a plurality of magnets
module . attached to the at least one platter or rotor, wherein the
16 . The electrical machine of claim 1, wherein one or at least one module is in spaced relation to the plurality
moremodules of the at least one module may be individually 40 of the magnets;
removed , added , or replaced during operation of the an differential coupled to at least one of the at least one
machine ,without substantially affecting the operational state platters or rotors, the at least one differential permitting
of the machine. the at least one platter or rotor to output at least two
17 . The electrical machine of claim 1, rotational outputs to corresponding shafts , wherein the
wherein the at least one module is capable of being 45 at least two rotational outputs are able to move the
reconfigured based at least in part on one or more of the shafts at different rotational velocities relative to one
following : another, and
at least one operating parameter during operation , wherein the quantity and configuration of the at least one
wherein the at least one operating parameter during module in the electricalmachine is determined based in
operation may be selected from one or more of the 50 part on one or more operating parameters;
parameters listed in claim 2 , at least one performance wherein the at least one module is capable of being
parameter during operation , wherein the at least one independently controlled ; and
performance parameter during operation may be wherein the at least one module is capable of being
selected from one or more of the parameter listed in reconfigured based at least in part on one ormore of the
claim 3 ; 55 following: at least one operating parameter during
or combinations thereof. operation , at least one performance parameter during
18 . The electrical machine of claim 1 , wherein the elec operation , or combinations thereof.
trical machine is a compact direct drive electric motor that * *

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US010211702B2

(12) United States Patent (10) Patent No.: US 10 ,211,702 B2

HIGH VOLTAGE DC -DC

* * * VRT?z 'z ' z 's KV

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Lot L21 L20

29 - *Mix pisode w w decrtid Convers mercita

HIGH VOLTAGE DC -DC

L38 438 438 438 438 438 L38

lcool coul locul locul lccul coul locul

438 L38 L38 L38 L38 L38

504 504 507 507 507 507

L- 38 L38 L38 L38 L38 L38 L38

locul locul locul locul locul locul locul

118 566 174

- 106 - 108 - 109 99 _ 103 105

126 127 128 129

other suitable shapes . 20

Example 31E .1 15 The electrical machine of one or more of the above E

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