Patent ID: 6049150
Filing Date: 2000-04-11
Classification: F16F,H02K,Y02E,Y10T

Abstract:
A flywheel comprising:(A) a flywheel cylinder made of a high yield strength magnetic material with a high saturation flux density and low retentivity, wherein said magnetic material is cold rolled ingot iron; said flywheel cylinder has following approximate dimensions: outer diameter of 19 cm, inner diameter of 16.2 cm, a 4 cm center section with diameter of 16 cm, wherein said 4 cm center section has two axial diametrically opposite slots of 0.1 cm deep and 0.1 cm wide, said axial diametrically opposite slots are for keeping a mercury level of a rotating mercury contact assembly equal on both sides of said 4 cm center section when said flywheel cylinder rotates;(B) two flywheel inner cylinders fitted tight inside said flywheel cylinder, wherein said two flywheel inner cylinders made of the same said magnetic material and having approximate dimensions of 2.5 cm long and 0.3 cm thick;(C) two flywheel end disks having the same outer diameter as said outer diameter of said flywheel cylinder, wherein each of said two flywheel end disks comprising an annular groove fitted over one end of said flywheel cylinder to provide a magnetic path and a high mechanical strength; each of said two flywheel end disks further comprising: a first centered cylindrical surface for inserting a flywheel bearing assembly in an outer peripheral face of said first centered cylindrical surface; a second centered cylindrical surface configured with a plurality of grooves or notches located parallel to an axis of said flywheel cylinder extending from a flywheel bearing assembly mounting surface through each of said flywheel end disks to an inner peripheral face of said second centered cylindrical surface;(D) two field coils containing winding turns of conductive material to provide a magnetomotive force to saturate a magnetic pathway within said flywheel when a current is applied from a voltage source not exceeding 12 volts; said two field coils each having an outer diameter approximately smaller than that of said two flywheel inner cylinders to allow low air friction with said two field coils mounted within said two flywheel inner cylinders, and said two field coils each having a width approximately equal to that of said two flywheel inner cylinders; said two field coils each having a centered hole for mounting within a magnetic loop and each having two wire leads to connect to an external power source;(E) two fixed pole pieces each comprising a first cylindrical surface having the same width as that of said two field coils and a predetermined diameter to allow said field coil to slide onto said fixed pole piece with a snug fit; an outer surface of said pole piece having two wire-lead grooves with predetermined dimensions to allow said wire leads to be inserted and not extend beyond said outer surface; wherein said wire-lead grooves extend radially inward from said first cylindrical surface of said fixed pole piece to a centered hole thereof, and said pole pieces extend radially outward along an inside surface of said field coils and in thermal contact with said field coils for heat exchanging; an approximate cylindrical-shaped air gap formed by a second cylindrical surface of said fixed pole piece, wherein said cylindrical-shaped air gap being parallel to said flywheel cylinder and extending axially to a first rounded point thereof, and, at said first rounded point, said cylindrical-shaped air gap tapers radially inward at an angle of 60 degrees for a predetermined distance and then changes to an angle of 85 degrees and continues to a second rounded point at an surface of said centered hole having a shoulder;(F) two pole-piece shafts each having a surface with a maximum diameter equal to that of said centered hole in said fixed pole pieces to provide a tight fit; said pole piece shaft extending from said shoulder near the center of said fixed pole pieces to near an inner edge of said flywheel bearing assembly mounting surface in said flywheel end disks, wherein said pole-piece shaft having a reduced diameter to snugly fit an inner race of a rotor bearing assembly and extending outwardly and up to an inner surface of said rotating mercury vacuum seal assembly; an input-output shaft assembly comprising at least one input-output shaft; said pole piece shaft having a centered hole having an approximate diameter of 0.08 cm which is larger than that of at least one input-output shaft, wherein said centered hole of said pole piece shaft extended through said at least one input-output shaft; wherein inner ends of said pole piece shafts have sixteen equally spaced radial slots each having width of 11.25 degrees and provided with a plurality of circumferential grooves at both inner and outer edges thereof for holding two or more turns of wire; wherein two output-wire grooves, being provided in said pole piece shafts for holding two output wires within an inner surface of said pole piece shafts, running a full length of said pole piece shafts and two holes being drilled at a 45 degree angle toward an end of said at least one input-output shaft near an area intersecting with said two output-wire grooves so that said two output wires passing through said at least one input-output shaft; wherein outer surfaces of said pole piece shafts each have four grooves configured the same as said two output-wire grooves located from outer ends of the pole piece shafts to said maximum diameter surface thereof, wherein said sixteen slots being radially equally spaced apart and each being configured with a predetermined depth for two or more turns of wire extend inward to an outer surface of said fixed pole piece; wherein said fixed pole piece having a first circumferential groove with a predetermined dimensions for holding two or more wires, a second circumferential groove which is similar to said first circumferential groove of said fixed pole piece is located at an outer edge of the radial slots, two of said sixteen slots are aligned with two of said four output-wire grooves and have another two grooves cutting the length of the slot, said another two grooves are aligned with said output-wire grooves in the outer surface of the fixed pole pieces to allow said field coil wires to pass under the windings in the said sixteen radial slots,(G) a rotor assembly comprising at least one rotor made of said magnetic material; said at least one rotor having an outer cylindrical surface with a diameter smaller than the inner diameter of the flywheel cylinder, and an inner cylindrical surface with a diameter larger than said maximum diameter of said fixed pole pieces to provide a low reluctance magnetic path from said fixed pole piece to said flywheel cylinder through the rotor cylinder with predetermined clearance to allow for expansion and contraction of said at least one rotor, an outer edge of said rotor disk portion being provided with notch to allow a contact ring to slip on, said rotor disk portion with an inner surface extends axially inwardly beyond the rounded point on the fixed pole piece where said fixed pole piece extends radially inward making an angle of 86 degrees with said rotor disk portion and follows a contour of the fixed pole piece allowing clearance for expansion and contraction while maintaining a gap with an inner end of the pole piece shaft where said inner surface of said rotor disk portion turns radially inward at 90 degrees to the pole piece shaft and extends to a hub on the rotor shaft, an radial surface of said rotor is provided with sixteen notches similar to those in the inner end of the pole piece shaft without the circumferential slots, the rotor mounts on said at least one input-output shaft with a tight fit for maintaining high torque without slipping at rotation rates up to 30,000 revolutions per minute, said rotor inner surface matches that of an exterior of said at least one input-output shaft;(J) said at least one input-output shafts with a 0.5 cm diameter 0.6 cm long extension on the inner end extends through the rotor; said diameter of said at least one input-output shafts increases to 2 cm for an axial distance of 1.2 cm where said diameter decreases to slightly over 1.0 cm and extends to the inner edge of the rotating mercury vacuum seal assembly where said diameter changes to 1.0 cm and extends through the rotating mercury vacuum seal assembly, a rotor bearing assembly, and a sun gear, the radial surface of the 2 cm diameter portion of said at least one input-output shafts has sixteen shallow grooves of 11.25 degrees wide which are aligned with grooves similar to that in the outer edge of the rotor;(K) said mercury vacuum seal assembly comprising two rotating mercury vacuum seals mounted on said at least one input-output shaft with their outer surface seated in the outer fixed safety shield next to said rotor bearing assembly,(L) two thin plastic washers which are mounted next to the outer face of the mercury vacuum seals to hold the mercury vacuum seals when the rotor shaft is in a stationary state;(M) said rotor bearing assembly comprising two rotor bearings between the rotor shaft and the outer safety shield for supporting an operation at 30,000 revolutions per minute;(N) said flywheel bearing assembly comprising two flywheel bearings between the fixed pole piece shafts and the flywheel end disks for supporting an operation at 30,000 revolutions per minute,(O) two plastic peak flux control shims mounted between the fixed pole pieces and the flywheel end disks to adjust the reluctance of the magnetic circuit,(P) one rotatable inconel safety shield mounted inside the outer safety shield on two cylindrical surfaces sealed with vacuum grease to hold said mercury vacuum seal during a stationary state;(Q) one outer fixed safety shield fitted on the ends of the fixed pole piece shafts and containing two holes for evacuating the interior of the rotatable inconel safety shield, and six holes in each end for electrical wires to pass through, outer ends of said outer fixed safety shield contain three mounting shafts located at 120 degrees to hold the flywheel bearings and planet gears used in a planetary gear train assembly, and two cylindrical mounting surfaces for a gear train housing assembly;(R) said planetary gear train assembly comprising two planetary gear trains each having a sun gear, three planet gears mounted on flywheel bearings, and an internal gear with an output drive shaft, all mounted inside a gear train housing assembly;(S) said gear train housing assembly comprising two gear train housings which mount on the fixed safety shield and provide cylindrical mounting surfaces surrounded by a vibration absorbing material which are used to mount the flywheel assembly on the vehicle frame;(T) two bushings centered in the mounting cylinder and supporting said at least one input-output shaft,(U) said mercury ring assembly comprising two fluid mercury rings approximately fill the two mercury slots when rotating.