Abstract:
An enhanced engine for improving output torque and a power distribution system for feeding power to the engine. In an embodiment, the engine comprises a central shaft, a plurality of armatures, and a plurality of motors. The central shaft is adapted to rotate about an axis. The armatures are coupled to the central shaft and extend radially therefrom. The motors are coupled to respective armatures, each of the motors having a respective shaft and a propeller affixed to an end of each respective shaft. Each propeller is driven to rotation by operation of the respective motor. The rotating propellers drive air movement, thereby providing a torque that causes the central shaft to rotate with a tangential force corresponding to the weight of the rotating mass multiplied by the length of the armatures providing a flywheel effect that yields horsepower greater than the sum of the horsepower of each motor.

Description:
CROSS-REFERENCE TO RELATED APPLICATION  
       [0001]     This application claims priority pursuant to 35 U.S.C. § 119(e) to U.S. Provisional Application No. 60/703,729, filed Jul. 29, 2005, which application is specifically incorporated herein, in its entirety, by reference. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Field of the Invention  
         [0003]     The present invention relates to an enhanced engine for improving output torque and a power distribution system for providing power to the engine.  
         [0004]     2. Description of Related Art  
         [0005]     Various motors and engines are known in the art for numerous applications, including transportation, industrial, and consumer uses. Engine manufacturers are faced with major challenges in their quest to build better engines or motors. Some challenges include achieving higher power per unit engine mass. Higher horsepower output is desired without changing the weight of the engine producing improved engine efficiency. Reduction of emissions and pollution is also a challenge due to the environmental impact of engine emissions. Manufacturers are challenged to produce engines with improved reliability to reduce repair costs to the consumer and improve customer satisfaction in order to garner manufacturer loyalty. Manufacturers are also challenged to select a fuel supply that is readily available. Alternative fuels (e.g., batteries or hydrogen cells) may provide advantages but are negated if the supply is not readily accessible for mass manufacturing.  
         [0006]     Electrical motors have no emissions, high efficiency and very good reliability, but their weight, including that of the batteries, is a major drawback. For example, battery weight becomes a limiting factor in the adoption of electric motors for transportation applications, as desired driving ranges cannot be achieved without excessive battery weight.  
         [0007]     An electric motor operates by turning a coil within an electromagnetic field. The radius of the coil is relatively small and an armature generally runs through the center of the coil. The electromotive force may be exerted a short distance from the center of rotation for the coil, providing little leverage. As an example, turning a bolt with a very short spanner is much more difficult than with a long handled spanner. The radius of the turning lever has a direct relationship to the ease at which the lever can be turned. As electric motors have relatively small armatures, a gearbox is usually used to increase the output torque, which, in turn, increases the effective engine mass and lowers efficiency.  
         [0008]     Power to a rotating shaft requires special power connections as wires will get tangled on the rotating shaft if a wired connection is used. Current systems use either a brush and commutator connection or a brushless motor connection. Power supplied by a brush and commutator apply power by connecting a battery or AC power to carbon or copper brushes that make contact with a commutator or slip ring. The brushes conduct current between stationary power wires and the rotor. Many of the limitations of the classic motor are due to the need for brushes to press against the commutator or slip ring, creating friction. At higher speeds, brushes have increasing difficulty in maintaining contact. Brushes may bounce off the irregularities in the commutator or slip ring surface, creating sparks and limiting the maximum speed of the machine. The output of the system is, likewise, limited by the current density per unit area of the brushes. The imperfect electric contact also causes electrical noise. Brushes eventually wear out and require replacement.  
         [0009]     Current systems using brushless power distribution comprise an intelligent electronic controller. The controller performs the same power distribution found in a brushed system, only without using a commutator and brush assembly. The controller comprises a bank of high-power metal oxide semiconductor field-effect transistor (MOSFET) devices to drive power, and a microcontroller to precisely orchestrate the rapid-changing current-timings required. Because the controller must follow the rotor, the controller needs some way of determining the rotor&#39;s orientation relative to the stator. Sensors are often used for determining the rotor orientation. The main disadvantage of current brushless systems is the higher cost, which arises from the requirement for high-power MOSFET devices in the fabrication of the electronic speed controller.  
         [0010]     It is desired, therefore, to improve torque output from an engine as well as supply power to the rotor without sacrificing efficiency or cost.  
       SUMMARY OF THE INVENTION  
       [0011]     The present invention addresses the shortcomings of the prior art systems and methods. In particular, the present invention is directed to an engine that uses leverage to create more torque, and more horsepower per unit weight, in order to improve effectiveness. By combining electric motors into a framework, increased torque can be achieved by creating leverage with respect to an output shaft. The benefit is that the increased torque through leverage means that smaller motors can be used to drive the same load as a larger single electric motor. Advantageously, smaller motors require less power. Additionally, power is supplied to the rotating output shaft through a conductive ball bearing assembly. The rotating shaft comprises two electrically isolated shaft portions. The electrical contacts of the motors are connected to the two shaft portions, which are each connected to one of two power contacts through the ball bearing assembly, thereby increasing efficiency and reducing cost over traditional brush and commutator and brushless motor power connections.  
         [0012]     In accordance with one aspect of the embodiments described herein, an engine comprises a central shaft, a plurality of armatures, and a plurality of motors. The central shaft is adapted to rotate about an axis. The plurality of armatures are coupled to the central shaft and extend radially therefrom. The plurality of motors are coupled to respective ones of the plurality of armatures, each of the plurality of motors having a respective shaft and a propeller affixed to an end of each respective shaft, and each propeller being driven to rotation by operation of the respective one of the plurality of motors. The rotating propellers drive air movement providing a torque that causes the central shaft to rotate with a tangential force corresponding to the weight of the rotating mass multiplied by the length of the armatures. This provides a flywheel effect that yields horsepower that is greater than the sum of the horsepower of each one of the plurality of motors.  
         [0013]     In another embodiment of the invention, the central shaft of the engine described above comprises a first central shaft portion and a second central shaft portion. The second central shaft portion is electrically insulated from and rigidly affixed to the first central shaft portion. The first central shaft portion is attached to a first conductive rolling-element rotary bearing and the second central shaft portion is attached to a second conductive rolling-element rotary bearing. The engine further comprises a power source connected to the first conductive rolling-element rotary bearing and the second conductive rolling-element rotary bearing. The power source comprises a first lead and a second lead. The first lead is connected to the first conductive rolling-element rotary bearing and the second lead is connected to the second conductive rolling-element rotary bearing. Power is supplied to each of the plurality of motors via a first connection to the first central shaft portion and a second connection to the second central shaft portion. Each of the plurality of motors are electrically insulated from the central shaft. The power connection described above provides more efficient rotation than brush/commutator distributions systems and provides a lower cost than conventional brushless distribution systems.  
         [0014]     A more complete understanding of the engine and power distribution system for providing power to the engine will be afforded to those skilled in the art, as well as a realization of additional advantages and objects thereof, by a consideration of the following detailed description of the preferred embodiment. Reference will be made to the appended sheets of drawings which will first be described briefly. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0015]      FIG. 1  is a top view showing an apparatus according to an embodiment of the invention;  
         [0016]      FIG. 2  is a simplified plan view showing an apparatus of the type shown in  FIG. 1 ;  
         [0017]      FIG. 3  is a cross-sectional view of an apparatus of the type shown in  FIG. 1 , showing details of the mounting system and power distribution, for a system using a single main shaft bearing;  
         [0018]      FIG. 4  is a cross-sectional view of an apparatus of the type shown in  FIG. 1 , showing details of the mounting system and power distribution, for a system using dual main shaft bearings;  
         [0019]      FIG. 5  is a plan view showing a gear-driven apparatus according to an alternative embodiment of the invention;  
         [0020]      FIG. 6  is a cross-sectional view showing a gear-driven apparatus according to an alternative embodiment of the invention;  
         [0021]      FIG. 7  is a cross-sectional view of an apparatus according to an alternative embodiment of the invention, showing details of the mounting system and power distribution;  
         [0022]      FIG. 8  is a sectional view of an apparatus of the type shown in  FIG. 7 , showing details of the mounting system and power distribution; and  
         [0023]      FIG. 9  is a side view of an apparatus according to an alternative embodiment of the invention and of the type shown in  FIG. 7 . 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0024]     The present invention provides an enhanced engine for improving output torque without sacrificing efficiency. By combining electric motors into a framework, increased torque can be achieved by using leverage with respect to an output shaft to create more torque, thereby generating more horsepower per unit weight. Additionally, power is supplied to the output shaft through a conductive ball bearing assembly. The electrical contacts of the motors are connected to the output shaft. The output shaft comprises two electrically isolated shaft portions that are each connected to one of two power contacts through the ball bearing assembly, thereby increasing efficiency and reducing cost over traditional brush/commutator and brushless motor power connections. In the detailed description that follows, like element numerals are used to describe like elements appearing in one or more of the figures.  
         [0025]      FIGS. 1 and 2  show an engine  100  according to an embodiment of the invention. Engine  100  comprises three electric motors  102 A-C attached to respective armatures  104 A-C extending radially from a main shaft  108 . It should be appreciated that the armatures  104 A-C may vary in length and the mounting angle of the motors  102 A-C with respect to the armatures  102 A-C may vary from the perpendicular arrangement shown. The motors  102 A-C are arranged radially around the main shaft such that the weight of the motors is balanced. Thus, the motors  102 A-C will not move due to gravity. The motors  102 A-C will remain stationary until an external force is applied to the rotating portion of the engine, which comprises the combination of motors  102 A-C, armatures  104 A-C, and main shaft  108  or until the motors  102 A-C exert a motive force at or near the end of the armatures  104 A-C using propellers  106 A-C. It should be further appreciated that the propellers  106 A-C may vary from those shown to provide different combinations of weight and thrust. The thrust derived from the motive force of the propellers  106 A-C reduces the negative effects of the dead load and creates more torque than would normally be generated from the summation of the three individual motors  102 A-C.  
         [0026]     A power shaft  110  supplies the electric motors with electricity through a conductive bearing  112 . Power may be supplied through a cord  114 . In the illustrated embodiment, the electric motors are installed in a star shaped configuration and the motion of the main shaft  108  around its axis results from forced air via the propeller  106 A-C function. It should be appreciated that other motive mechanisms, such as a gear mechanism described in further detail and shown in  FIGS. 5-6 , may also be used.  
         [0027]     There are different ways to calculate the power of the system  100 , for example one could calculate the kinetic energy of the system and convert kinetic energy to horsepower. Or, alternatively, one could calculate the torque and then derive the horsepower, which is the method used here.  
         [0028]     Torque is defined as the force at any one point on the edge of a circle in the exact direction of the rotation multiplied by the radius. In the metric system, force is calculated in Newtons, and distance in meters so the torque unit is Newton-meters. In the standard system, which will be used here, force is calculated in pounds and distance in feet providing a torque unit of foot-pounds.  
         [0029]     For rotational movement:
 
Torque=force*distance=weight* r 
 
         [0030]     Where:  
         [0031]     r (ft)=radius of the rotor armature  
         [0032]     weight (lbs)=engine and armature weight
 
Horsepower=(Torque/5,252)*RPM
 
         [0033]     Where RPM=revolutions per minute of the main shaft  
         [0034]     Therefore: Horsepower=((weight*r)/5,252)*RPM  
         [0035]     Each of the three electric motors used in an exemplary embodiment of the invention generates ⅓ horsepower (0.33 hp). The total power of the three motors should therefore be 3*0.33=0.99 hp.  
         [0036]     For the exemplary embodiment, the three electrical motors are each installed 1 foot from the main shaft. The total apparatus structure weighs 65.7 pounds. The motors each weigh 14.9 pounds and the mounting brackets each weigh 7 pounds. The exemplary embodiment torque is therefore:
 
Torque=weight* r= 65.7*1=65.7 ft-lbs
 
 With the RPM generated by the motors at  240 , the calculation becomes:
 
Horsepower=(Torque/5,252)*RPM=(65.7/5252)*240=3.002 hp
 
 The horsepower increase is a factor of 3 when comparing the horsepower generated for the exemplary embodiment (3.002) to the sum of the horsepower of the individual motors used (0.99). It should be appreciated that horsepower is directly related to the RPM, therefore a lighter shaft construction may utilize the distributed power more efficiently, thus generating higher RPM and producing exponentially greater horsepower from the present invention. 
 
         [0037]     Referring to the embodiments of the invention shown in  FIGS. 3 and 4 , an engine  100  is supported by a main shaft  130 . The main shaft  130  is equivalent to a rotor for this engine.  FIG. 4  shows a main shaft  130  supported by ball bearings  132 A-B at opposite ends.  FIG. 3  shows a main shaft  130  supported by a single ball bearing  134  at a lower end, which may be more suitable for small-scale operations.  
         [0038]      FIGS. 3 and 4  also show a center shaft  136 , an electrically insulating sleeve  138 , a main shaft  130 , armatures  104 A-B, motors  102 A-B, and two sets of ball bearings (main ball bearing  134  or  132 A-B and central shaft ball bearing  140 ). The central shaft  136  is rigidly affixed to main shaft  130  with an insulating sleeve  138  positioned between to provide electrical insulation. The main shaft  130  encloses the center shaft and the insulating sleeve  138  and all move together when rotating about their axis.  
         [0039]     The armatures  104 A-B are attached to the main shaft  130  and each armature is attached to a respective electrical motor  102 A-B. A third motor and corresponding structures are not shown in  FIGS. 3-4  as they are located behind the structure in the field of vision of the drawing. It should be appreciated that any number of motors and armatures may be used. Armatures  104 A-B may be replaced by a disk, frame, or any other suitable structure for holding the motors  102 A-B in a desired orientation relative to the rotating shafts.  
         [0040]     The central shaft  136  is attached to electrical terminals  146 A-B. These terminals are electrically insulated, by the insulating sleeve  138  and the insulating washers  142 ,  144 , from the electrical contacts  148 A-B that are attached to the main shaft  130 . The central shaft  136  is connected to ball bearing  140 , which, in turn, is connected to power line  116 . The main shaft  130  is connected to ball bearing  134 ,  132 A, which, in turn, is connected to power line  118 . Thus, one power supply line  118  is connected to the body of the main shaft  130  through the main shaft ball bearings  134 ,  132 A that act as connectors. The other line  116  is connected to the center shaft  136  distributing power through the center shaft ball bearing  140 .  
         [0041]     Wire  152  connects power between electrical contacts  146 A-B and the center shaft  136 . Likewise, wire  150  connects power between electrical contacts  148 A-B and the main shaft  130 . The electrical contacts  146 A-B,  148 A-B connect to the respective motors  102 A-B and create a complete electrical circuit. Electricity is distributed continuously to the motors  102 A-B while they are in motion as a result of the shaft design, which acts as an electrical circuit.  
         [0042]     In a battery powered application, a system battery may also be incorporated into or attached to the rotating shafts. A rotating battery advantageously increases the rotating mass to achieve an enhanced flywheel effect. The battery may be connected to a stationary (i.e., non-rotating) electrical system for associated equipment, such as in a motor vehicle, using electrical connectors as herein described.  
         [0043]      FIG. 5  shows an alternative embodiment in which a system  200  comprises a single motor  202  and counterweight  204  mounted to a disk-like rotating support  206 . A support system as previously described may be used to support and provide power to the motor  202 . An output shaft of motor  202  may rotate a suitable gear, e.g., a spur gear  208  or helical gear, which is meshed with a ring gear  210  around an outer periphery of disk support  206 . Hence, motor  202  drives disk  206  via gears  208 ,  210 . A central output shaft or main shaft  230  is connected to the center of rotation of disk  206  and may be used for any suitable purpose.  
         [0044]      FIG. 6  shows another alternative embodiment  300  in which motor  302  is mounted with an output shaft perpendicular to support  306 . A pair of helical gears  308 ,  310  may be used to provide traction for the motor around output shaft  330 . Other details may be as previously described.  FIGS. 5 and 6  illustrate that various different motor and drive configurations may be adapted for use as alternate embodiments of the invention.  
         [0045]      FIGS. 7-9  show an alternative embodiment of the enhanced engine comprising an alternative electrical connection to the engine  400 . The present embodiment comprises the following main components: a main shaft  430 ; two sets of ball bearings  432 A-B contained in ball bearing housings  464 A-B, respectively; armatures  404 A-B; and motors  402 A-B. The main shaft  430  operates similar to a rotor for the engine. At each end of the main shaft  430 , there is a ball bearing  432 A-B contained within a ball bearing housing  464 A-B that is attached to a pair of electrical terminals. The main shaft  430  is formed from two parts that are electrically insulated  438  from each other and are fastened together, via four electrically insulated sleeved bolts (only two are shown)  462 A-B, to form one rotating unit. The electrically insulated sleeved bolts  462 A-B are additionally insulated at each end by insulation washers  442 A-D. The first main shaft part is attached with wires  450 A-B to electrical terminals  448 A-B on motors  402 A-B, respectively. Similarly, the second main shaft part is attached with wires  452 A-B to electrical terminals  446 A-B on motors  402 A-B, respectively. The electrical insulation  438  insulates the first main shaft part terminals  448 A-B from the second main shaft part terminals  446 A-B.  
         [0046]     The first main shaft part is connected to conductive ball bearing  432 A, which is contained in ball bearing housing  464 A. The ball bearing housing  464 A is connected to power line  416 . The second main shaft part is connected to conductive ball bearing  432 B, which is contained in ball bearing housing  464 B. Ball bearing housing  464 B is connected to power line  418 . Thus, one power supply line  418  is connected to the body of the main shaft  430  through the conductive ball bearing  432 B that acts as a connector. The other power line  416  is connected to the other side of the main shaft  430  distributing power through the conductive ball bearing  432 A. Electrical insulation  460 A-B is affixed between each ball bearing housing  464 A-B and the containment unit to isolate the power to the ball bearing housing  464 A-B and main shaft  430  assembly.  
         [0047]     Each motor  402 A-B is fastened to a mounting plate  466 A-B that is connected to the main shaft  430  via armatures  404 A-B, respectively. It should be appreciated that although the mounting plate  466 A-B is shown parallel to the main shaft  430  assembly, it may instead be oriented at an angle. Each motor  402 A-B comprises a respective shaft that rotates when power is applied to the motor. A propeller  406 A-B is affixed to the respective shaft to provide tangential thrust and drives the rotation of the rotation portion of the engine which comprises the combination of motors  402 A-B, armatures  404 A-B, and main shaft  420 . Insulating material  468 A-B is used to electrically isolate the motor from the powered main shaft  430 , armature  404 A-B, and mounting plate  466 A-B assembly. Electrical contacts  446 A-B,  448 A-B connect power to the motors  402 A-B at the end of each armature  404 A-B through wires  450 A-B,  452 A-B that connect to the main shaft  430  to create a complete electrical circuit. Electricity is distributed continuously to the motors  402 A-B while they are in motion as a result of the shaft design, which acts as an electrical circuit.  
         [0048]     In an embodiment of the invention, an entire electric motor  402 A, including rotor, stator, and housing, is mounted on a rotating wheel or other rotor. A battery may also be mounted on the wheel. Preferably, the motor is mounted near an outer circumference of the wheel. One or more additional motors  402 B-C may similarly be mounted on the wheel, so as to maintain the wheel in a balanced configuration. In the alternative, or in addition, weights may be used to balance the wheel. The wheel is connected to and drives a central output shaft  430 , and is supported by one or more bearings  432 A-B, for example ball bearings. Electric power is supplied to the motor or motors through a pair of rotating contacts or through the conductive ball bearings  432 A-B. Each motor has an output shaft connected to a device for applying a tangential rotational force to the wheel. For example, the motor shaft may drive a spur gear that meshes with a ring gear around the circumference of the wheel. For further example, the motor may drive a propeller  406 A-C to provide tangential thrust. The motor therefore drives the wheel so as to rotate around its output shaft  430 . The benefit of the present invention is that force is applied at an increased lever armature relative to the output shaft  430 , resulting in higher output torque. A further benefit is that the entire weight of the electric motor  402 A is used to add mass and momentum to the rotating wheel, resulting in a beneficial flywheel effect at a lower total engine weight. Rotation of the motor also provides a beneficial cooling effect for the electric motor  402 A derived from the airflow produced the rotation of the system.  
         [0049]     Having thus described a preferred embodiment of an apparatus for enhancing performance of an engine and an apparatus for distributing power in a rotating device, it should be apparent to those skilled in the art that certain advantages of the described system have been achieved. It should also be appreciated that various modifications, adaptations, and alternative embodiments thereof may be made within the scope and spirit of the present invention. For example, an electric motor has been illustrated, but it should be apparent that the inventive concepts described above would be equally applicable to other types of motors such as pneumatic or hydraulic motors. The number and size of the engines would be related to the application.  
         [0050]     The invention is solely defined by the following claims.