Abstract:
The instant invention provides a magnetically controlled reciprocating engine having a unique electromagnet control system. The engine is constructed and arranged to operate from a stored power source such as batteries to provide extended run times by controlling the power supplied to the electromagnets in a manner that controls heat generation within the electromagnetic coils, thereby increasing coil life. The control system is also capable of controlling engine speed and/or torque outputs to make the engine versatile for a wide variety of uses. The system is constructed and arranged to be utilized on new or pre-existing engines of various configurations and may be utilized in other industries or devices that benefit from the use of electromagnets.

Description:
FIELD OF THE INVENTION 
     This invention relates generally to reciprocating engines. More specifically, the invention is a magnetically powered reciprocating engine and electromagnet control system adaptable for use wherever internal combustion engines are utilized. 
     BACKGROUND OF THE INVENTION 
     Reciprocating internal combustion engines, e.g. Otto and Diesel cycle engines are a major factor in just about every aspect of life here and abroad. Reciprocating internal combustion engines facilitate our way of life by providing us with transportation, consumer products, safety, medical assistance, and power generation to name only a few. However, reciprocating internal combustion engines suffer from disadvantages, many of which would no longer be acceptable if there were an alternative to the use of these engines. They require fossil fuel, and suffer from many inefficiencies that cause them to generate heat, noise, vibration and toxic by-products; all of which we tolerate only because we have no economically suitable alternatives. With the decline in the supply of fossil fuels and the increase in harmful atmospheric gasses, governments have a renewed interest in finding alternatives to internal combustion. 
     For example, some of the energy wasting features of internal combustion engines include friction, inefficient combustion, heat loss from the combustion chamber, aerodynamic drag of air moving through the engine, energy used by ancillary equipment like oil and water pumps, and imperfect valve timing. Another issue that affects the efficiency of these engines is that they must be designed to reduce emissions requiring compromises in design. As a result, the average engine is about 35% efficient and must be kept idling at stoplights, wasting an additional 17% of the energy, resulting in an overall efficiency of about 18%. This means that about 82% of the energy we put into our vehicles in the form of fossil fuels is wasted exiting the engine in the form of non-useful byproducts. 
     Attempts at eliminating the need for fossil fuels in reciprocating engines has been attempted for decades. Various types of alternative fuels and engine configurations have been suggested, some with more success than others, but overall most have met with very limited success. One such alternative is bio fuels. Bio fuels may be derived from plant materials such as corn or sugar cane. However, these fuels require agricultural land, tractors for planting and harvesting, and distilleries for converting the biomass into fuel. Bio fuels derived from algae, trash, or agricultural waste or other sources could help because they do not require agricultural land use but always seem to be several years away from large scale commercial development. Even if these fuels were developed on a scale suitable for use, there is no suitable system for distributing the fuel to the general public. The distribution system would require several more years for development. Therefore, most scientists agree that if we really want to develop biomass into energy, we should turn it into electricity and not automotive fuel. 
     Another category of alternative designs relies on electricity and/or magnets to cause reciprocation of or movement of a piston(s). For example, U.S. Pat. No. 2,296,554 issued to A. K. Hinchman. Hinchman&#39;s invention relates to a self-timing piston electric engine setting forth a cylinder which includes primary and secondary electromagnetic coils acting upon the piston to cause it to reciprocate. The coils are energized at proper periods by relay timers controlled or actuated by the movements of the piston. 
     U.S. Pat. No. 3,939,367 issued to Ramirez discloses a permanent magnet and electromagnet actuated mechanical unit that may be secured to an engine block assembly to actuate at least one piston, connecting rod and driveshaft that forms a part of the assembly to obtain rotary power. 
     U.S. Pat. No. 4,317,058 issued to Blalock, discloses an electromagnetic reciprocating engine. The electromagnetic engine replaces the cylinders with non-ferromagnetic material and the pistons are replaced with permanent magnets. The cylinder heads are replaced with electromagnets. 
     A shortcoming associated with all of the known prior art relates to the operation of the electromagnets. To make an engine suitable for use in applications such as an automobile requires fairly large electromagnets. Large electromagnets require a supply of high amperage and/or voltage electricity which must be rapidly turned on and off to simulate the firing of pistons in a reciprocating engine. This causes several problems, such as arcing between the contacts, and results in pre-mature failure. In addition, electromagnets operating at high current loads for extended periods of time generate a considerable amount of heat. The increase in heat significantly reduces efficiency and often results in failure of the electromagnetic coil. In addition, the magnetic fields generated by the electromagnets often cause problems such as cascading avalanche breakdown, induced EMF, spikes and voltage clips in other engine systems, such as the timing system. 
     Thus what is needed in the art is a magnetically operated reciprocating engine having a control system that addresses the problems associated with the prior art. The magnetically operated engine should be reliable and economical to produce. The magnetically operated engine should be constructed and arranged to operate from battery power. The magnetically operated engine should include a control system that provides extended run times by controlling the power supplied to the electromagnets in a fashion that controls heat generation for reliable coil life and efficient operation. The system utilized to control the operation of the electromagnets should also be capable of controlling engine speed and/or torque outputs. The control system should reduce or eliminate the problems often associated with large magnetic fields without compromising performance of the engine. 
     SUMMARY OF THE INVENTION 
     The instant invention provides a magnetically controlled reciprocating engine having a unique electromagnet control system for operation and control of the engine. The engine is constructed and arranged to operate from stored power sources, such as batteries, to provide extended run times by controlling the power supplied to the electromagnets in a manner that regulates heat generation within the electromagnetic coils without sacrificing magnetic flux. The control system is also capable of controlling engine speed and/or torque outputs to make the engine versatile for a wide variety of applications. The electromagnetic control system and magnetic components are constructed and arranged for utilization on new or pre-existing engines and may be utilized in other industries or devices that benefit from the use of electromagnets. 
     In general, an internal combustion reciprocating type engine is utilized by removing the cylinder heads and replacing them with electromagnetic coils. The piston(s) are modified to retain at least one and more, preferably a plurality, of permanent magnets. The standard timing system is also removed and is replaced with a fiber optic system which communicates with a high voltage DC switching mechanism for controlling the flow of power to the electromagnets in a manner that isolates the timing system from the magnetic impulses generated by the engine. In a preferred embodiment, power is supplied to the electromagnets via a series of electrical pulses that vary in duration to minimize power consumption and maximize the magnetic flux developed by the electromagnets. The power pulses facilitate delivery of different electrical pulses, thus magnetic flux, based on crankshaft angle to maximize torque delivery provided by the engine. The cooling system, if present, can also be removed, as well as the fuel delivery system. 
     Accordingly, it is an objective of the present invention to provide a magnetically operated reciprocating piston engine. 
     It is another objective of the present invention to provide a control system for electromagnets that is particularly suited for reciprocating piston engines. 
     It is yet another objective of the present invention to provide a magnetically operated engine that utilizes a combination of permanent and electromagnets. 
     It is still yet another objective of the present invention to provide an electromagnet control system that controls heat build-up within the electromagnets. 
     It is a further objective of the present invention to provide an electromagnet control system that provides at least one pulsed electric signal to each electromagnet during each firing window. 
     It is yet a further objective of the present invention to provide an electromagnet control system that provides two different pulsed signals to each electromagnet during each firing window. 
     It is still yet a further objective of the present invention to provide an electromagnet control system that provides variably pulsed electrical power to electromagnets based on crankshaft angle to maximize torque produced by the engine. 
     It is an even further objective of the present invention to provide an electromagnet construction having a unique core material. 
     Other objects and advantages of this invention will become apparent from the following description taken in conjunction with any accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. Any drawings contained herein constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         FIG. 1  is a top view partially in section illustrating one embodiment of the present invention; 
         FIG. 2  is a top perspective view partially in section illustrating a piston assembly of the present invention; 
         FIG. 3  is a perspective view illustrating one embodiment of a coil assembly of the present invention; 
         FIG. 4  is an electrical schematic of one embodiment of the present invention; 
         FIG. 5  is a partial view of the schematic illustrated in  FIG. 4 ; 
         FIG. 6  is a partial view of the schematic illustrated in  FIG. 4 ; 
         FIG. 7  is a partial view of the schematic illustrated in  FIG. 4 ; 
         FIG. 8  is a partial view of the schematic illustrated in  FIG. 4 ; 
         FIG. 9  is a partial view of the schematic illustrated in  FIG. 4 ; 
         FIG. 10  is a partial view of the schematic illustrated in  FIG. 4 ; 
         FIG. 11  is an electrical schematic of a power control circuit of one embodiment of the present invention; 
         FIG. 12  illustrates one embodiment of the power delivery to the electromagnetic coils when the power control circuit of  FIG. 11  is utilized. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred, albeit not limiting, embodiment with the understanding that the present disclosure is to be considered an exemplification of the present invention and is not intended to limit the invention to the specific embodiments illustrated. 
     Referring to  FIGS. 1 and 2 , a magnetically operated reciprocating engine  10  is illustrated. The magnetically operated reciprocating engine  10  includes at least one piston  12  constructed and arranged to reciprocate along a substantially linear path illustrated herein as a cylinder  14 . The piston  12  includes at least one, and preferably a plurality of permanent magnets  16  secured thereto. The magnets are preferably secured to a top surface of the piston  12  via a non-metallic sleeve  38 . The sleeve may be secured to the top surface of the piston with fasteners  40 , and a strap member  42  may extend over the magnets to further secure the position of the magnets. The piston  12  is pivotally secured to a connecting rod  18  that is rotationally connected to a crankshaft  20  to convert the reciprocating movement of the piston into rotary motion at the crankshaft. An electromagnet assembly  22  is secured beyond the end of the piston  12  stroke at a position to react with the permanent piston magnets  16  when energized in a controlled manner. A timing/firing system is utilized to monitor rotation of the crankshaft for causing the electromagnet assembly  22  to generate a magnetic field in response to crankshaft position. The electromagnet assembly  22  and permanent magnets  16  are preferably configured so that a pushing force is created between the coil banks and the pistons. In an alternative embodiment one bank may be electromagnetically pushing while the opposite bank is electromagnetically pulling. It should be noted that while a horizontally opposed engine is illustrated, the instant invention can be utilized on any reciprocating engine configuration known in the art without departing from the scope of the invention. Such engine configurations include, but should not be limited to, V-configurations, W-configurations, in line configurations, radial configurations and the like. 
     Referring to  FIG. 3 , a partial section view of an electromagnetic coil  22  is illustrated. The coil includes a central spool  24  having a pair of end caps  34 ,  36 ; all constructed of a ferromagnetic material suitable for creating a magnetic field. The end caps  34 ,  36  generally provide a barrier to prevent movement of the wire coil with respect to the core during operation. In a most preferred embodiment, the core is constructed of a material with high magnetic permeability and low coercivity and magnetostriction resulting in low hysteresis loss. In a most preferred embodiment, the core material is a nickel-iron alloy (approximately 80% nickel, 15% iron plus copper, silicone and molybdenum). The core material should be annealed in a magnetic field having a hydrogen atmosphere. The annealing alters the material&#39;s crystal structure, aligning the grains and removing some impurities, especially carbon which obstructs the free motion of the magnetic grain boundaries. A suitable core material may be purchased under the name MU-SHIELD available from the MuShield Company Inc. of Londonderry, N.H. Wrapped around the core is a barrier layer  26  of DuPont KAPTON insulation. A plurality of wire wraps  28  extend around the core  24  to create the electrical field. In the preferred non-limiting embodiment about 250 wraps of 8 gauge copper wire wrapped in KAPTON tape  28  insulation are provided. The distal ends  30  and  32  of the coil wire extend outwardly from the coil for attachment to the timing/firing system. It should be noted that providing more wraps of wire will provide a larger magnetic field when energized and less wraps will provide a smaller magnetic field as is known in the art. 
     Referring to  FIGS. 4-10 , a wiring diagram showing one embodiment of the timing/firing system  100  is illustrated. The timing/firing system generally includes a low voltage power supply module  102 , a high voltage supply module  104 , a timing module  106 , and a firing module  108 . The low voltage power supply module  102  is comprised of a power inverter  110  and a plurality of power supplies  112 ,  114 ,  116 ,  118  having various output voltages for operation of the electronic components that make up the timing and firing modules  106 ,  108  respectively. The power inverter  110  preferably converts a 12V DC  120  supply of power to 120V AC  122 , filtering and conditioning the 12V DC power to have a sine wave form. The converted power  122  is preferably supplied to four power supplies: a first  112  and a second  114  converting the 120V AC power  122  to 15V DC  124 , a third  116  converting the 120V AC power to 12V DC  126 , and a fourth  118  that converts 120V AC power to 5V DC  128 . Because the high magnetic pulse flux that the timing/firing system is subject to can interfere with signaling and sensing functions, the inverter  110  and power supplies  112 - 118  redundantly filter and condition the power for supply to the other electronic components. This construction greatly reduces the possibility of transient spike anomalies that could cause premature firings, distorted timing, over currents, over voltage or even avalanche breakdowns that could cause electronic components to fail. 
     The high voltage system (HVDC)  104  is preferably a plurality of batteries  130  and capacitors  132 . In a most preferred embodiment the array of batteries  130  comprises 12V DC batteries  134  hooked up in series to provide a total of 120V DC power  136  to the electromagnetic coils. The array of capacitors  132  preferably comprises about 12 10,000 picoFarad capacitors  138 . The capacitors are generally constructed and arranged to smooth the draw on the batteries to provide extended run times, reduce heat build-up in the batteries  134  and provide a smoother power signal to the coils. The positive polarity of the battery array  140  connects to the line side of a single pole single throw switch which acts as the main power switch  142  and can either energize or shut down all of the 120V DC supplied components throughout the HVDC system. From the load side of the main power switch  142  the 120v DC positive polarity is divided into two separate HVDC supply legs  144 ,  146 . A first leg  144  connects to the collector  149  of the first insulated gate bipolar transistor (IGBT)  148  supplying power to coil bank  1   150 , including coils  1  and  4   156 ,  158 , while the second leg  146  connects to the collector  151  of the second IGBT  152  supplying power to coil bank  2   154 , including coils  2  and  3   160 ,  162 . 
     In a preferred embodiment, the first and second IGBTs  148 ,  152  are MITSUBISHI part no. CM1200DC 34N and are each rated at 1,700 volts 1,200 amps. The first and second IGBTs  148 ,  152  are configured to include duel switching (two channels) capability and can be operated either independently, in tandem, or in an alternating pattern. When two IGBTs are utilized, Channel  1164 ,  166  respectively of each IGBT provides independent switching of the coil banks  1  &amp;  2 . It should also be noted that while the preferred embodiment includes two IGBTs, more or less IGBTs may be utilized without departing from the scope of the invention. From the Channel  1   164  emitter of the first IGBT  148  the 120v DC power passes through blocking diode  168 ; and from the Channel  1   166  emitter of the second IGBT  152  the 120v DC power passes through a blocking diode  170 . Diodes  168  and  170  are preferably power diodes, VISHAY part no. SDIIOOC16 B-PUK, rated at 1400 Amp 1600 Volts. Diode  168  is connected to coil bank  1   150 , and diode  170  is connected to coil bank  2   154 . Diodes  168  and  170  prevent any back EMF caused by a failure in fly-back diodes  172  or  174  from reaching the first or second IGBTs. 
     Still referring to  FIGS. 4-10 , the main components of the timing system  106  are two RT-610-10 U-shaped photoelectric infrared sensors  176 ,  178 . The infra-red sensors  176 ,  178  cooperate with timing disc  181  to provide timing with respect to position of the crankshaft  20 , and thus pistons  12  to initiate energizing coil bank  1   150  or coil bank  2   154  and when to shutdown/de-energize coil bank  1  and/or coil bank  2 . In this manner the infrared sensors operate to specify duration for independent operation of the coil banks. A low voltage ON or OFF digital signal regarding the specific duration is sent to a respective low voltage power modulator and pulse controller  180 ,  182 . In operation, each photoelectric infrared sensor  176 ,  178  senses rotation of the timing disc  181  signaling the respective power modulator and pulse controller  180 ,  182  when to send power to a respective IGBT  148 ,  152  to energize a respective coil bank  150 ,  154 . The signal is preferably a 12v DC signal of a specific duration via an EMF shielded cable to the respective true bypass (TB) opto-coupler  184 ,  186 . In a most preferred embodiment, one RT-610-10, one Power Modulator and Pulse Controller and one opto-coupler are provided for each bank of cylinders. Providing independent pulse width modulators (PWM) to TB opto-coupler groups for each coil bank isolates possibility of failures from cascading and increases options for function configurations of the coil banks. Each respective low voltage power modulator and pulse controller  180 ,  182  functions to interface the timing/firing system  106  with the fiber optically interfaced IGBTs  148 ,  152 . The power modulator and pulse controllers  180 ,  182  also convert the steady on/off digital signal received from the timing/firing module  106  to a signal that can be manually varied in duty cycle within the signal time frame/duration sent. The purpose is to reduce heat produced by the DC high voltage/amperage supply  104  to the IGBT switching components and the electromagnetic coils in their respective coil bank, to be able to manually vary the revolutions per minute (RPMs) of the motor  10  by reducing the effective voltage supplied to the electromagnetic coils  22  in their respective coil bank and to bring efficiency to the collection of back EMF. This is accomplished via a Pulse Width Modulator within the power modulator and pulse controllers. In operation, when the TB Opto-coupler component  184 ,  186  receives the shielded 12v DC ON digital signal from the RT-610-10 U-shaped photoelectric infrared sensor  176 ,  178  it closes an opto-isolating switch  188 ,  190 . This action allows a pulse width modulated 5v DC signal mirroring in duration the signal sent by the RT-610-10 photoelectric infrared sensor  176 ,  178  that is electrically isolated from the RT-610-10 in the Timing/Firing system. Opto-isolating is used to fire-wall one part of the system from another, preventing problems caused by cascading avalanche breakdown, induced EMF, spikes, and voltage clips. The pulse width modulated 5v DC signal powers a fiber optic transmitter  192 ,  194  on the TB Opto-coupler, converting the signal from a pulsed width modulated electrical signal to pulsed width modulated laser light signal. The pulsed width modulated laser light ON or OFF digital signal is sent via a fiber optic cable  196 ,  198  to the fiber optically interfaced IGBT Driver  200 ,  202  which in turn will open or close the IGBT controlling the high voltage DC power. It should be appreciated that because fiber optics are immune to the high magnetic flux environment, converting the pulsed electrical signal to a laser pulsed signal maintains very low attenuation and high integrity of the signal to maintain the integrity of the signal to eliminate the need for EMF shielding and give greater latitude to the range of pulse width that can be utilized. Thus, much higher pulsing can be employed, allowing system design options regarding back EMF that are excluded by standard hard-wired IGBT drivers. 
     Referring to the firing system  108 , the Fiber Optically Interfaced IGBT Driver is constructed and arranged to control the opening and closing of the IGBT gates, thus switching on or off the HVDC power to the coil banks. Power supplied to the IGBT driver  200 ,  202  is a filtered and conditioned 15v DC 0.5 Amp. via shield twisted pair wires  124  extending from power supplies  112 ,  114 . The IGBT Driver  200 ,  202  is also constructed and arranged to include features that can be incorporated as torque power output IC Controller/Sensors that allow the shift from a push-push system between the electromagnets and the permanent magnets to a system that a pushes on one coil bank while the other coil bank pulls (attracts) thus adding more torque to the power stroke. Shifting from a push-push mode to a push-pull mode may be accomplished on the fly. 
     High voltage DC switching is accomplished by two high voltage, high amperage insulated gate bipolar transistors (IGBT)  148 ,  152  and are preferably HVIGBT MODULES MITSUBISHI part no. CM1200DC 34N, each rated at 1700 volts 1200 amps. Each IGBT is controlled by a driver board  200 ,  202  that is fiber optically interfaced to a respective TB opto-coupler component  184 ,  186  located in the low voltage power modulator and pulse controller. Each IGBT gates power to a respective coil bank or cylinder independently of other IGBTs being utilized. Each electromagnetic coil bank  150 ,  154  preferably includes a flyback diode  204 ,  206  across its positive and negative connection. It has been found that VISHAY part no. SDI500030L B-PUK is rated at 1600 A 3000V diodes, and is suitable to eliminate flyback. Flyback is the sudden voltage spike seen across the inductive load presented by the coil banks when its supply voltage is abruptly changed by the systems pulsing and switching frequency. From each coil bank the high voltage DC continues through another isolation diode  208 ,  210 , preferably VISHAY part no. SD1500030L B-PUK 1600 A 3000V. Isolation diodes  208 ,  210  are to be considered legacy components; their primary function is to isolate the magnetic coil banks from one another. Isolation diodes  208 ,  210  connect to a common copper buss  212  which connects to the negative terminal of the high voltage DC 120V Power Supply battery array. 
     Referring to  FIGS. 11 and 12 , an alternative opto-isolator construction is illustrated. In this embodiment a timer circuit  222  and potentiometer  224  are included. With this arrangement, the firing window of the IGBTs can be broken into more than one pulse signal to allow additional control over the electromagnets and the power supply as illustrated in  FIG. 12 . This configuration allows an initial electrical impulse  226  followed by a second electrical pulse  228 . Those skilled in the art will recognize that this construction allows the duty cycle of the electromagnets to be customized to a particular application. This construction also allows the duty cycle of the electromagnets to be altered based upon inputs from sensors, such as torque sensors, to reduce power consumption based on engine load. Other advantages include control over peak torque produced during the firing window which may include a lower duty cycle during the first portion of the firing window and a higher duty cycle during the second portion of the firing window. 
     It should be noted that while not illustrated, power generation means well known in the art may be utilized to maintain supply of power in the batteries. Such power generation means may include, but should not be limited to, alternators, generators, magnetos, dynamic braking and the like. The power generation means may be operated directly from the engine by belt, shaft, gears, direct coupling, fluid drive, etc. Alternatively, the power generation means may be indirectly coupled to the engine such as through dynamic braking, wheel generators, and auxiliary internal or external combustion engines such as in a hybrid. It should also be noted that the engine of the present invention may be operated from a conventional power grid in a static setting thereby eliminating the need for the batteries. 
     All patents and publications mentioned in this specification are indicative of the levels of those skilled in the art to which the invention pertains. All patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference. 
     It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification and any drawings/figures included herein. 
     One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims.