Abstract:
An assembly and method for generating mass torque having a frame structure supporting at least one torque generating wheel coupled to a rotational load. The torque generating wheel has peripheral circumferential veins of spaced magnetic or non-magnetic keys which are driven by an electro-mechanical control system including a plurality of electromagnetic coils and a timing circuit. The timed activation of the electro-mechanical control system on the magnetic (or non-magnetic) keys accelerate the generating wheel to rotate at a high rotational speed to generate a high level of torque output. The wheel structure is a large diameter structure constructed of a plurality of radial segments, each segment formed of a strong, lightweight and reinforced material.

Description:
This application claims the benefit of U.S. Provisional Application Ser. No. 61/343,249, filed Apr. 26, 2010. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates generally to an assembly and method for generating rotational force or torque. Particularly, the invention relates to an assembly and method utilizing a wheel assembly rotated at varying speeds to generate a substantial amount of rotational energy. More particularly, this invention relates to a rotational energy generating assembly having means to accelerate and to maintain at high rpm&#39;s a large torque generating wheel to yield mass torque usable for multiple applications. 
     Rotating wheel structures for generating power, such as electrical energy, are known in the art. The torque and electrical output of such prior art structures have, however, been limited. For example, the material compositions and methods of construction of prior art structures have limited their size and ability to rotate at higher rpm&#39;s. Further, the ability of such prior art wheel assemblies to be accelerated and to reach high rotational speeds and provide a substantial amount of torque has also been limited. 
     The assembly and method of the present invention to generate substantial rotational energy at high rotational wheel velocities overcome the difficulties and limitations of the prior art. There exists a need for the efficient generation of mass rotational torque in the power industry among others. There also exists a need for an environmentally compatible method of generating energy which has no emissions and which in effect may function as a large brushless electrical motor. For example, in the generation of electrical power, conversion of solar energy, large ship propulsion, power inversion, providing mechanical energy for air movement and for providing electrical power to remote communities, there exists a long felt but unsolved need for these benefits that are provided by the present invention. 
     SUMMARY OF THE INVENTION 
     An assembly and method of generating substantial rotational energy having at least one torque generating wheel which is accelerated and rotated at a high rotational speed. A generator may be coupled to the torque generating wheel, for example, and which may be mounted to a base structure. The torque generating wheel is controlled by an electrical control system having a timing circuit to accelerate and rotate the wheel(s) at a high rotational velocity. 
     Each rotatable wheel may have a plurality of radial wheel segments which, when assembled, form a circular wheel having a peripheral circumferential header that have veins formed by peripheral magnetic and non-magnetic keys that are acted upon by electromagnetic coils. 
     The electrical control system operative on the electromagnetic coils may have, for example, an HMI (human machine interface), a PLC (programmable logic controller), a capacitor bank, an electrical power supply, electrical controllers, and a timing circuit for activating the electromagnetic coils for the keys aligned on the veins on the periphery or rim of the torque generating wheel. 
     The torque generating wheel may preferably be constructed of a plurality of interlocking radial segments of lightweight material such as composite carbon/fiber or carbon nano tube material forming a circular wheel assembly. Each wheel segment may have post tensioned cables and the wheel assembly may have a peripheral circumferential cable to further secure the wheel assembly into a unitary, lightweight structure. Each wheel has a peripheral circumferential rim or header from which magnetic and non-magnetic keys extend forming peripheral veins. Electromagnetic coils are radially positioned adjacent the peripheral veins which may have one or more magnetic key segments interposed with one or more non-magnetic key segments, for example. The electromagnets and electrical controllers are controlled by a firing matrix to accelerate and maintain a high rotational wheel velocity. 
     The torque generating wheel(s) may be a unitary structure and is preferably a lightweight, large diameter structure, i.e., 50 or more ft. in diameter that may be rotatable up to approximately 3600 rpm&#39;s to drive a generator, for example, which may yield several megawatts of electrical energy when multiple torque generating wheels are utilized in the mass torque generation assembly. 
     The assembly and process of the invention may generate rotational torque energy for a rotational load such as an electrical generator, an inverter, a mechanical means to provide propulsion or combinations thereof to provide rotational power. For example, the rotational load may be used to provide electrical power for a community of homes and businesses, to power a ship, or for any other use requiring a rotational torque energy source. The assembly of the present invention may be viewed and adapted for use as a large brushless electrical motor which generates a substantial amount of rotational energy. 
     The advantage of the present invention is to provide a torque generating assembly which may either be permanently constructed or assembled on a remote site and which efficiently provides sufficient rotational force, for example, to provide electrical power to operate a small community or sections of a larger community. Another advantage of the invention is to provide a lightweight wheel assembly which may rotate at high rpm&#39;s to provide mass rotational torque for multiple applications. Another advantage of the invention is to provide an assembly and method to efficiently provide energy without environmentally damaging emissions. 
     These and other benefits of this invention will become apparent from the following description by reference to the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an elevational view of the torque producing assembly of the present invention; 
         FIG. 2  is a lateral view of the assembly of  FIG. 1 ; 
         FIG. 3  is a schematic showing the electrical components of the assembly of the invention; 
         FIG. 4  is an enlarged view showing a portion of the schematic of  FIG. 3 ; 
         FIG. 5  is an enlarged view showing another portion of the schematic of  FIG. 3 ; 
         FIG. 6  a schematic showing an embodiment of the firing matrix of the assembly; 
         FIG. 7  is an enlarged view showing a portion of the firing matrix of  FIG. 6 ; 
         FIG. 8  is a plan view of a torque generating wheel of the assembly; 
         FIG. 9  is a plan view of a torque generating wheel section; 
         FIG. 10  is a sectional view of the torque generating wheel segment; and 
         FIG. 11  is an enlarged sectional view showing the veins on the torque generating wheel periphery. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The assembly and method of the invention for generating rotational energy is described by reference to drawing  FIGS. 1-11 , wherein  FIGS. 1 ,  2 , and  8 - 11  show the structural components of the assembly and  FIGS. 3-7  show the electrical components and an exemplary firing matrix that may be utilized in the present invention. 
     Referring to  FIGS. 1 and 2 , the mass torque generating assembly  10  is shown mounted on a base  11 , such as concrete or steel base structure. Energy generating wheels  12  and  13  are shown mounted on base  11  and axle  26  is shown driving generator  14 . The peripheral rim or header of the wheels  12  and  13  are shown to have veins defined by keys  16  which are aligned magnetic and non-magnetic segments which are further shown and described with respect to  FIG. 11 . 
     An electrical pacing motor  37  for the wheel  12  controlled by a variable frequency drive  38 , as shown in  FIGS. 1 and 3 , may be directly connected to the axle  26  to assist in the start up of the wheel rotation process, in the sequence timing and for any overload conditions. 
     Referring further to  FIGS. 1 and 2 , keys  16  are shown mounted to the rotating wheel  12 ,  13  in rows or veins  36  and are arranged to interact with the electromagnetic coils  23  mounted on a rigid base  22  such as steel framing, thereby producing the wheel rotation. Veins  36  are defined by the metallic keys and non-metallic keys  16  mounted in a row on the peripheral face or header of the generation wheel  12 , as shown particularly in  FIGS. 10 and 11 . Wheel  12  is shown to have four veins  36  ( 1 - 4 ) and wheel  13  also has four veins  36 , which may be referred to as veins  5 - 8 . 
     Referring to  FIG. 3 , the electric circuit and the various electrical components of the control system of the invention are shown. Each component and its function are generally as follows: The human machine interface (HMI)  17  is generally a main frame computer which stores and executes a specific process program and which communicates the commands to the programmable logic controller (PLC)  18 . The PLC  18  interprets the commands from the HMI  17  and turns the commands into electrical signals that are sent to the field apparatuses to perform specified functions. The PLC  18  also receives status signals from the field and reports them to the HMI program. This activity is commonly known in the industry as processing discrete inputs, outputs and analog controls. The electric pacing motor  37  is shown in communication with variable frequency drive (VFD)  38  and PLC  18 . 
     The assembly  10  has a power source  19  for incoming power that is approximately 480 volts and between approximately 1,500-3,000 amps per power supply  21   a . A capacitor bank  20  is utilized to restore the power factor that may be disrupted during the process of controlling the electrical flow to the electromagnetic coils  23 . Electrical power supplies  21   a , labeled  1 - 8 , are shown utilized to supply both sufficient electrical current and voltage to provide magnetic propulsion and torque for rotating the generation wheels  12 ,  13  to produce electricity or for any other rotational torque use. 
     Controllers  21   b  are installed in specified quantities to allow the PLC  18  time to execute the program. The controllers  21   b  also control the amount, duration, sequence and physical placement of electricity from the electric power supplies to the electromagnetic coils following a predetermined firing matrix to propel the keys  16  mounted in the veins  36  on the face or header of the generation wheel  12 , for example. Electromagnetic coils  23  may be rigidly mounted to frame  22 , i.e., a permanent steel structure, and along the circumference of the generation wheel  12 ,  13 , respectively, and are energized utilizing a predetermined matrix (HMI program), thus producing a desired amount of propulsion. Exemplary sequential and increasing or cascading outputs of the coils  23  are shown in  FIG. 6 . 
     Referring further to  FIG. 3 , eight electrical power supplies  21   a  are shown connected to eight sets of three electrical controllers  21   b  which provide the electrical power to the three sets of magnetic coils  23 . Referring further to the enlarged views of  FIGS. 4 and 5 , the power supplies  21   a  shown to power the smaller 75 volt pre-saturation power supplies, are identified as Power supply # 1 , 150 volt, Power supply # 2 , 200 volt, Power supply # 3 , 250 volt, and in 50 volt increments to Power supply # 8 , 500 volt. The voltage output from power supplies  1 - 8  can be adjusted by the HMI program via the PLC prospectively or independently to refine or modify the output of the torque generation assembly. The electrical controllers  21   b  are shown identified with respect to Power supply # 1 , 150 volt as rows ( 1 A,  1 D,  1 G), ( 1 B,  1 E,  1 H) and ( 1 C,  1 F,  1 I) and as columns ( 1 A,  1 B,  1 C), ( 1 D,  1 E,  1 F) and ( 1 G,  1 H,  1 I). The electrical controller  21   b  with respect to Power supply # 2 , 200 volt are similarly identified in rows ( 2 A,  2 D,  2 G), etc. and in columns ( 2 A,  2 B,  2 C) etc. With respect to Power supply # 3 , 250 volt, the electrical controller  21   b  are identified in rows ( 3 A,  3 D,  3 G), etc. and in columns ( 3 A,  3 B,  3 C), etc. With respect to Power supply # 4 , 300 volt to Power supply # 8 , the electrical controllers  21   b  are similarly identified. 
     Referring to  FIG. 5 , three sets of electromagnetic coils  23  are each shown having a column identifying the first vein to the eighth vein, each with three power supply values, i.e., first vein;  1 A,  1 D,  1 G, first vein;  1 B,  1 E,  1 H, first vein;  1 C,  1 F,  1 I, to eighth vein;  8 A,  8 D,  8 G, eighth vein;  8 B,  8 E,  8 H, eighth vein;  8 C,  8 F,  8 I. These power supply values, as shown in  FIG. 3 , increase from 150 volts, (vein  1 ) by 50 volt increments to 500 volts (vein  8 ). 
     Referring to  FIGS. 6 and 7 , an exemplary cascading sequential firing matrix  39  shows the activation of the power supplies with respect to time and the degree of rotation of the generating wheel. The time (in seconds) is shown at a 3600 RPM wheel rotation and shows the power (voltage) imparted to veins  1 - 8 . In the enlarged view of  FIG. 7 , for example, the cascading voltage imparted to veins  1 - 8  is shown from 0 to 0.0996 seconds and which correspond to the values set forth in  FIG. 5 . In summary, the sequential cascading power imparted to electromagnets  23  provide for the high rotational velocity of the wheel and thus the high rotational torque provided by the invention. 
       FIGS. 8 and 9  show that the energy generating wheel  12  is constructed of a plurality of radial segments  27 , each having a tongue  28  and groove  29 , which permit the easy formation of the completed circular wheel of  FIG. 8 . Each segment  27  is shown to have a tapered end  30  at the bottom and a header  15  at the top. The radial length of the wheel segments directly effects the output torque of the generating wheel  12 . Post tension (PT) cables  31  (three) are shown extending within the wheel segment  27 , as further shown in  FIG. 10 . A circumferential cable band  34  is also shown disposed on the periphery of the generation wheel  12  structure. Although wheel segments  27  are shown forming wheel  12 , the torque generating wheel may be a solid, unitary structure formed of materials other than the tensioned lightweight materials discussed herein.  FIG. 8  shows the formed wheel  12  having an arbor  25 , formed of Aluminum, for example, and an aperture for axle  26 . At the periphery of wheel  12 , a peripheral cable band  34  is shown to hold and maintain the wheel segments  27  in a circular configuration. The keys (magnetic/non-magnetic)  16  and non-metallic key  24  are also shown extending outwardly from the wheel  12  periphery as is an electromagnetic coil  23  spaced therefrom. 
       FIG. 10  further shows the keys  16  at the outer periphery of wheel  12  and shows the PT cable  31  held within PT cable anchor pocket  32 . The wheel segments  27  as discussed are preferably formed of a lightweight material such as carbon fiber or like composite and lightweight material and the bottom tapered end portions  30  are shown held in tapered grooves  33  and  41  milled into the arbor  25 . The wheel segment  27  body is shown to have a tapered bow or spoon-shaped structure  40  to provide added strength and an aerodynamic configuration.  FIG. 11  shows circumferential cable  34  at the periphery of wheel  12  and further shows veins  36  having the keys  16  mounted within the milled grooves  42  of the header  15 . The sectional view of the wheel segment  27  is further shown held in tapered groove  43  of header  12 . 
     Post tension (PT) cables  31  are important to the generation wheels&#39; integrity and rigidity under high centrifugal forces. The PT cables  31  are implemented to directly cancel out the outward pressure component developed by the centrifugal force of the wheel  12 . A circumferential cable band  34  under tension is utilized to further provide for the integrity and rigidity of the generation wheels  12 ,  13  due to centrifugal forces, as shown in  FIG. 11 . 
     The generation wheel  12  utilizes tapered joints to insure rigidity and to tighten the joints under the pressure from the post tension cables  31  and band cables  34 . The generation wheel  12  operates at a high rate of speed in order to transfer the electromagnetic force directly to the generator or load  14  using its size to maximize leverage. The placement and spacing of the keys  16  within the veins  36  and the combination or layer of veins mounted in a cascading fashion onto the face of the wheels and which are affixed to a common axis provide effectively an infinite or continuous length of metallic or non-metallic track for the magnetic coils  23  to obtain traction. 
     In summary, the propulsion of the magnetic/non-magnetic keys aligned in the veins on the generating wheel periphery by the oppositely and adjacently positioned electromagnetic coils at the wheel periphery produce the wheel rotation. The torque produced by the wheel is dependent upon its radius or radial length and the implementation of the cascading magnetic force applied to the magnetic/non-magnetic keys by the electromagnetic coils. 
     It has also been found that the use of electromagnetic coils may also cause the propulsion of non-magnetic or non-ferrous key structures. Regarding the key(s) of the veins, at least one key or key segment may be utilized in the veins of the invention, although three key segments interposed by non-magnetic keys per vein are shown in the drawings and discussed herein. The keys of the respective veins are shown staggered with respect to each other on the wheel periphery to effectively accelerate the keys by means of the electromagnetic coil energy, the latter being most effective at the tail end of the non-magnetic or non-ferrous key structure length. 
     As discussed, above, although it is preferred that the generating wheel of the invention be lightweight and segmented, it is within the purview of the invention to utilize a solid wheel structure which may be constructed of other material compositions than those set forth in the present specification. 
     As many changes are possible to the assembly and method for mass torque generation embodiments of this invention, utilizing the teachings thereof, the description above and the accompanying drawings should be interpreted in the illustrative and not in the limited sense.