The invention relates to a reciprocating piston machine which may be configured to be highly balanced. In one form the machine may comprise an electrical generator or alternator.
In broad terms in one aspect the invention comprises a machine including at least one piston reciprocally movable in a cylinder, a pair of balancing rotors mounted for oscillating rotational movement about an axis or axes transverse to the axis of motion of the piston, one balancing rotor having a centre of mass on one side of and another balancing rotor having a centre of mass on an opposite side of the axis or axes of motion of the rotors, and at least one connecting member or mechanism between the piston and rotors so that the rotors to move in opposition to the reciprocal movement of the piston.
The machine may be a single cylinder or multi-cylinder machine as will be further described.
In one form the machine is an electrical machine. The machine may comprise a generator driven by the piston(s), of an external or internal combustion engine for example, or an electric motor driving the piston(s), of a pump or compressor for example. Thus in a further aspect the invention comprises an electrical machine including at least one piston reciprocally movable in a cylinder, balancing rotors mounted for oscillating rotational movement and connected to the piston so that the rotors to move in opposition to the reciprocal movement of the piston, where one or both of the rotors comprise a magnet or a winding, and optionally a stator or stators associated with the rotors.
Where the machine is an electrical machine and in particular a generator, in one embodiment each of the rotors may comprise a permanent magnet or an electromagnet and the machine may comprise a stator associated with the rotors movement of the rotors generates an emf in the stator. In another embodiment a stator or stators may comprise a permanent or electromagnet and the rotors a winding or windings—movement of the rotors generates an emf in the rotor winding(s). In a further stator-less embodiment one rotor may comprise a permanent or electromagnet and another rotor may comprise a winding or windings—relative movement between the rotors generates an emf in the winding or windings.
Where the machine is an electrical machine and in particular an electric motor driving the piston(s), which do work pumping a fluid such as a liquid or gas, or compressing a gas, for example, in one embodiment each of the rotors may comprise a permanent or an electromagnet and a voltage may be applied to a stator or stators to drive oscillating movement of the rotors and movement of the piston(s). In another embodiment a stator or stators may comprise a permanent or electromagnet and the rotors a winding or windings to which a voltage is applied to drive movement of the rotors and pistons. In a further embodiment a stator-less embodiment one rotor may carry a permanent or electromagnet and another rotor a winding to which a voltage is applied to drive movement of the rotors and piston.
Benefits and advantages of the invention or at least of embodiments hereof are described subsequently in relation to specific embodiments that are next described in detail.
In this specification and claims the term “generator” includes electrical machines which generate either dc or ac power.
The term ‘comprising’ as used in this specification and claims means ‘consisting at least in part of’, that is to say when interrupting independent claims including that term, the features prefaced by that term in each claim will need to be present but other features can also be present.
The invention is further described with reference to the accompanying drawings, by way of example and without intending to be limiting, in which:
The machine of
Two balancing rotors 3 are mounted about axes transverse to the axis of motion of the piston, at beatings 4. The piston 1 and rotors 3 are coupled by connecting rods 6. The major part of the mass of each of the rotors 3 are on opposite sides of the pivot axes 4, and the connecting rods 6 couple to minor parts 3a of the rotors 3 on the other side as shown.
The configuration is such that during operation of the machine, reciprocal linear motion of the piston 1 in the cylinder 2 drives or is driven by oscillating rotational motion of the rotors 3, with the rotors moving in opposition to the movement of the piston 1. That is, during downward movement of the piston 1 in the direction of arrow P1 in
The connecting rods 6 can be either flexible in the plane of the machine but stiff axially, or have articulation don joints where the connecting rods couple to the piston and/or to the rotors 3, to accommodate a small rotational motion of the connecting rods.
The machine can be substantially dynamically balanced. The rotors can be formed to have a mass distribution that will substantially balance the reciprocating mass of the piston, and to also have near equal rotary moments of inertia so that the rotating inertia of the two cranks substantially balances and negates each other. The mass of the two rotors and piston should lie in substantially the same plane to avoid out of balance moments. The sum of the rotary inertia moments of the two connecting rods will be zero due to the opposite direction of their rotation. A high degree of balance can be obtained whilst the stroke is short in comparison to the lever arm length of the two contra-rotating rotors. Also because the contra-rotating cranks are dynamically balancing the piston inertia and are fixed in unison the motion of the piston can vary away from sinusoidal motion whilst maintaining the high degree of balance. That is non-sinusoidal piston motion can be used without compromising engine balance.
In an embodiment of the machine which is an electric generator or alternator, in one form the rotors 3 may comprise magnets particularly around the curved periphery of each rotor, and a stator (not shown in
Should the electrical load be lost at any time during operation, the inherently balanced nature of the mechanism means the machine would not violently shake.
In an embodiment of the machine which is an electric motor and the pistons are driven, such as in a pump or compressor for example, each of the rotors may comprise a permanent magnet or an electromagnet connected to a power source via brushes, springs or flexible wires for example, and a voltage may be applied to windings of a stator to drive the rotors. Alternatively a stator on either side may each comprise a permanent or electromagnet and the rotors winding or windings to which a voltage is applied to drive the rotors and pistons.
As shown in
Also in the embodiment shown in
Again in an embodiment which is an electrical generator the rotors 3 may comprise peripheral permanent magnets or electromagnets, and a surrounding stator, or alternatively (but less preferably) the stator may comprise a permanent magnet or electromagnet, the flux of which is cut by windings on the rotors.
In a further embodiment the two moving rotors may each comprise a compound wound winding connected to the output connectors through brushes, springs, flexible wires or similar.
In a yet further embodiment which is a generator and which is similar to the embodiment of
An embodiment of
An electronic control system comprising for example a micro-processor, optionally with one or more sensors on piston and/or rotor position and/or movement, may be arranged to control piston motion, such as piston velocity and/or position, for example to cause the pistons to move with a non-sinusoidal motion, or to vary the effective capacity or swept area of the cylinder(s) by the piston(s) in either an engine or in a pump or compressor embodiment, by controlling the or each piston so that the piston(s) operate(s) only at the top of the cylinder(s) for example. In a generator embodiment this may be used to control or alter the waveform of the electrical output of the generator.
In principle the thrust required for moving the piston at the desired velocity and/or to the desired top dead centre (TDC) and/or bottom dead centre (BDC) position(s) is calculated for different crank angles. The magnetic circuit and the electric circuit of the machine are designed to generate the force required.
The machine may be implemented as a stepper machine, BLDG machine, induction machine, reluctance machine, synchronous machine, limited angle torque machine, servo machine, vernier hybrid machine, or a PM synchronous machine for example, in single or (some cases) multiphase.
A prototype motor of the embodiment shown in
In normal operation mechanism has a natural rest position at state 3 above, and in one full cycle the rotors can oscillate to BDC, then to TDC, and then return to state 3. The stroke of rotor movement was is 15° on either side of state 3.
To control the stroke length, the cycle in one mode can be limited to between state 5 and state 1 on either side, instead of between BDC and TDC. This limits the stroke to 20° or 16.7 mm. Alternatively in another mode the stroke length can be limited to 10° or 8.35 mm stroke. For stroke control in the prototype, the minimum resolution achievable was 10°.
Another control variable is the DC level or bias. With a stroke of 10°, the natural rest position can be at any of the five states above. For example, state 1 can be the natural rest position and the machine can then in operation oscillate between TDC and state 2. Alternatively when the natural rest position is state 2, then the machine can in operation oscillate between state 1 and state 3 for a 10° stroke or between TDC and state 5 for a 20° stroke. In general, when the natural rest position is state 2 or state 4, stroke lengths of 20° and 10° are possible. When the natural rest position is state 1 or state 5, a stroke of 10° is possible.
The dwell time of the piston at TDC or BDC or both can be controlled to obtain non-linear or non-sinusoidal travel of the piston ie the piston can be controlled to pause at TDC and BDC to generate a trapezoidal motion profile.
The instantaneous position of the piston can be determined by a position sensing system such as for example an encoder to provide a piston position input signal to the machine controller 25. The position signal(s) are used for generating drive signals to the power electronic switches S1-S8 driving the individual stator coils 26-29 to achieve the desired piston motion. The prototype machine was driven in a closed loop with the position sensing system providing the feedback to decide the instant for commutation (changing between the stator poles 26-29 by operating switches S1-S8 to redirect the current into a different set of stator poles). The position sensing system also helps in controlling the modulation level to obtain the appropriate control parameters (for example-speed and dwell). The control system 25 may be arranged to drive the stator windings to achieve a flux profile to achieve accurate motion profile (similar to the micro stepping of stepper motors). The waveform can be a non-linear one with individual power control to achieve any non-linear motion profile required.
The machine may alternatively be arranged as an electrical generator driven by the piston(s), in which the power electronic circuitry is switched according to piston position and the energy generated in the windings is extracted. Energy can be extracted by non-switching methods also. Alternatively, it can be designed as any other electrical machine with suitable grid tie electronics to export the power generated.
The electrical machine may be connected to a utility grid without any power electronics by designing it as an induction machine or a synchronous machine. The generator may produce an output wave form which is non-sinusoidal by controlling the piston motion to be non-sinusoidal.
In all embodiments of electric machines which comprise a generator, very preferably for each oscillating rotor the distance between the axis about which the rotor moves, and the axis at which the connecting rod from the piston attaches to the rotor, is less than the distance from the same axis of motion of the rotor to the external peripheries of the rotors, so that the linear speed of the magnets and/or windings is greater than the linear speed of the piston(s). This makes it possible to increase the output voltage and simultaneously reduce the output current for the same output power, enabling in a lighter and more economic rotor design.
In a particularly preferred faun an engine and generator of the invention may be the engine and generator of a micro-combined heat and power (microCHP) unit, in which engine and engine exhaust heat are exchanged for water or space heating. In particular the microCHP unit may be suitable for wall mounting as the engine has can be configured to have low or minimal vibration.
A further benefit of the invention is that conventional stator lamination construction may be used in preferred embodiments (which comprise stator(s)), whereas prior art linear alternator electrical machines have unconventional stator lamination construction, which increases manufacturing costs.
In a further embodiment (not shown) but similar to that of
In the embodiment of
or alternator. This is further described by way of example, in relation to the embodiment of
In all embodiments described above a biasing arrangement, of for example a mechanical spring or springs, may be provided to bias the rotors to a neutral position (a position at which the piston is intermediate of its stroke length in the cylinder). A spring arrangement may operate between the two rotors or each pair of rotors, or separately between one or more rotors and a fixed (non-moving) part of the machine. The bias arrangement may be configured to create a natural working frequency of the machine. Alternative to a mechanical spring arrangement the bias arrangement may utilise gas cylinders or similar, or magnetic force. Alternatively the spring, magnet or gas spring could act on the piston or piston rod.
In an embodiment of the machine which is an electric generator the machine may be a wave energy generator. The piston may be coupled to a diaphragm or other part which is moved by wave motion.
In another particular embodiment the machine may be both an electric motor and a generator, in an application in which a gas is compressed (work is done of the gas) and subsequently it expands (work is done by the gas) in the cylinder(s). Electric power may be put into the machine to drive the piston(s) to compress the gas during movement of the piston(s) in one direction, but the machine may act as a generator during the expansion phase of the gas, where the piston(s) drive(s) the rotors.
The foregoing describes the invention including a preferred form thereof. Alterations and modifications as would be obvious to those skilled in the art are intended to be incorporated within the scope hereof as defined in the accompanying claims.
Number | Date | Country | Kind |
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549050 | Aug 2006 | NZ | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/NZ07/00212 | 8/9/2007 | WO | 00 | 10/23/2009 |
Number | Date | Country | |
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60839281 | Aug 2006 | US |