CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a completion application of co-pending U.S. Provisional Patent Application Serial No. 62/444,997 for SEGMENTED MOTOR/GENERATOR STRUCTURE, filed January 11, 2017, the disclosure of which is incorporated by reference in its entirety, including the drawing.

BACKGROUND OF THE INVENTION

1. Field of the Invention

[0001] The present invention pertains to a brushless rotary electric motor/generator structure for larger motors. More particularly, the present invention concerns a segmented and individually encapsulated brushless rotary electric motor/generator structure.

2. Description of Related Art

[0003] In general, brushless electric motors may be termed "axial gap" or "radial gap." In each, magnets are mounted on a rotor and an induction structure or electrical coils are mounted on a stator.

[0004] In the axial gap motor, the coils and magnets are in juxtaposed relation with one another on respective co-axial cylindrical planes and in respective axially spaced planes.

[0005] In the radial gap motor, the coils and magnets are in radially spaced juxtaposed relation with one another in respective co-axially disposed cylindrical planes.

[0006] Axial gap motors employing coil armatures and brush commutation have been in use since the late 1950's. In a conventional (brushed) DC motor, the brushes make mechanical contact with a set of electrical contacts on the rotor (called the commutator), forming an electrical circuit between the DC electrical source and the armature coil-windings. As the armature rotates on its axis, the stationary brushes come into contact with different sections of the rotating commutator.

[0007] Brushless disc-type axial gap motors were later developed, employing rotating magnets, coil stators, and electronic commutation. In such brushless motor, the electromagnets do not move; instead, the permanent magnets rotate and the armature remains static. This gets around the problem of how to transfer current to a moving armature.

[0008] Additionally, brushless axial gap motors have been used in large numbers in audio and video tape recorders and computer disc drives. In such a motor, a magnetic rotor disc with alternating North/South pole pieces rotates above and/or below a plane containing several flat, stator coils lying adjacent to one another. Current flowing in the conductor wires of the coils interacts with the alternating magnetic flux lines of the disc, producing Lorentz forces perpendicular to the radially directed conductors and thus tangential to the axis of rotation. While current flows through the entire coil, only the radial extending portions of the conductors (called the working conductors) contribute torque to the rotor. See, for example, U.S. Patent Nos. 3,988.024; 4,361,776; 4,371,801; and 5,146,144. A variation of this arrangement is known in which the circumferential portions (nonworking conductors) of the wire- wound coils overlap each other. See, for example, U.S. Patent Nos. 4,068,143; 4,420,875; 4,551,645; and 4,743,813. While this arrangement allows closer packing of the working conductors, it also requires that the gap between the rotor's magnets and flux return be about twice as thick as would be required for a single thickness of a non-overlapping coil, thus reducing the magnetic flux density and thus reducing the motor's efficiency. [0009] The brushless axial gap motor offers several advantages over brushed DC motors, including higher efficiency and reliability, reduced noise, reduced maintenance, longer lifetime (no brush erosion), elimination of ionizing sparks from the commutator, and overall reduction of electromagnetic interference. The maximum power that can be applied to a brushless motor is exceptionally high, limited almost exclusively by heat, which can damage the coils and affect the strength of the magnets.

[0010] Accordingly, an arrangement for obviating the deleterious effects of heat and temperature build-up in the brushless motor during operation thereof is desirable.

[0011] In view of the these disadvantages in the above-mentioned prior art, U. S. Patent

5,744,896 to Kessinger et al., which issued Apr. 28, 1998, discloses a motor which employs an axial gap magnetic structure wherein complementary faces of the stator and rotor are disposed in axially spaced relation and each receives a flat array of coil winding segments and a flat array of permanent magnets. The segments and magnets are arranged in angularly spaced side-by- side relation and extend radially relative to the rotor axis of rotation. The coil winding segments are alike and generally trapezoidal to form a ring-shaped structure that overlaps with one another to form a thin planar electromagnetic structure. Electrical wires are wound about the coil structures and the longer legs (or sides) of the trapezoidal shape form the working portions of the coil windings.

[0012] Kessinger teaches that the individual coils making up each coil array be flat and rectangular in shape to form a thin disc coil array so as to maximize the electromotive interaction for a motor/generator of a given diameter and maximize the torque, which may be produced by a motor, or the voltage produced by a generator. [0013] While believed useful for the purposes then desired, certain problems are believed to remain in an axial gap arrangement. During operation and rotation of the rotor, an outward radial shearing force is placed on the securement between the permanent magnets and the rotor. Because of these forces and possible adverse effects of heat buildup during continued use, the magnets may break free. Additional bonding material may be needed to overcome such situation, possibly resulting in increased cost and size of the structure.

[0014] Further, Kessinger proposes that the individual flat shaped rectangular coil structures closely abut one another and that individual coils be overmolded with a moldable material to form a suitable ring of suitable structural integrity and heat tolerance. However, such configuration suggests that some mechanism be provided to tolerate, but not transfer, heat from the coils during performance of their electric motor function.

[0015] Similar to the overmolded coils in Kessinger, U.S. Patent No. 9,124,144 to Prucher, which issued September 1, 2015 and is hereby incorporated by reference, teaches a dual radial gap motor/generator structure including a stator having a plurality of coil segments fully encapsulated by a polymer overmold. The polymer overmold in Prucher overcomes the issue of Kessinger in not being able to transfer heat away from the coils by functioning as a heat sink. The motor/generator disclosed in Prucher utilizes a cooling manifold to lower the overall temperature of the stator during operation.

[0016] While the motor/generator taught in Prucher is suitable for the uses and problems it intends to solve, there is an ongoing need for a motor/generator structure that can be utilized for larger motors without having to provide a single large polymer overmold which can be extremely cost prohibitive.

[0017] It is to this to which the present invention is directed. SUMMARY OF THE INVENTION

[0018] The present invention provides an electric motor comprising: (a) a stator, the stator including (i) a stator frame; (ii) a plurality of induction modules mounted or secured to the stator frame and extending downwardly therefrom; (iii) a heat sink integrally formed with the stator frame; and (iv) a cooling manifold disposed within the stator frame and secured therein; and (b) a rotor, the rotor including (i) a rotor frame for rotation relative to the stator frame; and (ii) a pair of opposed, annular magnet arrays mounted to opposing surfaces of the rotor frame and in juxtaposed relation with the plurality of induction modules, the pair of magnet arrays being spaced apart from the plurality of induction modules to provide generally thin, uniform radial gaps on respective sides of the plurality of induction modules.

[0019] The cooling manifold comprises a pair of cooling pipes in fluid connection with one another via a substantially U-shaped connector. The connector allows a working fluid to flow between the two cooling pipes. Additionally, each of the cooling pipes include a stopper that prevents continual circulation through the cooling pipes. Instead, when the working fluid comes into contact with the stopper in one cooling pipe, the working fluid is directed through the connector into the other cooling pipe. Thereafter, the working fluid contacts the other stopper and is directed out of the cooling pipe.

[0020] Furthermore, each of the induction modules of the stator is individually encapsulated in a molded polymer. The stator frame and a compression ring hold the induction modules in place therebetween by a plurality of fasteners. This individual encapsulation substantially reduces costs where the motor of the present invention is large and would otherwise require an equally large overmold. Furthermore, individually encapsulating the stator in this manner provides for more easily replacing defective components within the stator when necessary. [0021] By initially passing current through the coils, the radial gaps formed between the induction modules and the magnet arrays creates an increase in magnetic flux density that is acted upon by the induced magnetic field to produce the force that results in the rotational motion of the rotor.

[0022] The motor is particularly useful in accomplishing function such as drilling, bending, or the like when used in combination with an appropriate tool, such as a flywheel, secured to the rotor in order to rotate therewith.

[0023] For a better understanding of the present invention, reference is made to the detailed description and accompanying drawing. In the drawing, like reference numerals refer to like parts through the several views, in which:

BRIEF DESCRIPTION OF THE DRAWING

[0024] Fig. 1 is a perspective view as seen from the top of a motor in accordance with the present invention including a stator and a rotor;

[0025] Fig. 2 is a perspective view as seen from the bottom of the motor;

[0026] Fig. 3 is a partial perspective view of the motor;

[0027] Fig. 4 is a partial perspective view as seen from the top of the stator;

[0028] Fig. 5 is a perspective view of a coil;

[0029] Fig. 6 is a perspective view of the coil wrapped around a core;

[0030] Fig. 7 is a perspective view of an induction module comprising the coil and the core encapsulated in a molded polymer;

[0031] Fig. 8 is a perspective view of a plurality of induction modules arranged in a circumferential configuration; [0032] Fig. 9 is a perspective view of a pair of induction modules disposed on a compression ring;

[0033] Fig. 10 is a perspective view as seen from the top showing the induction modules being mounted onto the compression ring;

[0034] Fig. 11 is a perspective view as seen from the bottom showing the induction modules being mounted onto the compression ring;

[0035] Fig. 12 is a partial perspective view of a pair of induction modules disposed on the stator;

[0036] Fig. 13 is a partial perspective view as seen from the bottom of the stator;

[0037] Fig. 14 is a partial perspective view as seen from the top of a cooling manifold;

[0038] Fig. 15 is a partial perspective view as seen from the bottom of the cooling manifold;

[0039] Fig. 16 is a perspective view of the rotor;

[0040] Fig. 17 is a perspective view of the motor including a busbar on the stator;

[0041] Fig. 18 is an enlarged, perspective view of the busbar;

[0042] Fig. 19 is a perspective view of the mounting bracket mounted to the motor;

[0043] Fig. 20 is a cross-sectional front view of the motor used in combination with the mounting bracket and a flywheel; and

[0044] Fig. 21 is a cross-sectional front view of a screw press secured within the flywheel.

DETAILED DESCRIPTION OF THE INVENTION

[0045] As used herein, the electric motor/generator in accordance with the present invention, which produces mechanical power output in the form of rotational torque, is referred to as an electric motor throughout the ensuing description and appended claims. However, it is to be understood that the present invention can be suitable for use as both a motor or a generator.

[0046] Now, and in accordance with the present invention and with reference to the drawing, there is provided a dual radial gap electric motor denoted at 10.

[0047] As shown in Figs. 1-3 and 16, the motor 10 hereof, generally, comprises: (a) a stator

12; and (b) a rotor 14.

[0048] The stator 12 and rotor 14 are centered on a common central geometrical axis A.

The rotor 14 is mounted for rotation about the stator 12 and the central axis A.

[0049] The stator 12 includes: (i) a non-magnetic stator frame 16; (ii) a plurality of induction modules 18 mounted or secured to the stator frame 16 and extending downwardly therefrom; (iii) a mounting flange 20 integrally formed with the stator frame 16; and (iv) a cooling manifold 22 disposed within the stator frame 16 and secured therein.

[0050] The rotor 14 includes: (i) a non-magnetic rotor frame 24 for rotation relative to the stator frame 16; (ii) a pair of magnetically permeable back-up iron rings 32, 34 mounted to opposing surfaces of the rotor frame 24; and (iii) a pair of opposed, annular magnet arrays 26, 28 to complete a magnetic circuit, the pair of magnet arrays 26, 28 being mounted to opposing surfaces of the pair of back-up iron rings 126, 128 and in juxtaposed relation with the plurality of induction modules 18, the pair of magnet arrays 26, 28 being spaced apart from the plurality of induction modules 18 to provide generally thin, uniform radial gaps 30, 32 on respective sides of the plurality of induction modules 18.

[0051] An inner cylindrical annular or radial gap 30 is defined between the inner magnet array 26 and the induction modules 18 and an outer cylindrical annular or radial gap 32 is defined between the outer magnet array 28 and the induction modules 18. It should be noted that the utilization of the dual radial gaps 30, 32 enables an increase in magnetic flux density that is acted upon by an induced magnetic field created by passing current through the induction modules 18 to produce a force that results in the rotational motion of the rotor 14.

[0052] As shown in Fig. 4, and with more particularity, the stator frame 16 is generally cylindrical and includes a base 36 and a pair of opposed, upstanding sidewalls 38, 40 integrally formed with the base 36. A stator key way 42 is formed in the base 36 and mates with the plurality of induction modules 18 to position the induction modules 18 on the stator frame 16, as described below. The stator frame 16 further includes an open stator channel 44 defined by the pair of sidewalls 38, 40 and the interconnecting base 36. A divider 46 extends upwardly from the base 36 dividing the stator channel 44 into a pair of substantially equal canals 48, 50. The cooling manifold 22 is disposed therein. The divider 46 is also utilized for securing the induction modules 18 in position via a plurality of fasteners 52, such as bolts, screws, or the like.

[0053] The stator frame 16 further includes a mounting flange 20 integrally formed therewith. Preferably, the mounting flange 20 is a generally circular member secured about sidewall 16 of the stator frame 16 opposite the base 36. The mounting flange 20 further includes a plurality of mounting apertures 154 to facilitate securing the motor 10 to a mounting bracket 146, as described below. In addition to providing mounting capabilities to the mounting bracket 146, the mounting flange 20 further assists in drawing heat away from the induction modules 18.

[0054] Referring now to Figs. 5-8, each of the induction modules 18 of the stator 12 includes a coil 54 formed from a conductive material, typically copper, although other conductive materials may possibly be used such as aluminum, silver, carbon fiber, or the like. The coil 54 includes at least one, and, preferably, a plurality of windings 56. Each coil 54 has leads or termini 58 at opposing ends of the coil 54. The termini 58 of the coil 54 are connectible in electric circuit relation to a management controller (not shown) via a busbar 130 described below.

[0055] Each induction module further comprises an I-shaped core 60 including a linear medial portion 62 and two opposed, radially arched flange portions 64, 66 interconnected by the medial portion 62. The core 60 is formed from a magnetically permeable material such as a silicon steel, iron, or the like. The core 60 may also be made of any soft magnetic or ferromagnetic material. The I-shaped configuration of the core 60 supports the beneficial application of Grain Oriented Electrical Steel material and increases the induced magnetic flux at the opposing flange portions 64, 66.

[0056] The windings 56 of the coil 54 are wound around the core 60. Preferably, the two termini 58 project from the same side of the corresponding core 60, after winding, to facilitate connection to a busbar 130.

[0057] A substantial portion of the core 60 and the coil 54 associated with each induction module 18 is individually encapsulated in a thermally conductive, electrically insulating molded polymer 68 such as a plastic or an epoxy. By individually encapsulating the induction modules 18, the need for a single encapsulation of the stator 12 is eliminated, thereby reducing the cost of manufacturing.

[0058] Preferably, the molded polymer 68 has good heat transfer properties to rapidly and uniformly effectuate transfer of heat build-up from the induction module 18 to the stator frame 16, which functions as a heat sink to dissipate heat.

[0059] The molded polymer 68 which encapsulates the coil 58 and the core 60 includes a substantially planar top surface 70, a bottom surface 72, a front surface 74, a back surface 76, and opposing sides 78, 80. The molded polymer 68 further includes a pair of tapered edges 82, 84 interconnecting the top surface 70 and the front and back surfaces 72, 74, respectively.

[0060] As shown in Fig. 8, the opposing flanges 64, 66 of the core 60 are left exposed through the inside and outside surfaces 74, 76 of the molded polymer 68 and the termini 58 of the coil 54 extend through the top surface 70 of the molded polymer 68. The molded polymer 68 is specifically molded such that it allows the plurality of induction modules 18 to be arranged in a circular manner. Thus, the width of the inside surface 74 of the molded polymer 68 is tapered toward the front surface 74 to facilitate this arrangement.

[0061] Further, each molded polymer 68 includes an upper key 86 protruding upwardly from the top surface 70 thereof. The upper key 86 mates with the stator key way 42 described above to ensure that the induction modules 18 maintain their position within the stator 12.

[0062] Similarly, each molded polymer 68 includes a lower key 88 protruding downwardly from the bottom surface 72 thereof. A compression ring 94 mates with the lower key 88, as described below, opposite the stator frame 16 in order to secure the induction modules 18 between the stator frame 16 and the compression ring 94.

[0063] The molded polymer 68 further comprise a male keyway 90 and a female keyway

92 on opposing sides 78, 80, respectively, thereof to facilitate mounting each induction modules 18 onto the stator frame 16 and the compression ring 94 using a pair of fasteners 52 extending therethrough.

[0064] As shown in Fig. 8, the plurality of induction modules 18 are circumferentially disposed in abutting relation with one another. Each male keyway 90 of one molded polymer 68 fits within a female keyway 92 of a corresponding and adjacent molded polymer 68. [0065] Figs. 9-11 shows a pair of the induction modules 18 being positioned on the compression ring 94. The compression ring 94 is a circular, non-magnetic member formed from aluminum, carbon fiber, tin, a rigid plastic such as an ABS plastic, and the like. The compression ring 94 has a top surface 96 and a bottom surface 97. The top surface 96 of the compression ring 94 comprises a circular groove 98 formed therein along the entire circumference of the compression ring 94. The groove 98 mates with the lower key 88 of the molded polymer 68. The compression ring 94 further comprises a plurality of fastener holes 100 that vertically extend therethrough. Once each of the induction modules 18 is positioned within the groove 98, the male and female keyways 90, 92 align and are in registry with the respective fastener holes 100. Thereafter, a fastener 52 is inserted into a respective one of each of the male and female keyways 90, 92 and an associated fastener hole 100 to secure the induction modules 18 in place on the compression ring 94.

[0066] Due to the excessive buildup of energy within the stator 12, it is essential that the induction modules 18 be cooled, otherwise there can be substantial overheating. Thus, the stator frame 16 is formed from a thermally conductive structural material such as aluminum or the like in order to function as a heat sink and for lowering the temperature of the induction modules 18 during use.

[0067] The stator frame 16 facilitates the flow of heat as it radiates from the induction modules 18. As shown in Fig. 12, in order for heat to transfer from the induction modules 18 to the stator frame 16, the top surface 70 of the molded polymer 68 of each induction module 18 lies flush against the base 36 of the stator frame 16. This flush fitting between the induction modules 18 and the base 36 of the stator frame 16 allows heat from the induction modules 18 to dissipate. This elimination of heat from the induction modules 18 allows the motor 10 to continue operating at higher power levels by reducing risk of overheating and damage to any of the components.

[0068] Furthermore, the stator frame 16 includes a plurality of fastener holes 101 for securing the induction modules 18 to the stator 12. Each one of the plurality of fastener holes 101, similar to those in the compression ring 94, is in registry with the male and female keyways 90, 92. Additionally, a plurality of coil holes 102 are formed in the stator frame 16 that allow the termini 58 of the coils 54 to extend therethrough and connect to a busbar 130, as described below.

[0069] As noted above, the motor 10 includes a cooling manifold 22 disposed within the stator channel 44 of the stator 12 for further cooling the induction modules 18 during operation thereof.

[0070] Referring now to Figs. 4, 14, and 15, the cooling manifold 22 comprises a pair of circular, hermetically sealed, hollow cooling pipes 104, 106 that sit within a respective canal 48, 50 of the stator channel 44 separated by the divider 46. Each of the cooling pipes 104, 106 comprises an upstanding fluid port 108, 110, respectively, in fluid communication therewith which functions as either an inlet or outlet for a working fluid, such as water or the like, to enter or exit the cooling pipes 104, 106. Furthermore, the cooling manifold 22 includes a substantially U- shaped connector 112 in fluid communication with each of the cooling pipes 104, 106 which allows the working fluid to pass from one cooling pipe 104 to the other cooling pipe 106, or vice versa.

[0071] Each cooling pipe 104, 106 includes a stopper 114, 116, respectively, that acts as a blockage and forms a closed-loop configuration within each of the cooling pipes 104, 106. The stoppers 114, 116 are located between the connector 112 and the associated fluid port 108, 110 of each cooling pipe 104, 106 to direct the working fluid into the connector 112 or out of the fluid ports 108. 110 as the working fluid circulates through each of the cooling pipes 104, 106. [0072] It is to be understood that any suitable tubing system (not shown), such as a hose or the like, is connectable to each of the fluid ports 108, 110 in order to inject the working fluid into the cooling manifold 22 and remove the working fluid from the cooling manifold 22 after it is fully circulated through each of the cooling pipes 104, 106.

[0073] Referring now to Fig. 16, the rotor 14, which rotates about the stator 12 when in use, comprises a generally cylindrical, non-magnetic rotor frame 24. The rotor frame 24 includes a base 118 and a pair of opposed, upstanding sidewalls 120, 122 integrally formed with the base 118. The sidewalls 120, 122 each have an interior surface 120a, 122a and an exterior surface 120b, 122b. The rotor frame 24 includes a cylindrical central shaft housing 123 defined by sidewall 120. The shaft housing 123 facilitates rotation of any suitable tool to be inserted therein, such as a flywheel 142 or a screw press 144, as described below.

[0074] The rotor frame 24 further includes an open rotor channel 124 defined by the pair of sidewalls 120, 122 and the interconnecting base 118. The rotor channel 124 provides a clearance for allowing the induction modules 18 to pass therethrough as the rotor 14 rotates about the stator 12.

[0075] The rotor 14 further comprises a circular, inner back-up iron ring 126 and a circular, outer back-up iron ring 128 in opposition to one another. The inner and outer back-up iron rings 126, 128 are magnetically permeable and secured to the interior surfaces 120a, 122a of respective sidewalls 120, 122 of the rotor frame 24.

[0076] As noted above, the rotor 14 comprises a pair of continuous, generally cylindrical, annular magnet arrays, including an inner magnet array 26 and an outer magnet array 28. The inner and outer magnet arrays 26, 28 are secured in opposition to one another to the inner and outer back-up iron rings 126, 128, respectively. [0077] Each magnet array 26, 28 comprises a succession of separate permanent magnets

34 that are disposed in side-by-side abutting relation to one another with respective North and South poles of successive magnets 34 being adjacent to one another. Each of the magnet arrays 26, 28 is centered on the central axis A. While many magnets are known and available, a preferred magnet is the Neodymium-Iron-Boron magnet known for its ability to provide high power in a small size.

[0078] Optionally, the permanent magnets 34 may be formed into what is termed a

Halbach array. While the Halbach array will not be described in detail herein, it is understood by those skilled in the art that such an arrangement of permanent magnets increases the magnetic flux on one side of a device while reducing the flux to near zero on the other side.

[0079] The magnet arrays 26, 28 are axially displaced by a sufficient distance to accommodate the induction modules 18 passing therebetween during operation of the motor 10.

[0080] Preferably, an elastomeric material (not shown) may be used to bond and fixedly mount the permanent magnets and/or Halbach array against the outer back-up iron ring 128. Rotation of the rotor 14 operates to apply outward radial forces against the pair of magnet arrays 26, 28, forcing the magnets 34 radially outwardly and against sidewall 122 of the rotor frame 24, thereby obviating the development of axial shearing forces. Desirably, the positioning of the magnet arrays 26, 28 against the interior surfaces 120a, 122a of the inner and outer back-up iron rings 126, 128 results in a less expensive elastomer being needed, less elastomer to position the magnets 34, and a reduction in the weight of the motor 10 formed.

[0081] As shown in Figs. 17 and 18, and as noted above, the present invention further comprises a busbar 130, which includes a plurality of phase busbar rings 132, 134, 136 and at least one common busbar ring 138. Each of the phase busbar rings 132, 134, 136 and the common busbar ring 138 are disposed within the stator channel 44 and, preferably atop the divider 46.

[0082] The coils 54 are each connected to an associated phase busbar ring 132, 134, 136 at a first one of the termini 58 and to the common busbar ring 138 at the other termini 58. The termini 58 are soldered or otherwise electrically bonded to their associated busbar rings 132, 134, 136 and common busbar ring 138, thus providing a completed electrical circuit.

[0083] In this particular arrangement, the induction modules 18 are electrically connected to one of the three phase busbar rings 132, 134, 136, in a three phase "Y" configuration. Other configurations such as a Δ configuration including any number of phases can be achieved by merely modifying the connection pattern.

[0084] The busbar 130 further includes a plurality of insulating spacers 140 disposed between each phase busbar ring 132, 134, 136 in order to prevent electrical shorting and excessive mechanical interference therebetween.

[0085] A lid 164 may be employed to cover the stator 12 in order to substantially conceal the busbar 130 from external, physical interference. The lid 164 has a plurality of openings 166 formed therein to provide access to the fluid ports 108, 110 and the terminal pins 132', 134', 136', 136' for connecting the tubing system and a controller (not shown), respectively. It is understood that the lid 164 is removably secured to the stator 12 or mounting flange 20 in any suitable manner.

[0086] As noted above, the present invention can function as either a motor or a generator.

[0087] When functioning as a motor, electricity is supplied to the motor 10 via a driver

(not shown), in the manner described in detail above, which generates an electrical induction that operates on the poles of the pair of magnet arrays 26, 28. This electrical induction generates an electromagnetic field that is tangent to the rotor 14 which produces torque on the rotor 14 and causes the rotor 14 to turn. Thereafter, the rotor 14 rotates a tool or machinery operably connected thereto.

[0088] As shown in Figs. 19-21, the motor 10 of the present invention is particularly useful when used in combination with a flywheel 142 and a screw press 144.

[0089] In securing the motor 10 to the flywheel 142, a mounting bracket 146 is employed.

The mounting bracket 146 includes an upper circular frame 148 and a lower circular frame 150. A cross bracing 152 interconnects the upper and lower frames 148, 150. Preferably, the cross bracing 152 includes a torsional structure for added support. The mounting bracket 146 is mounted to either the stator frame 16 or the mounting flange 20 in any well-known manner. The upper frame 148 of the mounting bracket 146 is secured by any suitable fastener or the like to the mounting flange 20 via the mounting apertures 154 formed therein.

[0090] The flywheel 142 is inserted into the shaft housing 123 of the motor 10 and secured to the rotor 14 to rotate therewith. In order to maintain its position, the flywheel 142 is held in place between the rotor 14, within the shaft housing 123, and the lower circular frame 150 of the mounting bracket 146. A plurality of bearings 156 is disposed between the flywheel 142 and the mounting bracket 146 at any suitable location to ensure the flywheel 142 is able to rotate within the shaft housing 123 of the rotor 14 and above the lower frame 150 of the mounting bracket 146 with minimal friction.

[0091] The flywheel 142 includes a central port 158 for the insertion of a piece of machinery or a tool. Additionally, the flywheel 142 may include a screw press 144 illustrated in Fig. 21 integrally formed with the flywheel 142 within the central port 158. The screw press 144 includes a first end 160 connected to the flywheel 142 and a second or working end 162 opposite the first end 160. The first end 160 of the screw press 144 extends within the central port 158 of the flywheel 142 and secured therein. The second end 162 of the screw press 144 extends downwardly to a work surface (not shown) and accomplishes any desired function such as drilling, bending, or the like.

[0092] It is to be understood that the use of a flywheel 142 and screw press 144 is just one exemplary use of the motor 10 in accordance with the present invention. The present invention can additionally be used with respect to rotationally powered devices such as similar heavy industrial equipment, marine environments, aviation and, when employed as a generator, for power generation such as in windmills.

[0093] As a generator, the rotor 14 rotates via a driver in the same manner as described above, thereby creating electricity via the induction modules 18 which is then drawn through the busbar 130 connected to the termini 58 of the coils 54 forming a completed electrical circuit. The electrical circuit ends at a plurality of terminal pins 132', 134', 136', 138' that are provided to receive and connect to an electronic motor controller or other mechanical mechanism (not shown) to facilitate commutation and control the direction and speed of the motor 10.

[0094] The motor 10 of the present invention allows for the application of high volume, cost effective, manufacturing processes that assure the necessary accuracy and consistency in the assembly of various components.

[0095] It is to be understood that various alterations, modifications, or permutations of the present invention will be readily apparent to those skilled in the art. For example, the magnet arrays 26, 28 and the induction modules 18 could be reversed, such that the stator 12 and induction structure 18 encircle the rotor 14 and the magnet arrays 26, 28. In such an arrangement, the rotor 14 would be mounted for rotation within the stator 12. [0096] Additionally, it is possible that the number of windings 56 in one coil 54 around an associated core 60 may differ than the number of windings 56 in another coil 54. For example, there may be X number of windings 56 around one core 60 and Y number of windings 56 around another core 60, each connected to its own electric circuit of the busbar 130. The two individual groupings of coils 54 produce two separate distinct voltages when the rotor 14 is rotated relative to the stator 12. The difference between the two voltages unique to each of the separate circuits is a function of the difference between the numbers of windings 56 within the individual coils 54 in each grouping. The grouping with the greater number of windings 56 within its coils 54 will produce a current at a higher voltage than the grouping with the lower number windings 56. In this manner, various voltages may be drawn off from the present invention when functioning as a generator.

[0097] Therefore, it should be understood that the invention is not to be limited to the specific features shown or described, but it is intended that all equivalents be embraced within the spirit and scope of the invention as defined by the appended claims.