CROSS REFERENCE TO RELATED APPLICATIONS

This application is related to provisional patent application 62/348,504 by Leininger et al. entitled TORQUE MULTIPLICATION DEVICE AND SPLINE filed on June 10, 2016, the entirety of which is hereby incorporated by reference and is related to provisional patent application 62/348,504 by Leininger et al. entitled TORQUE MULTIPLICATION DEVICE AND COUPLING RING filed on October 7, 2016, the entirety of which is hereby incorporated by reference.

TECHNICAL FIELD

Various aspects of the present invention relate generally to a torque multiplier and more particularly to a torque multiplication device for use in energy generation. BACKGROUND ART

A flywheel is a rotating mechanical device that may be used to store energy for future use. For example, once a flywheel rotates, the kinetic energy of that rotation may be tapped off to supply energy to a load. More particularly, the rotating flywheel transfers energy by applying a torque to a mechanical load, thus decreasing the speed of the flywheel's rotation. Accordingly, a torque must then be applied back to the flywheel to increase/restore the flywheel's rotational speed. Through this action, a flywheel finds application as part of a power storage system (e.g., in an uninterruptable power supply), in electrical power/grid power storage, for use with an engine, transmission, as well as other energy storage applications.

DISCLOSURE OF INVENTION

According to aspects of the present disclosure, a torque multiplication device comprises a frame that supports a drive shaft with an axis for axial rotation within the frame and an oblique orbital member comprising a peripheral edge. A coupler couples the oblique orbital member concentrically to the drive shaft for rotation therewith. As such, the oblique orbital member couples to the drive shaft at an oblique angle such that the oblique orbital member couples to the drive shaft concentrically but not coaxially. Moreover, a guide couples to the frame and comprises a channel to fit the peripheral edge of the oblique orbital member so as to create a contactless guide bearing such that when the drive shaft rotates axially, a point of the oblique orbital member travels in a helical path relative to the drive shaft. The coupler may be a splined coupler, a coupling ring, a magnetic coupler (e.g., a spherical base and magnetic arcs forming a ring), etc.

According to aspects of the present disclosure, a torque multiplication device comprises a frame that supports a drive shaft with an axis for axial rotation within the frame and an oblique orbital member comprising a peripheral edge. A coupling ring couples the oblique orbital member concentrically to the drive shaft for rotation therewith. As such, the oblique orbital member couples to the drive shaft at an oblique angle such that the oblique orbital member couples to the drive shaft concentrically but not coaxially. Further, the coupling ring may pivot around a line perpendicular to the axis of the drive shaft (i.e., pitch rotation). Moreover, a guide couples to the frame and comprises a channel to fit the peripheral edge of the oblique orbital member so as to create a contactless guide bearing such that when the drive shaft rotates axially, a point of the oblique orbital member travels in a helical path relative to the drive shaft.

According to further aspects of the present disclosure, a coupling ring assembly comprises a coupling ring comprising four bores: a first ring-shaft bore, a second ring- shaft bore, a first ring-orbital bore, and a second ring-orbital bore. The coupling ring assembly further includes four pins: a first ring-shaft pin disposed in the first ring-shaft bore for coupling to a drive shaft, a second ring-shaft pin disposed in the second ring-shaft bore for coupling to the drive shaft, a first ring-orbital pin disposed in the first ring-orbital bore for coupling to an orbital member, and a second ring-orbital pin disposed in the second ring-orbital bore for coupling to the orbital member.

According to yet further aspects of the present disclosure, hydrostatic and/or hydrodynamic bearings are created in the coupling ring assembly using fluid channels and sub-channels. The first shaft-ring pin further comprises a first fluid sub-channel and a second sub-channel, and the second shaft-ring pin further comprises a first fluid subchannel and a second sub-channel. Further, the coupling ring includes a first fluid channel from the first ring-shaft bore to the first ring-orbital bore, wherein the first fluid subchannel of the first shaft-ring pin feeds fluid to the first fluid channel of the coupling ring, and the coupling ring further includes a second fluid channel from the second ring-shaft bore to the second ring-orbital bore, wherein the first fluid sub-channel of the second shaft-ring pin feeds fluid to the second fluid channel of the coupling ring. Moreover, the second sub-channel of the first shaft-ring pin feeds fluid to the first ring-shaft bore of the coupling ring, and the second sub-channel of the second shaft-ring pin feeds fluid to the second ring-shaft bore of the coupling ring.

According to aspects of the present disclosure, a torque multiplication device comprises a frame that supports a drive shaft, including a spline, for axial rotation within the frame. Further, the torque multiplication device comprises an oblique orbital member mounted concentrically with the drive shaft for rotation therewith. The oblique orbital member has a peripheral edge and a groove that couples to the spline of the drive shaft. For instance, the oblique orbital member can be mounted concentrically with the drive shaft such that the spline is partly within the groove. A guide is coupled to the frame and comprises a channel to fit the peripheral edge of the oblique orbital member so as to create a contactless guide bearing when the drive shaft rotates axially. Thus, a point of the oblique orbital member travels in a helical path relative to the drive shaft when the oblique orbital member rotates.

According to further aspects of the present disclosure, an orbital spline comprises a base and a key. The key includes a conical frustum that extends into a cavity of the base such that the key is free to rotate within the base. Further, the key includes a fin that protrudes from the conical frustum.

According to yet further aspects of the present disclosure, a torque multiplication device provided. The torque multiplication device comprises a frame having a lubricant channel, where the frame supports a drive shaft for axial rotation within the frame. The drive shaft comprises a lubricant channel coupled to the lubricant channel of the frame. The drive shaft also comprises splines. Each spline is comprised of a base having a lubricant channel coupled to the lubricant channel of the drive shaft, and a key. Each key includes a conical frustum portion that extends into the base such that the key is free to rotate within the base. Moreover, each key includes a fin that protrudes from the conical frustum. The torque multiplication device also comprises a first balancing flywheel disposed on one side of the splines, and a second balancing flywheel disposed opposite the first balancing flywheel with respect to the splines.

Yet further, the torque multiplication device comprises an oblique orbital member configured as a flywheel mounted concentrically with the drive shaft for rotation therewith. The oblique orbital member includes grooves that couple to the splines of the drive shaft, and a peripheral edge with a dense mass near the peripheral edge. Still further, the torque multiplication device comprises a guide coupled to the frame. The guide includes a channel to fit the peripheral edge of the oblique orbital member so as to create a contactless guide bearing such that when the drive shaft rotates axially, the dense mass of the oblique orbital member travels in a helical path relative to the drive shaft. Additionally, the guide includes a lubricant channel coupled to the lubricant channel of the frame. As such, the lubricant channel of the base allows for a lubricant to be delivered to an interface between the key and the base, and the lubricant channel of the frame allows for the lubricant to be delivered to an interface between the channel of the guide and the peripheral edge of the oblique orbital member.

In further, aspects of the present disclosure, a magnetic coupler comprises a spherical core, a set of northern magnetic arcs that each create a magnetic field in a first polar direction; and a set of southern magnetic arcs that each create a magnetic field in a second polar direction opposite the first polar direction. In some embodiments of the magnetic coupler, the set of northern magnetic arcs includes three northern magnetic arcs, and the set of southern magnetic arcs includes three southern magnetic arcs. The ring includes a pattern of alternating northern magnetic arcs and southern magnetic arcs.

BRIEF DESCRIPTION OF DRAWINGS FIG. 1 is an illustration of an embodiment of a torque multiplication device with a coupling ring and an oblique orbital member, according to aspects of the present disclosure;

FIG. 2 is an illustration of a first embodiment of a torque multiplication device with a spline and an oblique orbital member, according to aspects of the present disclosure;

FIG. 3 is an illustration of a second embodiment of a torque multiplication device having an oblique orbital member, illustrating a partial view with some components removed for clarity of illustration, according to aspects of the present disclosure;

FIG. 4 is an illustration of a spline that can be used with the torque multiplication device of FIG. 2 and/or FIG. 3, where the spline is in a first position, according to aspects of the present disclosure;

FIG. 5 is an illustration of the spline of FIG. 4 in a second position according to aspects of the present disclosure;

FIG. 6 is an illustration of aspects of the spline and a lubricant delivery system for an interface between a base and a key of a spline, according to aspects of the present disclosure FIG. 7 is an isometric illustration of a coupling ring, according to aspects of the present disclosure;

FIG. 8 is an illustration of an oblique orbital member, according to aspects of the present disclosure;

FIG. 9 is an illustration of a drive shaft coupled to an oblique orbital member via a coupling, according to aspects of the present disclosure;

FIG. 10 is an illustration of a magnetic coupler according to aspects of the present disclosure;

FIG. 11 is an illustration of the magnetic coupler and the drive shaft to which it couples, according to aspects of the present disclosure;

FIG. 12 is an illustration of a lubricant delivery system for an interface between a guide and an oblique orbital member, according to aspects of the present disclosure;

FIG. 13 is an illustration of a lubricant delivery system for an interface between a hub and a key and for an interface between the hub and a base, according to aspects of the present disclosure;

FIG. 14 is an illustration of a drive shaft with lubrication channels, according to aspects of the present disclosure;

FIG. 15 is an illustration of a lubricant delivery system for a coupling ring, according to aspects of the present disclosure;

FIG. 16 is an illustration of a lubricant delivery system for a pin that couples a coupling ring to a drive shaft, according to aspects of the present disclosure;

FIG. 17 is an illustration of an air bearing, according to aspects of the present disclosure;

FIG. 18 is an illustration of a coupling of a drive shaft to a frame, according to aspects of the present disclosure; and

FIG. 19 is block diagram of a system for power generation using a torque multiplication device, according to aspects of the present disclosure.

MODES FOR CARRYING OUT THE INVENTION FIG. 1 illustrates a torque multiplication device 100 for enhancing kinetic energy stored in flywheels, according to aspects of the present disclosure. In a first configuration, the torque multiplication device 100 comprises a frame 102 and oblique orbital member 104. The frame 102 supports a drive shaft 106 for axial rotation within the frame 102. In practical applications, the drive shaft 106 is coupled to a suitable drive device, an example of which is a drive motor. Likewise, an output load device, an example of which is a generator can couple to the torque multiplication device 100 via the oblique orbital member 104, the drive shaft 106, combination thereof, etc. Because of the oblique orientation of the oblique orbital member 104 relative to the drive shaft 106, a point of the oblique orbital member 104 travels in a helical path (or elliptical, depending on the point of reference) relative to the drive shaft 106 when the oblique orbital member 104 rotates.

One or more flywheels are added to the drive shaft 106. For instance, as illustrated, two flywheels 108a, 108b are coupled to the drive shaft 106. These flywheels 108a-b are used to balance the torque multiplication device 100 as well as store additional energy from the drive motor. As the oblique orbital member 104 rotates, energy supplied by a drive source coupled to the drive shaft 106 is used by the oblique orbital member 104 to enhance kinetic energy stored in the flywheels 108a-b.

The oblique orbital member 104 mounts concentrically with the drive shaft 106 for rotation therewith. The oblique orbital member 104 includes in general, a peripheral edge 1 10 that defines an outer extent. In some example implementations, the oblique orbital member 104 has a circular cross-section and a generally cylindrical overall shape. In other example configurations, the oblique orbital member 104 can be substantially annulus-shaped, can have a recessed rim between a center of the oblique orbital member 104 and the peripheral edge 110, can be spoked (or other structure other similar structure), etc. In yet other configurations, the oblique orbital member 104 can have other shapes including shapes that bulge, protrude or otherwise extend outward between a center of the oblique orbital member 104 and the peripheral edge 110. The oblique orbital member 104 can be constructed from carbon fiber, a carbon-composite, steel, other alloys, a metal such as titanium, one or more hybrid materials, a combination thereof, etc.

The above-description represents an embodiment of the present disclosure in a first configuration. However, the torque multiplication device 100 of FIG. 1 is illustrated with certain additional optional components, structures, configurations, functions, features, etc., for sake of a convenient and thorough disclosure. In this regard, the torque multiplication device 100 can also be implemented with any one of more of the following components, structures, configurations, functions, features, etc., alone or in any combination, examples of which are set out below.

As mentioned above, the oblique orbital member 104 can be mounted concentrically with the drive shaft 106; however, the oblique orbital member 104 is not mounted coaxially with the drive shaft 106. Thus, the oblique orbital member 104 is not perpendicular to the drive shaft 106.

In another optional example configuration, the oblique orbital member 104 is mounted to the frame 102 via a tilt plate 112 that is mounted to the frame 102 via a tilt- plate bracket 114 that may slide on a glider 116 of the frame 102. Further, the tilt-plate bracket 114 includes a wing nut 118 and adjustable slotted arm 120. As such, the angle of the tilt plate 112 (and thus the oblique orbital member 104) may be adjusted by gliding the bracket 114 along the glider and moving the adjustable slotted arm 120 before tightening the wing nut 118. In other embodiments, the angle of the oblique orbital member 104 is not adjustable. In such embodiments, the tilt-plate bracket 114 may be fixedly mounted to the frame 102 and the wing nut 118 and adjustable slotted arm 120 may just be a fixed arm. Alternatively, in embodiments with a fixed angle for the oblique orbital member 104, the tilt-plate bracket 114, the wing nut 118, and the adjustable slotted arm 120 are not included, and the tilt plate 112 mounts directly to the frame 102.

In further embodiments, the tilt plate 112 may include guides 122a, 122b that keep the oblique orbital member 104 from changing its non-perpendicular angle relative to the frame 102, thus maintaining the oblique orbital member's 104 oblique angle relative to the drive shaft 106 while the oblique orbital member 104 rotates. For example, the peripheral edge 110 of the oblique orbital member 104 fits into the guides 122a, 122b so as to create a contactless guide bearing when the drive shaft 106 rotates axially.

As the oblique orbital member 104 rotates, any specific point on the peripheral edge 110 of the oblique orbital member 104 travels in a helical path relative to the drive shaft 106. In some embodiments, dense masses (e.g., made from the same material as the oblique orbital member 104 or different material than the oblique orbital member 104) are embedded or affixed near the peripheral edge 110 of the oblique orbital member 104. As noted above, in several embodiments, the oblique orbital member 104 is a flywheel, while in other embodiments, the oblique orbital member 104 is a disk. In various alternate embodiments, the oblique orbital member 104 is a spoked wheel.

Tests have indicated that the angle of the oblique orbital member can range from zero to thirty degrees from a line perpendicular to the drive shaft. Optimal results may be shown around twenty-seven degrees. Example Embodiment 1: Spline

FIG. 2 illustrates an example embodiment 200 of the torque multiplication device (100, FIG. 1). As with the device (100, FIG. 1) above, the torque multiplication device 200 comprises a frame 202 and oblique orbital member 204. The frame 202 supports a drive shaft 206 for axial rotation within the frame 202. In practical applications, the drive shaft 206 is coupled to a suitable drive device. Likewise, an output load device can couple to the torque multiplication device 100 via the oblique orbital member 204, the drive shaft 206, combination thereof, etc. Because of the oblique orientation of the oblique orbital member 204 relative to the drive shaft 206, a point of the oblique orbital member 204 travels in a helical path relative to the drive shaft 206 when the oblique orbital member 204 rotates.

The oblique orbital member 204 mounts concentrically with the drive shaft 206 for rotation therewith. The oblique orbital member 204 includes in general, a peripheral edge 210 that defines an outer extent. In some example implementations, the oblique orbital member 204 has a circular cross-section and generally cylindrical overall shape. In other example configurations, the oblique orbital member 204 can be substantially ring- shaped, have a recessed rim between a center of the oblique orbital member 204 and the peripheral edge 210, spokes or other structure. In yet other configurations, the oblique orbital member 204 can have other shapes including shapes that bulge, protrude or otherwise extend outward between a center of the oblique orbital member 204 and the peripheral edge 210. The oblique orbital member 204 can be constructed from carbon fiber, a carbon-composite, steel, other alloys, a metal such as titanium, one or more hybrid materials, a combination thereof, etc.

The above-description represents an embodiment of the present disclosure in a first configuration. However, the torque multiplication device 200 of FIG. 2 is illustrated with certain additional optional components, structures, configurations, functions, features, etc., for sake of a convenient and thorough disclosure. In this regard, the torque multiplication device 200 can also be implemented with any one of more of the following components, structures, configurations, functions, features, etc., alone or in any combination, examples of which are set out below.

In a first example implementation, the oblique orbital member 204 includes a groove 224a, 224b that couples to a coupler (in this case a spline) 226 of the drive shaft 106. As shown in FIG. 2, the oblique orbital member 204 includes two grooves 224a, and 224b; however, any number of grooves 224 may be included (e.g., one, four, six, etc.). When a source such as a drive motor (not shown) axially rotates the drive shaft 206, the spline 226 of the drive shaft 206 rotates. Moreover, because of the relationship between the grooves 224a, 224b of the oblique orbital member 204 in cooperation with the spline 226, rotation of the spline 226 causes corresponding rotation of the oblique orbital member 204.

As mentioned above, the oblique orbital member 204 can be mounted concentrically with the drive shaft 206; however, the oblique orbital member 204 is not mounted coaxially with the drive shaft 206. Thus, the oblique orbital member 204 is not perpendicular to the drive shaft 206.

In another optional example configuration, guides 222a, 222b are coupled to the frame 202 keep the oblique orbital member 204 from changing its non-perpendicular angle relative to the drive shaft 206, thus maintaining the oblique angle oblique (relative to the drive shaft 206) of the orbital member 204 while the oblique orbital member 204 rotates. For example, the illustrated guides 222a, 222b include a channel 228a, 228b that fits the peripheral edge 210 of the oblique orbital member 204 so as to create a contactless guide bearing when the drive shaft 206 rotates axially, an example of which is discussed in greater detail below.

As the oblique orbital member 204 rotates, any specific point on the peripheral edge 210 of the oblique orbital member 204 travels in a helical path relative to the drive shaft 206. In some embodiments, dense masses (e.g., made from the same material as the oblique orbital member 204 or different material than the oblique orbital member 204) are embedded or affixed near the peripheral edge 210 of the oblique orbital member 204. As noted above, in several embodiments, the oblique orbital member 204 is a flywheel, while in other embodiments, the oblique orbital member 204 is a disk. In various alternate embodiments, the oblique orbital member 204 is a spoked wheel.

In yet another optional embodiment of FIG. 2, one or more flywheels 208 are added to the drive shaft 206. For instance, as illustrated, two flywheels 208a, 208b are coupled to the drive shaft 206 on either side of the spline 226. These flywheels 208a-b are used to balance the torque multiplication device 200 as well as store energy from the drive motor. Regardless, as the oblique orbital member 204 rotates, energy supplied by a drive source coupled to the drive shaft 206 is stored in the oblique orbital member 204, which is used to enhance the energy stored in the flywheels 208a-b. As such, in practical applications, the torque multiplication device 200 can comprise the first configuration alone or in any combination with one or more of the groove(s) 224 and spline 226; one or more guides 222, one or more flywheels 208, etc.

Turning now to FIG. 3, another embodiment of a torque multiplication device 300 with a spline 326 is shown. As with the embodiment of FIGS. 1-2, the embodiment of FIG. 3 includes a frame 302, an oblique orbital member 304, and a drive shaft 306. The drive shaft includes a spline (not shown in FIG. 3) similar to the spline 226 of FIG. 2 (although other couplers as described herein may be used instead (e.g., coupling ring, magnetic coupler, etc.)). Further, the embodiment of FIG. 3 includes guides 322a-b with a channel 328a-b to ensure the oblique orbital member 304 remains at its oblique angle relative to the drive shaft 306.

However, there are several differences between the embodiment 300 of FIG. 3 and the embodiment of FIG. 2. For example, the frame 302 of the embodiment of FIG. 3 does not completely encompass the torque multiplication device 300. Further, the flywheels 208a-b of FIG. 2 are not included in the embodiment of FIG. 3. Other embodiments of the torque multiplication device may be created by using elements of one embodiment with another embodiment. For example, a third embodiment of the torque multiplication device may include the flywheels 208a-b of FIG. 2 and the frame 302 of FIG. 3. As another example, a fourth embodiment may use the frame 202 of FIG. 2, yet lack flywheels as provided in FIG. 3. Further, while two guides are shown in both embodiments, there may be more or less than two guides in other embodiments of the torque multiplication device 200 or the torque multiplication device 300. As another example, different embodiments of the torque multiplication device 300 may include an oblique orbital member 304 that is a flywheel, a disk, or a spoked wheel in a manner analogous to that described with reference to FIG. 2. Yet further, the oblique orbital member 304 can comprise any of the materials described with reference to the oblique orbital member 204 of FIG. 2.

Turning to FIGS. 4-5, as noted in greater detail herein, an example manner of coupling the oblique orbital member to the drive shaft is via a spline. An example configuration of a spline 426 coupled to a drive shaft 406 is accordingly illustrated. The spline 426 and drive shaft 406 can be used as the spline and drive shaft in any one or more of the preceding embodiments of the torque multiplication device (e.g., 100, 200, 300 of FIGS. 1-3, respectively). The spline 426 comprises a base 430 and a key 432, where the key 432 fits a corresponding groove of the oblique orbital member (104, 204 of FIGS. 1-2, respectively).

Further, the key 432 may be free to rotate within the base 430 (as shown in comparing FIG. 4 to FIG. 5). As the oblique orbital member rotates obliquely around the spline 426, the groove of the oblique orbital member changes its angle relative to the key 432 of the spline 426. Thus, the free rotation of the key 432 within the base 430 allows for the key 432 to maintain contact with the groove throughout the oblique orbital member's rotation about the drive shaft 406 without slipping out of the groove or causing unnecessary forces on the spline 426. In some embodiments, the key 432 is free to rotate only within a limited range within the base 430.

Further, the spline 426 may include more than one key 432. For example, as shown in FIG. 2, the spline 226 has two keys. Preferably, there is one key 432 per groove of the oblique orbital member.

Turning to FIG. 6, a cutaway of a spline 626 is shown. The spline 626 can be utilized as the spline in any one or more of the preceding embodiments of the torque multiplication device.

Analogous to that discussed above, the spline 626 includes a base 630 and a key 632 that is free to rotate within the base 630. As represented in FIG. 6, the base 630 is a sphere, but any balanced shape may be used for the base 630.

In this example implementation, the key 632 includes a conical frustum 634 that extends into a cavity 636 of the base 630. In some embodiments, the conical frustum 634 is a spherical-conical frustum (i.e., a conical frustum with a partial sphere for a large base 638 instead of a flat base). Further, in various embodiments, the conical frustum 634 may have a flat smaller base 640. In other example implementations, the smaller base 640 need not be flat; instead the smaller base 640 may include a bore to help stabilize the conical frustum 634 within the cavity 636 of the base 630 (which would include a protrusion matching the bore).

Further, the key 632 includes a fin 642. The fin 642 fits into the groove of the oblique orbital member (an example of which is illustrated in FIG. 2). The fin 642 should be wide enough to maintain contact with the groove as the oblique orbital member rotates around the spline 626. Here, contact does not require direct physical contact. Rather, the fin 642 can fit into the groove of a corresponding oblique orbital member and form contact via an oil bearing, magnetic bearing or other frictionless/low friction arrangement so that there is no physical contact directly between the fin 642 and the groove of the oblique orbital member itself.

Example Embodiment 2: Coupling Ring

Turning now to FIG. 7, an embodiment of a coupler (coupling ring) 726 for coupling the oblique orbital member to the drive shaft includes two ring-shaft bores 744a, 744b and two ring-orbital bores 746a, 746b. The ring-orbital bores 746a, 746b include a collar 748a, 748b that protrudes slightly from the coupling ring.

As shown in FIG. 7, the coupling ring 726 is rectangular with a rounded rectangular hole. However, the coupling ring 726 and hole may be any desired shape, even different shapes from each other.

FIG. 8 illustrates an embodiment of the oblique orbital member 804 for use in torque multipliers. As shown, the oblique orbital member 804 includes an aperture 850. While the aperture 850 is a rounded rectangle in FIG. 8, the aperture 850 may be any desired shape as long as the coupling ring (726, FIG. 7) may fit inside the aperture 850.

Further, the oblique orbital member 804 includes two orbital-ring bores 852a, 852b. Thus, the coupling ring may be coupled to the oblique orbital member 804 using an orbital-ring pin (not shown) disposed within the ring-orbital bores of the coupling ring and the orbital-ring bores 852a, 852b. The orbital-ring pin is then held in place by two screws that thread with threaded bores 854a-d of the oblique orbital member 804. Alternatively, the pin may be held in place in any other suitable manner. The collars (748a-b, FIG. 7) abut the oblique orbital member 804 when the coupling ring is coupled to the oblique orbital member 804.

FIG. 9 illustrates the coupling ring 926 coupling the oblique orbital member 904 to the drive shaft 906. Basically, the coupling ring 926 may be coupled to the oblique orbital member 904 using an orbital-ring pin (not shown) disposed within the ring-orbital bores (FIG. 7) of the coupling ring 926 and the orbital-ring bores (FIG. 8). Further, the coupling ring 926 may be coupled to the drive shaft 906 by disposing pins 956 within the ring-shaft bores of the coupling ring 926 and shaft-ring bores (FIG. 8) of the drive shaft 906.

Using the drive shaft 906 as a body, the coupling ring 926 can rotate around a pitch axis of the drive shaft 906. This is important to allow the oblique orbital member 904 to be placed at any desired angle. Further, the oblique orbital member 904 may also rotate around a yaw axis of the drive shaft 906. This is important to allow for a slight yaw rotation in the oblique orbital member 904 as the guides (122, FIG. 1) keep the oblique orbital member 926 at a constant angle relative to the frame.

Example Embodiment 3: Magnetic Coupler

FIG. 10 illustrates a third embodiment of the coupler 1026 for the torque multiplier 1000. In the third embodiment, the coupler 1026 includes a spherical core 1058 (which may be magnetic or non-magnetic material) coupled to the drive shaft 1006. The coupler further includes magnet made of several magnetic arcs 1060a-c, 1062a-c deposed in the oblique orbital member 1004. The magnetic arcs 1060a-c, 1062a-c include alternating polarities (e.g., magnetic arcs 1060a-c are polar north facing the coupler 1026, while magnetic arcs 1062a-c are polar south facing the coupler 1026. Thus, a ring created by the magnetic arcs on an inside of the oblique orbital member includes a pattern of alternating northern magnetic arcs and southern magnetic arcs, which create eddy currents to drive oblique orbital member 1004. As shown, there are three arcs of each polarity, but any number of arcs should be used. However, in a preferred embodiment, the number of arcs of a first polarity should be equal to the number of arcs of the opposite polarity.

As the drive shaft 1006 rotates, the coupler 1026 interacts with the magnetic fields created by the magnetic arcs 1060a-c, 1062a-c to create the eddy currents that cause the oblique orbital member 1004 to rotate as well. Thus, there is very little loss as the drive shaft 1006 interacts with the oblique orbital member 1004.

FIG. 11 illustrates another embodiment of the magnetic coupler 1126 including the spherical core 1158. The magnetic coupler 1126 further includes two collars 1164a-b that include recesses 1166 for keys 1168a-b. Further, the drive shaft 1106 includes two recesses 1170a-b. Thus, the keys 1168a-b can be used to couple the core 1158 to the drive shaft 1106 via the recesses 1166, 1170a-b. Moreover, the coupler 1126 is held in place on the drive shaft 1106 by a stop 1172 on one side and a nut 1176 and a lock 1174 on the other side.

Example Lubricant Delivery System: Spline

Turning back to FIG. 6, a lubricant delivery system 674 for embodiments using the splined coupler (FIGS. 2-6) is shown. The lubricant may be oil, air, or any other fluid. The spline 626 and drive shaft 606 include a lubricant delivery system 674 comprising a drive-shaft lubricant channel 676 and two (or more) base lubricant channels 678a-b that feed a reservoir 680 to hold lubricant. As shown, the reservoir 680 appears as two wells 680a-b, but the reservoir 680 may be any number of wells or may be one contiguous well around the conical frustum 634. Lubricant within the reservoir 680 provides lubrication between an interface 682a-c between the key 632 and the base 630, which creates a hydrostatic bearing at the interface between the key 632 and the base 630. The lubricant may be supplied to the drive-shaft lubricant channel 676 via a pump (e.g., fluid pump, air compressor, etc.) and a lubricant channel of the frame (e.g., a hose from the pump to the drive-shaft lubricant channel 676, a channel cut into the frame, etc.).

If the spline had two keys 632a-b, there would be a mirror image of the key 632 on the base 630 (which would include another cavity), including the conical frustum, fin, reservoir, and base lubricant channel(s).

A lubricant delivery system can also be provided to form a bearing between the peripheral edge of the oblique orbital member and one or more optional guides that are provided in the frame. For instance, referring to FIG. 12, a portion of an example lubricant delivery system 1274 is provided for an interface 1284a, 1284b between the oblique orbital member 1204 and the guide 1222. In this regard, the frame 1202, oblique orbital member 1204 and guide 1222 can be implemented as the frame, oblique orbital member and guide as described in any of the preceding embodiments of the torque multiplication device.

A pump supplies lubricant to a lubricant channel 1286 of the guide 1222 through a channel 1290 (e.g., a hose from the pump to the lubricant channel 1286 of the guide 1222) of the frame 1202, which feeds wells 1288a-b of the guide 1222 to supply the lubricant to the interface 1284a-b between the oblique orbital member 1204 and the guide 1222. Thus, the lubricant creates a hydrodynamic (or hydrostatic) bearing at the interface 1284a-b between the oblique orbital member 1204 and the guide 1222. Alternatively, instead of hydrostatic or hydrodynamic bearings, magnetism may be used to reduce or eliminate friction between the interfaces discussed above. In the case of the use of a magnetic bearing, the above lubricant delivery system may be unnecessary, and hence, not provided in a particular implementation.

As shown, there is a relatively large gap 1292 between the peripheral edge 1210 of the oblique orbital member 1204 and the channel 1228. Thus, no hydrostatic or hydrodynamic bearing is required. However, if the gap 1292 is small enough where friction may occur between the peripheral edge 1210 of the oblique orbital member 1204 and the channel 1228, then another well for lubricant may be required. As noted above, in certain embodiments, it may be desirable to provide a bearing for the interface of the spline of the drive shaft and the groove of the oblique orbital member. In this regard, FIG. 13 illustrates a portion of a lubricant delivery system 1374 for an interface between a spline 1326 and a hub 1394 (which includes the groove 1324a, 1324b) of an oblique orbital member 1304. Here, the representative coupler 1326 and oblique orbital member 1304 can implement the coupler and oblique orbital member in any one or more of the preceding embodiments of the torque multiplication device.

As illustrated, the hub 1394 includes a stationary portion 1396, which remains stationary when the oblique orbital member 1304 is rotating, and a rotary portion 1398, which rotates with the oblique orbital member 1304. The stationary portion 1396 couples to a pump via a channel 1390 (e.g., a hose from the pump to a lubricant channel 1301 of the hub 1398) of the frame to fill a reservoir 1303 of the hub 1394 with lubricant.

A lubricant channel 1305a-d of the rotary portion 1398 of the hub 1394 allows lubricant to lubricate an interface 1307 between the coupler 1326 and the hub 1394. For example, the lubricant may fill key reservoirs 1309a-b to create a hydrostatic bearing at an interface between the key 1332a-b and the groove 1324a-b. As another example, the lubricant may fill base reservoirs 131 la-b to create a hydrostatic bearing between the base 1330 and the hub 1394. The hydrostatic, hydrodynamic, air, bonded (etc.) bearings discussed above reduce friction between interfacing parts. Again, as noted above, the illustrated lubricant delivery system can be replaced with or utilized with other friction reducing techniques, e.g., via the use of magnets, etc.

Example Lubricant Delivery System: Coupling Ring

Turning now to FIG. 14, a lubricant delivery system 1474 for the drive shaft 1406 is shown. Basically, a pump supplies a lubricating fluid to an inlet 1439a, 1439b of a fluid channel 1441a, 1441b that leads to shaft-ring bores 1445a, 1445b. When the lubricating fluid reaches the shaft-ring bores 1445a, 1445b, the fluid channel 1441a, 1441b spreads into two sub-channels each 1447a-d, which feed two shaft wells 1449a, 1449b. Fluid pumped into the fluid channels 1441a, 1441b eventually lubricates an interface between the coupling ring and the shaft-ring pins.

Turning to FIG. 15, an illustration of the shaft-ring pins 1556 is shown. The shaft-ring pins 1556 include two fluid sub-channels: an interface fluid sub-channel 1551 and a ring fluid sub-channel 1553. When the shaft-ring pin 1556 is coupled to the drive shaft properly, the two fluid sub-channels 1551, 1553 align with the sub-channels (1447a and or 1447b and 1447d, FIG. 14) of the drive shaft. Thus, when the lubricating fluid is pumped into the fluid channels (1441a, 1441b FIG. 14) of the drive shaft, some fluid eventually reaches the interface fluid sub-channel 1551 and the ring fluid subchannel 1553 of the shaft-ring pin 1556.

The interface fluid sub-channel 1551 directs the fluid to an interface between the shaft-ring pin 1556 and the coupling ring (see FIG. 16). On the other hand, the ring fluid sub-channel 1553 directs the lubricating fluid to a fluid channel (see FIG. 16) of the coupling ring.

FIG. 16 illustrates a fluid system of the coupling ring 1626. Similar to the coupling rings discussed above, the coupling ring 1626 of FIG. 16 includes a ring-shaft bore 1644a, 1644b and a ring-orbital bore 1646a, 1646b. The ring-shaft bore 1644a, 1644b includes a perimeter fluid groove 1655a, 1655b and several lateral fluid grooves 1657. The perimeter groove 1655a, 1655b aligns with the interface fluid sub-channel (1551, FIG. 15) of the shaft-ring pin such that fluid from the shaft spreads throughout the perimeter groove 1655a, 1655b. Further, the perimeter groove 1655a, 1655b spreads the fluid to the lateral grooves 1657. As shown in FIG. 16, the coupling ring has six lateral grooves 1657 per ring-shaft bore 1644 spaced sixty degrees apart. However, any number of lateral grooves 1657 may be used, and the spacing may be any desired spacing (uniform or non-uniform). Further, the lateral grooves 1657 are not required to be parallel; they can be helical, spiral, etc.

The coupling ring 1626 further includes a fluid channel 1659a, 1659b that couples the ring-shaft bore 1644a, 1644b to the ring-orbital bore 1646a, 1646b, respectively. Moreover, the fluid channel 1659a, 1659b of the coupling ring 1626 aligns with the ring sub-channel (1553, FIG. 15) of the shaft-ring pin such that fluid from the shaft flow to the ring-orbital bore 1646a, 1646b. At the ring-orbital bore, the fluid spreads through a perimeter groove 1661a, 1661b and lateral grooves 1663. Further, the collar includes a collar groove 1665a, 1665b (also fed from the fluid channel 1659a, 1659b) that spreads fluid at an interface between the collar and the oblique orbital member.

Thus, through the channels, sub-channels, and grooves discussed above, fluid from the pump creates a hydrostatic bearing, hydrodynamic bearing, air bearing, bonded bearing, or combinations thereof wherever two components (coupling ring, shaft-ring pin, orbital-ring pin, drive shaft, oblique orbital member, collar, etc.) interface.

Hoses, plumbing, piping, or combinations thereof (not shown in FIG. 1 for the sake of understandability) direct fluid from the pump to the guides (and shaft) to form a hydrostatic bearing, hydrodynamic bearing, air bearing, bonded bearing, or combinations thereof between the guides and the oblique orbital member. In practical implementations where a lubricant is utilized, a torque multiplication device may incorporate the lubricant delivery systems of FIGS. 6 and 12-16, a combination thereof, etc.

Example Air Bearing

FIG. 17 illustrates an example air bearing 1713 created from the oblique orbital member guides 1722. Basically, as with the lubricant delivery systems above, the air delivery system 1774 includes a pump (in the case of air being the fluid, the pump is actually an air compressor) delivering air through a hose 1790 to several channels to guide the air to the gap near the interface between the peripheral edge 1710 of the oblique orbital member 1704 and the oblique orbital member guide 1722. A peripheral bearing channel 1715 is inside a peripheral bearing 1717 portion of the guide 1722. Thus, air is pumped at a steady pressure between the peripheral edge 1710 of the oblique orbital member 1704 and the oblique orbital member guide 1722, which reduces friction between the peripheral edge 1710 of the oblique orbital member 1704 and the oblique orbital member guide 1722 and also maintains the position of the oblique orbital member 1704.

Further, the guide 1722 includes side bearings 1719 that include side bearing channels 1721 also use air bearings between an interface between the oblique orbital member 1704 and the oblique orbital member guide 1722. Air from the compressor (i.e., pump) goes through the side bearing channels 1721 to provide a pressure between the oblique orbital member 1704 and the oblique orbital member guide 1722. Thus, there is little frictional loss between the oblique orbital member 1704 and the oblique orbital member guide 1722 while the oblique orbital member 1704 is rotating at its oblique angle. Thus, the oblique orbital member 1704 does not contact the tilt plate (112, FIG. 1) due to gravity or any other force. As shown in FIG. 17, there is only one side bearing 1719 on the guide 1722, however, there may be more than one (e.g., side bearing 1719 on each side of the guide 1722). Shaft Connection

FIG. 18 illustrates a simplified implementation of coupling the drive shaft 1806 to other components of the system 1800. Specifically, the drive shaft 1806 couples to the frame 1802 on one side with any standard coupler 1821 that allows for rotational movement. However, the drive shaft 1806 couples to the frame 1802 on the other side through the use of a pillow block bearing (e.g., a D-lock) 1843, which prevents linear slippage of the drive shaft 1806 during operation of the system 1800.

As mentioned above, the drive shaft 1806 couples to the spherical core 1858 via keys 1868. In FIG. 18, the coupler 1826 between the drive shaft 1806 and the oblique orbital member 1804 is the spherical core/magnetic coupler. However, any of the couplers (e.g., spline, ring coupler, etc. (i.e., reference number x26 throughout the figures)) described herein may be used.

Example System

FIG. 19 illustrates a system 1923 in which any of the embodiments of the torque multiplication device 1900 discussed herein may be used. The torque multiplication device 1900 may be coupled to a drive motor 1925 such that the drive motor 1925 starts rotation of the oblique orbital member via the drive shaft and the coupler of the torque multiplication device 1900. A pump (e.g., oil pump, air compressor, etc.) 1927 of a lubricant delivery system 1974 delivers lubricant (e.g., oil, air, etc.) to interfaces of the torque multiplication device 1900 as discussed above via a hose 1990. For example, the pump 1927 may supply the lubricant at a pressure of fifty pounds per square inch (psi) to ensure that reservoirs are filled and lubricant is transferred from the reservoirs to the lubricant channels or interfaces as discussed above.

In systems that use a recoverable lubricant (e.g., oil), a splash cover 1931 and lubricant reclamation system 1933 recycle the lubricant through a filter (not shown) for future use within the system 1923. The torque multiplication device 1900 drives a generator 1935 to generate electricity.

Regardless of which lubricant is used (if any), an electro-magnetic-pulse shield (1937) may surround the system 1923.

Further, as shown in the embodiments herein, there is one oblique orbital member and two flywheels associated with the torque multiplication devices. However, there may be any number of flywheels and/or any number of oblique orbital members (along with corresponding couplers). Thus, a torque multiplication device may have two or more oblique orbital members, each with its own coupler (and the couplers do not need to be the same type for all oblique orbital members).

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as orifice, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and/or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. Aspects of the invention were chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.