FIELD OF INVENTION

The present invention relates to an energy converter. More particularly, the present invention is related to an energy convenor, capable of producing one or more forms of energy or designed power. The energy convertor has a counter rotating assembly to rotate first and second rotor in counter directions to produce designed electrical energy in lower RPM.

BACKGROUND OF INVENTION

Various systems for conversion of electrical energy into mechanical rotation and mechanical rotation into electrical energy are known in prior art. The electrical generator and motor commonly used to convert mechanical energy obtained from an external source into electrical energy as the output and to convert electrical energy obtained from an external source into mechanical energy as the output are well known.

In traditional systems, armature is a power-producing component of a generator, alternator or dynamo or motor. The armature can be either a rotor or a stator. The stator is a stationary part of generator/motor, generally an outside housing of generator/motor. Rotor is moving part, generally internal to the motor, the rotor in general attached to a shaft or axle that rotates during operation. In both the generator and motor, the armature carries current and a magnetic field is established, which is called the armature flux. The effect of armature flux on the main field is called the armature reaction. The armature reaction is meant for the influence of the stator ampere turns upon the value and distribution of the magnetic flux in the air gaps between the poles and stator core. This movement creates a voltage difference between the two ends of the wire or electrical conductor, which in turn causes the electric charges to flow, thus generating electric current. For driving electric loads, the high power/energy is desirable at the output of generator. Hence, it is required to increase the size of the generator and its rotor. With the increment in the size of rotor, the moment of inertia of the rotor also increases. Thus, there is tendency of idling the speed of the machine. Because of the size limitation conventional systems do not meet the sufficient power requirement. To solve this problem and in order to generate additional electrical energy with moderate size, the systems having torque tool with a conventional generators are disclosed in prior art. However, these systems also require large space and involve high cost.

Moreover, most of the electrical machines known are adapted to operate in an electric-only mode. There are few systems that are operable in both modes; as a generator and a motor. However, in such systems, a switching mean is required between motor and generator circuits. This arrangement needs additional components; hence a high cost is involved to develop such systems.

Furthermore, conventionally used electric motors are severally affected from the problem of cogging or jerk due to non-uniform torque. Cogging torque occurs in permanent magnet machines in the air gap between rotor and stator. As the rotor rotates, the reluctance change in the air gap due to the slots creates the cogging torque. This problem is usually more apparent at low speeds.

Further, several systems of prior art do not consist of appropriate ventilating means, in result; they are affected by the problem of over-heating. Consequently, it is desirable to develop a single system that can recognize one or more of the above mentioned limitations and capable to be used as both a motor and a generator with high efficiency and less space requirement. SUMMARY OF INVENTION

Embodiments of present invention relate to an efficient energy convertor, capable of producing or converting one or more forms of energy with designed electrical energy with the lower RPM. In an embodiment, the energy convertor consists of a counter rotating assembly, stator and rotors that further could be combined with a converter including but not limited to a generator, motor, and prime mover.

The energy convertor comprises a stator having a plurality of armature windings fixed to a stationary housing. The stationary housing is an outer stationary member that comprises an inner facet and an outer facet. The energy convertor further comprises: a plurality of rotors co-axially mounted on a main shaft and is configured to produce electro-motive force. A first rotor and a second rotor are inner rotational members wherein the first rotor is configured to receive the rotational drive from an external source; a third rotor is an outer rotational member that is mounted on an outer surface of the second rotor and placed underneath the stator. The third rotor is further configured to generate electric current by interacting with the stator armature.

The energy convertor further comprises a rotation transmission assembly for transmitting rotational torque from the first rotor to a second rotor in such that the first rotor and the second rotor counter rotate with respect to each other and one or more current carrying and power collecting assemblies that are selectable to operate the energy convertor in a first mode and a second mode.

It is an object of invention to provide an energy convertor that is operable in a first and second mode. The first mode may be a mode in which the energy convertor is adapted to produce electrical energy while in second mode may be a mode in which the energy convertor is adapted to produce mechanical energy.

It is another object of invention to provide an energy convertor capable to produce one or more forms of energy by being coupled with a motor or generator or internal combustion engine or prime mover or any combination thereof.

It is a further object of invention to provide a mechanism for increasing the efficiency of an energy convertor. The mechanism comprises the steps, in combination: incorporating a counter rotational assembly into the energy convertor, rotating a first rotor being an outer rotational member in first direction about an axis, rotating a second rotor being an inner rotational member in second direction, incorporating electrical conducting windings into at least one of said rotational members, creating a magnetic field by one or more means incorporated into at least one of said rotational members.

The invention further comprises a planetary gear assembly consisting of a plurality of gears for rotating at least a first rotor and second rotor of the counter rotating assembly.

It is another object of invention to provide an energy convertor in which one or more consisting are having diverse materials that enable the first rotor and the second rotor to counter-rotate to generate designed powered. The diverse materials may include the material having high tensile strength and yield strength to efficiently hold the stress and displacement. Increased efficiency of converter are achieved by identifying alternative material and having two rotors that rotate at opposite direction driven by means of gear mechanism or belt drive or direct driven. It is yet another object of invention to provide an energy convertor that comprises a counter rotation assembly and generator or motor coupled to reside in a single system to generate designed electrical energy in lower RPM.

This invention is pointed out with particularity to the appended claims. Additional features and advantages of the system will become apparent to those skilled in the art by referring to the following detailed description taken in conjunction with the accompanying drawings.

BRIEF OF THE DRAWINGS

The features of the present invention, which are believed to be novel, are set forth with particularity in the appended claims. The invention may be best understood by reference to the following description, taken in conjunction with the accompanying figures. These figures and the associated description are provided to illustrate some embodiments of the present invention, and not to limit the scope of the invention.

Figure 1 is a schematic view of a conventional generator with prime mover in accordance with an embodiment of the present invention;

Figure 2 is sectional view of conventional converter's stator and rotor arrangement in accordance with an embodiment of the present invention;

Figure 3 is schematic view of counter rotating assembly with gear box arrangement in accordance with an embodiment of the present invention;

Figure 4 is sectional view of counter rotating assembly with gear box arrangement in accordance with an embodiment of the present invention;

Figure 5a is schematic arrangement of planetary gear set in accordance with an embodiment of the present invention;

Figure 5b is schematic view of planetary gear arrangement in accordance with an embodiment of the present invention;

Figure 6a is schematic view of bevel gear mechanism and belt, pulley arrangement to produce counter rotation in accordance with an embodiment of the present invention;

Figure 6b is schematic view of bevel gear mechanism to produce counter rotation in accordance with an embodiment of the present invention;

Figure 6c is sectional view of bevel gear mechanism to produce counter rotation in accordance with an embodiment of the present invention; Figure 7a is schematic view of helical and spur gear mechanism with belt pulley arrangement to produce counters rotating assembly in accordance with an embodiment of the present invention; Figure 7b is sectional view for helical and spurs gear mechanism with belt pulley arrangement to produce counter rotation in accordance with an embodiment of the present invention;

Figure 8 is schematic view for internal spur and helical gear arrangement to create counter rotation in accordance with an embodiment of the present invention;

Figure 9 is schematic view for counter rotating assembly combined with conventional generator

(stator and rotor) in accordance with an embodiment of the present invention;

Figure 10 is sectional view for counter rotating assembly combined with conventional generator (stator and rotor) in accordance with an embodiment of the present invention;

Figure 11a is schematic drawing for counter rotating assembly combined with conventional generator (stator and rotor) in accordance with another embodiment of the present invention; Figure lib is schematic drawing to show counter rotating assembly and conventional generator/motor (stator and rotor) in accordance with another embodiment of the present invention;

Figure 12 is schematic view for counter rotating assembly combined with electric motor / prime mover in accordance with an embodiment of the present invention;

Figure 13 is sectional view for counter rotating generator combined with electric motor / prime mover in accordance with an embodiment of the present invention; and

Figure 14 is isometric view for rotor with permanent magnets arrangement in accordance with an embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The features of the invention illustrated above and below in the specification, are described with reference to the drawings summarized above. The reference numbers shown in the drawings may be used at one or more places to indicate the functional relation between the referenced elements. It should be noted that the drawings, associated descriptions, and specific implementation are provided to illustrate embodiments of the invention and not to limit the scope of the disclosure.

It should be further be noted that the terms "a" or "an" or "first" as used herein, may defined as one or more than one. The term "another" or "second", as used herein, is defined as at least a second or more. The terms "including" and/or "having" as used herein, are defined as comprising (i.e. open transition].

An embodiment of present invention provides an energy convertor that consists of a counter rotating assembly and at least one including but not limited to a generator, motor and prime mover. The energy convertor further comprises a stator fixed to a stationary housing. The stationary housing is an outer stationary member comprising an inner facet and an outer facet. The stator consists of a plurality of stator armature winding that configured to generate an electrical current when the energy convertor is functioning as a generator. The energy convertor further comprises a plurality of rotors that are co-axially mounted on a main shaft. The rotors are inside the stationary housing and configured to produce electro-motive force. A first rotor and a second rotor are inner rotational members and a third rotor is an outer rotational member. The first rotor is configured to receive the rotational drive from an external actuator and the third rotor is mounted on an outer surface of the second rotor and placed underneath the stator inside the stationary housing. The third rotor is further configured to generate electric current by interacting with the stator armature. The energy converter comprises a rotation transmission assembly for transmitting rotational torque from the first rotor to a second rotor. The torque is transmitted in such a way that the first rotor and the second rotor counter rotate with respect to each other. In an embodiment of present invention, the rotation transmission assembly is a planetary gear assembly that transmits rotational torque from the first rotor to a second rotor. In another embodiment of present invention the rotation transmission assembly may be belt pulley assembly or bevel gear assembly or any other assembly now known or later developed.

As depicted in figures 1 and 2, in the conventional generator (100), the rotor shaft (102) is made of ferrous based material, for example steel alloys, cast iron etc. In an embodiment of present invention, the materials are selected due to high yield and tensile strength to withstand the stress resulting from dynamic and cogging torque generated. Lighter material with high tensile and yield strength will reduce the input torque required to rotate the rotor.

A comparison table for various materials is shown in Annexure 1. As shown in the comparison table, aluminium alloy and titanium alloy are having greater tensile strength values with 65% and 45% lighter than iron-based alloy respectively. The required torque to rotate aluminium alloy rotor is only 1/3 of the torque required to move iron-based rotor. For titanium alloy required torque is being reduced by half. Reduced torque for rotor will lead to reduced input power and reduced fuel consumption comparison to ferrous based rotor. The torque value will vary according to the generator size and running RPM. For aluminium based rotor (102) the generator can be directly coupled to the prime mover with the gear box (104) or belt drive. The selection can be dependable on the generator size (106) and availability of space. In an embodiment of present invention, an aluminium type rotor is used that is suitable for a generator with internal combustion engine. Referring to figures 3 and 4, in an embodiment of present invention, the energy convertor (300) has two rotatory components. The two rotatory components rotate in opposite direction relatively. The first rotor (301) and second rotor (302) consist of a number of magnets or electromagnets and a cooling fan (306). The electromagnet or permanent magnet function is to create magnetic field between the first rotor (301) and second rotor (302). The armature core material can be iron base (electrical steel or silicone steel), nickel alloy, cobalt alloy or amorphous alloy. The main shaft is affixed to the sun gear and the prime mover.

In the embodiment of present invention, the first rotor (301) is fitted with two internal bearings (303) inside second rotor hollow housing, which concentrically centre for each other. The first rotor (301) concentrically aligned with central gear, which will create counter rotating mechanism. The second rotor consists of a hollow shaft, slip ring (304), carbon brush, armature core and conductors. The slip ring can be mounted in both rotors which is having winding coils. The second rotor is attached to two bearing at opposite end of the shaft and further attached to the generator body. The second shaft is attached to the gear carrier. Both the rotors are attached to the generator body to ensure their co-axial alignment and are arranged to keep the air gap/clearances between the inward stator and outward electromagnet/ permanent magnet between 0.5 to 1.5mm. The cogging torque can be minimized either by making air gap flux zero or the rate of change of the air gap reluctance dR/d6 zero. Air gap flux cannot be made zero, therefore in an embodiment of present invention, the materials are selected due to high yield and tensile strength to withstand the stress resulting from dynamic and cogging torque generated.

Referring to figure 5b, in an embodiment (500) of invention, epi-cyclic gear train has a central sun gear (502) which meshes with and is surrounded by planet gears (504). The outer most gear, the ring gear (501) meshes with and is surrounded by planet gears. The ring gears are held to a cage or carrier that fixes the planets in their orbit relative to each other. In the embodiment, gear box is connected to a prime mover. The connection can be a direct coupling or by a belt drive (506) or an external gearing mechanism or any other way of connection now known or later developed. The gear transmission system converts the input energy to a desired torque to rotate the rotatory component. The gear mechanism can be planetary gear or epicyclical gear or any other mechanism now known or later developed. The gear consist sun gear, ring gear, plurality of planetary gear and gear carrier. The sun gear is attached to the main shaft. The gear is lubricated using lubrication oil or grease. The specification of the lubricant depends on the gear material, sizing, load factor and amount of heat generated.

In an exemplary embodiment, the planetary gear box consists of a ring gear and sun gear. The sun gear, ring gear and planetary gear further comprises teeth Nl, N2 and N3 respectively. In the embodiment, the ring gear is having 68 teeth (N2) with 210mm of pitch circle diameter (PCD) and pressure angle of 30 degree. Sun gear consists of 42 teeth (Nl) with 96mm of PCD and pressure angle of 20 degree. Three planetary gears consist of 13 teeth (N3) with 54mm of Pitch circle diameter and pressure angle of 20 degree. Hence the gear box ratio for the embodiment is obtained from the below formula:

Gear Box ratio (i)=(N2 / Nl) = 68 / 42 =1:0.62

From this ratio the speed is reduced by 0.62 and subsequently the torque is increased. Torque is carried out by gear carrier and it is further transferred to the second rotor body. In another embodiment of the present invention, the planetary gear box may consist of variable components with variable number of teeth. The shape and number of the teeth can be altered as necessary. The invention should not be restricted to the particular numbers and shape. Referring to figures 5a and 5b, when the main shaft is turned by an external force or energy, it rotates the first rotor and the sun gear in the gearbox at the same time. The sun gear then turns the planetary gears. The planetary gears further rotate ring gear and gear carrier thus rotates the second rotor. The gears are arranged in such a manner so that the second rotor rotates in the direction opposite to the direction of the rotation of the first rotor. The rotation speed and desired torque will be defined by the gear ratios.

When the rotors rotate, the stator conductors are cut by the magnetic flux, hence an induced Electro Motive Force (EMF) produced due to changes in the magnetic poles. Hence, current flows in the first direction and then in second direction. The current is collected using carbon brush from a slip ring or commutator (304).The amount of the electricity generated depends on various factors such as the rotation speed, number of pole, magnetic strength and sizing of the stator (number of coil turns and conductor material properties). Further, the size of the system depends on the amount of energy need to be generated.

In an embodiment of present invention, a cooling and ventilation system is provided to ensure the operation of the energy convertor (500) at a specified temperature. Air cooling using a fan may also be provided to allow the hot air inside the generator to be sucked and pass through the ventilation cover holes at the end of the generator. In other embodiments, cooling agents including but not limited to air, water and hydrogen may also be utilized.

In an embodiment of present invention, the generator is driven by an internal combustion engine. Additionally, battery banks can used to store electric power instead of direct supply. Referring to figures 6a, 6b and 6c, in an embodiment of present invention, input source is coupled with bevel gear box system (602). Main bevel gear generates torque and passes the torque through both meshed bevel gears. There are two output shafts attached to bevel gear box; both are further coupled to the rotors (604) through belt pulley drive (608) or directly. The rotational torque further rotates the rotors and creates the movement in counter clock wise direction. In the embodiment of the present invention, one or more cooling devices such fan, cooler, condenser or others, can be used to draw the internal heat of the system.

In an embodiment of invention, an electrical current is generated because of the relative moment between the two rotors. Typically one rotor provides magnetic field which may be established by either a permanent magnet or an electromagnet. The other rotor provides a conductor in which the electric current is generated upon movement of the conductor through magnetic field.

Referring to figures 7a, 7b and 8, in an embodiment of present invention, a generator consists of a first rotor (702) and second rotor (704), the rotors counter rotates at relative angular speed refer to but not restricted by means of a gear and belt drive mechanism. Prime mover is directly coupled to the main shaft (708) at the gear box end. The main helical or spur gears are attached to the main shaft (708), supported by two or more bearings attached to the gear body and are aligned to the generator body. The main shaft (708) is directly coupled to the prime mover. The second helical gear is fitted to a shaft supported by two bearings attached to the gear body. The second shaft (706) is aligned concentrically parallel to the main shaft (708). The shaft is connected to the generator rotor by means of pulley and belt drive (710). A support gear works as load balancer between the main gear and second gear to ensure proper mating between the gears. In an embodiment of present invention, the generator unit consists of first rotor (702) and second rotor (704). The first rotor (702) component consists of the main shaft (708), stator (core and conductors) and cooling fan. The first rotor (702) is fitted with two internal bearings attached to the second rotor (704) hollow shaft housing which concentrically aligning to the second rotor (704) of hollow shaft, magnets (electromagnet or permanent magnet) and a pulley and belt (710). The second rotor (704) is mounted with two or more bearings and affixed to the generator body. The rotor must be aligned accordingly to first rotor (702) and the second helical gear unit.

According to figure 8, an embodiment of invention provides a generator (800) with a cylindrical body/ housing (802) and rotor (804) that counter rotates at relative angular speed. The cylindrical body produces the magnetic field by means of the permanent magnets or electromagnets (806) that are mounted at the inner housing. The stator and cooling fan are attached to the main shaft (808) of the rotor (804). The rotor (804) and cylinder body (802) rotates oppositely at relative speed by means of the pinion gears. Main shaft (808) is further connected to a prime mover (810).The rotor rotates when input energy are supplied via prime mover (810). A main pinion gear (812) rotates the two secondary pinion gears (814). Secondary pinion gears (814) are relatively small in size. The inner cylinder housing (802) is fitted with inner pinion gear that is coupled to the smaller pinion gears causing the cylindrical body (802) to rotate when input is supplied.

In the embodiment, two bearings are affixed to the main shaft of the rotor and mounted to the generator body. Similarly, two journal bearings will be affixed at the outer cylindrical body and mounted to the generator body horizontally. Both cylindrical housing (802) and rotor (804) are aligned parallel to achieve the desired air gap between the magnet and stator. In accordance to figures 9, 10, 11a and lib, an embodiment of present invention provides a system that can function as a conventional generator and a counter rotating assembly concurrently. The first rotor (1101) and the second rotor (1102) act as a counter rotating assembly and the third rotor (1103) and outer housing stator (1104) acts as conventional generator or motor. In one or more embodiments of the present invention, the counter rotating assembly can be a generator. This counter rotating assembly and generator/motor, in combination, consists of three major members i.e. an outer stationary member called the stator and three inner rotating members called first rotor, second rotor and the third rotor also known as the armature and permanent magnets or electro magnet, which is mounted within each other coaxially on the same rotating axis.

In the embodiment of the present invention, the third rotor which is outer layer of hollow housing is mounted inside the stator and is made of plurality of permanent magnets arranged in such a way that there are pluralities of alternating poles is available on both the outer and inner surface (second rotor). It is the plurality of alternating poles on the outer surface that is used to interact with the magnetic field from the outer housing stator windings.

In the embodiment of present invention, the inner alternating poles (second rotor) are used to interact with the alternating magnetic field from the coil windings on first rotor which is mounted on main shaft. This construction apparently consist of three members i.e. an outer stationary member and three inner rotating members which is known as first rotor, second rotor and third rotor respectively. The outer stationary member is enabled to function as an excitation field winding and also known as a stator when it is in an electrical motor arrangement. The outer stationary member is enabled as a coil winding to generate EMF or voltage, when it is in a generator arrangement. The winding on this stator is wound in such a way that the pluralities of alternating poles are adjacent to each other. The core of the outer housing fixed stator is made of laminated iron thereby providing greater magnetic flux density, thus creating more torque and heat dissipation. The second member is the outer layer rotor, that is voluntarily called the third rotor, is mounted on the outside housing of the hollow shaft housing. Both the stator and the third rotor are separated by an air gap in-between. This third rotor and second rotor can consist of excitation coil windings or permanent magnets with a plurality of alternating poles on the outer surface as well as the inner surface.

In an embodiment of present invention, the stationary stator is made of laminated iron sheets or other materials having a high magnetic permeability as well as a high degree of thermal conductivity. There are slots in the stator running lengthwise that will house the insulated coil windings. The number of slots in the stator will correspond to the number of poles available on the outer surface of third rotor. The number of ampere-turns per coil is limited by the size and depth of the slots. Referencing figures 9, 10 and 11, one or more single input mechanical energy driving source is used in an embodiment of invention. It may be prime mover, internal combustion engine, and wind force, water force from a dam, a gas jet or any source of rotational force whether by using fuel. In the embodiment of invention, the counter rotation assembly and conventional generator may be resided inside single system.

In an embodiment of present invention the mechanical energy is given to the energy convertor (1300) as an input. The energy convertor (1300) is capable to generate an output power that may be the combined energy generated by counter rotating assembly that is the coupling of first and second rotor and by generator or motor that is the coupling stator and third rotor. Hence the additional power is generated at the output that may drive the additional loads. In the embodiment the input source coupled with main shaft. Main shaft connected with sun gear which is in middle of the gear box. Rotational energy from sun gear, passed through planetary gear arrangement. This system is similar as counter rotation assembly which is described earlier in other embodiments. Additionally, third rotor and stator with housing is employed to work as a generator or motor or as both generator and motor.

Referring to figures 12 and 13, the figures depict electrical machine that converts mechanical energy into electrical energy and or electrical energy into mechanical energy as in electric generator and motor respectively. In general, electrical machines consist of an outer stationary member and an inner rotating member. The stationary and rotating member consist of iron cores; and an air-gap separates the stationary and rotating members. A magnetic flux is produced in the magnetic circuit by current following through the windings situated on the two said members.

In various embodiments of the present invention, the energy convertor (1300) is having one of more components and assemblies as electric motor/prime mover and counter rotating generator arrangement as described in the specification, a hollow cylindrical counter rotating generator second rotor (1301) and first rotor (1302) is mounted on a main shaft connected to an internal combustion engine and an electric motor/prime mover third rotor is also connected to a main shaft.

In an embodiment of present invention, one or more motor/prime mover and counter rotation generator are combined in one housing with a fixed stator (1303) for motor which is coaxially aligned with counter rotation assembly. Both the first rotor and second rotor of counter rotation generator and the third rotor (1304) of the electric motor/prime mover coaxially mounted on main shaft. In accordance with figures 12 and 13, the input shaft of the electric motor/prime mover and generator, which is connected to a drive source such as an internal combustion engine, wind turbine, gas turbine, steam turbine or which it can give rotational moment is supported from the housing by two internal bearings at both ends in the housing. The first rotor of counter rotation assembly is supported by two bearings inside the housing.

In an embodiment of present invention, inside the system, stator of electric motor/generator/prime mover can be electromagnet or permanent magnet which is the fixed portion. The third rotor of electrical motor/generator/prime mover usually has conductors laid into it which carry currents that interact with the magnetic field of the stator to generate the forces that turn the shaft. Mechanical energy from electric motor/prime mover is transmitted through the shaft to the gear driving system, it increases torque force for counter rotation assembly (generator) which is further converted into the electrical energy. Counter rotation assembly (generator) and electric motor/prime mover coaxially connected each other through main shaft. The stator generates the magnetic field from the given electrical energy and the conductors of the third rotor create force to rotate shaft. Mechanical energy has been created by electrical motor; energy is flown to counter rotation assembly which is coaxially connected with each other. In this system motor may act as prime mover itself, to generate mechanical energy. In the embodiment, counter rotation assembly generates electrical energy from mechanical energy which is produced by electric motor/prime mover. In this system gear box/belt drive creates torque for the counter rotation assembly. First rotor of hollow housing can be electromagnet or permanent magnet that is connected to gear carrier, it is further connected with outer ring gear. Sun gear is connected with the second rotor which is fitted with main shaft can be an electromagnet or permanent magnet. Planet gears are connected with generator housing and are meshed with sun gear and ring gear. Various formulas applicable in one or more embodiments of invention are given in annexure 2. In accordance with figure 14, the arrangement of permanent magnets (1402) in first rotor is shown. In an embodiment as depicted in figure, permanent magnets are not aligned parallel to each other. Each permanent magnet of the first rotor is inclined to an angle of 4 degree to 5 degree respectively. In some embodiments, permanent magnets strength is minimum 4000 Gauss, which would produce designed voltage (V) and electric current (I).

It should be noted that the various embodiments of present invention may be combined and also the other modification may be made over the invention. It should further be noted that the description of various embodiments stated above should not be construed to limit the scope of the invention but the provided illustrations are some of the presently preferred embodiments of this invention. Therefore, it will be appreciated that the scope of the present invention fully encompasses other embodiments which may become obvious to those skilled in the art, and that the scope of the present invention is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean "one and only one" unless explicitly so stated, but rather "one or more." All structural and functional equivalents to the elements of the above-described preferred embodiments that are known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be included by the present claims. Moreover, it is not necessary for an embodiment to address each and every problem sought to be solved by the present invention, for it to be encompassed by the present claims.

ANNEXURE 1

A comparison table for various materials:

Ferrous

Material Alloy Steel Al Alloy Ti Alloy Zinc Alloy Mg Alloy

Alloy

Armature

Shaft Volume, 0.002857 0.002857 0.002857 0.002857 0.002857 0.002857 V(m3)

Material

Density, p 7900 7900 2800 4400 6600 1800 (kg/m3)

Mass, m (kg) 22.57 22.57 8.00 12.57 18.86 5.14

Tensile

Strength 420.51 420.51 495 1050 358 275 (Mpa)

Yield Strength

351.57 351.57 435 827.37 358 145 (Mpa)

Calculated

250.62 250.62 88.83 139.58 209.38 57.10 Torque (Nm)

ANNEXURE 2

Formulas:

1. Power in KW = 2 * ττ*Ν* Τ / 60 *1000

where, N = Speed in RPM (revolution per Minute)

T = Torque in N.m

π = Constant (22/7)

2. P = V*I in watts

where, V = Voltage (Electro Motive Force (E.M.F))

I = Ampere

3. V = I * R

where, R= Resistant in Ohms

4. Kinetic Torque T = F*r in N.m

where, F = Force in N

r = radius in m

5. Force F = m*a in N

where, m = mass

a = acceleration in m/s ²

6. Angular Acceleration a = X / I

where, X = Torque in Nm

I = Moment of Inertia

7. Angular Velocity ω = 2 * π *N / 60 in rad/sec

8. Number of turns of copper in stator

(N)= -1 * (-v / (Tesla * Magnet size / time period for one cycle))

where, V = voltage

9. Amperes for Direct Current (DC) = Horse power * 746 / ( Volts* Efficiency) where, 1 Horse Power (HP) = 746 watts

Amperes for Single Phase = Watts / (Volts * Power Factor) Kilovolt-Amperes = Volts * Amperes / 1000

10. Speed in rpm = 120 * F / P

where, F = frequency in Hz

P = Number of pole

11. Full load Torque = HP * 5252 / rpm