A POWER GENERATION SYSTEM

FIELD OF THE INVENTION

The present invention relates in general to power generation systems, but more particularly, to a mechanical electrical power generation system that can continuously generate its own green energy power and supply continuous surplus power.

BACKGROUND OF THE INVENTION

Typically, when a drive motor is connected to drive a single gearbox or an array of multiple gearboxes which are connected to a permanent magnet generator or some other equipment driven by a drive motor, the operating performance characteristics of the drive motor and gearboxes are determined by the manufacturer who is following Newton’s Third Law of Motion, which states that for every action, there is an equal and opposite reaction. In other words, if object A exerts a force on object B, object B simultaneously exerts an equal and opposite force on object A.

Expressed as a formula, the aforementioned Newton’s Law is as follows: torque (Nm) = constant x power (kW) / speed (rpm)

Normally, a motor takes power in the form of voltage and current taken from a source that is operating 24 hours per day / 7 days per week / 365 days per year. This source is either generated from a company power station, or purchased from an external power source, generally through a local utility provider. This power is converted over time into mechanical energy; for example, in the form of rotation of a shaft attached to the drive motor to operate another device, such as a gearbox, pump, or permanent magnet generator.

Generally, the manufacturer of a drive motor also manufactures gearboxes. Drive motors and gearboxes require speed to be expressed as rpm and torque to be expressed as newton-meters, both calculated according to the aforementioned Newton’s Law formula.

A person skilled in the art will claim that it is not possible to get more out of a system than what is put into the system. In other words, for units of energy used to power into a system, the system can only return same number of units of energy; and most likely less units, due to inherent system inefficiency.

United States Patent Application Number US 2011/0181048 Al, dated July 28, 2011, titled “Gear Driven Energy Transfer System”, issued to Mr. Christopher Scotti, teaches of an energy transfer system comprising: a first power conversion system, wherein the first conversion system further comprises: an electric drive motor; a gearbox, wherein the gearbox is in communication with the electric drive motor; a transmission, wherein the transmission is in communication with the gearbox; a first generator, wherein the first generator is in communication with the transmission; a second power conversion system, wherein the second conversion system is disposed to be in electric communication with the first power conversion system and further comprises: a second electric drive motor; a second gearbox, wherein the second gearbox is in communication with the second electric drive motor; a second transmission, wherein the second transmission is coupled to the second gearbox; a second generator, wherein the second generator is coupled to the second transmission; and a plurality of energy sources, wherein the plurality of power sources is disposed to operate the electric drive motor of the first power conversion system.

It could be argued that the aforementioned “Gear Driven Energy Transfer System” in the name of Mr. Scotti has no commercial value since, according to its specification, the plurality of power sources is disposed to operate the electric drive motor of the first power conversion system. If the power generated only drives the first electric drive motor, then it has no commercial value because it only produces electricity to power itself. In other words, said system does not produce any additional or surplus power that may be used outside of powering or driving itself. Mr. Scotti’s system undoubtedly follows Newton’s Law being that for every action, there is an equal and opposite reaction. United States Patent Application Number US 2011/0181048 Al relies upon a connecting belt drive to transfer speed and torque from a transmission to a gearbox. His design includes two (2) drive motors, two (2) gearboxes, two (2) generators, two (2) transmissions, collectively totaling eight (8) separate mechanical pieces of equipment. By comparison, the present invention comprises one (1) drive motor, two (2) gearboxes and one (1) permanent magnet generator, for a total of four (4) separate mechanical pieces of equipment.

Philippine Application Number PH 1-2013-000284, titled “A New Mechanical Assembly with An Efficient and Multi-Purpose Gearbox System For Fuelless Motor And Fuelless Generator”, filed on September 24, 2013 by Mr. Genaro Francis Tabag, teaches of the construction of a new mechanical arrangement with an efficient multi-purpose gearbox system assembly adaptably suited to induction motors and generator motors that may produce free electricity. The base frame is designed with a stainless 1 and * inch square tube having a length of the base frame at 40 inches, width of 13 inches and height of 4 inches. Motors can be fixed/adjusted horizontally and vertically to mesh with the gearbox gears with proper alignment. The base frame can also be used for different motor sizes ranging from 1 to 10 horsepower. Gearbox can be fixed/adjusted vertically.

In the specification of its patent application, Mr. Tabag mentions that “if the input gear is 1740 rpm the output gear should have 150 top 200 rpm for the generator motor to produce sufficient power” . A person skilled in the art would know that a generator and a motor have two different functions. The generator will produce electricity when the shaft will be turned, and the motor will turn when the electricity will be powered and produces speed and torque. However, no generator with a speed between 150 to 200 rpm can produce sufficient power. The lowest speed that a synchronous, induction or permanent magnet generator can produce power is 600 rpm and the performance efficiency is not greater. However, in the excitation generator may be can produce power below 600 rpm but it was not mentioned what kind of generator is being utilized.

Mr. Tabag mentions a fuelless motor and fuelless generator, but there is no mention of the source of energy and the amount energy required to operate the system. There is mention of production of ‘greater power’, but the energy required by the system and produced by the system, are not quantified.

SUMMARY OF THE INVENTION

To solve the drawbacks and disadvantages of the aforementioned existing power generation systems, it is therefore the main object of the instant invention to provide a power generation system that is efficiently capable of producing power in addition to the power required to operate itself. The instant invention not only produces more power from the system than is used to drive the system, but also provides power to return to drive the system as well as surplus power for supply outside the system.

The prototype embodiment of the subject gear-driven self-powered permanent magnet generator system comprises a bespoke asynchronous drive motor of only 2.2 kW capacity 1750 rpm, driving and connected by coupling to a bespoke high speed to low speed gearbox #1 connected by coupling to a bespoke low speed to high speed gearbox #2 connected by coupling to a bespoke 12 kW capacity 1200 rpm synchronous permanent magnet generator.

Attached through two (2) gearboxes to the 2.2 kW asynchronous drive motor which starts from a 12 VDC lead-acid or lithium battery, (24 VDC lead-acid or lithium battery, 48 VDC lead acid or lithium battery, or 480 VDC charger inverter with battery bank for 5.5 kW and above asynchronous drive motors) powering a variable frequency drive inverter which provides 380 VAC to the 2.2 kW asynchronous drive motor which starts for 1 to 2 minutes turning the 12 kW gear-driven self-powered permanent magnet generator and, after synchronization with the asynchronous drive motor and the two (2) gearboxes, will come online and after deduction of 7% or 0.84 kW efficiency loss, 0.1% or 0.01116 kW for system instrumentation and controls, 0.052 kW for the cooling fan motor and 2.2 kW is returned back to the asynchronous drive motor, with the balance of 8.897 kW or 74.6% of the 12 kW rated power output is available to the system owner for powering other equipment or it is dispatched to the local utility provider. As to balancing the system, if the set point of how much power percent is required to feed to the local utility provider, the variable frequency drive inverter will maintain the speed (rpm) to achieve the exact demand of the set point and the output of the gear-driven self-powered permanent magnet generator.

The subject gear-driven self-powered permanent magnet generator system is unique and novel as it was created by not following Newton’s Law formula of torque (Nm) = constant x power (kW) / speed (rpm) for the output gear of gearbox #2. Newton’s Law formula is only followed for the torques and speeds of the asynchronous drive motor, gearbox #1, input gear of Gearbox #2 and the synchronous permanent magnet generator.

A prototype embodiment of the instant invention being a 2.2 kW asynchronous drive motor connected directly coupled to a high speed to low speed gearbox #1 which is connected by coupling to a low speed to high speed gearbox #2 which is connected by coupling and turning a 12 kW synchronous permanent magnet generator from which, after deducting 7% efficiency loss, 2.2 kW is returned back to the asynchronous drive motor, 0.052 kW for the cooling fan motor, 0.1% used to power system control instruments and the balance of 8.897 kW was dispatched for local power use.

The prototype embodiment comprised an asynchronous drive motor with rated power of 2.2 kW at 1750 rpm rated speed (reduced to 1500 rpm) and torque of 12.0 Nm (increased to 14.0 Nm) coupled to drive gearbox #1 (high speed to low speed) with a rated input speed / torque of 1500 rpm / 14.0 Nm and a rated output speed / torque of 188 rpm / 112.0 Nm, coupled to gearbox #2 (low speed to high speed) with a rated input speed / torque of 188 rpm / 112.0 Nm and, except for the output gear of gearbox #2, is still following Newton’s Law formula, with a rated output speed of 1500rpm.

The material hardness of the output gears and the adjustment of the size of the output shaft diameter are customized to resist the rated speed and torque of the gear-driven self-powered permanent magnet generator at 1200 rpm with rated torque at 96.9 Nm, respectively. Specifically, the diameter and width of the output gear of gearbox #2 must be equal to or greater than the input gear of gearbox #1 and the output shaft diameter of gearbox # 2 is identical to the input shaft of the permanent magnet generator.

The asynchronous drive motor speed is rated at 1750 rpm but is controlled by the proportional integral controller that signals the variable frequency drive inverter to reduce speed, either manually or automatically and the asynchronous drive motor speed is controlled to 1200 rpm to equal to the 1200 rpm speed of the gear-driven self-powered permanent magnet generator. In order not to damage either or both gearboxes installed in the system, the set point of the proportional integral controller for the asynchronous drive motor is set at 80% to reduce the input speed of the gearbox #1 from 1500 rpm (14.0 Nm torque) to 1200 rpm (17.55 Nm torque) with an output speed reduced from 188 rpm (112.0 Nm torque) to 150.4 rpm (140.1 Nm torque). Gearbox #2 will operate at a reduced input speed of 150.4 rpm / 140.1 Nm torque (down from 188 rpm / up from 112.0 Nm torque) and reduced output speed of 1200 rpm (down from 1500 rpm).

However, as the gearbox #2 output shaft is the same diameter as the permanent magnet generator shaft diameter which requires a larger than normal diameter of the output gear with both shaft and gear manufactured from high grade materials 20CrNi2MoA (gear) & 42CrMo (shaft) respectively and hardness HRC58-62 (gear ) & HB580 (shaft) respectively, the torque of gearbox # 2 output shaft will be minimum 112.0 Nm (same as input torque); thus being sufficient torque to drive the gear-driven self-powered permanent magnet generator which has a rated torque of 96.9 Nm.

Once the 80% set point is reached from the speed of the asynchronous drive motor, the feedback signal from the speed of the permanent magnet generator at 1200 rpm will give a signal to activate the switch gear for readying of synchronization control for the load shedding and load sharing and the 12 kW gear-driven self-powered permanent magnet generator will by itself return 2.2 kW power back to the battery bank 12 VDC, 24 VDC, 48 VDC or 480 VDC charger inverter with battery bank which will power the variable frequency drive inverter (380 VAC to 380 VAC) which will power the 2.2 kW asynchronous drive motor and cooling fan motor, as well as share 0.1% for powering system instrumentation and the excess power will feed to the user’s other equipment or directly to the utility distributor, with the system running continuously 24/7 365 days.

A person skilled in the art will recognize that multiple embodiments of the present gear-driven self-powered permanent magnet generator system (such as but not limited to asynchronous drive motor, gearboxes and permanent magnet generator combinations being combinations of but not limited to 5.5 kW / 20 kW, 10 kW / 35 kW, 15 kW / 60 kW, 20 kW / 80 kW, 25 kW / 100 kW, 30 kw / 115 kW, 35 kW / 135 kW, 40 kW / 160 kW, 45 kW / 200 kW, 45 kW /280 kW, 250 kW / 600 kW, 250 kW / 1000 kW, 500 kW / 1250 kW, 650 kW / 3000 kW, 1120 kW / 5000 kW, 1120 kW / 6500 kW and 1200 kW / 6500 kW, can be implemented with the following new speed combinations being the asynchronous drive motor from 1750 rpm to 900 rpm, gearbox #1 input speed from 1500 rpm to 450 rpm and output speed from 188 rpm to 360 rpm, gearbox #2 input speed from 188 rpm to 360 rpm, output speed from 1500 rpm to 1890 rpm and the permanent magnet generator from 1200 rpm to 1800 rpm. Torques are adjusted accordingly, using Newton’s Law formula based on the rated power of the asynchronous drive motor and the permanent magnet generator, as the case may be. Multiple same combinations can be linked in an array in parallel to operate as a stand-alone power station that can be connected to substations for distribution of power to factories, or for public use. As a multiple array of identical connected systems is self-generating power, this should address the problem of brownouts or blackouts that frequently occur in the Philippines.

The instant gear-driven self-powered permanent magnet generator system is novel and inventive, because it is not following and is not guided by Newton’s Law formula in the design and operation of gearbox #2 used to drive the gear- driven self-powered permanent magnet generator. It is also unique and novel, in that the small 2.2 kW input of the drive motor drives the bigger 12 kW output of the gear-driven self-powered permanent magnet generator. Because this generator system is self-powered and operating 24/7 365 days, its end users do not have to suffer brownouts/blackouts, as they sometimes do when power is supplied by a local utility provider. This system runs against Newton’s Third Law of Motion and the Law of Thermodynamics in power of energy input is equal to input or 1: 1, in that it produces more energy than it needs to operate.

An embodiment of the instant invention will enable a gear-driven self- powered permanent magnet generator continuous green power supply system to be operated but without returning power back to the asynchronous drive motor. Initially, power to the asynchronous drive motor will come from either wind, solar energy, charger inverter with battery bank and if not available, the backup power from the local utility provider. Except for 7% efficiency loss of the 12 kW permanent magnet generator plus about 0.011 kW (0.1%) for power to the system instrumentation and 0.052 kW for the cooling fan motor, a total of 11.15 kW or 92.9 % of the 12 kW permanent magnet generator rated power capacity would be available for other use elsewhere in the factory/plant or to sell to the local utility provider. It will require 2.2 kW to be purchased from the local utility provider to power the asynchronous drive motor. The commercial value of such an embodiment will depend upon the purchase price of the 2.2 kW source power and the sale price of the 11.15 kW surplus power.

A further embodiment of the instant invention will enable the gear-driven self-powered permanent magnet generator continuous green power supply system to be operated with combinations of different types of drive motors and generators. It will be possible to use asynchronous drive motors driving induction generators, synchronous drive motors driving induction generators and synchronous drive motors driving permanent magnet synchronous generators. All embodiments will generate surplus power available for other use, or for sale to local utility providers after deducting power to be returned to the drive motor, cooling fan motor and also for system control purposes.

Another object of the instant invention is to provide a power generation system that is very efficient and easy to operate and cost effective to maintain. Still, another object of the instant invention is to provide a power generation system that can be easily manufactured using locally available materials and technology.

Although specific advantages have been enumerated herein, various embodiments may include some, none, or all of the enumerated advantages.

There are additional features of the instant invention that will be described hereinafter, and which will form the subject matter of the claims appended hereto. In this respect, before explaining at least one embodiment of the instant invention in detail, it is to be understood that the instant invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The instant invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.

The objects of the instant invention, and its novel and inventive features, are pointed out with particularity in the claims forming part of this specification. For a better understanding of the instant invention, its operating advantages and the specific objects attained by its uses, reference should be made to the detailed description below, and the accompanying formal drawings which illustrate the preferred embodiments of the instant invention.

Other technical advantages may become readily apparent to one of ordinary skill in the art after review of the following description figures and drawings.

Although exemplary embodiments are illustrated in the figures and described below, the principles of the present disclosure may be implemented using any number of techniques, whether currently known or not. The instant invention should in no way be limited to the exemplary implementations and techniques illustrated in the drawings and described in this specification. BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

An exemplary embodiment of the present invention is illustrated by way of example in the accompanying drawings in which like reference numbers indicate the same or similar elements and in which:

FIG.l is a perspective view of the power generation system in accordance with the present invention;

FIG.2. is a side view thereof;

FIG. 3 is a single line diagram of the prototype showing the interconnection of the main equipment;

FIGS. 4 and 5 is the control panel and internal circuit;

FIG. 6 and 7 is an external power and internal power supply of the variable frequency drive to power up the drive motor; -

FIG. 8 is a schematic drawing with external power supply to the local electricity provider; and

FIG. 9 is a schematic drawing showing the switching power supply from the external source to self-power from generator.

DETAILED DESCRIPTION OF THE INVENTION

This present invention was designed and innovated based on an understanding of Newton’s Third Law of Motion and the Law of Thermodynamics meaning that mechanical power of energy input is equal to output or 1:1, the low & high voltage electrical controls, instrumentation controls such as open loop control, closed loop control, cascaded control, telemetry control & SCADA (Supervisory Control And Data Acquisition), combined with principles of mechanical and civil engineering utilizing a asynchronous drive motor (drive motor) 2, two (2) gearboxes 3 & 4 with customization of the materials & hardness of the output shaft and gear teeth of the output gear of gearbox #2 4 which provides the force or starting torque expressed as newton-meters (Nm) and the speed expressed as revolutions per minute (rpm) of a synchronous permanent magnet generator 5 to operate at its rated torque. Civil Engineering is used to determine the exact location for the sound level, soil bearing test for the foundation & slab as well as minimize the vibration of the moving equipment.

FIGS. 1 and 2 illustrate the four (4) mechanical components that are used in the gear-driven self-powered permanent magnet generator continuous green power supply system. Start power 1 required is 5 kVA from a source such as wind, solar, bio-diesel generator, charger inverter 10 with battery bank or local utility provider. The system for the prototype is comprised of a 2.2 kW asynchronous drive motor 2 0-380 VAC, 0-60 Hz with rated speed of 1750 rpm, torque of 14 Nm as shown in figure 1 coupled with the gearbox #1 3 with input speed of 1500 rpm, input torque of 14 Nm and output speed of 188 rpm, output torque of 112 Nm. The output shaft of gearbox #1 3 with diameter of 30 mm is connected by coupling 6 to the input shaft of gearbox #2 4 with diameter of 35 mm. Gearbox #2 4 input speed is 188 rpm with input torque of 112 Nm and output speed is 1500 rpm with a torque that supplants the Newton’s Law torque with higher grade and hardness of gear and shaft materials. The output shaft of gearbox #24 with a diameter of 42 mm is connected by coupling 7 to the same size 42 mm shaft of the 12 kW synchronous permanent magnet generator 5 with a rated speed of 1200 rpm with 380 / 220 VAC 60 Hz output.

While this instant invention is based on an embodiment prototype of a 2.2 kW asynchronous drive motor 2 and a 12 kW permanent magnet generator 5, the instant invention has various embodiments of size meaning that it can be up- scaled to allow for installation of drive motor 2 / permanent magnet generator 5 combinations such as but not limited to 5.5 kW / 20 kW, 10 kW / 35 kW, 15 kW / 60 kW, 20 kW / 80 kW, 25 kW / 100 kW, 30 kW / 115 kW, 35 kW / 135 kW, 40 kW / 160 kW, 45 kW / 200 kW, 45 kW /280 kW, 250 kW / 600 kW, 250 kW / 1000 kW, 500 kW / 1250 kW, 650 kW / 3000 kW, 1120 kW / 5000 kW, 1120 kW / 6500 kW and 1200 kW / 6500 kW. The aforementioned different size combinations can be adopted to the other speed and torque combinations of the various asynchronous drive motor from 1750 rpm to 900 rpm, gearbox #1 input speed from 1500 rpm to 450 rpm, output speed from 188 rpm to 360 rpm, gearbox #2 input speed from 188 rpm to 1890 rpm and the permanent magnet generator speed from 1200 rpm to 1800 rpm. Identical size combinations could be linked together to operate in parallel as a single power station. Embodiments of other drive motor 2 permanent magnet generator 5 combinations will be possible but subject to equipment availability, optimum operating parameters, and cost.

FIG. 3 illustrates the single line diagram of the prototype of the Gear-Driven Self-Powered Permanent Magnet Generator Continuous Green Power Supply System. The external power supply 1 is initially coming from either a wind, solar, bio-diesel generator, charger inverter 10 with battery bank connected to a variable frequency drive (VFD) inverter 20 or local utility provider. The input power supply 8 with 3 pole, 30 ampere circuit breaker and 2 pole circuit breaker connected to the magnetic contactor KM1 9 connected to the variable frequency drive (VFD) inverter from the variable frequency drive (VFD) inverter 20 connected to the drive motor 2 the shaft of the drive motor 2 connected to the input shaft of gearbox #1 3, and the output shaft of gearbox #1 3 is connected by coupling 6 to the input shaft of gearbox # 2 4 , the output shaft of gearbox #2 4 is connected by coupling 7 to the shaft of the 12 kW permanent magnet generator 5, to drive the 12 kW permanent magnet generator 5. A magnetic pick up speed sensor 11 is connected to the outboard shaft of the 12 kW permanent magnet generator 5 to monitor and indicate the speed of the 12 kW permanent magnet generator 5 in the control room, when the system operates, the 12 kW permanent magnet generator 5 output voltage indicator light 12 is illuminated, the current indicator light 13 is illuminated, and the test load panel light 14 is illuminated, the magnetic contactor KM2 15 will energize to take over the power from the external source 1, upon which occurrence the system is powered by itself. At this stage, the load to energize magnetic contactor KM3 16 with 50% load, 75% load for magnetic contactor KM4 17 and 100% load of magnetic contactor KM5 18.

The 2.2 kW asynchronous drive motor 2 starts from a 12 VDC lead-acid or lithium battery bank (24 VDC lead-acid or lithium battery bank, 48 VDC lead acid or lithium battery bank or 480 VDC lithium or lithium battery bank with charger inverter 10 for 5.5 kW and above drive motors 2) powering a variable frequency drive (VFD) inverter 20 which provides 380 VAC to power the 2.2 kW asynchronous drive motor 2.

FIGS. 4 and 5 illustrate the control panel indications and the internal circuit of the prototype of the gear-driven self- powered permanent magnet generator continuous green power supply system. The front view outside cabinet control panel 21, shows the indicators monitoring of frequency, voltages, amperes, indicating light, start & stop push button. The front view of the internal cabinet control panel 22 shows the internal installation of the circuit breakers, magnetic contactors 9 15 16 17 18 25, terminal block, wiring ducting, control wirings and power wirings termination.

For 200 kW and above asynchronous drive motors 2 a variable frequency drive (VFD) inverter 20 will provide 380 VAC to 380 VAC to power the larger asynchronous drive motors 2.

The temporary battery start-up power for the variable frequency drive (VFD) inverter 20 will automatically disengage when the asynchronous drive motor 2, gearboxes 3 & 4 and permanent magnet generator 5 system is stabilized and reaches the required 1200 rpm speed of the permanent magnet generator 5 and will return 2.2 kW to the charger inverter 10 with battery bank of the variable frequency drive (VFD) inverter 20 and 0.1% (0.01116 kW) for operating electronic and electrical controls of the system, 0.052 kW for the cooling fan motor and 2.2 kW to the asynchronous drive motor 2.

For the single system prototype it takes 1 to 2 minutes to synchronize between the temporary start-up power supply and the installed gear-driven self- powered permanent magnet generator 5 and produces the correct frequency (60 Hz) and voltages output (Line to Neutral 220 VAC & 380 VAC) from the said gear-driven self-powered permanent magnet generator 5.

The asynchronous drive motor 2 has a rated speed at 1750 rpm but with the installation of a variable frequency drive (VFD) inverter 20, to control the output speed of the drive motor 2, as well as the high speeds of the two (2) intermediate gearboxes 3 & 4 (high speed to low speed / low speed to high speed), all of which are reduced to 1200 rpm to match the 1200 rpm speed of the gear-driven self- powered permanent magnet generator 5 which forms the power generation part of the system.

Gearbox #1 3 has a rated input torque of 14.0 Nm which is increased to 17.55 Nm (due to the rated input speed of 1500 rpm reduced to the lower input speed of 1200 rpm from the asynchronous drive motor 2) and is necessary to drive the input gear at 1200 rpm (reduced from 1500 rpm) resulting in the rated output torque of 112.0 Nm (increased to 140.1 Nm) necessary to achieve a reduction in the rated output speed from 188 rpm to 150.4 rpm thus operating at a high speed to low speed configuration.

Gearbox #1 3, is connected to gearbox #2 4 inducing an input torque of 17.55 Nm (increased from the rated 14.0 Nm input torque) driving the input gear speed at 150.4 rpm (reduced from the rated input speed of 188 rpm) which is connected to the gearbox #1 3 output gear with an output torque of 140.1 Nm (increased from the rated output torque of 112.0 Nm) at 1200 rpm (reduced from the rated 1500 rpm) which is the speed to match the 1200 rpm rated speed of the gear-driven self-powered permanent magnet generator 5 thus operating at a low speed to high speed configuration.

Gearbox #2 4, with its bespoke-designed torque (Nm), speed (rpm) ratios, shaft sizes and output gear (increased diameter and width) as well as shaft material & hardness, produces an increased output shaft torque and required high speed of 1200 rpm needed to drive the attached gear-driven self-powered permanent magnet generator 5, which in turn generates the required electrical power output of 0.4 kW to run the variable frequency drive (VFD) inverter 20 and 0.1% (0.01116 kW) for operating electronic and electrical controls of the system, 0.052 kW for the cooling fan motor and returning 2.2 kW to the asynchronous drive motor 2, with the surplus power of 8.897 kW being dispatched to the local utility provider or for other use in the plant/factory.

The control instrumentation, switchgear & magnetic contactors, stepdown transformer and step-up transformer form part of the gear-driven self- powered permanent magnet generator 5 continuous green power supply system and are designed to provide a control loop for the distribution of the net generated electrical power to the local utility provider and other end users while reserving electricity to return back to the drive motor 2 in order to maintain and perform a continuous operating cycle.

ASYNCHRONOUS DRIVE MOTOR - for the prototype, a smaller asynchronous drive motor 2 is utilized with a capacity of 2.2 kW, 3-Phase, 1750 rpm, 380 VAC, 60 Hz. The selection of the asynchronous drive motor 2 is based on adopting a centralized control system that can control the frequency, voltage and rpm with the added advantage of driving the combination of two (2) gearboxes 3 & 4 linked by couplings 6 & 7 to the gear-driven self-powered permanent magnet generator 5.

The initial power source is delivered through the 12 VDC, 24 VDC, 48 VDC or 480 VDC charger inverter 10 with a battery bank that will give 380 VAC to power the variable frequency drive (VFD) inverter 20, to power up and control the asynchronous drive motor 2, with manual control or in auto mode control, with two (2) input signals (4-20 ma), rpm and load respectively, with a cascade control instrument with one (1) output signal (4-20 ma) that will proportionally control the speed of the asynchronous drive motor 2 and to synchronize the speed of gear-driven self-powered permanent magnet generator 5.

Under Newton’s Law formula being torque (Nm) = constant x power (kW) / speed (rpm), the force of the 2.2 kW asynchronous drive motor 2 is equal to a torque of 17.55 Nm with speed at 1200 rpm (rated at 12.0 Nm torque at 1750 rpm and 14.0 Nm torque at 1500 rpm). This force will be controlled proportionally in terms of speed, frequency, load capacity and rated torques for the starting of the combined equipment and electronic controls that make up the system.

The rated speed of the asynchronous drive motor 2 is 1750 rpm and can be controlled at speeds ranging from 1 rpm to 1750 rpm or a set point ranging from 0% to 100%, which depends on the actual status of the operations that the control room operator decides to fix the set point based on the demand of the power control system. The set point is fixed so that the output speed of the asynchronous drive motor 2 is equal to the speed of the gear-driven self-powered permanent magnet generator 5 which for the prototype is 1200 rpm thus the set point of the asynchronous drive motor 2 will be fixed as required within a range between 1170 rpm and 1230 rpm which frees up 580 rpm to 640 rpm for operational adjustments of the two (2) gearboxes 3 & 4 and the gear-driven self-powered permanent magnet generator 5.

The combination of the power control system being the 2.2 kW asynchronous drive motor 2 coupled to the two (2) gearboxes 3 & 4, of which gearbox #2 4 is a bespoke design, as well as the 12 kW gear-driven self-powered permanent magnet generator 5, the system can be adjusted and operated 24/7 and 365 days to produce continuous green energy power supply.

VARIABLE FREQUENCY DRIVE INVERTER - the asynchronous drive motor 2 of the gear-driven self-powered permanent magnet generator 5 continuous green power supply system will be powered through one single variable frequency drive (VFD) inverter 20, the specification of which depends upon the power requirement of the system to be powered by the gear driven self-power permanent magnet generator 5.

■Per Asynchronous drive motors 2 of all sizes will require only one (1) variable frequency drive (VFD) inverter 20. Asynchronous drive motors 2 will be coupled to either a 12 VDC, 24 VDC, 48 VDC or 480 VDC charger inverter 10 with battery bank, which is charged continuously from a connected inverter 10, which receives power from the gear-driven self-powered permanent magnet generator s.

When the battery bank is fully charged it will be switched off and goes to standby mode and the charger inverter 10 will send either 12 VDC, 24 VDC, 48 VDC or 480 VDC to the variable frequency drive (VFD) inverter 20 which will then send 380 VAC to the asynchronous drive motor 2. FIGS. 6 and 7 illustrate the external power and internal power supply of the variable frequency drive (VFD) inverter 20 to power up the asynchronous drive motor 2 of the prototype of the gear-driven self-powered permanent magnet generator continuous green power supply system. The external power source 1 to supply single phase 220 VAC to the variable frequency drive (VFD) inverter 20 is specifically coming from the local utility provider being CEBECO 1. The output of the variable frequency drive (VFD) inverter 20 is 0 to 380 VAC 0 to 60 Hz to control the 2.2 kW asynchronous drive motor 2. The pilot input power supply is coming from the output load from the permanent magnet generator 5 to take over the power from the external power source 1 thus the gear-driven self-powered permanent magnet generator continuous green power supply system switches to self-power.

GEARBOX #1 - gearbox #1 3 is customized with the design and specification made to order by the gearbox manufacturer, with input speed of 1500 rpm, rated input torque at 14.0 Nm, and rated output speed of 188 rpm, rated output torque at 112.0 Nm, has been selected based on the required designed combination of the high-speed input gear and low- speed output gear with the necessary starting force expressed as rated torque.

Gearbox #1 3 giving a higher rated output torque of 112.0 Nm, which torque must be equal to or higher than the gear-driven self-powered permanent magnet generator 5 with its rated torque of 96.9 Nm. However, to enable the 2.2 kW asynchronous drive motor 2 to operate the 12 kW gear-driven self-powered permanent magnet generator 5 with its rated speed of 1200 rpm the rated input speed of gearbox #1 3 has to be reduced from 1500 rpm to 1200 rpm which will come from the input speed of the asynchronous drive motor 2 which is set to operate at 1200 rpm. Accordingly, the input speed will be set within the range of 1170 rpm to 1230 rpm.

The required energy (torque) for each equipment is calculated according to Newton’s Law formula as follows: torque (Nm) = constant x power (kW) / speed (rpm) With an increased output torque of 140.1 Nm, which output torque will more than cover the 96.9 Nm lower rated torque of the gear-driven self-powered permanent magnet generator 5 and will overcome and easily drive the force generated by the 2.2 kW asynchronous drive motor 2, set from the variable frequency drive (VFD) inverter 20 to operate within the range of 1170 rpm to 1230 rpm with the rated input speed reduced from 1500 rpm to 1200 rpm.

In the other words, the set point output speed of gearbox #1 3 is only 150.4 rpm inducing an output torque increased from 112.0 Nm to 140.1 Nm. However, gearbox #1 rated output speed of 188 rpm will not match the 1200 rpm rated speed of the gear-driven self-powered permanent magnet generator 5 which also has a rated torque of 96.9 Nm.

Hence, due to the 1200 rpm input speed from the drive motor 2, gearbox #1 3 now has its rated input speed of 1500 rpm reduced to 1200 rpm with input torque increased from 14.0 Nm to 17.55 Nm and the rated output torque increased from 112.0 Nm to 140.1 Nm with an output speed reduced from the rated 188 rpm to 150.4rpm.

The bespoke design of gearbox #2 4 is essential to transform gearbox #1 3 low output speed of 150.4 rpm to the required 1200 rpm high output speed of gearbox #2 4 having a set point allowance to be adjusted to match the 1200 rpm speed of the gear-driven self-powered permanent magnet generator 5, thus completing the operation of the bespoke integrated system.

GEARBOX #2 - gearbox #2 4 is bespoke and has been specifically and carefully designed and invented (shaft diameter, gearwheel diameters & widths of the gear teeth, material specification and hardness to overcome the rated torque from gear-driven self-powered permanent magnet generator 5 without affecting the speed ratio of the input speed and output speed of the gearbox #2 4) to convert the required speed ratio from the low output speed of gearbox #1 3 to the 1200 rpm high speed of the gear-driven self-powered permanent magnet generator 5, from the 1200 rpm set on the asynchronous drive motor 2. The rated input speed of gearbox #2 4 is reduced from 188 rpm to 150.4 rpm to match the reduced 150.4 rpm output speed of gearbox #1 3. The rated output speed of gearbox #2 4 is decreased from 1500 rpm to 1200 rpm, which lower speed is able to drive the gear-driven self-powered permanent magnet generator 5 at the required speed of 1200 rpm.

Gearbox #2 4 does not follow the formula of Newton’s Law for calculating the output gear speed and torque. Despite having the reverse speed ratio from the input and output speed and torques of gearbox #1 3 & gearbox #2 4 from high speed at 1500 rpm to low speed at 188 rpm and low speed 188 rpm to high speed 1500 rpm respectively, the output gear diameter in gearbox #2 4 is adjusted to a larger size as well as the diameters of the input and output shafts without affecting the ratios of the speed. The input gear has a 76 mm diameter / 45 mm width and output gear has a 164 mm diameter / 38 mm width.

Both gearboxes have the same gear & shaft materials: 20CrNi2MoA & 42CrMo and gear & shaft hardness: HRC58-62 & HRC580. In addition, the output shaft diameter of gearbox #2 is bespoke, at 42 mm being the same 42 mm shaft diameter of the gear-driven self-powered permanent magnet generator 5.

Accordingly, the bespoke design of gearbox #2 4 results in an output speed at 1200 rpm which has an allowance to anticipate the friction arising from the operation of the system for matching the operating speed of the gear-driven self- powered permanent magnet generator 5 at 1200 rpm.

By duplicating the set point input speed of 1200 rpm (rated at 1500 rpm) and the output speed of 150.4 rpm (rated at 188 rpm) of gearbox #1 3 and then turning gearbox #2 4 by 180 degrees to mirror gearbox #1 3 with an input speed of 150.4 rpm and output speed of 1200 rpm, the two (2) gearboxes 3 & 4 are precisely synchronized during the starting operation without load, since the starting torque of the gearbox #1 3 is 17.55 Nm (rated at 14.0 Nm) at the input speed of 1200 rpm (rated at 1500 rpm) and the starting torque of the gear-driven self-powered permanent magnet generator 5 is 2.4 Nm at the speed of 1200 rpm which is equal to the set point of 1200 rpm on the asynchronous drive motor 2 thus ensuring the system operates smoothly.

In view of the above, in multiple operations and in order to operate during the synchronization of the load shedding and load sharing controller, the gear- driven self-powered permanent magnet generator 5 starts on the output speed of gearbox #2 4 at 1200 rpm by modifying the size and strength of the material utilized for the output gear teeth thus equaling the output torque of gearbox #1 3 gear teeth, with a calculated torque at 140.1 Nm.

To ensure the integrity of the output gear teeth of gearbox #2 4, a high-grade material (20CrNi2MoA) with hardness (HRC58-62) is utilized and has been specifically procured to have the same hardness (HRC58-62) as the input gear teeth thus the output force is equal to or greater than the hardness-created torque in the system, at or above 140.1 Nm.

The materials (20CrNi2MoA for gear & 42CrMo for shaft) and hardness (HRC58-62 for gear & HB580 for shaft) have been designed and customized to ensure the desired speed and torques. The aforementioned changes will overcome the created force to drive the rated torque of 96.9 Nm of the gear-driven self- powered permanent magnet generator 5.

Being that the calculation is superseded in practical ways of a lower force load that the output torque creates from the speed of gearbox #2 4 at 1200 rpm, plus gearbox #2 4 output shaft is being also customized with the 42 mm diameter to be the same 42 mm diameter as the shaft of the gear-driven self-powered permanent magnet generator 5, then mathematically, the material reinforcement method strengthens the gear teeth so as not to sustain damage or fail when the system operates.

In summary, the hardness of the materials override the guiding principles of power in energy calculated, being “energy input is equal to the output or 1:1”, thus the Newton’s Law formula of “output being equal to input” is superseded by the now claimed Barinan’s Law of “small input drives the bigger output”, to match up the speed and equaling the created force from the system comprising the 2.2 kW asynchronous drive motor 2, gearbox #1 3, gearbox #2 4 and the 12 kW gear-driven self-powered synchronous permanent magnet generator 5.

With the adjustment of the sizes of the input shaft and the output shaft and the output diameter and width of the gears, it is called small input will drive the bigger output, precisely designed and invented so as to not to cause damage of any gear teeth of the two (2) gearboxes 3 & 4 when running, not only during the starting torque phase but also the rated torque load of the gear-driven self- powered permanent magnet generator 5. In all respects the formula under Newton’s Law is diligently followed for the asynchronous drive motor 2, gearbox #1 3 and input gear of gearbox #2 4 and gear-driven self-powered permanent magnet generator 5. Categorically, Newton’s Law is intentionally not followed for the specification of the output gear of gearbox #2 4 which is in fact and is so deliberately designed and invented. Instead Barinan’s Law is followed.

PERMANENT MAGNET GENERATOR - the gear-driven self-powered synchronous permanent magnet generator 5 is a special order supplied according to the requested specifications, with a rated power capacity of 12 kW, 380 VAC, 60 Hz, 3-phase with four (4) wires, 4 poles with line and neutral and rated speed of 1200 rpm, rated current of 18.2 Amp, starting torque of 2.4 Nm, rated torque of 96.9 Nm.

This gear-driven self-powered permanent magnet generator 5 has been selected to initially complete the design parameters of the instant invention based on the doctrine of “small input drives the bigger output and to self-power” to operate 24/7 365 days supplying green energy electricity with very low maintenance with no brownouts & blackouts.

FIG. 6 illustrates the schematic drawing showing the permanent magnet generator 5 taking over the power supply from the external source 1 by providing power to the asynchronous drive motor 2 for the prototype of the gear-driven self- powered permanent magnet generator continuous green power supply system. When the system stabilizes from the load of the permanent magnet generator 5 and the voltages, amperes, frequency are reached, the operator will press the start button 26 to energize the magnetic contactor KM2 15 to take over the external power and at this stage the system is powered by itself, the operator will push the start button 40 of magnetic contactor KM6 25 and the test-load indicating light 27 for a test-load ready, the test-not-ready indicating light 28 will switch off. The over-voltage indicating light 29 and also the over-frequency indicator 30 will shut off at which time the operator will press the start button 31 for test load #1 to energize the magnetic contactor KM3 16 and simultaneously the test-load indicating light 32 will illuminate and the test load red indicating light 33 will switch off, thereafter, the operator will push the start button 34 of test load #2 to energize the magnetic contactor KM4 17 and simultaneously the test load #2 indicating light 35 will illuminate and the red-light indicator 36 will switch off thereafter, the operator will press the load test #3 start button 37 to energize the magnetic contactor KM5 18 and simultaneously the test-indicating light 38 will switch and the red test load #3 indicating light 39 will shut off.

FIG. 8 illustrates the schematic drawing with external power supply from either the local utility provider 1 or the charger inverter 10 with battery bank for the prototype of the gear-driven self-powered permanent magnet generator continuous green power supply system. When the power supply from either the local utility provider 1 or the charger inverter 10 with battery bank are not available, the external indicating light 22 will illuminate and when the external power is available it will switch off and the external power supply indicating light 23 will illuminate at which time the operator will start the drive motor 2 by pressing the start push button 24, thereafter, the magnetic contactor KM1 9 will close and power up the input power supply of the variable frequency drive (VFD) 20. The magnetic contactor KM1 9 will automatically de-energize when the internal power takes over from either the local utility provider 1 or the charger inverter 10 with battery bank because the normally closed contact of the magnetic contactor KM2 15 takes over supply of the load from the permanent magnet generator 5. INTERLOCKING SYSTEM - the gear-driven self-powered permanent magnet generator system is protected with a range of monitoring devices such as resistance temperature device, speedometer transmitter, power transducer / current transducer, and vibration transmitter. Each monitoring device is connected to the programmable logic controller.

Programmable logic controller is programmed to monitor the electrical & instrument control interlocking system and will initiate a break of the circuit once any transducer identifies an abnormality against the alarm set point and trips off the circuit. Each device has an additional trip amplifier monitoring all signals with the transmitter feed to the programmable logic controller, each having a certain alarm setting & trip point.

Resistance temperature devices are monitoring the temperatures of the asynchronous drive motor 2 bearings, permanent magnet generator 5 bearings, gearbox #1 3 oil and gearbox #2 4 oil. Once a bearing or oil temperature reaches the temperature set point, an alarm will trigger alerting the control room operator. If the temperature goes too high, it will trip an amplifier which will give a signal to the programmable logic controller and it will automatically break the logic circuit interlocking and stop the operation of the system for immediate maintenance action.

Speedometer transmitter is connected to the input shaft of the gear-driven self-powered permanent magnet generator 5 to signal the programmable logic controller to proportionally synchronize the speed and load of the asynchronous drive motor 2. The signal is also connected, in series, to the input of the proportional integral controller via the trip amplifier.

Once the 1200 rpm rated speed of the gear-driven self-powered permanent magnet generator 5 is reached, it will signal the power transducer to activate the switch gear to take over the power from either the 12 VDC, 24 VDC, 48 VDC or 480 VDC charger inverter 10 starting power and switch to the variable frequency drive (VFD) inverter 20 to maintain 2.2 kW power to the asynchronous drive motor 2 to maintain the speed and the load of the system in full operation.

In other words, the 12 kW gear-driven self-powered permanent magnet generator 5 will be self-generating its own power by returning 2.2 kW to the variable frequency drive (VFD) inverter 20 which will provide 380 VAC to the asynchronous drive motor 2.

Power transducer & current transducer are connected to the power from the gear-driven self-powered permanent magnet generator 5 and the asynchronous drive motor 2 to monitor the load that it will activate after the synchronization of the system. The signals of these devices are connected to the programmable logic controller to activate the switch gear and to trip to off position when the system is overloaded.

Proportional integral controller receives signals from the speedometer installed on the outer surface of the permanent magnet generator 5 shaft to monitor the speed of the gear-driven self-powered permanent magnet generator 5. The output signal of the proportional integral controller will, through the variable frequency drive (VFD) inverter 20, control the speed of the asynchronous drive motor 2.

Vibration transmitters monitor all bearings of the asynchronous drive motor 2, gearbox #1 3, gearbox #2 4 and the gear-driven self-powered permanent magnet generator 5. Each bearing has an individual alarm and trip indicator in the control room and if any bearing records a high vibration level, the alarm will be indicated for immediate preventative maintenance.

Step-down transformer converts high-voltage, low-current power into low- voltage, high-current power. The larger-gauge wire used in the secondary winding is necessary due to the increase in current. A person skilled in the art will know that a step-down transformer works on the principle of Faraday’s Law of Electromagnetic Induction and the number of turns in the primary winding is greater than the number of turns in the secondary winding, due to which it takes high electrical voltage at its primary terminal and gives low electrical voltage at its secondary terminal.

Step-down transformers are not required for a 2.2 kW / 12 kW, 5.5 kW / 20 kW, 10 kW / 35 kW, 15 kW / 60 kW, 20 kW / 80 kW, 25 kW / 100 kW, 30 kW / 115 kW, 35 kW / 135 kW, 40 kW / 160 kW, 45 kW / 200 kW permanent magnet generator 5 systems but are required for each 45 kW /280 kW, 250 kW / 600 kW, 250 kW / 1000 kW, 500 kW / 1250 kW, 650 kW / 3000 kW, 1120 kW / 5000 kW, 1120 kW / 6500 kW and 1200 kW / 6500 kW permanent magnet generator 5 systems.

SYSTEM OPERATION

Independent start-up green power source (5 kVA) will be required to start the 2.2 kW / 12 kW gear-driven self-powered permanent magnet generator continuous green power supply system. The green power source can be either wind, solar, a bio-diesel generator, local utility provider connection or 12, 24, 48, 480 VDC charger inverter with battery bank, connected to a variable frequency drive (VFD) inverter with capability of producing at least 5 kVA 3 -phase 60 Hz 380 VAC power supply.

The external independent start-up green power source is switched on with an expected duration of only 1 to 2 minutes of stabilization of the speed, frequency, current and voltages from the gear-driven self-powered permanent magnet generator after which time the operator will switch on the load of the gear-driven self-powered permanent magnet generator to take over the 220 VAC from the charger inverter of the VDC to VAC variable frequency drive (VFD) inverter to power by itself thus being self-sustaining and running 24/7 365 days.

In a fully integrated power system in which multiple gear-driven self-powered permanent magnet generator continuous green power supply systems are installed the switch to the gear-driven self-powered permanent magnet generator will be under auto-mode rather than switched by the system’s operator.

In a multiple installation, say a 100 MW power station, of the present gear- driven self-powered permanent magnet generator continuous green power supply systems, it will not be necessary to install an independent start-up green power source for each system. Once started and synchronized, the surplus power from the designated starting system can be used to ‘cascade’ start the other systems that are interconnected and forming part of the multiple power generation installation. In fact, surplus power from any system can be used to start any other connected system operating within the installation. Depending upon the number of interconnected systems installed, multiple designated starting systems could be included say every 5, 10 or 20 systems, depending on the overall system size and the number of separate gear-driven self-powered permanent magnet generator continuous green power supply systems that are installed.

The asynchronous drive motor capacity of the prototype is 2.2 kW, 0 - 380 VAC, 0 - 60 Hz and is set to operate at 1200 rpm (rated at 1750 rpm) which is coupled to gearbox #1 with an input speed of 1200 rpm (rated at 1500 rpm), and output speed at 150.4 rpm (rated at 188 rpm), with input torque at 17.55 Nm (rated at 14.0 Nm) and output torque of 140.1 Nm (rated at 112.0 Nm).The 2.2 kW drive motor has a rated speed of 1750 rpm with a natural force of 12.0 Nm which is increased to 14.0 Nm with a reduced speed of 1500 rpm. The asynchronous drive motor was sized and selected to drive gearbox #1 with the input speed of 1500 rpm with a starting torque of 14.0 Nm, and an output speed of 188 rpm with a rated output torque of 112.0 Nm. As only 1200 rpm is required to drive the gear- driven self-powered permanent magnet generator the speed and torque of the asynchronous drive motor, gearbox #1 & gearbox #2 are adjusted or set to operate at 1200 rpm, accordingly.

Gearbox #1 output shaft (rated speed at 188.0 rpm) is coupled at 150.4 rpm to the input shaft (rated at 188.0 rpm) of gearbox #2, the output speed of gearbox #2 is 1200 rpm (rated speed at 1500 rpm) and is coupled to the shaft of the gear- driven self-powered permanent magnet generator with a rated speed at 1200 rpm, 12 kW capacity with 220 VAC single phase line to neutral and 3 -phase 380 VAC. Gearbox #2 has an input torque of 140.1 Nm (rated torque at 112.0 Nm) and an output torque of 25.2 Nm (rated torque at 14.0 Nm). Through the larger input and output gear diameters and widths, gearbox #2 will drive the lower force or torque of 96.9 Nm of the gear-driven self-powered permanent magnet generator. When power from either wind, solar, bio-diesel generator, local utility provider or charger inverter with battery bank is available, the control room operator will start up the gear-driven self-powered permanent magnet generator system. The operator will switch first into manual mode and to manually adjust the proportional integral controller at the maximum speed of the asynchronous drive motor, up to 1200 rpm +/-2.5%.

Once the speed of the asynchronous drive motor and the two (2) gearboxes are established and synchronized after 1 to 2 minutes with the rated speed of the gear-driven self-powered permanent magnet generator as well as the output voltage, frequency and the load capacity, the operator will switch the variable frequency drive (VFD) inverter to auto mode.

When all correct readings are established and steady, the operator will activate the circuit breaker connected from the output voltage and load from the gear- driven self-powered permanent magnet generator to deliver power back to the asynchronous drive motor and at the same time shut off the standby start-up power supply circuitbreaker.

When switched to auto mode, the gear-driven self-powered permanent magnet generator system is powered by itself, with the remaining load balance sent for use in the plant/factory or to the local electric utility and operates non-stop 24/7 365 days.

The drive motor is controlled by the proportional integral controller via an input signal from the speedometer of the gear-driven self-powered permanent magnet generator and the other input signal is connected in series to the power transducer of the asynchronous drive motor.

The input signal of the speedometer transmitter connected to the output shaft of the gear-driven self-powered permanent magnet generator and the output signal from the proportional integral controller are connected to the variable frequency drive (VFD) inverter to control the speed of the asynchronous drive motor from 1750 rpm to 1200 rpm which is fixed with the set point in auto mode at maximum of 1230 rpm.

To avoid over-speeding gearbox #1 as well as gearbox #2, the output signal of the proportional integral controller is connected in series to the trip amplifier to arm the interlocking system which will ensure safety of the equipment thus avoiding overloading, over-speeding, vibration, and over-heating by providing temperature monitoring.

The asynchronous drive motor is coupled to gearbox #1 & gearbox #2, with gearbox #1 having a reduced input speed of 1200 rpm (rated at 1500 rpm) and the increased input torque to 17.55 Nm (rated at 14.0 Nm) and a rated output speed of 188 rpm creating an output torque of 112.0 Nm according to the Newton’s Law formula of torque (Nm) = constant x power (kW) / speed (rpm).

The rated 112.0 Nm output torque of gearbox #1 with a rated output speed of 188 rpm which coupled to gearbox #2 with a rated input speed of 188 rpm and rated output speed of 1500 rpm is needed to drive the 12 kW gear-driven self- powered permanent magnet generator with a rated torque of 96.9 Nm which is lower than the rated 112.0 Nm output torque of gearbox #1.

Theoretically computed, the set point of the asynchronous drive motor is only 80% necessary to cover the 100% rated speeds of gearbox #1 & gearbox #2, and the gear driven self-powered permanent magnet generator, respectively.

To achieve and satisfy the rated speed of the gear-driven self-powered permanent magnet generator operating at 1200 rpm with a rated torque of 96.9 Nm, gearbox #2 is designed and customized to transform the rated input speed from 188 rpm to an output speed of 1500 rpm set at 1200 rpm thus providing a 300 rpm allowance higher than the speed of the gear-driven self-powered permanent magnet generator in order to overcome the friction tendency of the overall system.

Instead of following the Newton’s Law formula, the design of gearbox #2 requires the material specification (20CrNi2MoA for gear & 42CrMo for shaft) & hardness (HRC58-62 for gear & HB580 for shaft) of the output gear teeth and shafting as well as customizing the output shaft to ensure that the gear components are identical in strength.

Due to the hardness of output gear teeth and shaft, the bearings used in gearbox #2 have been specified to be high resistance.

These changes sustain the force created (140.1 Nm) from the input speed of 150.4 rpm and output speed up to 1200 rpm which is the rated speed of the gear- driven self-powered permanent magnet generator.

The question arises concerning loads placed on gearbox #1 and gearbox #2 with a force of 112.0 Nm which theoretically there will be a friction impact from the asynchronous drive motor, which occurs when the asynchronous drive motor runs coupled with the two (2) gearboxes without the gear-driven self-powered permanent magnet generator installed. In such circumstances gearbox #1 will run freely, without load, with an input speed of 1500 rpm and output speed of 188 rpm.

Accordingly, when the gear-driven self-powered permanent magnet generator is coupled with gearbox #2, the actual load of the asynchronous drive motor is 96.9 Nm being the rated torque of the gear-driven self-powered permanent magnet generator, which is lower than the force of 140.1 Nm and it is equivalent set point of the asynchronous drive motor.

The load of the asynchronous drive motor still has an allowance to overcome the friction impact while gearbox #1 and gearbox #2 are running at 80% of the rated speeds and rated torques, to match the rated 1200 rpm speed of the gear- driven self-powered permanent magnet generator.

During operation, the proportional integral controller and the variable frequency drive (VFD) inverter both play a key role of controlling the asynchronous drive motor with two input signals from the shaft of the gear-driven self-powered permanent magnet generator, the speedometer and from the power transducer of the load of the asynchronous drive motor. The output of the proportional integral controller is connected to the variable frequency drive (VFD) inverter.

With an input speed signal from the speedometer transmitter installed on the shaft of the gear-driven self-powered permanent magnet generator and the signal from the power transducer of the load of the asynchronous drive motor as a cascaded control of the proportional integral controller, when the input signal (rpm & load) will be synchronized after 1 to 2 minutes, the switchgear will be energized and the 2.2 kW power will be returned back to the 2.2 kW asynchronous drive motor to be powered by itself and the excess power will be used elsewhere in the plant/factory or dispatched to the local utility provider.

The premise of the gear-driven self-powered permanent magnet generator is to be initially started from an external independent green power source (5 kVA) starting the low-power (2.2 kW) asynchronous drive motor and through the rpm and torque differentials of the two in-line gearboxes, drive a higher-powered permanent magnet generator (12 kW less 7% efficiency loss = 11.16 kW net) from which 2.2 kW is returned to the asynchronous drive motor for the system to be powered by itself, 0.052 kW for the cooling fan motor and another 0.1% operates the electronic and electrical controls of the system, with the balance of 8.897 kW (12 kW less 7% = 11.16 kW less 0.01116 kW = 11.149 kW less 2.2 kW = §.897 kW less 0.052 kW = 8.897 kW) being sent to the plant/factory or local power utility provider and the cycle continues indefinitely until either a breakdown occurs or scheduled maintenance of the gear-driven self-powered permanent magnet generator system or is switched off.

The system will operate with a 93% performance efficiency at 1200 rpm set point from the asynchronous drive motor and 74.14% of the rated power output of the gear-driven self-powered permanent magnet generator delivered to the local utility provider under 24/7 365 days operation.

The instant invention is not intended to be restricted to the details of the above described embodiments. It is understood that the embodiments described herein are merely illustrative of the instant invention. Variations in the applications and implementation of the gear-driven self-powered permanent magnet generator system may be contemplated by one of ordinary skill in the art without limiting the intended scope of the instant invention disclosed herein and as defined by the following claims.

Additional advantages and modifications of the present invention will readily occur to those skilled in the art in view of these teachings. The present invention in its broader aspects is not limited to the specific details, representative contrivances, and illustrative examples shown and described herein. Accordingly, various modifications may be made without departing from the spirit and scope of the general concept as defined in the appended claims and their equivalents.