A SYSTEM AND METHOD FOR CONTROLLING A MULTI-TUNNEL

ELECTRIC MACHINE

RELATED APPLICATIONS

[0001] This application claims priority to: U.S. provisional application serial number 62/793,359 entitled “A Circumferential Flux Electric Machine with an Electronic

Transmission” filed on January 16, 2019; U.S. provisional application serial number 62/801 ,237 entitled “A Circumferential Flux Electric Machine with an Electronic

Transmission” filed on February 5, 2019; and U.S. provisional application serial number 62/804,102 entitled “A System and Method for Controlling a Multi-Tunnel Electric Motor/Generator” filed February 1 1 , 2019. The disclosures of which are all incorporated by reference for all purposes.

[0002] This application is also commonly owned with the following U.S. patent applications: U.S. patent application serial number 15/657,173, entitled“An Improved Multi-Tunnel Electric Motor,” filed July 23, 2017, which is a Continuation of U.S. patent application serial number 15/492,529, entitled “An Improved Multi-Tunnel Electric Motor,” filed April 20, 2017, which is a Continuation-in-Part of PCT International application serial number PCT/US2016/026776, entitled “An Improved Multi-Tunnel Electric Motor,” filed on April 8, 2016, which claims the benefit of U.S. provisional patent application serial number 62/173,349 entitled“Multi-Tunnel Electric Motor,” filed on June 9, 2015; U.S. provisional patent application serial number 62/167,412 entitled“Multi- Tunnel Electric Motor,” filed on May 28, 2015; and U.S. provisional patent application serial number 62/144,654 entitled“Multi-Tunnel Electric Motor,” filed on April 8, 2015, and said U.S. patent application serial number 15/492,529, is also a Continuation-in- Part of U.S. patent application serial number 14/866,788, entitled“Brushless Electric Motor,” filed on September 25, 2015, which claims the benefit of U.S. provisional patent application serial number 62/056,389, entitled “DC Electric Motor with Enhanced Permanent Magnet Flux Densities,” filed on September 26, 2014; U.S. provisional patent application serial number 62/055,615, entitled“DC Electric Motor with Enhanced Permanent Magnet Flux Densities,” filed on September 25, 2014; and U.S. provisional patent application serial number 62/055,612, entitled“DC Electric Motor with Enhanced Permanent Magnet Flux Densities,” filed on September 25, 2014; and which is a Continuation-in-Part of U.S. patent application serial number 13/848,048, entitled“DC Electric Motor with Enhanced Permanent Magnet Flux Densities,” filed on March 20, 2013, which claims the benefit of U.S. provisional patent application serial number 61/613,022, entitled“Electric Motor,” filed March 20, 2012; U.S. patent application serial number 15/413,228, entitled“Brushless Electric Motor,” filed on January 23, 2017; U.S. patent application serial number 14/866,787, entitled“Brushed Electric Motor,” filed on September 25, 2015; U.S. patent application serial number 14/608,232, entitled “Brushless Electric Motor,” filed on January 29, 2015; U.S. patent application serial number 14/490,656, entitled“DC Electric Motor with Enhanced Permanent Magnetic Flux Densities,” filed on September 18, 2014, the disclosures of which are hereby incorporated by reference for all purposes.

TECHNICAL FIELD

[0003] The invention relates in general to a new and improved electric machine, and in particular to an improved system and method for producing rotary motion from an electro-magnetic motor or generating electrical power from a rotary motion input.

BACKGROUND INFORMATION

[0004] Electric motors use electrical energy to produce mechanical energy, very typically through the interaction of magnetic fields and current-carrying conductors. The conversion of electrical energy into mechanical energy by electromagnetic means was first demonstrated by the British scientist Michael Faraday in 1821 and later quantified by the work of Hendrik Lorentz.

[0005] In a conventional electric motor, a central core of tightly wrapped current carrying material creates magnetic poles (known as the rotor) spins or rotates at high speed between the fixed poles of a magnet (known as the stator) when an electric current is applied. The central core is typically coupled to a shaft which will also rotate with the rotor. The shaft may then be used to drive gears and wheels in a rotary machine and/or convert rotational motion into motion in a straight line. In many applications there is a need for a high torque output at relatively low revolutions per minute (RPM) or wattages, then as RPMs increase, the torque can be decreased. In electric vehicle applications, low speed operation often requires constant torque operation at less than the base speed for moving heavy loads, traversing rough terrain, or inclines such as hills. For instance, high torque may be required for local trash pickup when the trucks are moving slowly from house to house, but there is less need for high torque when the truck is in on the highway at higher speeds. Similarly, construction vehicles and tractors may have a need for high torque during earth moving and plowing, but low torque when the vehicles are in transport mode or moving along a street. Conveyor motors may need a high torque when they first start and lower torque after they have reached their operational speed.

[0006] In many cases, high speed operation requires double or triple the base speed for cruising on level roads or developed industrial sites. In this high-speed mode, torque requirements are low and constant power operation is desired. In constant power operation the available torque is inversely proportional to the speed. Constant power mode in an electric motor equipped with a mechanism that controls back emf provides an operation that is similar to shifting gear ratios in a conventional mechanical transmission of a vehicle, that is, higher speeds are traded for lower available torque by changing gear ratios.

[0007] Thus, there is a need for motors to generate high torque in one mode, and relatively lower torque in another mode once higher speeds have been reached. An electric motor that is able to shift from constant torque mode to constant power mode with speed extending beyond the base speed can be utilized as a magnetic variable transmission. Conventionally, this may be accomplished through a transmission device. However, transmission devices result in inefficiencies and additional costs. What is needed is an electric motor that can switch between a high torque low speed configuration and a low torque high speed configuration.

[0008] Generators are usually based on the principle of electromagnetic induction, which was discovered by Michael Faraday in 1831 . Faraday discovered that when an electrical conducting material (such as copper) is moved through a magnetic field (or vice versa), an electric current will begin to flow through that material. This electromagnetic effect induces voltage or electric current into the moving conductors.

[0009] Conventional power generation devices such as rotary alternator/generators and linear alternators rely on Faraday’s discovery to produce power. In fact, rotary generators are essentially very large quantities of wire spinning around the inside of very large magnets. In this situation, the coils of wire are called the armature because they are moving with respect to the stationary magnets (which are called the stators). Typically, the moving component is called the armature and the stationary components are called the stator or stators.

[0010] In most conventional electric motors, both linear and rotating, enough power of the proper polarity must be pulsed at the right time to supply an opposing (or attracting) force at each pole segment to produce a particular torque. In conventional electric motors at any given instant only a portion of the coil pole pieces are actively supplying torque.

[0011] With conventional electric motors, a pulsed electrical current of sufficient magnitude must be applied to produce a given torque/horsepower. Horsepower output and efficiency then is a function of design, electrical input power plus losses.

[0012] With conventional generators, an electrical current is produced when the rotor is rotated. The power generated is a function of flux strength, conductor size, number of pole pieces, and RPM. However, the electrical current is a sinusoidal output which inherently has losses similar to that of conventional electric motors.

[0013] Specifically, the pulsed time varying magnetic fields produces undesired effects and losses, i.e. iron hysteresis losses, counter-electromotive forces (EMF), inductive kickback, eddy currents, inrush currents, torque ripple, heat losses, cogging, brush losses, high wear in brushed designs, commutation losses and magnetic buffeting of permanent magnets. In many instances, complex controllers are used in place of mechanical commutation to address some of these effects.

[0014] Additionally, in motors or generators, some form of energy drives the rotation and/or movement of the rotor. As energy becomes scarcer and more expensive, what is needed are more efficient electric motors and generators to reduce energy consumption, and hence costs.

SUMMARY

[0015] In response to these and other problems, there is presented various embodiments disclosed in this application, including methods and systems of increasing flux density by permanent magnet manipulation using multiple magnetic tunnels. Disclosed are various embodiments for an electrical machine comprising: a plurality of coils radially positioned about a coil assembly, a plurality of magnetic tunnels forming a relative rotational path for the coil assembly, wherein the all of plurality of magnets forming each magnetic tunnel have like poles facing inward toward the interior of the magnetic tunnel or facing outward away from the interior of the magnetic tunnel such that each magnetic field of any magnetic tunnel is of an opposite polarity to the magnetic field of an adjacent magnetic tunnel.

[0016] These and other features, and advantages, will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings. It is important to note the drawings are not intended to represent the only aspects of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Fig. 1 is an exploded view of one embodiment of an electrical machine component according to certain aspects of the present disclosure.

[0018] Fig. 2 is a detailed isometric view of a magnetic cylinder/stator element or magnetic cylinder/rotor element of the electrical machine component illustrated in Fig. 1 .

[0019] Fig. 3 is an exploded view of the magnetic cylinder/stator element or the magnetic cylinder/rotor element of Fig. 2.

[0020] Fig. 4 is an isometric view of a coil assembly.

[0021] Fig. 5 illustrates one embodiment of a toroidal magnetic cylinder.

[0022] Fig. 6 illustrates a conceptual two-dimensional radial segment of a toroidal magnetic cylinder.

[0023] Fig. 7 is a detailed isometric view of one embodiment of a radial portion or radial segment of the toroidal magnetic cylinder illustrated in Fig. 5.

[0024] Fig. 8 is a detailed isometric view of one embodiment of the radial portion or radial segment illustrated in Fig. 7 with the addition of direction arrows.

[0025] Fig. 9 is a detailed isometric view of one embodiment of the radial portion or radial segment illustrated in Fig. 7 with the addition of a portion of a coil assembly illustrated in Fig. 4. [0026] Fig. 10 illustrates one embodiment of the coil assembly of Fig. 4 positioned within the toroidal magnetic cylinder of Fig. 5.

[0027] Fig.1 1 illustrates the magnetic cylinder of Fig. 10 coupled to a back-iron circuit with a portion of the side back iron circuit positioned in an exploded view for clarity.

[0028] Fig. 12 is a diagram of one embodiment of a system having a brushless motor controller and an electric electrical machine.

[0029] Fig. 13 is a flow chart of a method that may be executed with the brushless motor controller of Fig. 12.

[0030] Fig. 14 is a diagram of one embodiment of a system illustrating how a brushless motor controller may be coupled to a coil assembly having six winding phases via H-bridges.

[0031] Fig. 15 illustrates a graph of three sinusoidal voltage waveforms as is known in the art.

[0032] Fig. 16-1 illustrates a back emf plot of one embodiment of the present invention.

[0033] Fig. 16-2 illustrates a back emf plot of one embodiment of the present invention.

[0034] Figs. 17-1 and 17-2 illustrate back emf plots of one embodiment of the present invention.

[0035] Fig. 18 is one embodiment of a coil assembly illustrating groups of coils in a 6-phase arrangement.

[0036] Figs. 18-1 through 18-12 illustrate a coil firing and tunnel segment rotation sequence over time of a six-phase“winding” configuration illustrating one embodiment of the present invention.

[0037] Fig. 19 is one embodiment of a coil assembly illustrating groups of coils in a three-phase arrangement. [0038] Figs. 19-1 through 19-6 illustrate a coil firing and tunnel segment rotation sequence over time of a three-phase “winding” configuration illustrating one embodiment of the present invention.

[0039] Figs. 20-1 through 20-25 illustrate a coil firing and tunnel segment rotation sequence over time of a two-phase“winding” configuration illustrating one embodiment of the present invention.

[0040] Fig. 21 is a flow chart of a method that may be executed with the brushless motor controller of Fig. 12.

[0041] Fig. 22 is a diagram of one embodiment of a system illustrating a more detailed embodiment of a brushless motor controller.

[0042] Fig. 23 is a diagram of one embodiment of a system illustrating how a brushless motor controller may be coupled to a coil assembly having six winding phases via H-bridges.

[0043] Fig. 24 illustrates an adaptive electronic transmission adjusting a coil firing sequence to transition from emulating a six-phase winding, to a three-phase winding, and then to two-phase winding of a conventional motor illustrating one embodiment of the present invention.

[0044] Figs. 25-1 and 25-2 are flow charts illustrating a method that may be executed with the brushless motor controller of Fig. 12 to emulate an adaptive electronic transmission adjusting a coil firing sequence to emulate a six-phase winding and a three-phase winding of a conventional motor.

DETAILED DESCRIPTION

[0045] Specific examples of components, signals, messages, protocols, and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to limit the invention from that described in the claims. Well-known elements are presented without detailed description in order not to obscure the present invention in unnecessary detail. For the most part, details unnecessary to obtain a complete understanding of the present invention have been omitted inasmuch as such details are within the skills of persons of ordinary skill in the relevant art. Details regarding conventional control circuitry, power supplies, or circuitry used to power certain components or elements described herein are omitted, as such details are within the skills of persons of ordinary skill in the relevant art.

[0046] When directions, such as upper, lower, top, bottom, clockwise, or counterclockwise are discussed in this disclosure, such directions are meant to only supply reference directions for the illustrated figures and for orientation of components in the figures. The directions should not be read to imply actual directions used in any resulting invention or actual use. Under no circumstances, should such directions be read to limit or impart any meaning into the claims.

Electrical machine Element and Back-Iron Circuit

[0047] Fig. 1 is an exploded isometric view of an electrical machine 100 illustrating a first portion 202 of a back-iron circuit 200, a second portion 204 of the back-iron circuit 200, a rotor hub 300, and a magnetic disc assembly 400. Embodiments of the electrical machine 100 are also known as the Hunstable Electric Turbine, or“HET” or a circumferential flux, four rotor electric machine.

[0048] The back-iron circuit 200 is theoretically optional. It serves to position and strengthen magnetic elements (described below) and constrain the magnetic circuit to limit reluctance by removing or reducing the return air path. The first portion 202 of the back-iron circuit 200 comprises a first outer cylindrical wall 206 made of a suitable back iron material as described below. When the electrical machine 100 is assembled, a first inner cylindrical wall 208 is concentrically positioned within the first outer cylindrical wall 206. A first flat side wall 210 which is also made of back iron material is positioned longitudinally next to the first outer cylindrical wall 206 and the first inner cylindrical wall 208.

[0049] A second portion of the back-iron circuit includes a second inner cylinder wall 218 concentrically positioned within a second outer cylindrical wall 216 (when the electrical machine 100 is assembled). A second flat side wall 220 of back iron material is positioned longitudinally next to the second outer cylindrical wall 216 and the second inner cylindrical wall 218. In certain embodiments, the second inner cylinder wall 218 and second outer cylinder wall 216 have a plurality of longitudinal grooves sized to accept and support a plurality of magnets. [0050] For purposes of this application “back iron” may refer to iron or a soft magnetic material, such as any ferrous compound or alloy, such as a steel, iron, nickel or cobalt or the like alloy, soft magnetic material, sintered specialty magnetic powder, or any laminated metal comprising laminated sheets of such material. In certain embodiments, such laminated materials may include such Supermendur, Somaloy, or M19-29G.

[0051] In some embodiments, the back iron may be produced with a transformer tape winding method using tape wound lamination steel. This production method reduces the waste during the manufacturing process. In yet, other embodiments, the back iron may be electric steel (magnet steel) that also serves as structural integrity due to high rigidity/stiffness. In embodiments using a Halbach array such heavy materials are not needed (although a stiff structure may be required for structural integrity - such as plastic (PEEK), aluminum or carbon fiber). In some embodiments, the ring core 504 may be hollow or have passages defined therein to allow for liquid or air cooling.

[0052] In certain embodiments, there is a radial gap 212 between the first outer wall 206 and the first side wall 210. The radial gap 212 allows for the passage of a support structure, control wires and electrical conductors (not shown) into the magnetic disc assembly 400 as well as for heat dissipation and/or a thermal control medium. In other embodiments, the gap 212 may be defined within the first outer wall 206 or between the first outer wall 206 and the second outer wall 216. In yet other embodiments, the gap 212 may be located in other locations to optimize performance.

[0053] A plurality of inner longitudinal grooves 242 are defined and radially spaced around an inner surface of the first outer cylinder wall 206 (not visible in Fig. 1 ) and the second outer cylinder wall 216. Similarly, a plurality of outer longitudinal grooves 244 are defined and radially spaced around an outer surface of the first inner cylinder wall 208 and the second inner wall 218.

[0054] As will be described in detail below, a plurality of outer magnets forming a portion of an outer magnetic wall 406a (from the magnetic disc 400 discussed below) are sized to fit within the plurality of inner longitudinal grooves 242 and outer longitudinal grooves 244. [0055] When the electrical machine 100 is assembled, the first portion 202 of the back-iron circuit 200 and the second portion 204 of the back-iron circuit physically support and surround the magnetic disc 400. The first inner wall 208 and second inner wall 218 also radially surrounds and is radially coupled to the rotor hub 300. In certain embodiments, the rotor hub 300 positions and structurally supports certain components of the back-iron circuit 200 (which in turn, supports the magnetic components of the magnetic disc 400).

Magnetic Disc Assembly

[0056] Fig. 2 is a detailed isometric view of the assembled magnetic disc 400 of Fig. 1 . Fig. 3 is an exploded view of the magnetic disc 400. In the embodiment illustrated in Figs. 2 and 3, with respect to a longitudinal axis 401 , there is a top or first axial or side wall of magnets 402. Similarly, there is a bottom or second axial or side wall of magnets 404. An outer cylindrical wall of magnets 406 is longitudinally positioned between the first axial or side wall 402 and the second axial or side wall of magnets 404. In certain embodiments, the outer cylindrical wall of magnets 406 comprises two pluralities of magnets 406a and 406b which are sized to couple with the back-iron walls 206 and 216, as described above with respect to Fig. 1 .

[0057] An inner cylindrical wall of magnets 408 is also longitudinally positioned between the first axial or side wall 402 and the second axial or side wall of magnets 404 and concentrically positioned within the outer cylindrical wall of magnets 406. In certain embodiments, the inner cylindrical wall of magnets 408 comprises two pluralities of magnets 408a and 408b which are sized to couple with the back-iron walls 208 and 218, as described above in reference to Fig. 1 .

[0058] In certain embodiments, the magnets forming the axial side walls 402-404 and cylindrical walls 408-406 discussed herein may be made of out any suitable magnetic material, such as: neodymium, Alnico alloys, ceramic permanent magnets, electromagnets or Halbach Arrays. The exact number of magnets or electromagnets will be dependent on the required magnetic field strength or mechanical configuration. The illustrated embodiment is only one way of arranging the magnets, based on certain commercially available magnets. Other arrangements are possible - especially if magnets are manufactured for this specific purpose. Coil Assembly

[0059] As illustrated in Fig. 3, when the electrical machine 100 is assembled, a coil assembly 500 is concentrically positioned between the outer cylinder wall 406 and the inner cylinder wall 408. The coil assembly 500 is also longitudinally positioned between the first axial side wall 402 and the second axial side wall 404. In certain embodiments, the coil assembly 500 may be a stator. In yet other embodiments, the coil assembly 500 may be a rotor.

[0060] The coil assembly 500 comprises a coil assembly support 502, which in one embodiment, may be a portion of a stator used in conjunction with a rotor formed by the magnetic axial walls 402-404 and magnetic longitudinal walls 406-408 and the back iron circuit portions 202 and 204 discussed above in reference to Figs. 1 A through 3. In certain embodiments, the coil assembly support 502 comprises a cylindrical or ring core (not shown) or yolk 504 coupled to a plurality of teeth 506 radially spaced about the ring core.

[0061] In certain embodiments, the ring core 504 and teeth 506 may be made out of iron or back iron materials (discussed above) so that it will act as a magnetic flux force concentrator.

[0062] In yet other embodiments, the coil assembly support 502 may be made from a composite material which would allow it to be sculptured to allow for cooling and wiring from inside. The composite material may be formed of a“soft magnetic” material (one which will produce a magnetic field when current is applied to adjoining coils). Soft magnetic materials are those materials which are easily magnetized or demagnetized. Examples of soft magnetic materials are iron and low-carbon steels, iron-silicon alloys, iron-aluminum-silicon alloys, nickel-iron alloys, iron-cobalt alloys, ferrites, and amorphous alloys.

[0063] In certain embodiments, a wiring connection (not shown) can also be formed in the shape of a“plug” for coupling to the stator teeth. Thus, certain teeth of the plurality of teeth 506 may have holes for such plugs (or wires) defined on one side for attachment to a structural support in embodiments where the coil assembly 500 acts as a stator.

Coils or Coil Windings [0064] Fig. 4 is a detail isometric drawing of the coil assembly 500. The teeth 506 supported by the core ring 504 form radial slots 524 within the coil assembly support structure 502. A plurality of coils or coil windings 526 may be positioned radially about the ring core 504 and within the slots 524.

[0065] Each individual coil 526 in the coil assembly 500 may be made from a conductive material, such as copper (or a similar alloy) wire and may be constructed using conventional winding techniques known in the art. In certain embodiments, concentrated windings may be used. In certain embodiments, the individual coils 526 may be essentially cylindrical or rectangular in shape being wound around the ring core 504 having a center opening sized to allow the individual coil 526 to surround and be secured to the ring core 504. Thus, in such embodiments, the winding does not overlap.

[0066] By positioning the individual coils 526 within the slots 524 defined by the teeth 506, the coils are surrounded by the more substantial heat sink capabilities of the teeth which, in certain embodiments, can incorporate cooling passages directly into the material forming the teeth. This allows much higher current densities than conventional electric motor geometries. Additionally, positioning the plurality of coils 526 within the slots 524 and between teeth 506 reduces the air gap between the coils. By reducing the air gap, the coil assembly 500 can contribute to the overall torque produced by the motor or generator.

[0067] The number of individual coils 526 can be any number that will physically fit within the desired volume and of a conductor length and size that produces the desired electrical or mechanical output as known in the art. In yet other embodiments, the coils 526 may be essentially one continuous coil, similar to a Gramme Ring as is known in the art.

[0068] The windings of each coil 526 are generally configured such that they remain transverse or perpendicular to the direction of the relative movement of the magnets (e.g. the rotor) comprising the coil assembly 500 and parallel with the longitudinal axis 401 . In other words, the coil windings are positioned such that their sides are parallel with the longitudinal axis 401 and their ends are radially perpendicular to the longitudinal axis. As will be explained below, the coil windings are also transverse with respect to the magnetic flux produced by the individual magnets of the rotor at their interior face. Consequently, the entire coil winding or windings may be used to generate movement (in motor mode) or voltage (in generator mode).

[0069] Because the coil windings are surrounded by the magnetic fields, there are no passive or overlapped end-windings. This results in a high utilization of copper and a compact stator. The result is higher flux utilization density than in conventional electric motors which equates to a higher force. With a coil surrounded by magnets on all sides, and substantially all the magnetic fluxes confined and constrained within the most effective torque producing areas (minimal magnetic flux leakage), substantially all the coils and the copper are involved in the energy conversion process. So, there is no or little wasted copper and no end windings as found in prior art motors.

The Magnetic Cylinder

[0070] Fig. 5 is an isometric view of the magnetic disc assembly 400 (Fig. 1 ) with the coil assembly 500 removed for clarity. The magnets of the magnetic disc assembly 400 form a toroidal magnetic cylinder 430 defining one or more toroidal magnetic tunnels 440 positioned about the longitudinal axis 401 . As described previously, the toroidal magnetic cylinder 430 includes: the top axial or side wall of magnets 402, the bottom or second axial or side wall of magnets 404, the outer cylindrical wall 406 of magnets positioned longitudinally between the first side wall 402 of magnets and the second side wall 404 of magnets; and the inner cylindrical wall 408 of magnets positioned concentrically within the outer cylindrical wall 406 of magnets. In certain embodiments, the outer cylindrical wall 406 may be formed by two pluralities of magnets 406a and 406b, where each plurality of magnets is sized to couple with the back-iron circuit walls 206 and 216, respectively. Similarly, in certain embodiments, the inner cylindrical wall 408 may be formed by two pluralities of magnets 408a and 408b, where each plurality of magnets is sized to couple with the back-iron circuit walls 208 and 218, respectively.

[0071] Note that in the illustrative embodiment of Fig. 5, there are eight radial“slices” or magnetic tunnel segments 420 forming a complete toroidal magnetic cylinder 430. However, the exact number of segments depends on the size, performance characteristics, and other design factors. Each magnetic may also be thought of as a three dimensional pole region of like magnetic polarity. The number of tunnels can vary. For instance, in an eight-pole motor, each pole region represents 45 degrees of rotation. In contrast, in a four-pole motor, each pole region represents 90 degrees of rotation.

[0072] Fig. 6 is a cross-sectional conceptual view of one embodiment of a partial radial magnetic cylinder 650. The radial magnetic slice 650 is conceptually similar to the radial segment 420 of the toroidal magnetic cylinder 430 of Fig. 5 above. Fig. 6 conceptually illustrates the flow of the flux lines in the radial slice of the magnetic tunnel or partial magnetic cylinder 650 when the cylinder is removed from the entire cylinder. In certain embodiments, the partial magnetic cylinder 650 comprises an outer curved wall 602 and an inner curved wall 604. The outer curved wall 602 and inner curved wall 604 may be made with a plurality of magnets. In a lateral section view, such as illustrated in Fig. 6, it can be seen that the outer curved wall 602 is comprised of a plurality of magnets 606, comprising individual magnets, such as magnets 606a, 606b, 606c, etc. Similarly, the inner curved wall 604 may be comprised with a plurality of magnets 608, comprising individual magnets 608a, 608b, etc. It should be noted that only one polarity of the magnets is utilized within (or facing into) the magnetic cylinder portion 650. For instance, in the illustrative embodiment of Fig. 6, the north poles of the magnets 606 are each pointing radially towards the center or longitudinal axis 401 (which is coming out of the page in Fig. 6). On the other hand, the north poles of the magnets 608 each point radially away from the longitudinal axis 401 and towards an interior cavity or tunnel 624 of the partial magnetic cylinder 650.

[0073] When the plurality of magnets 606 and 608 are arranged into the outer wall 602 and inner wall 604 to form a partial cylinder 650, the density of the magnetic flux forces will form particular patterns as represented in a conceptual manner by the flux lines 612 illustrated in Fig. 6. The actual shape, direction, and orientation of the flux lines 612 depend on factors such as the use of an interior retaining ring, a center core, a back-iron circuit, material composition and/or configuration.

[0074] To generally illustrate this magnetic arrangement, the flux line 612a (or flux lines) from the magnet 606a of the exterior wall 602 tends to flow from the north pole (interior face) of the magnet in a perpendicular manner from the face of the magnet into and through the interior tunnel 624 of the partial cylinder 650, exiting through the open end 614 into the open area 615, then flow around the exterior of the partial cylinder 650, and back to an exterior face of the magnet 606a containing its south pole. [0075] Similarly, the flux line 612b from the magnet 606b of the exterior wall 602 tends to flow from the north pole of the magnet in a perpendicular manner from the face of the magnet into and through the interior tunnel 624 of the partial cylinder 650, exiting through the open end 614 into the open space 615, then flow around the exterior of the cylinder 650, and back to the face of the magnet 606b containing its south pole. Although only a few flux lines 612 are illustrated for purposes of clarity, each successive magnet in the“top portion” of the plurality of magnets will produce similar flux lines. Thus, the magnetic flux forces for each successive magnet in the plurality of magnets 606 tend to follow these illustrative flux lines or patterns for each successive magnetic disc in the plurality of magnets 606 until the magnets at the open ends 614 or 616 of the partial magnetic cylinder 650 are reached.

[0076] As illustrated, the magnet 606a is positioned circumferentially adjacent to the magnet 606b. In turn, another magnet 606c is positioned circumferentially adjacent to the magnet 606b. Additional magnets in the group 606 may be positioned circumferentially adjacent to others until the open end 614 is reached. The flux lines 612 generated from the adjacent magnetic poles in the magnetic group 606 are concentrated at the open ends of the tunnel segment where they turn back towards an exterior face of the respective magnet.

[0077] Magnets in the “bottom portion” of the plurality of magnets 606, such as magnet 606d tend to generate flux lines 612d from the magnet 606d on the exterior wall 602 which tends to flow from the north pole (interior face) of the magnet in a perpendicular manner from the face into and through the interior tunnel 624 of the partial cylinder 650, exiting through an open end 616 into the open space, then flow around the exterior of the partial cylinder 650, and back to an exterior face of the magnet 606d containing its south pole. Although only a few flux lines on the opposing side of the partial cylinder 650 are illustrated for purposes of clarity, each successive or magnet in the plurality of magnets will produce similar flux lines which will also be concentrated at the opening 616 as described above. In embodiments with an iron core, the flux lines will generally flow in a similar manner but will tend to flow through the core and be concentrated within the core. Thus, in certain embodiments, the core may act as a flux concentrator. [0078] The interior magnetic wall 604 also produces flux forces, which also may be illustrated by flux lines, such as exemplary flux lines 618. For instance, the flux line 618a from the magnet 608a on the interior wall 604 tends to flow from interior face (e.g., the north pole) in a perpendicular manner from the face of the magnet, into and through the interior tunnel 624 of the partial cylinder 650, out the open end 614 (or open end 616) and into the open space 615, then around the interior wall 604 to the face of the magnet 608a containing its south pole.

[0079] The magnetic flux forces for each successive magnet in the plurality of magnets 608 tend to follow these illustrative flux lines or patterns 618 for each successive magnet in the plurality of magnets 608 until the open ends 614 or 616 of the partial magnetic cylinder 650 are reached. Thus, the flux forces produced by the magnets of the interior wall 604 of the partial cylinder 650 have an unobstructed path to exit through one of the open ends of the partial cylinder and return to its opposing pole on the exterior or interior of the cylinder.

[0080] As discussed above, the magnetic flux lines 612 and 618 will tend to develop a concentrating effect and the configuration of the exterior magnetic cylinder manipulates the flux lines 612 and 618 of the magnets in the partial magnetic cylinder 650 such that most or all of the flux lines 612 and 618 flow out of the open ends 614 and 616 of the partial cylinder.

[0081] The partial magnetic cylinder 650 is a simplified two-dimensional section illustration of a three-dimensional magnetic arrangement concept. The three- dimensional arrangement also has magnetic top and bottom magnetic walls with their north magnetic poles facing the interior of the tunnel 624 (not shown). Additionally, similar results can be obtained by replacing the plurality of magnets 606 with a single curved plate magnet magnetized in a similar manner (e.g., a north pole is formed on the interior face and a south pole is formed on an exterior face). Similarly, the plurality of magnets 608 may be replaced with a single curved plate magnet having its north pole on the surface facing the interior tunnel 624 and the south pole on the surface facing towards the longitudinal axis 401 .

[0082] For instance, Fig. 7 is a detailed perspective view of a portion or segment 420 of the toroidal magnetic cylinder 430 (see Fig. 5). The radial segment 420 is conceptually similar to the partial magnetic cylinder 650 discussed in reference to Fig. 6 because the radial segment 420 has an outer curved magnetic wall 406 and an inner curved magnetic wall 408. In addition to the curved or cylindrical magnetic walls 406 and 408, there are also magnetic axial or lateral walls 402 and 404 which in this illustrated embodiment may be made of wedge-shaped plate magnets.

[0083] The magnetic poles of the magnets forming the outer cylindrical wall 406 and the inner cylindrical wall 408 have their magnetic poles orientated radially pointing towards the longitudinal axis 401 (see Fig. 5). In contrast, the magnetic poles of the magnets forming the top or first axial wall 402 and the bottom or second axial wall 404 have their magnetic poles orientated or aligned parallel with the longitudinal axis 401. The individual magnets in the magnetic walls 402, 404, 406, and 408 all have their similar or“like” (e.g. north) magnetic poles orientated either towards or away from the interior of the tunnel 440 of the toroidal magnetic cylinder 430 to form a “closed” magnetic tunnel 440. The closed magnetic tunnel 440 runs circumferentially from the open end or exit 412 to the open end or exit 414 (similar to the tunnel 124 and open ends 1 14 and 1 16 discussed above with reference to Fig. 6).

[0084] For purposes of this disclosure and to illustrate the orientation of magnetic poles at the surfaces of the magnets forming the radial segment 420, the top axial wall 402 is labeled with an “S” on its exterior top face to indicate that in this particular configuration, the south pole of the magnet (or magnets) forming the top axial wall 402 faces away from the tunnel 440. Thus, the north pole of the magnet 402 faces towards the tunnel segment 440. Similarly, the lower axial or side wall 404 is labeled with a“N” on its interior side face to indicate that the north pole of the magnet forming the side wall 404 is facing towards the tunnel segment 440 (however, in this view the“N” is partially obscured). The two magnets forming the outer longitudinal wall 406 are labeled with an “N” on their interior surfaces to indicate that their north magnetic poles face the interior of the magnetic tunnel 440. In contrast, the two magnets forming the inner longitudinal wall 408 are labeled with an“S” on their exterior surfaces to indicate that their south poles are facing away from the tunnel 440. Thus, their north poles face towards the tunnel 440.

[0085] In this illustrative embodiment of the radial segment 420, all the magnets of the walls 402, 404, 406 and 408 have their north poles facing towards the interior or tunnel 440. So, the radial segment 421 has an NNNN magnetic pole configuration. Thus, the magnetic forces which tend to repel each other. When the radial segment 420 is removed from the entire toroidal magnetic cylinder, the magnetic flux flows circumferentially along the tunnel 440 in a circumferential direction and out the tunnel exits 412 and 414 similar to that described above in reference to Fig. 6. Fig. 8 is an illustration of the radial segment 420, but with the addition of directional arrows. Arrow 422 illustrates a circumferential direction and the arrow 424 illustrates a radial direction.

[0086] The term“closed magnetic tunnel” as used in this disclosure refers to using an arrangement of the magnets forming a tunnel that“forces” or“bends” the majority of the magnetic flux“out of plane” or circumferentially through the tunnel or interior cavity then out through one of the openings 412 or 414 as illustrated by the circumferential arrow 422 of Fig. 8. In contrast, if the magnetic tunnel were not magnetically“closed,” the flux forces would generally flow in a radial manner in the direction of the radial or lateral arrow 424 (or in a plane represented by the arrow 424). Conventional electric motors usually allow flux forces to flow in a radial direction as illustrated by the arrow 424.

[0087] Turning now to Fig. 9, there is illustrated an isometric view of the radial segment 420 which has been removed from the entire magnetic cylinder 430 and coil assembly 500 (see Fig. 10). The rest of the coil assembly 500 has been removed for clarity. In an un-energized state, the magnetic flux tends to flow from the north poles of the magnetic walls 402, 404, 406 and 408 into the coil assembly 500 and to the coil core 504. Because of opposing magnetic forces, the magnetic flux continues to flow circumferentially through the coil core 504 until the flux reaches an opening (for instance, open end 414) of the tunnel 440. The flux then bends back around an open end (e.g. open end 414) of the radial segment 420 to an exterior face of the respective magnetic wall containing a south pole. Arrows 426 of Fig. 9 are meant to illustrate the three-dimensional flux path as the flux reaches an open end 412 or 414 of the radial segment and bends back around to an exterior face (or in this case, the south pole) of the appropriate magnetic wall. Thus, the radial segment 420 generates a flux field which is conceptually similar to the flux fields 1 12 and 1 18 discussed above in reference to Fig. 6 (In situations where a radial segment 420 is adjacent to another radial segment of an opposite magnetic polarity configuration, the flux lines could extend into the adjacent partial toroidal magnetic cylinder). [0088] In certain embodiments, the core 504/coil assembly 500 may generate its own magnetic field fluxes as current is introduced into the coils 526 (not shown in Fig. 9). The majority of magnetic field fluxes are also constrained and channeled to interact with the magnetic flux generated from the magnetic tunnel (e.g., from permanent magnets) in a similar manner to that described above. Thus, all portions of the core 504 and coil assembly 500 may interact with the flux lines of the magnetic tunnel 440 to allow full utilization of the flux lines and all forces working together in the direction of motion.

[0089] As opposed to “pancake style” or axial flux electric motor, in certain embodiments, the longitudinal length or“width” of the outer walls 406 and 408 are greater than the radial or lateral depth (or length) of the side walls 402 and 404 as illustrated in Figs. 9. This exemplary geometric proportion results in greater torque generation along the interface of the outer wall 406 and coil assembly 502. In certain alternate embodiments, the thickness of the magnets comprising the outer wall 406 may also be increased to increase the generation of torque. In any event, the contribution to torque from the outer wall 406 and the inner wall 408 may be greater than the contribution from the side walls 402 and 404 due to the geometry of the cross-section of the radial segment 420 and the varying radius of the components.

[0090] Although the core, coil assembly, and magnetic radial segments are illustrated in cross-section as rectangular, any cross-sectional shape may be used depending on the design and performance requirements for a particular motor or generator. In certain embodiments, there is more magnetic material positioned in or along an outer wall (such as the magnetic wall 406) along the longitudinal direction than magnetic material positioned in or along a radial wall (such as the axial or side walls 402 or 408). For instance, if the magnets forming the magnetic walls are all the same thickness, the length of the outer wall in the longitudinal direction is greater than the length of the axial or side walls in the radial direction. In alternative embodiments, the length of the magnets forming the outer magnetic wall may be the same or shorter than the length of the magnets forming the axial or side walls.

[0091] The unique configurations illustrated in Fig. 9 also leads to several unique properties. For instance, an individual coil 526 and core portion 504 will tend to move out of the tunnel 440 on its own accord (e.g. with no power applied). The natural tendency of this configuration is for the coil 526 to follow the flux lines to the nearest exit 412 or 414. Conversely if a current is applied the coil 526, the coil 526 will move though the entirety of the magnetic tunnel depending on polarity of the power applied. The encapsulation of the coil 526 in the magnetic flux of the magnetic tunnel 440 also allows all magnetic fields to be used to generate motor or electric power. Cogging effects can be reduced while in the tunnel as the coil will tend to travel out of the tunnel when no current applied. This also means that the coil 526 does not have to be pulsed with an opposing magnetic field at any point while in the magnetic tunnel 440. Additionally, the coil 526 will travel through the entire magnetic tunnel 440 length with a single DC pulse of the correct polarity. Non-sinusoidal torque or voltage is generated throughout the duration of time that the coil 526 is under the influence of the magnetic tunnel 440 and alternating polarities are not required for this effect to occur.

[0092] Fig. 10 is an illustrative embodiment of the toroidal magnetic cylinder 430 that comprises eight radial segments where four radial segments 421 are interspersed between the four radial segments 420. The four radial segments 421 are identical to the radial segments 420 except that the magnetic pole orientation of the magnets has been reversed. So, in the radial segment 420, all of the interior facing magnetic poles are north forming a NNNN magnetic tunnel configuration as illustrated in Fig. 10. In contrast, in the radial segment 421 , all of the interior facing magnetic poles are south forming a SSSS magnetic tunnel configuration as illustrated in Fig. 10. Thus, the tunnels radial segments 420 generate flux fields which are of an opposite polarity to the flux fields generated by the radial segments 421 . In traditional motor terminology, each radial segment is a motor magnet pole. Therefore, each radial segment is a three- dimensional magnetic pole which can create a three-dimensional symmetric magnetic field. Alternating the radial segments then produces the changing magnetic field.

[0093] With regard to the toroidal magnetic cylinder 430, each magnetic or radial segment (e.g. radial segments 420 or 421 ) has their respective magnetic configuration (NNNN or SSSS) of like magnetic polarities reversed for each adjacent radial segment. Although, an eight-segment toroidal magnetic cylinder 430 is illustrated in Fig. 10, in other embodiments, two, four, six, ten, etc. segments may be used. The number of segments selected for any given application may be based on engineering design parameters and the particular performance characteristics for an individual application. The ratio of magnetic segments and slot/teeth counts can be any number that satisfies the design requirements. The scope of this invention specifically includes and contemplates multiple segments having an opposite polarity to the adjacent partial toroidal magnetic cylinders. For simplicity and illustrative purposes, an eight-segment toroidal magnetic cylinder is described herein. However, this design choice is in no way meant to limit the choice or number of segments for any multi-segment toroidal magnetic cylinder.

[0094] As described above, in certain embodiments, the individual magnets forming the toroidal magnetic cylinder 430 couple to various components of the back-iron circuit 200. The back-iron circuit 200 may be used to channel part of the magnetic flux path.

Defining the Flux Path with the Back-Iron Circuit

[0095] Fig. 1 1 is an isometric view illustrating the coil assembly 500 positioned within the toroidal magnetic cylinder 430 which is coupled to and surrounded by the back-iron circuit 200. The first flat side wall 210 has been repositioned in an exploded view for clarity. As described above, in the illustrative embodiment, the back-iron circuit 200 may include a first side or axial wall 210 and the second side or axial wall 220. In this embodiment, the first outer cylindrical wall 206 and the second outer cylindrical wall 216 forms and couples to and surrounds the outer magnetic walls 406a and 406b of the toroidal magnetic cylinder 430, respectively (see Fig. 5). The first inner cylindrical wall 208 and the second inner cylindrical wall 218 is coupled to and surrounded by the inner wall magnets 408a-408b of the toroidal magnetic cylinder 430 (see Fig. 5). Thus, the entire back iron circuit 200 includes the inner cylindrical walls 208 and 218, the outer cylindrical walls 206 and 216, and the side or axial walls 210 and 220 as illustrated in Fig. 8. In certain embodiments, the back-iron circuit 200 combined with the toroidal magnetic cylinder 430 may form a rotor (or a stator depending on the motor configuration). In certain embodiments, the back-iron circuit 200 may be used to channel part of the magnetic flux path. The back-iron material channels the magnetic flux produced by the toroidal magnetic cylinder 430 through the back-iron material (as opposed to air) to reduce the reluctance of the magnetic circuit. In certain embodiments, therefore, the amount or thickness of the magnets forming the toroidal magnetic cylinder (if permanent magnets are used) may be reduced when using the appropriately designed back iron circuit. Applying Mechanical Torque or Current

[0096] In “motor” mode, current is induced in the coils 526, which will cause electromotive forces to move the coil assembly 500 relative to the toroidal magnetic cylinder 430 or vice versa. In“generator” mode, on the other hand, the movement of the coil assembly 500 relative to the toroidal magnetic cylinder 430 will cause current to be generated in the individual coils 526 to produce a DC current of a particular polarity as the individual coils move through each tunnel or radial segment 420 or 421.

[0097] In order to maintain the generated torque and/or power the individual coils 526 in the coil assembly 500 may be selectively energized or activated by way of a switching or brushless motor controller (not shown). The individual coils 526 in the coil assembly 500 may be electrically, physically, and communicatively coupled to switching or brushless motor controller which selectively and operatively provides electrical current to the individual coils in a conventional manner.

[0098] For instance, the brushless motor controller may cause current to flow within an individual coil 526 when the individual coil is within a magnetic tunnel segment 420 with a NNNN magnetic pole configuration as illustrated in Fig. 10. On the other hand, when the same individual coil rotates into an adjacent magnetic tunnel segment 421 with a SSSS magnetic pole configuration, the brushless motor controller causes the current within the individual coil 526 to flow in a direction opposite to that when the coil was in the NNNN magnetic pole segment 420 so that the generated magnetic force is in the same direction as coil rotates from one adjacent magnetic segment to the other.

[0099] As discussed above, the individual coils 526 may use toroidal winding without end windings and in some embodiments, the individual coils may be connected to each other in series. In other embodiments, a multi-phasic winding arrangement such as six phase, three phase, etc. winding connection may be used where the proper coils 526 are connected together to form a branch of each phase. For instance, two adjacent coils may be phase A coils, the next two adjacent coils may be phase B coils, and the next two adjacent coils may be phase C coils. This three-phase configuration would then repeat for all individual coils 526 within the coil assembly 500. In one embodiment, there are eight (8) pairs of adjacent phase A coils for a total of 16 phase A coils. Similarly, there are eight (8) pairs of adjacent phase B coils for a total of 16 phase B coils, and there are eight (8) pairs of adjacent phase C coils for a total of 16 phase C coils. Thus, in such an embodiment, there are 48 individual coils.

[00100] When the coils are energized, the multi-phasic winding can produce a rotating magnetomotive force in the air gap around the coil assembly 500. The rotating magnetomotive force interacts with the magnetic field generated by the toroidal magnetic tunnel 430, which in turn produces torque on all sides of the coil assembly 500 and relative movement between the coil assembly and the toroidal magnetic tunnel.

[00101] In such embodiments, the individual coils 526 may be connected to a brushless motor controller (not shown) to be activated by a controller or in a similar manner known in the art. For each phase, the brushless motor controller can apply forward current, reverse current, or no current. In operation, the brushless motor controller applies current to the phases in a sequence that continuously imparts torque to turn the magnetic toroidal tunnel in a desired direction (relative to the coil assembly) in motor mode. In certain embodiments, the brushless motor controller can decode the rotor position from signals from position sensors or can infer the rotor position based on back-emf produced by each phase. In certain embodiments, two brushless motor controllers may be used. In other embodiments, a single brushless motor controller may be used. The brushless motor controller(s) controls the application of current of the proper polarity for the proper amount of time at the right time and controls the voltage/ current for speed control. Regardless, the brushless motor controllers allow for a switching action and a varying voltage action.

[00102] In other embodiments, a brushed electrical machine may be used. In such embodiments, one or more commutators (not shown) may be used and positioned, for instance, within the rotor hub 300 (see Fig. 1 ). In certain embodiments, the number of brushes used may equal the number of toroidal magnetic segments used in the design of the particular electrical machine. For instance, if eight toroidal magnetic segments are used, then eight brushes may be used. The individual coils 526 in the coil assembly 500 may be connected in series having toroidal wound windings. In a brushed design in motor mode, a simplified reverse switching circuit is all that is necessary to switch the current direction as the coils enter and exit the respective toroidal magnetic segment.

[00103] By way of example, in the embodiment illustrated in Fig. 10 and 1 1 , there are 48 coils which may be positioned in a coil assembly of an electric motor having eight magnetic“tunnels” or motor poles. Thus, each magnetic tunnel surrounds 6 of the 48 coils as will be explained below. Optimum torque may be achieved when all six coils are energized sequentially with large overlapping energization periods and for the full duration that each coil is within the tunnel segment. Unlike conventional machines, the coil pole pitch is not dependent on any magnet pole piece width to function. The result is that in certain embodiments, compared to conventional motors, the electrical machine 100 may generate approximately two times the torque density, three times the power density, and two times the output for a given motor size.

[00104] In a conventional motor, the magnet pole face and the coil pole face are basically the same size. So, the coil approaches the magnet pole face, one has a short period of time to make use of the magnetic attraction. This results in a limited pulse. Conventional AC motors, used in vehicles or an industrial machine, typically use a three-phase sinusoidal power supply where the three phases are 120 electrical degrees apart. The pulses fire for only a short period of time, then they advance to the next one. This means at any one point, one only one set of coils, one phase, is energized and producing peak torque in conventional motor. Other sets of coils fire a sequential pattern to create a rotating magnetic field. So, phase A fires, then phase B fires, then phase C fires. In other words, basically two of the coils are off and only one of them is on at any given time. So, your output torque is an average or an RMS value for the three phases. In contrast, certain embodiments of the electrical machine 100, two or more of the coils or phases can fire at the same time.

[00105] Because of the geometry of the electrical machine 100, when a single coil is energized as it enters the pole region it may remain energized and thus will produce torque the entirety of its travel through the pole region. In other words, an energized coil will move completely through a magnetic tunnel or like polarity region on a single DC pulse. The coil will then change polarity as it moves through the next tunnel or polarity region. Thus, in the example illustrated in Figs. 10 and 1 1 , the energized coil will change polarity eight times during a single rotation. A conventional switching mechanism (not shown) may be used to change current direction in the coils as they move from one magnetic tunnel to another. Of course, if the coil assembly is the stator, the coils do not actually move, but the magnets move relative to the coils. In this specification, movement is relative and may refer to either the coil physically moving or the magnets physically moving. [00106] In another embodiment, not shown, there may be four motor poles or tunnels. In this embodiment the current in the coil would change its polarity four times as the coil moves through four tunnels of approximately 90 degrees each as explained above.

[00107] In sum, the windings are placed in an axial/radial direction in multiple slots 524 (e.g. 48 slots) which can form a single phase or multi-phase winding. The radial/axial placement of the windings may create a maximum force in the direction of motion for all four sides of the windings. Current direction or polarization determines direction of travel. In other words, a particular direction of current in a coil determines the direction of rotation. Thus, individual coils/phases can be energized to slow or boost rotation. This allows for precise braking or positioning of rotor - including forward, reverse, and regenerative braking.

A Brushless Motor Controller

[00108] Fig. 12 is a block diagram of one embodiment of a system 1200 that includes one or more brushless motor controllers 1202 and a brushless motor or generator 1204. The brushless motor 1204 may be similar or identical to the electrical machine 100 described in previous embodiments. Accordingly, in some embodiments the brushless motor 1204 includes a coil assembly 500 that is similar or identical to the coil assembly 500 described above. For purposes of explanation, like parts will be numbered as in previous embodiments. It is understood that the brushless motor controller 1202 and the methods described herein may be applied to other configurations of brushless motors and/or generators.

[00109] The brushless motor controller 1202 may be configured to manage the application of current to the phases in a sequence that continuously impacts torque to turn the magnetic toroidal tunnel in a desired direction, relative to the coil assembly, in motor mode. The brushless motor controller 1202 controls the application of current of the proper polarity for the proper amount of time at the right time and further controls the voltage/current/ for speed control. Accordingly, the brushless motor controller 1202 enables a switching action and a varying voltage action. Therefore, a brushless motor overcomes the requirements for a mechanical commutator in a conventional electric motor by reversing the motor configuration, such that the windings become the stator and the permanent magnets become part of the rotor assembly. That is, the windings are commutated in a sequence that produces a rotating magnetic field that drags the rotor assembly around and drives an attached load. The sequence is determined by the relative positions of the stator and rotor assembly. In some embodiments, the timing of the sequence is determined by Hall-effect sensors and/or the magnitude of the back electromagnetic force (BEMF) generated by the rotating rotor assembly.

[00110] In some embodiments, the brushless motor controller 1202 may be designed to work regardless of the constraints of a particular winding assembly 500 to achieve the desired system performance. Accordingly, in some embodiments, the brushless motor controller 1202 may be highly configurable to allow the brushless motor controller 1202 to adapt to a variety of brushless motor 1204 configurations or system constraints. For example, the brushless motor controller 1202 may be configured or processor associated with the brushless motor controller 1202 may be programmed with motor parameters and system parameter that include the maximum current, the maximum speed, the maximum speed, number of poles, the operation voltage, and the like.

Motor and System Parameters

[00111] In some embodiments, the brushless motor controller 1202 may be programmed with the number of poles of the brushless motor 1204. Each magnetic tunnel, 420 or 421 , of Fig. 10 may be thought of as a pole region of like magnetic polarity material. Continuing with the illustrative embodiment of Fig. 10, an eight-pole brushes motor, each pole region represents 45 degrees of the rotor region. Accordingly, the number of pole pairs is defined as the number of magnetic poles divided by 2. In some instances, the number of poles may be specified on the manufacture’s datasheet, motor nameplate, or the like, for the brushless motor 1204. In some instances, the number of poles may be not be specified but can be determined experimentally by injecting a current with a power supply, which is less than the rated current of the brushless motor 1204, into phase A allowing the motor to settle into an initial position. By rotating the brushless motor 1204 through one revolution and counting the number of settle down positions the number of pole pairs can be determined. The number of poles is determined by multiplying the number of pole pairs by 2.

[00112] In some embodiments, the brushless motor controller 1202 may be programmed with the number of coils 526. Continuing with the illustrative embodiment of Fig. 10, there are 48 coils 526 and each individual coil 526 forms a 7.5-degree stator region. Therefore, each magnetic tunnel or pole may surround 6 of the 48 coils.

[00113] In some embodiment, the brushless motor controller 1202 may be programed with the number of phase groups. Continuing with the illustrative embodiment of Fig. 10, the 48 coils are divided into six phase groups A-F, with the expectation that 8 coils in a phase group will be energized together.

[00114] In some embodiments, the brushless motor controller 1202 may be programmed with the operating voltage of the brushless motor 1204. In certain embodiments, the operating voltage of the brushless motor 1204 may be a voltage range where the brushless moto/generator 1204 characteristics may be substantially constant, and the operating voltage does not adversely affect the life of brushless motor 1204. In some instances, an upper voltage value may be based, at least in part, on the value beyond which the magnetic portion of the brushless motor 1204 may be saturated. In contrast, a lower value may be based, at least in part, below which the current under rated load may increase to a value that causes excessive heating and damages the brushless motor 1204. In certain instances, the operating voltage may be specified on the manufacture’s datasheet, motor nameplate, or the like. In some embodiments, the operation voltage of the system may be constant, that is, the operating voltage may be provided by a regulated power supply. In certain embodiments, the operating voltage of the system may be unregulated and may vary. For instance, the system may be powered by a battery and a battery terminal voltage may decay as the battery discharges or drop with increasing load current because of the internal resistance of the battery. In some embodiments, a speed of the brushless motor 1204 may be adjusted by modifying the magnitude of the operation voltage. For instance, the brushless motor controller 1202 may modify a speed of the brushless motor 1204 by modifying a PWM/duty cycle of a motor drive circuit. Further, the brushless motor controller 1202 may measure the operating voltage.

[00115] In some embodiments, the brushless motor controller 1202 may be programmed with a maximum current. The maximum current may be defined as a steady state current that does not cause an increase in heating resulting in a shortening of the brushless motor’s 1204 life. In certain embodiments, the maximum current may be defined for a no-load speed and/or a full load speed. In certain embodiments, the maximum current may be a current consumption during startup and/or during acceleration. The brushless motor controller 1202 may measure the current as described herein.

[00116] In some embodiments, the brushless motor controller 1202 may be programmed with a motor resistance. In some instances, the motor resistance may be specified on the manufacture’s datasheet, motor nameplate, or the like. In other instances, the motor resistance may be determined experimentally by measuring the resistance of a phase, for instance, phase A.

[00117] In some embodiments, the brushless motor controller 1202 may be programmed with the motor velocity constant. The motor velocity constant is defined as the motor’s phase-to-phase back electromotive force (BEMF) voltage as a function of the motor velocity (mV/Hz). In some instances, the motor velocity constant may be specified on the manufacture’s datasheet, motor nameplate, or the like. In other instances, the motor velocity constant may be determined experimentally. For example, in systems where the motor BEMF is correctly set the enveloped of the motor phase current may be substantially constant, corresponding to current maximum acceleration, as the brushless motor controller 1202 ramps up the speed over time. However, if the motor BEMF is set to high, the envelope of the motor phase current may ramp up over time as the speed of the motor increases. Alternatively, if the motor BEMF is set too low, the envelope of the motor phase current may decrease as the speed of the motor increases.

[00118] In some embodiments, the brushless motor controller 1202 may be programmed with the electrical time constant of the brushless motor 1204. The electrical time constant (TLR) of the brushless motor 1204 is defined as the motor phase-to-phase inductance divided by the motor phase-to-phase resistance. In one embodiment, a control advance time of the system may be based on the electrical time constant of the brushless motor.

[00119] In some embodiments, the brushless motor controller 1202 may be programed with the rotor inertia (kgm ² ) or angular mass. Rotor inertia is a function of the rotor structure and/or load and is the tendency of the rotor to keep moving as a constant velocity when no drive force is applied to the motor or to remain stationary when a drive force is applied at startup. [00120] In some embodiments, the brushless motor 1204 parameter’s may be stored on an EEPROM, or the like, associated within the motor 1204. In certain embodiments, the brushless motor controller 1202 may access the stored parameters through a data bus at startup.

[00121] In some embodiments, the brushless motor controller 1202 may be programed with only the motor phase resistance and the motor BEMF constant. For instance, default values may be used for the other brushless motor parameters.

Detecting the Initial Alignment of the Rotor

[00122] In some embodiments, the brushless motor controller 1202 may include Initial Position Detection (IPD) to detect the rotor alignment of the brushless motor 1204 at startup. Initial position detection may be used in applications where reverse rotation of the rotor is unacceptable at startup. For instance, where reverse rotation of the rotor and/or load is visible or would cause a vehicle to jolt/move backwards. In certain embodiments, initial position detection may be implemented to allow a faster startup of the brushless motor 1204.

[00123] In some embodiments, an initial position of the rotor may be determined with one or more sensors. For instance, the initial position of the rotor may be determined with a Hall sensor(s). Alternatively, the initial position of the rotor may be determined with optical encoders, resolvers, and the like.

[00124] In some embodiments, the position of the rotor may be determined based on the back electromagnetic force (BEMF) generated by the rotating rotor. In some instances, the position of the rotor may be determined with a BEMF integration method. In other instances, the position of the rotor may be determined by detecting zero crossing points in the BEMF. In another instance, the position of the rotor may be determined using a third-harmonic BEMF sensing method. In some instances, an inductance of a phase of the brushless motor 1204 may vary as a function of rotor position. In one embodiment, an inductive sense method may be used to determine the initial position of the rotor at start-up. For instance, the rotor position may be determined by pulsing a current, that does not cause the rotor to rotate, through the phase winding(s) and determining the corresponding inductance. For example, a voltage may be sequentially applied across the phases according to the following sequence: A, B, C, D, E, and F, until the current reaches a preterminal current threshold value. The time it takes from when the voltage is applied, until when the current threshold is reached, may be measured. Because the time will vary as a function of the inductance in the motor windings, the state with the shortest time will corresponds to the state with the minimum inductance, which occurs when a pole of the brushless motor 1204 is aligned with this particular driving state.

[00125] In certain embodiments, the brushless motor controller 1202 may be configured for align and go. For instance, where reverse rotation of the rotor and/or load at startup may not be important the align and go method may be used. The align and go method may force the rotor into alignment by applying a voltage across one of the brushless motors 1204 phases to force the rotor to rotate into alignment with this particular phase at startup.

[00126] In certain embodiments, the brushless motor controller 1202 may be configured to transition between IPD detection and the like, to BEMF detection of the rotor position. In one embodiment, a handoff threshold may be implemented by the brushless motor controller 1202 to avoid a startup failure. In certain embodiments, the handoff threshold may be based on the rotor speed. For instance, a minimum speed may have to be obtained by rotor before the magnitude of the BEMF can be reliability measured by the brushless motor controller 1202. In one embodiment, the handoff threshold may be based on the rated motor speed. For instance, the handoff threshold may be between about 0.1 and about 0.5 of the rated brushless motors’ 1204 speed.

[00127] In some embodiments, the brushless motor controller 1202 may be configured to receive an analogy input speed command proportional to the rotor speed. For instance, the magnitude an analogy voltage/current may be directly proportional to the rotor speed. In certain embodiments, the brushless motor controller 1202 may be configured to receive a PWM speed command. For instances, the duty cycle of a PWM signal may be directly proportional to the rotor speed. In one embodiment, the brushless motor controller 1024 may be configured to receive rotor speed commands via a data bus. For instance, the speed of the rotor may be transmitted via l ² C speed/data commands.

[00128] In some embodiments, the brushless motor controller 1202 may be configured to measure the initial speed of the rotor at start-up. In one embodiment, the brushless motor controller 1202 may be configured to measure the direction of rotation of the brushless motor at start-up. In certain embodiments, the brushless motor controller 1202 may be programed with an initial forward speed wait threshold. In one embodiment, the brushless motor 1204 may be configured to wait for the rotor to stop if the brushless motor is spinning below the initial forward speed wait threshold. In certain embodiments, the decision to wait may be based on the rotor inertia because high inertia/low friction motors will take a long time to coast down to zero speed if a reverse motor drive and/or brake function is not implemented.

[00129] In some embodiments, the brushless motor controller 1202 may be configured to implement a brushless motor 1204 brake function by turning one or more low-side drivers of one or more ½ H-bridges. In certain embodiments, the brushless motor controller 1202 may a set brake speed threshold. In one embodiment, the brushless motor controller 1202 may be configured to brake, based on, at least in part, the initial forward speed, the initial forward speed wait threshold, the set brake speed threshold, the direction of rotation, or the rotor inertia.

[00130] In some embodiments, the rotor position may be unknown after the brushless motor 1204 has stopped when the brake function is implemented requiring either the brushless motor controller 1202 to use either IPD or Align and Go method at start-up. After the brushless motor 1204 has stopped spinning a brushless motor start-up sequence may be initiated. In one embodiment, the brushless motor controller 1202 may be configured to go directly into a closed loop mode by resynchronizing a spinning rotor. In one embodiment, to achieve the quickest start-up time the brushless motor controller 1202 may be configured to go directly into closed loop mode if the forward speed is greater than a threshold value. In certain embodiments, the brushless motor controller 1202 may be programmed with an initial reverse speed wait threshold. In one embodiment, the brushless motor 1204 may be configured to wait if the brushless motor is spinning below the initial reverse speed wait threshold. In certain embodiments, the decision to wait may be based on the rotor inertia. In certain embodiments, the brushless motor controller 1202 may be configured to brake, based on, at least in part, the initial reverse speed threshold, the reverse speed wait threshold, the direction of rotation, and the rotor inertia. In one embodiment, the brushless motor controller 1202 may be configured to brake, based on, at least in part, the initial reserve speed, the initial reverse speed wait threshold, the set brake speed threshold, the direction of rotation, or the rotor inertia. After the brushless motor has stopped spinning the brushless motor start-up sequence may be initiated.

[00131] In some embodiments, the brushless motor controller 1202 may be configured to implement a brushless motor reverse drive option. In one embodiment, the system may be configured to reverse the motor drive, such that the brushless motor accelerates through zero velocity. This embodiment achieves the shortest possible spin-up time in a system where the brushless motor is spinning in the reverse direction at startup. In certain embodiments, the brushless motor controller 1202 may be configured to transition between forward motor drive, reverse motor drive, and/or the brake function in real time. In one embodiment, the brushless motor controller 1202 has a built-in thermal shutdown function, which shuts down the brushless motors driver when the system temperature is greater than a shutdown threshold value. In certain embodiments, the system recovers when the system temperature is less than a recover threshold value.

[00132] In one embodiment, the brushless motor controller 1202 has built-in overcurrent protection to protect the device if the current as measured from the drive MOSFETs exceeds a shutdown threshold value. In certain embodiments, the brushless motor controller 1202 places the MOSFETs into a high-impedance state until the overcurrent condition is no longer detected.

[00133] In certain embodiments, the brushless motor controller 1202 determines an acceleration current value, which is based, at least in part, on the motor inertia. In one embodiment, the brushless motor controller 1202 may be programmed to determine whether the acceleration current value is too high by monitoring a phase current and the motor rpm. If the brushless motor 1204 is not rotating and the phase current keeps increasing, then the acceleration current value may be too high. In one embodiment, the brushless motor controller 1202 may be programmed to reduce the acceleration number until a reliable startup is achieved.

[00134] In some embodiments, the brushless motor controller 1202 may programmed with an acceleration current limit. In one embodiment, the acceleration current limit may be configured by the brushless motor controller 1202 to be less than the full-speed operation current. In one embodiment, the acceleration current may be configured by the brushless DC controller 1202 for a soft start-up. In one embodiment, the acceleration current may be ramped over a period of time. In one embodiment, the acceleration current may be based on the motor inertia value. In one embodiment the brushless motor controller configures the acceleration current to reduce/minimize acoustic noise at startup. In one embodiment, the acceleration current is greater than the current at maximum speed under full load. In certain embodiments, the brushless controller 1202 configures the acceleration current to be less than a lock current limit threshold.

[00135] In some embodiments, the brushless motor controller 1202 may be programmed with a lock detection current threshold. The lock detection current threshold may be configured to protect the brushless motor 1204 and/or brushless controller when the rotor is restricted from rotating by an external force.

[00136] In some embodiments, the brushless motor controller 1202 includes a dead time for the gate drive between the high-side and low-side H-Bridge drivers, wherein the dead time may be enough to avoid shot through. In certain embodiments, the dead time is based, at least in part, on the supply voltage.

[00137] In some embodiments, the brushless motor controller 1202 may be configured to optimize the brushless motor’s 1202 efficiency by modifying a control advance angle. In the present embodiment, the control advance angle is defined as the difference between the phase voltage and the phase current of the brushless motor 1204. In some embodiments, the optimum control advance angle may be determined by one or more of: adjusting the control advance angle to minimizes the supply current at a given speed, the phase current waveform being stable, and/or the motor rotor assembly spinning smoothly. In certain embodiments, the control advance angle may be increased. In one embodiment, the control advance angle may be decreased.

[00138] In some embodiments, the brushless motor controller 1202 may be programmed with an anti-voltage surge function. The phase windings of the brushless motor 1204 are an inductive load. When current is driven through an inductive load energy is stored. The anti-voltage surge function may prevent the voltage from surging when the brushless motor 1204 is transitioning from high speed to low speed and/or from a driven state to a coasting state. In some embodiments, the brushless motor controller 1202 may be programmed to actively drive the low side MOSFET(s) of the H- Bridge driver(s) into a high-impedance state, corresponding to coasting. Further, the brushless motor controller 1202 may be programmed to actively drive the high side MOSFETs high, such that the inductive energy in the inductive windings may be returned to the supply.

Energizing Windings/Coils

[00139] In some embodiments, a plurality of coils or coil windings 526 of the coil assembly 500 may be individually controllable using electronic switches and the brushless motor controller 1202 may therefore energize each coil winding 526 separately. This enables the coil windings 526 to be dynamically grouped into sets to be energized by the brushless motor controller 1202, and the particular set to which a coil winding 526 is assigned may be dynamically altered by the brushless motor controller 1202 based on desired operational parameters. In this manner, the brushless motor controller 1202 may be able to configure a single brushless motor 1204 to dynamically achieve a multi-phasic winding by controlling when each coil winding 526 is energized.

[00140] In certain embodiments the brushless motor controller 1202 may be programmed to identify one or more of the coil windings that are faulty. The brushless motor controller 1202 may use the ability to individually control when each coil windings 526 is energized to omit one or more of the coil windings 526 that are faulty, such that, the faulty coil winding(s) 526 may not be energized.

[00141] In certain embodiments, each coil 526 of the coil assembly 500 may be individually controllable using electronic switches and the brushless motor controller 1202 may therefore energize each coil 526 separately. This enables a plurality of coils to be dynamically grouped into a coil winding to be energized by the brushless motor controller 1202, and the particular winding to which a coil is assigned can be dynamically altered by the brushless motor controller 1202 based on the desired operational parameters.

[00142] In certain embodiments, the brushless motor controller 1202 may be programmed to identify one or more of the individually coil(s) 526 that are faulty. The brushless motor controller 1202 may use the ability to individually control each coil 526 to omit or isolate one or more of the individually controllable coil(s) 526 that are faulty from a coil winding using electronic switches. In certain embodiments, the brushless motor controller 1202 may be programmed to omit one or more of the individually controllable coil(s) that are faulty and one or more coil(s) that are not faulty to balance the torque of each coil winding of the brushless motor 1204.

[00143] The brushless motor controller 1202 may use the ability to isolate one or more of the coils or coil windings 526 that are faulty to implement a limp mode or“limp- home mode.” That is, limp-home mode may be activated by the brushless motor controller 1202 when the system detects a fault with one or more of the plurality of coils or coil windings 526 that could damage the brushless motor 1204 and/or brushless motor controller 1202. While isolating one or more faulty coils or coil windings 526 may reduce the torque/power of the brushless motor 1204 it may also allow a vehicle powered by the brushless motor 1204 to drive home, complete a journey, be taken to a service center, or the like. In certain embodiments, the brushless motor controller 1202 may be programmed with the one or more of the individually controllable coil(s) 526 that are faulty. For instance, during the manufacturing process, at a service center, or the like. In some embodiments, the brushless motor controller 1202 may be configured to modify the energization of one or more coil windings of the brushless motor 1204 to compensated for one or more faulty coils or coil windings 526. For instance, the brushless motor controller 1202 may increase the duty cycle of the PWM driver signal for a coil winding containing one or more faulty coils 526. In some instances, the brushless motor controller 1202 may decrease the duty cycle of the PWM driver signal for coil winding(s) that do not contain one or more faulty coil(s) 526 to balance the torque.

[00144] In some embodiments, one or more the electronic switch(s) may be a power thyristor or silicon-controlled rectifier, SCR. A power thyristor is a solid-state semiconductor device with four layers of alternating p-type doped material and n-type doped material. A SCR functions as a bi-stable switch, which conducts when a gate of the power thyristor receives a current trigger and continues to conduct until the voltage across the power thyristor is reversed biased, or until the voltage is removed.

[00145] In some embodiments, one or more of the electronic switch(s) may be a power metal-oxide-semiconductor field-effect transistor, MOSFET which designed to handle significant higher power levels than a conventional MOSFET. Specifically, a power MOSFET is designed to have a lower on resistance than a conventional low power MOSFET and the oxide layer of the MOSFET gate is thicker with a higher threshold voltage. It can therefore withstand a higher input voltage than a conventional MOSFET.

[00146] In some embodiments, one or more of the electronic switches may be a power bipolar transistor, BJT.

[00147] In some embodiments, one or more of the electronic switches may be a three-terminal insulated-gate bipolar transistor, (IGBT). An IGBT is a power switching transistor which combines the advantages of MOSFETS and a Bipolar Junction Transistors, (BJTs). That is, the high input impedance and high switching speeds of a MOSFET, with the low saturation voltage of a bipolar transistor, making the IGBT ideal for driving inductive loads, such as the coil windings of brushless motors.

[00148] In some embodiments, one or more of the electronic switches may be a solid- state relay, SSR. A solid-state relay is an electronic switching device that switches on or off when a small external voltage is applied across the control terminals of the device, which in many devices, energizes an internal LED which illuminates and switches on a photo-sensitive diode. The photo-sensitive diode current turns on a back-back power thyristor, SCR, or MOSFET. The optical coupling allows the control circuit to be electrically isolated from the load.

[00149] Fig. 13 illustrates one embodiment of a method 1300 that may be executed with the brushless motor controller 1202. The method 1300 uses the ability of the brushless motor controller 1202 to separately energize each coil 526 and to group the coils 526 together as desired. Accordingly, in step 1302, the total number of available coils is identified. For purposes of example, there are forty-eight (48) coils. In step 1304, the number of desired phases for the current configuration is defined. For example, a six-phase configuration may be desired and therefore defined in step 1304, for example as phases A-F. In step 1306, each of the forty-eight coils is assigned to one of the six phase groups A-F. In step 1308, all coils in a phase group are energized based on a defined timing sequence. The timing sequence identifies which phase group(s) A-F should be energized at a particular time, with the option to have some or all phase groups simultaneously energized. [00150] Fig. 14 illustrates one embodiment of a system for modifying the phase of brushless motor 1204 to provide multi-phasic capability. Continuing with the illustrative embodiment of Fig. 10, the 48 coils are divided into six phase groups A-F, with the expectation that the 8 coils in a phase group will be energized together. In the illustrative embodiment of Fig. 14 two half-H-bridges A1 , A2 are connected to each end of the phase A coils, two half-H-bridge B1 , B2 are connected to each end of the phase B coils, two half-H-bridge C1 , C2 are connected to each end of the phase C coils, two half-H-bridge D1 , D2 are connected to either end of the phase D coils, two half-H-bridge E1 , E2 are connected to each end of the phase E coils, and two half-H-bridge F1 , F2 are connected to each end of the phase F coils.

[00151] Further, half-H-bridge A2 is connected to half-H-bridge B1 by electronic switch S1 , half-H-bridge B2 is connected to half-H-bridge C1 by electronic switch S2, half-H-bridge C2 is connected to half-H-bridge D1 by electronic switch S3, half-H-bridge D2 is connected to half-H-bridge E1 by electronic switch S4, half-H-bridge E2 is connected to half-H-bridge F1 by electronic switch S5, and half-H-bridge F2 is connected to half-H-bridge A1 by electronic switch S6. As will be understood by persons of ordinary skill in the relevant art the output of each half-H-bridge may be driven (switched) high, low, or configured as a high impedance output stage.

[00152] The, brushless motor controller 1202 may control the firing sequence of the half-H-bridges to emulate the 6-phase winding of a conventional motor by configuring each of the electronic switches S1 through S6 to be open and by driving each of half-H- bridge A1 , A2, B1 , B2, C1 , C2, D1 , D2, E1 , E2, F1 , and F2 with the appropriate 6-phase firing sequence.

[00153] In another embodiment, the brushless motor controller may configure the half- H-bridges and electronic switches to emulate the 3-phase winding of a conventional motor. For instance, the brushless motor controller 1202 may close electronic switches S1 , S3, and S5 to connect coil winding A in series with coil winding B, coil winding C in series with coil winding D, and coil winding E is series with coil winding F. The brushless motor controller 1202 may also configures the outputs of half-H-bridges A2, B1 , C2, D1 , E2, and F1 to be high impedance. Further, the brushless motor controller 1202 may drive each of the half-H-bridges A1 , B2, C1 , D2, E1 , and F2 with the appropriate three- phase firing sequence. [00154] In yet another embodiment, the brushless motor controller may configure the half-H-bridges and electronic switches to emulate the 2-phase winding of a conventional motor. For instance, the brushless motor controller 1202 may close electronic switches S1 , S2, S4, and S5 to connect coil windings A, B, and C in series with coil windings D, E, and F in series. The brushless motor controller 1202 may also configures the outputs of half-H-bridges A2, B1 , B2, C1 , D2, E1 , E2, and F1 to be high impedance. Further, the brushless motor controller 1202 may drive each of the half-H-bridges A1 , C1 , D1 and F2 with the appropriate two-phase firing sequence.

An Adaptive Electronic Transmission:

[00155] In order to take maximum advantage of various embodiments of the brushless motor 1204, a new method of control has also been developed. Although conventional six phase methodologies of supplying power for this machine will work, torque production may be optimized, and torque pulsation may be minimized by using methods described below. Specifically, the software of the brushless motor controller 1202 emulates phase firing and changes through the speed range and or by torque demand.

[00156] With the brushless motor 1204, an adaptive electronic transmission can be used to adjust torque, speed, and loading capabilities. With the ability to continuously adjust the coil firing sequence, firing up to 90% of segments all at once or the adaptive electronic transmission can emulate six-phase, three-phase, two-phase and one-phase windings of conventional motors. In some embodiments, the adaptive electronic transmission can start with twelve or even eighteen-phases, then emulate lower phases.

[00157] As previously discussed, in the motor 1204, two or more of the coils 526 may fire at the same time. In fact, essentially all coils 526 within the magnetic tunnel segment may fire at the same time. This results in a more output torque compared to conventional motor. Therefore, the brushless motor 1204 can produce torque values based on the average of five of the six phases that are firing. In other words, the brushless motor 1204 may utilize the additive effect of all five coils within the tunnel segment to produce torque. This also results in comparatively smooth acceleration and low torque pulsation. [00158] Turning now to Fig 15, there is graph illustrating three sinusoidal voltage waveforms as commonly known in the art of a conventional motor. In Fig. 15, the three sinusoidal waveforms are 120 electrical degrees out of phase from each other. As known in the art, this waveform represents a three phase or six phase supply (120 electrical degrees or 60 electrical degrees respectively). As can be inferred from the graph of Fig. 15, at any given instant essentially only one phase of the conventional motor is actively providing torque. Differing phase coils cannot be energized concurrently as an optimum rotating magnetic field would not be produced and rotation would cease.

[00159] Turning now to Fig. 16-1 there is a graph illustrating a plot or waveform of the back-emf of a single phase of the brushless motor 1204 of Fig. 10 having a trapezoidal power input. To match the back-emf, every 7.5 degrees a coil/phase enters a 45- degree pole region and is energized for the duration of its travel through the pole region. This is only possible because in this magnetic configuration each coil produces a Lorentz force and a reluctance force that peak simultaneously through the entire 45 degrees of rotation. As there are 8 coils per phase (one for each of the 8 polar regions discussed above) a six-phase supply may provide the greatest torque production and the least torque pulsation.

[00160] Plots of the back-emf illustrate the trapezoidal nature of the voltage produced for all six phases as illustrated in Fig. 16-2. It will be noted that essentially all the phases are producing torque continuously. This indicates that a high torque and smooth acceleration of the rotor mass is possible when power is input to the phase conductors.

[00161] For the brushless motor 1204, polarity transition of the coils/phase is only required when a coil is entering the next alternate polarity region. As the timing and polarity of the power inputs may be controlled by an indexed position indicator signal and software it is also possible to change the pole count electronically. The torque produced is an average of the voltage pulses over time. Similarly, the software of the brushless motor controller 1202 may also emulate the three phase, two phase or single phase grouping of phases of a conventional motor.

[00162] For instance, to emulate a three-phase motor, software processes in the brushless motor controller 1202 can group phase A and B together, group phase C and D together, and group phase E and F together. So, instead of six poles in the motor, the motor acts as if there are three poles. Transitioning from six poles to three poles, acts in part like gear teeth on a manual transmission because as the RPM’s get higher, the user shifts to a higher, for example second gear to increase speed. The frequency does not change, but as the pole count transitions from six to three, the rotations per second will increase. With any electric motors, when there is a reduction in pole count and the frequency is kept constant, the speed increases. That is, the poles determine the speed for a given power input.

[00163] Then, as the motor continues to accelerate, a transition can occur from the three-phase emulation to a two-phase emulation. For a two-phase emulation, software processes in the brushless motor controller 1202 can group the coils A, B, and C to fire at the same time and coils D, E, F, to fire at the same time. Again, this emulation lowers the pole count which results in an increase in speed.

[00164] This method retains all the inherent benefits of the four-rotor circumferential flux technology including continued operation after loss of a phase, emulation of a mechanical gearbox, etc. When a lead position indicator signal is received the coil/phase groupings can be changed to emulate any poly-phase input as desired. For example, if Phase A and Phase B, Phase B and C, and Phases D and E are grouped to energize at the same instant, an emulated lower pole count machine is created. The frequency and timing of polarity changes per revolution can be easily adjusted resulting in an increased rotor speed with no changes to voltage or current inputs. See for instance, the waveforms graphed in Fig. 17-1 .

[00165] The torque produced is an average of the voltage pulses over time. Similarly, the software of the brushless motor controller 1202 may also produce an emulated two phase or single-phase grouping of phases. This method retains all the inherent benefits of the four-rotor circumferential flux technology including continued operation after loss of a phase, emulation of a mechanical gearbox, etc. See for instance, the waveforms graphed in Fig. 17-2.

[00166] Fig. 18 illustrates one embodiment of the coil assembly 500 with forty-eight (48) individual coils 526 that may be separately energized. Continuing the six-phase coil arrangement of Fig. 10, the coils 526 are divided into six phase groups A-F, with the expectation that all the coils in a phase group will be energized together. In the present example, a particular coil 526 is denoted by its group and a coil number within that group. For example, the first coil in phase A is labeled as 526A-1 , the second coil in phase A is labeled as 526A-2, and so on through the last coil of the last group 526F-8. It is understood that this labeling scheme is merely an example and is not intended to be limiting. Furthermore, the labeling of a coil as "first," "second," and so forth is meant for clarity and is not intended to be limiting or to necessarily indicate that there is a particular order within a group.

[00167] In some embodiments, to form a six phase winding arrangement using the coil assembly 500 with forty-eight (48) coils 526, the brushless controller 1202 may set the eight coils 526A-1 through 526A-8 as phase A coils, the eight coils 526B-1 through 526B-8 as phase B coils, the eight coils 526C-1 through 526C-8 as phase C coils, the eight coils 526D-1 through 526D-8 as phase D coils, the eight coils 526E-1 through 526E-8 as phase E coils, and the eight coils 526F-1 through 526F-8 as phase F coils.

[00168] As discussed above, with the brushless motor 1204, an adaptive electronic transmission may be used for adjustable torque, speed, and loading capabilities. With the ability of the four rotor electric machine to continuously adjust the coil firing sequence, firing up to 90% of segments all at once, the adaptive electronic transmission of the brushless motor 1204 may emulate 6-phase, 3-phase, 2-phase and 1 -phase windings of conventional motors by various means. In some embodiments, the coil assembly 500 may be dynamically managed to provide a multi-phasic capable motor. The following embodiments are meant to illustrate the flexibility of the Hunstable Electric Turbine or a circumferential flux, four rotor electric machine and are not intended to be limiting.

Six-Phase Winding Configuration

[00169] Further, while the embodiment of Fig. 18 illustrates the coils 526 of a particular phase group A-F as being distributed evenly around the coil assembly 500 with no adjacent coils being in the same phase group, it is understood that the groupings may be defined differently. For example, in an alternate embodiment (not shown), to form a six phase winding arrangement using the same coil assembly 500 with forty-eight (48) coils 526, the brushless motor controller 1202 may set two adjacent coils as phase A coils, the next two adjacent coils as phase B coils, the next two adjacent coils as phase C coils, the next two adjacent coils as phase D coils, the next two adjacent coils as phase E coils, and the next two adjacent coils as phase F coils. This six-phase configuration would then repeat for all individual coils 526 within the coil assembly 500. Accordingly, with the forty-eight coils 526 would be arranged with four (4) pairs of adjacent phase A coils, four (4) pairs of adjacent phase B coils, four (4) pairs of adjacent phase C coils, four (4) pairs of adjacent phase D coils, four (4) pairs of adjacent phase E coils, and four (4) pairs of adjacent phase F coils.

Six-Phase Winding Coil Firing Sequence

[00170] Continuing with the embodiment of Fig. 18, Figs. 18-1 through 18-12 illustrate a coil firing and tunnel segment rotation sequence over time emulating a six phase “winding” configuration illustrating one embodiment of the present invention. (Figs. 18-1 , 18-3, 18-5, 18-7, 18-9, and 18-1 1 are identical, but the“off” coils/phases appear to be rotating as the polar region transition passes over a particular phase group.)

[00171] In Fig. 18-2, the 8 coils in the first phase are not firing, for example the eight coils in winding A are not energized, and the coils of the other five phases are being energized concurrently. That is, four coils of winding A are transitioning from within the four evenly spaced magnetic tunnel segments 420 having a NNNN magnetic pole configuration, as illustrated in Fig. 10, and four coils of the winding A are transiting from within the four evenly spaced magnetic tunnel segments having a SSSS pole configuration, as illustrated in Fig. 10 to adjacent magnetic tunnel segments of opposite polarity. Further, four coils of winding B, winding C, winding D, winding E, and winding F are within the four evenly spaced magnetic tunnel segments 420 having a NNNN magnetic pole configuration, and four coils of the winding B, winding C, winding D, winding E, and winding F are within the four evenly spaced magnetic tunnel segments having a SSSS magnetic pole configuration, as illustrated in Fig. 10. The eight coils in winding B and the like, may be configured, such that, the current flow in the 4 energized coils in the magnetic segment 420 having a NNNN configuration and the current flow in the B energized coils in the magnetic segment 420 having a SSSS configuration, generated magnetic forces that are in the same direction as the coil rotates from one adjacent magnetic segment to the other. In some embodiments, the coils of windings B through F are being energized sequentially with large overlapping energization periods for the full duration that each coil is within the tunnel segment. [00172] In Fig. 18-4, the 8 coils in the second phase are not firing, for example the eight coils in winding B are not energized. The four coils of winding A, C, D, E and F are within the four evenly spaced magnetic tunnel segments 420 having a NNNN magnetic pole configuration, and the four coils of the winding A, C, D, E, and F within the four evenly spaced magnetic tunnel segments having a SSSS magnetic pole configuration are being energized. In certain embodiments, the coils of windings A, C, D, E, and F are being energized sequentially with large overlapping energization periods for the full duration that each coil is within the tunnel segment.

[00173] In Fig. 18-6, the 8 coils in the third phase are not firing, that is the eight coils in winding C are not being energized. The four coils of winding A, B, D, E and F are within the four evenly spaced magnetic tunnel segments 420 having a NNNN magnetic pole configuration, and the four coils of the winding A, B, D, E, and F within the four evenly spaced magnetic tunnel segments having a SSSS magnetic pole configuration are being energized. In certain embodiments, the coils of windings A, B, D, E, and F are being energized sequentially with large overlapping energization periods for the full duration that each coil is within the tunnel segment.

[00174] In Fig. 18-8, the 8 coils in the fourth phase are not firing, that is the eight coils in phase D are not energized. The four coils of winding A, B, C, E, and F are within the four evenly spaced magnetic tunnel segments 420 having a NNNN magnetic pole configuration, and the four coils of the winding A, B, C, E, and F within the four evenly spaced magnetic tunnel segments having a SSSS magnetic pole configuration are being energized. In certain embodiments, the coils of windings A, B, C, E, and F are being energized sequentially with large overlapping energization periods for the full duration that each coil is within the tunnel segment.

[00175] In Fig. 18-10, the 8 coils in the fifth phase are not firing, that is the eight coils in phase E are not energized. The four coils of winding A, B, C, D, and F are within the four evenly spaced magnetic tunnel segments 420 having a NNNN magnetic pole configuration, and the four coils of the winding A, B, C, D, and F within the four evenly spaced magnetic tunnel segments having a SSSS magnetic pole configuration are being energized. In certain embodiments, the coils of windings A, B, C, D, and F may be energized sequentially with large overlapping energization periods for the full duration that each coil is within the tunnel segment. [00176] In Fig. 18-12, the 8 coils in the sixth phase are firing, that is the eight coils in phase F are not energized. The four coils of winding A, B, C, D, and E are within the four evenly spaced magnetic tunnel segments 420 having a NNNN magnetic pole configuration, and the four coils of the winding A, B, C, D, and E within the four evenly spaced magnetic tunnel segments having a SSSS magnetic pole configuration are being energized. In certain embodiments, the coils of windings A, B, C, D, and F may be energized sequentially with large overlapping energization periods for the full duration that each coil is within the tunnel segment.

[00177] In Figs. 18-1 , 18-3, 18-5, 18-7, 18-9, and 18-1 1 the four coils of winding A-F are within the four magnetic tunnel segments 420 having a NNNN magnetic pole configuration, and the four coils of the windings A-F are within the four evenly spaced magnetic tunnel segments having a SSSS magnetic pole configuration are being energized. In certain embodiments, the coils of windings A-F may be energized simultaneously. In the embodiment of Fig. 18, the coils in a phase group are being energized together to emulate a six-phase arrangement of a conventional motor.

[00178] At some point, as discussed above, there may be need a need to increase the brushless motor 1204 speed while reducing the torque produced. For instance, the brushless motor 1204 may accelerate to the point where the coil switching mechanism can no longer keep up with the acceleration. In conventional motors, this would be the rotational limit of the motor because the switching mechanism can only switch so fast. However, by using the embodiments of the electronic transmission disclosed herein, the coils can be grouped together, thereby decreasing the number of current switching required per cycle. Thus, the motor can keep accelerating - similar to conventional motor with a manual transmission. When the coils are grouped together, the torque produced by each coil does not change, but the period of time the coil is“on” decreases - which means that average torque drops. So, as the speed of the brushless motor 1204 increases, the average torque will drop.

[00179] In certain embodiments, an encoder attached to the shaft may provide a control signal to the brushless motor controller 1202 so that the brushless motor controller 1202 knows when to shift or group the coils together, based on motor speed or a variety of other factors.

Three-Phase Winding [00180] Fig. 19 illustrates one embodiment of the coil assembly 500 with forty-eight (48) individual coils 526 that may be separately energized. Continuing the example of Fig. 18, the coils 526 are divided into six phase groups 526A-526F, with the coils in a phase group being energized together but in this case the coil/phase groups are physically connected in series rather than emulated.

[00181] In the present embodiment of Fig. 19, the brushless motor controller 1202 joins groups together. This means that individual coils do not need to be reassigned to new groups. For example, using the forty-eight coils assigned to phases A-F as described above, the groups may be paired as follows: phases A and F are paired, phases B and C are paired, and phases D and E are paired. The coils in each paired group are then energized together. This effectively reduces the number of phases from six to three without requiring reassignment of individual coils 526 to new groups by the brushless motor controller 1202. In another embodiment (not shown), the brushless motor controller 1202 may define three new phase groups A-C and then assign each coil 526 to one of the three groups.

[00182] While the embodiment of Fig. 19 illustrates the coils 526 of a particular phase group A-F as being distributed evenly around the coil assembly 500 with no adjacent coils being in the same phase group, it is understood that the groupings may be defined differently. For example, in an alternate embodiment (not shown), to form a three phase winding arrangement using the same coil assembly 500 with forty-eight (48) coils 526, the brushless motor controller 1202 may set two adjacent coils as phase A coils, the next two adjacent coils as phase B coils, and the next two adjacent coils as phase C coils. This three-phase configuration would then repeat for all individual coils 526 within the coil assembly 500. Accordingly, with the forty-eight coils in the present embodiment, there will be eight (8) pairs of adjacent phase A coils, eight (8) pairs of adjacent phase B coils, and eight (8) pairs of adjacent phase C coils.

Three-Phase Winding Coil Firing Sequence

[00183] Figs. 19-1 through 19-6 illustrate a coil firing and tunnel segment rotation sequence over time emulating a three phase“winding” configuration illustrating another embodiment of the present invention. (Figs. 19-1 , 19-3, and 19-5 are identical, that is all of the windings in each phase are being energized) but the“off” coils appear to be rotating as they track the transition period between magnetic polar regions. In this embodiment, the coils of the 6 individual winding will be energized in pairs. In Fig. 19-2, the 16 coils in the first phase are not firing, for example the eight coils in winding A are not energized and the eight coils in winding F are not energized. That is, the coils in the other four windings B, C, D, and E are energized.

[00184] In Fig. 19-4, the 16 coils in the second phase are not firing, for example the eight coils in winding B are not being energized and the eight coils in winding C are not energized. That is, the coils in the other four windings F, A, D, and E are energized.

[00185] In Fig. 19-6, the 16 coils in the third phase are not firing, for example the eight coils in winding D are not energized and the eight coils in winding E are not energized. That is, the coils in the other four windings F, A, B, and C are energized. Therefore, in this embodiment, windings A and F fire together, windings B and C fire together, and windings D and E fire together so that the electronic transmission of the brushless motor essentially emulates the 3 phase windings of a conventional motor.

[00186] At some point, there may be a further need to increase the brushless motor 1204 speed while reducing the torque produced. For instance, the brushless motor 1204 may accelerate to the point where the coil switching mechanism can no longer keep up with the acceleration of the emulated 3 phase winding of a conventional motor. By using the embodiments of the electronic transmission disclosed herein, the coils can be grouped together to further decrease the number of current switching required per cycle. Thus, the brushless motor 1204 can keep accelerating.

Two-Phase Winding

Fig. 20 illustrates another embodiment of the coil assembly 500 with forty-eight (48) individual coils 526 that may be separately energized. Continuing the example of Fig. 18, the coils 526 are divided into six phase groups 526A-526F, with the coils in a phase group being energized together. In the present embodiment of Fig. 20, the brushless motor controller 1202 energizes groups together to emulate a two-phase arrangement of a conventional motor. This means that individual coils do not need to be reassigned to new groups. For example, using the forty-eight coils assigned to phases A-F as described above, phases F, A, and B may be energized together, and phases C, D, and E may be energized together. This effectively reduces the number of phases from six to two without requiring reassignment of individual coils 526 to new groups by the brushless motor controller 1202. In another embodiment (not shown), the brushless motor controller 1202 may define two new phase groups A and B and then assign each coil 526 to one of the two groups.

[00187] Further, the brushless motor controller 1202 may vary the control process based on factors such as the particular configuration of the coil assembly 500 and/or the desired output of the motor 1204. The particular coil pattern executed by the brushless motor controller 1202 at a given time may be preset and/or may be based on dynamically changing inputs. For example, the brushless motor controller 1202 may emulate a mechanical transmission by eliminating torque pulsation during low speed- high torque operation and enabling high speed operation with little torque drop-off, and the particular pattern of energized coils may depend on the need to "shift" as defined by one or more inputs received by the brushless motor controller 1202.

[00188] It is understood that the phase groupings may be defined in different ways and may vary based on the total number of coils 526, the physical wiring of the coils 526 (e.g., whether each coil is individually selectable), the desired number of phases and the configuration of those phases, and/or other criteria. For example, in some embodiments, multiple coils may be physically connected to form a group and may be controllable only as a group rather than individually. In another example, a motor that is only expected to provide a one or two-phase arrangement may be wired differently than a motor that is expected to provide six, three, and two-phase arrangements. While some configurations may provide less flexibility, overall costs and/or complexity may be reduced compared to a coil assembly 500 with individually selectable coils 526. The brushless motor controller 1202 may be designed to work regardless of the constraints of a particular coil assembly 500 and desired motor parameters. Accordingly, the brushless motor controller 1202 is intended to be highly flexible and configurable to adapt to a variety of motor configurations.

Two-phase Winding Coil Firing Sequence

[00189] Figs. 20-1 through 20-7 illustrate a coil firing and tunnel segment rotation sequence over time emulating a two phase “winding” configuration illustrating one embodiment of the present invention. In this embodiment, the coils of the 6 individual windings will be energized three at a time. [00190] In Figs. 20-1 and 20-2, the 24 coils in the first phase are firing, for example the eight coils in winding F are energized, the eight coils in winding A are energized, the eight coils in winding B are energized. In Fig. 20-2, the rotor has rotated clockwise one coil width with respect to Fig. 20-1 . In Fig. 20-3 the rotor has rotated clockwise a further coil width with respect to Fig. 20-2 and the coils in the second phase are now firing. For example, the eight coils in winding C are energized, the eight coils in winding D are energized, the eight coils in winding E are energized. In Figs. 20-3 through 20-6, the coils of the first phase are energized, and the rotor continues to rotate clockwise. In Fig. 20-7 the coils of the second phase are again firing and the coils in the second phase are again off.

[00191] Fig. 21 illustrates one embodiment of a method 2100 that may be executed with the brushless motor controller 1202. The method 2100 enables the brushless motor controller 1202 to modify the operation of the brushless motor 1204 by modifying the manner in which the coils 526 are energized. This enables the brushless motor controller 1202 to dynamically modify the phase to provide the multi-phasic capability of the motor 1204 and electronically reduce or increase the motor's pole count. Accordingly, in step 2102, the brushless motor controller 1202 receives input that indicates the brushless motor controller 1202 should modify the current phase arrangement.

[00192] In step 2104, a determination is made as to whether a lead position indicator signal has been received recently or since the input was received in step 2102. The lead position indicator signal provides an index indicator that enables the brushless motor controller 1202 to determine when to change the phase arrangement. More specifically, polarity transition of the coils/phase may occur when a coil is entering the next alternate polarity region. The brushless motor controller 1202 can modify the timing and polarity of the power inputs based on the lead position indicator signal in order to change the pole count electronically.

[00193] If the lead position indicator signal has not been received recently, the method 2100 may repeat step 2104 until the lead position indicator signal is received. Once the lead position indicator signal is received, the method 2100 moves to step 2106, where the brushless motor controller 1202 alters the coil and/or phase groupings. An example of this is described in greater detail below. In step 2108, the brushless motor controller 1202 energizes the coils based on the altered grouping arrangement.

Controller

[00194] Referring to FIG. 22, one embodiment of a controller 2200 is illustrated. The brushless motor controller 2200 is one possible example of a portion or all of the brushless motor controller 1202 of Fig. 12. The brushless motor controller 2200 may include a processor/central processing unit (“CPU”) 2202, a memory unit 2204, an input/output (“I/O”) interface 2206, and a network interface 2208. The components 2202, 2204, 2206, and 2208 are interconnected by a data transport system (e.g., a bus) 2210. A power supply (PS) 2212 may provide power to components of the brushless motor controller 1202 via a power transport system 2214 (shown with data transport system 2210, although the power and data transport systems may be separate).

[00195] It is understood that the brushless motor controller 1202 may be differently configured and that each of the listed components may actually represent several different components. For example, the CPU 2202 may actually represent a multi processor or a distributed processing system; the memory unit 2204 may include different levels of cache memory, main memory, hard disks (including solid state), and remote storage locations; the I/O interface 2206 may include monitors, keyboards, and the like, and/or interfaces to such devices; and the network interface 2208 may include one or more network cards or chips providing one or more wired and/or wireless connections to a network 2216. Therefore, a wide range of flexibility is anticipated in the configuration of the brushless motor controller 1202, which may range from a single physical platform configured primarily for a single user or autonomous operation to a distributed multi-user platform such as a cloud computing system.

[00196] The brushless motor controller 1202 may use any operating system (or multiple operating systems), including various versions of operating systems provided by Microsoft (such as WINDOWS), Apple (such as Mac OS X), UNIX, and LINUX, and may include operating systems specifically developed for handheld devices (e.g., iOS, Android, Blackberry, and/or Windows Phone), personal computers, servers, and other computing platforms (including vehicle specific platforms) depending on the use of the brushless controller 1202. The operating system, as well as other instructions (e.g., for performing some or all of the methods described herein), may be stored in the memory unit 2204 and executed by the processor 1902. For example, the memory unit 2204 may include instructions for dynamically managing the coil assembly 500 in order to provide the multi-phasic capabilities described in previous embodiments.

[00197] The network 2216 may be a single network or may represent multiple networks, including networks of different types, whether wireless or wireline. For example, the brushless motor controller 1202 may be coupled to external devices via a network that includes a cellular link coupled to a data packet network, or may be coupled via a data packet link such as a wide local area network (WLAN) coupled to a data packet network or a Public Switched Telephone Network (PSTN). In some embodiments, the I/O interface 2206 and/or the network interface 2208 may couple the controller 1202 to a vehicle bus, such as a Controller Area Network (CAN), Local Interconnect Network (LIN), Avionics Full-Duplex Switched Ethernet, and/or other specialized types of vehicle networks. Accordingly, the brushless motor controller 1202 may be configured to communicate using any needed communication protocol(s), and many different network types and configurations may be used to couple the controller 1202 with external devices.

Driver Adaptive Electronic Transmission

[00198] Fig. 23 illustrates one embodiment of a system 2300 illustrating how a brushless motor controller 1202 may be coupled to a coil assembly 500 having six individual coil windings, phase A-F, with multiple H-bridges 2302-2312. The multiple H- bridges 2302-2312 may form the driver portion of the adaptive electronic transmission described herein. That is, the brushless motor controller 1202 may control the firing sequence of the H-bridges 2302-2332, as illustrated in the embodiments of Figs. 18 through 20, to emulate the 6 phase, 3 phase, or 2 phase windings of conventional motors. In the present example, H-bridge 2302 is used to control the firing of the phase A coils. H-bridge 2304 is used to control the firing of the phase B coils, H-bridge 2306 is used to control the firing of the phase C coils, H-bridge 2308 is used to control the firing of the phase D coils, H-bridge 2310 is used to control the firing of the phase E coils, and H-bridge 2312 is used to control the firing of the phase F coils. Each H-bridge may comprise four switches connected as two independent half-H-bridge outputs or channels. In the present example, the two half-H-bridge outputs of H-bridge 2302 are connected to each end of phase A coils, the two half-H-bridge outputs of H-bridge 2304 are connected to each end of the phase A coils etc. In one embodiment, the two switches of the half-H-bridge output may be a pair of N-channel power MOSFETS connected in series between the supply rails. That is, a high-side MOSFET and low- side MOSFET, where the center connection between the high-side MOSFET and low- side MOSFET is the output of each half-H bridge. The output of each half-H-bridge may be driven (switched) high, low, or configured as a high impedance output stage by the brushless motor controller 1202. For instance, the outputs of the half-H-bridge(s) may be configured as high impedance when a brushless motor 1204 coast function is implemented by the brushless motor controller 1202. In another instance, all the outputs the half-H-bridge(s) may be driven low when a brushless motor 1204 brake function is implemented by the brushless motor controller 1202.

[00199] The brushless motor controller 1202 may be coupled to the H-bridges 2302- 2312-via the I/O interface 2306 and/or the network interface 2208, depending on the configuration of the system 2300. It is understood that the system 2300 is only an example and many possible combinations of hardware and/or software may be used to implement such a system and connect the brushless motor controller 1202 with the coil assembly 500.

[00200] In some embodiments, a current-sense resistor may be place in one or more of the low-side MOSFET connection(s) to ground to provide current sensing of one of more of the phase windings. In certain embodiments, a current-sensing MOSFET may be use for one or more of the low-side MOSFETS. The voltage across the sense resistor(s) may be compared with a reference voltage to provide overcurrent protection of the MOSFETs by the brushless motor controller 1202. In some embodiments, the local voltage supply for brushless motor controller 1202 may include a low value decoupling capacitor to suppress the high frequency noise associated with the high slew rate switching MOSFETs. In one instance, the value of the decoupling capacitor(s) 0.01 pF to 0.001 pF.

[00201] As previously discussed, with the ability of the adaptive electronic transmission to continuously adjust the coil firing sequence the adaptive electronic transmission can emulate a plurality of conventional motors having different winding configurations. For instance, the adaptive electronic transmission can emulate a conventional motor having a six-phase winding configuration, and a different conventional motor having a three-phase winding configuration, and a different conventional motor having a two-phase winding configuration, and different conventional motor having a 1 -phase winding. That is, a single brushless motor 1204 having an adaptive electronic transmission can emulate a plurality of conventional motors having different winding configurations. Further, with the ability of the adaptive electronic transmission to continuously adjust the firing coil firing sequence to emulate the windings of different conventional motors allows the adaptive electronic transmission can emulate the optimum conventional winding in dynamically. For instance, the adaptive electronic transmission can emulate a conventional six-phase winding, for torque performance at low speed, and then emulate a conventional two and/or three phase winding for improved high-speed performance than a conventional six-phase winding.

[00202] Fig. 24 illustrates one embodiment of an adaptive electronic transmission adjusting a coil firing sequence to transition from emulating a six-phase winding, to a three-phase winding, and then to two-phase winding of a conventional motor. Continuing with the example of Fig. 10 the coil assembly 500 having a rotor with eight (8) magnetic tunnels or motor poles, and a stator having forty-eight (48) individual coils 526 is illustrated. Each magnetic tunnel forms a 45-degree pole region and each individual coil 526 forms a 7.5-degree stator region. Thus, each magnetic tunnel may surround 6 of the 48 coils. The 48 coils are divided into six phase groups A-F, with the expectation that the 8 coils in a phase group will be energized together. Thus, 4 coils of winding A, four coils of winding B, and the like, may be within the four evenly spaced magnetic tunnel segments 420 having a NNNN magnetic pole configuration, as illustrated in Fig. 10, and four coils of winding A, four coils of winding B, and the like, may be within the four evenly spaced magnetic tunnel segments 420 having a SSSS magnetic pole configuration, as illustrated in Fig. 10. The eight coils in winding A may be configured, such that, current flow in the 4 coils in the magnetic segment having a NNNN configuration and the current flow in the 4 energized coils in the magnetic segment 421 having a SSSS configuration, generate magnetic forces that are in the same direction, such that the coils rotates from one adjacent magnetic segment to the other using the multiple H-bridges 2402-2412 of illustrated embodiment of Fig. 24. [00203] For clarity, only a representative quarter (¼) segment the coil assembly 500, that is, 12 winding coils are illustrated. The waveforms are sliding from right to left, that is, the waveforms at position 1 , collectively transition to the waveforms shown at position 2, at position 3 and the like. As will be understood by persons of ordinary skill in the relevant art the transitions may speed up as the adaptive electronic transmission adjusts the coil firing sequence emulate conventional motors having a lower number of phases.

[00204] In the illustrative example of Fig. 24, the adaptive electronic transmission is emulating the six-phase winding of a conventional motor in positions 1 through 12. As the rotor of the brushless motor 1204 rotates a coil/phase enters a 45-degree pole region and is energized to match the back-emf every 7.5 degrees. For instance, at position 1 , coil 526A-1 of phase A may enter a magnetic segment 420 having a NNNN configuration. Continuing with the example of Fig. 19, the brushless motor controller 1202 may configure H-bridge 2402 to drive a current to energize coil 526A-1. Specifically, H-bridge 2402 comprises two half H-bridges and the output of one half H- bridge will be driven high, supply, and the output of the other half H-bridge will be driven low, ground, causing current to flow through coil 526A-1 and a force to act on the coil perpendicular to both the directions of the current flow and the magnetic field of the magnetic segment 420 having a NNNN configuration. The shaded region is representative of drive waveform for H-bridge 2402. The coils in the coil assembly 500, are configured, such that, the current flow in the 526A-1 coil entering the magnetic segment 420 having a NNNN configuration and the current flow in the corresponding 526A-2 coil entering the magnetic segment 421 having a SSSS configuration, generated magnetic forces that are in the same direction, such that, the coils rotates from one magnetic segment to the adjacent magnetic segment with a single DC pulse. The black line is representative of the direction of current flow in coil 526A-1 and illustrates the slew rate, change in current over time, of the H-bridge 2402 output.

[00205] As the rotor of the brushless motor rotates through an additional 7.5 degrees coil 526B-1 of phase B enters the magnetic segment 420 having a NNNN configuration and coil 526B-2 enters the magnetic segment 421 having a SSSS configuration. The brushless motor controller 1202 configures H-bridge 2404 to drive a current to energize coils 526B-1 and 526B-2. In some embodiments, the brushless motor controller may continue to energize coils 526A-1 and 526A-2 using H-bridge 2402 which are still within their respective pole regions. This is illustrated by the waveforms at position 2. That is, at position 2, two winding phases, phase A and phase B may be on at the same time. In certain embodiments, the brushless motor controller 1202 may configure H-bridge 2402 and H-Bridge 2404 drive current to energize only coils 526B-1 and 526B-2.

[00206] As the rotor rotates through each additional 7.5 degrees the coils of phase C at position 3, the coils of phase D at position 4, the coils of phase E at position 5, and the coils of phase F at position 6 may be energized by their respective H-bridges. In certain embodiments, at position 6, the coils of all 6 phases are being energized at the same time.

[00207] At position 7, coil 526A-1 of phase A may leave the magnetic segment 420 having a NNNN configuration and enter an adjacent magnetic segment 421 having a SSSS configuration. In some embodiments, the brushless motor controller 1202 may reconfigure the two half H-bridges of H-bridge 2402 to reverse the direction of current flow in the energized coil 526A-1 . That is, the flow of current through coil 526A-1 at position 7 is in the opposite direction to that at position 1.

[00208] As the rotor rotates through each additional 7.5 degrees the direction of current in the phase B coils at position 8, the direction of current in the phase C coils at position 9, the direction of current in the phase D coils at position 10, the direction of current in the phase E coils at position 1 1 , and the direction of current in the phase F coils is also reversed. At position 12, the coils of all 6 phases are being energized at the same time.

[00209] At position 13, coil 526A-1 of phase A may leave the magnetic segment 421 having a SSSS configuration and enter an adjacent magnetic segment 420 having a NNNN configuration. In the illustrative embodiment of Fig. 24, the adaptive electronic transmission adjusts the coil firing sequence to emulate the three-phase winding of a conventional motor at this transition. In certain embodiments, the adaptive electronic transmission may adjust the coil firing sequence to emulate the three-phase winding of when the rotor is in a different position with respect to coil 526A-1 . For instance, the adaptive electronic transmission may adjust the coil firing sequence to emulate the three-phase winding of a conventional motor when coil 526A-1 is about to enter an adjacent magnetic segment 421 having a SSSS configuration. In another instance, the adaptive electronic transmission may adjust the coil firing sequence to emulate the three-phase winding of a conventional motor base on the position of coil 526A-1 within one of the pole regions. In yet another instance, the adaptive electronic transmission may adjust the coil firing sequence to emulate the three-phase winding of a conventional motor base on, at least in part, the relative positions of coil 526B-1 , 526C- 1 , 526D-1 , 526E-1 , or 526F-1 and one of the pole regions. In one embodiment, the brushless motor controller 1202 the outputs of the half-H-bridge(s) may be configured as high impedance, such that a coast function is implemented.

[00210] . Continuing with the example of Fig. 24, at position 13 the brushless motor controller 1202 reconfigures the two half H-bridges of H-bridge 2402 to reverse the direction of current flow in the energized coil 526A-1 . The brushless motor controller 1202 further reconfigure the two half H-bridges of H-bridge 2014 to reverse the direction of current flow in the energized coil 526B-1 thereby synchronizing the firing of phase B coils with the firing of the phase A coils. That is, the energizing of the phase A coils, and the phase B coils is now occurring at the same time thereby emulating a single phase winding. Since, the firing of the phase B coils is now occurring at the same time as the firing of the phase A coils the current in coil 526B-1 will be reversed prior to it leaving the magnetic segment 420 having a NNNN configuration and entering an adjacent magnetic segment 421 having a SSSS configuration. Further, the slew rate will change, that is the transition of current flow will take longer compared to the six-phase configuration.

[00211] At position 14, the rotor has rotated through an additional 7.5 degrees and coil 526B-1 leaves the magnetic segment 421 having a SSSS configuration and enters the magnetic segment 420 having a NNNN configuration.

[00212] At position 15, the rotor has rotated through an additional 7.5 degrees and coil 526C-1 leaves the magnetic segment 421 having a SSSS configuration and enters an adjacent NNNN pole region. The brushless motor controller 1202 reconfigures the two half H-bridges of H-bridge 2406 to reverse the direction of current flow in the energized coil 526C-1 . The brushless motor controller 1202 further reconfigures the two half H-bridges of H-bridge 2408 to reverse the direction of current flow in the energized coil 526D-1 thereby synchronizing the firing of the phase D coils with the firing of the phase C coils to emulate a single phase winding. [00213] At position 16, the rotor has rotated through an additional 7.5 degrees and coil 526D-1 leaves the magnetic segment 421 having a SSSS configuration and enters the NNNN pole region.

[00214] At position 17, the rotor has rotated through an additional 7.5 degrees and coil 526E-1 leaves the magnetic segment 421 having a SSSS configuration and enters an adjacent NNNN pole region. The brushless motor controller 1202 reconfigures the two half H-bridges of H-bridge 2410 to reverse the direction of current flow in the energized coil 526E-1. The brushless motor controller 1202 further reconfigures the two half H-bridges of H-bridge 2412 to reverse the direction of current flow in the energized coil 526F-1 synchronizing the firing of the phase F coils with the firing of the phase E coils to emulate a single phase winding. The adaptive electronic transmission has now modified the coil firing sequence of phase A, B, C, D, E, and F to emulate the three- phase winding of a conventional motor.

[00215] Continuing with the example of Fig. 24, at position 25 the brushless motor controller 1202 reconfigures the two half H-bridges of H-bridge 2402 and H-bridge 2014 to reverse the direction of current flow in the energized coil 526A-1 and 526B-1. The brushless motor controller 1202 further reconfigure the two half H-bridges of H-bridge 2014 to reverse the direction of current flow in the energized coil 526C-1 thereby synchronizing the firing of phase C coils with the firing of the phase A coils. That is, the energizing of the phase A coils, the phase B, and the phase C coils is now occurring at the same time thereby emulating a single-phase winding. The brushless motor controller 1202 further 1202 further modifies the firing sequence of the phase D so that it is no longer synchronized to phase C coils.

[00216] In the illustrative embodiment of Fig. 24, the adaptive electronic transmission adjusts the coil firing sequence to emulate the two-phase winding of a conventional motor as coil 526A-1 of phase A leaves the magnetic segment 421 having a SSSS configuration and enters an adjacent NNNN pole region. In certain embodiments, the adaptive electronic transmission may adjust the coil firing sequence to emulate the two- phase winding of when the rotor is in a different position with respect to coil 526A-1. For instance, the adaptive electronic transmission may adjust the coil firing sequence to emulate the two-phase winding of a conventional motor when coil 526A-1 is about to enter an adjacent magnetic segment 421 having a SSSS configuration. In another instance, the adaptive electronic transmission may adjust the coil firing sequence to emulate the two-phase winding of a conventional motor when coil 526A-1 is within one of the pole regions. In yet another instance, the adaptive electronic transmission may adjust the coil firing sequence to emulate the two-phase winding of a conventional motor base on, at least in part, the relative positions of coil 526B-1 , 526C-1 , 526D-1 , 526E-1 , or 526F-1 with respect to one of the pole regions.

[00217] At position 28 the brushless motor controller 1202 reconfigures the two half H-bridges of H-bridge 2408 to reverse the direction of current flow in the energized coil 526D-1 . The brushless motor controller 1202 further reconfigure the two half H-bridges of H-bridge 2410 and H-bridge 2412 to reverse the direction of current flow in the energized coil 526E-1 and the energized coil 526F-1 thereby synchronizing the firing of phase E and F coils with the firing of the phase D coils. That is, the energizing of the phase D coils, the phase E, and the phase F coils is now occurring at the same time thereby emulating a single-phase winding. Further, the slew rate will change, that is the transition of current flow will take longer compared to the three-phase configuration. The adaptive electronic transmission has now modified the coil firing sequence of phase A, B, C, D, E, and F to emulate the 2 -phase winding of a conventional motor.

[00218] In the illustrative example of Fig. 24, the adaptive electronic transmission sequentially transitions from emulating the six-phase winding of a convention, to emulating the three-phase winding of a conventional motor, to emulating the two-phase winding of a conventional. This was for clarity and is not intended to be limiting or to necessarily indicate that there is a particular order within the group. As will be understood by persons of ordinary skill in the relevant art the adaptive electronic transmission has the ability to dynamically adjust torque, speed, and loading capabilities of the brushless motor 1204 as needed by adjusting the coil firing sequence.

[00219] Fig. 25 illustrates one embodiment of a method 2500 that may be executed by a brushless motor controller 1202 to emulate an adaptive electronic transmission by adjusting a coil firing sequence to emulate a six-phase winding and a three-phase winding of a conventional motor. The method 2500 uses the ability of the brushless motor controller 1202 to separately energize coil windings.

[00220] In step 2502, the brushless motor controller 1202 detects a start command. In some embodiments, the brushless motor controller 1202 is configured to receive the start command in the form of an analogy input. For example, the start command may be an analog input voltage corresponding to a speed greater than zero for the system. That is, the target speed.

[00221] In certain embodiments, the brushless motor controller 1202 is configured to receive the start command in the form of a PWM waveform. For example, the start command may be a PWM waveform having a duty cycle corresponding to a speed greater than zero. In one embodiment, the brushless motor controller 1202 is configured to receive the start command via a data bus. For example, an l ² C (Inter- integrated Circuit) data bus, which is a synchronous, multi-master, multi-slave, packet switched, single-ended, serial computer bus.

[00222] In step 2504, responsive to the detection of the start command, the brushless motor controller 1202 configures the coil windings of the brushless motor 1204 in the start configuration. In certain embodiments, the coil windings 526 of the brushless motor 1204 are energized in the six-phase configuration at startup, because this configuration provides more torque at low speeds than the corresponding three-phase configuration. In one embodiment, rotor position sensors are connected to the brushless motor controller 1202 enables the proper timing of the rotating magnetic field in the stator required to initiate and maintain the rotation of the rotor at low speed. In certain embodiments, different rotor position sensors are used for the six-phase configuration and the three-phase configuration. Subsequently, the brushless motor controller 1202, configures the rotor to accelerate by synthesizing a six-phase rotating magnetic field in the coil windings 526.

[00223] In step 2506, the brushless motor controller 1202 monitors the rotor speed of the accelerating brushless motor 1204 to determine whether the target speed has been reached. Responsive to the target speed being reached, the brushless motor controller 1202 continues to synthesize a six-phase rotating magnetic field in the stator windings to maintain the target speed until an input changes the target speed.

[00224] In some embodiments, the brushless motor controller 1202 may further configure the windings 526 of the brushless motor 1204 to emulate the three-phase configuration of a conventional motor, step 2508, to reduce current and improve efficiency at the target speed. That is, the brushless motor controller 1202 synthesizes a three-phase rotating magnetic field in the coil windings to maintain the target speed. [00225] Otherwise, the brushless motor controller 1202 continues to monitor the speed of the accelerating rotor having a six-phase configuration to determine whether the six-phase speed threshold has been reached, step 2510. The six-speed threshold is the predetermined speed above which the higher speed, but lower torque, performance of the three-phase emulation is needed. Responsive to the six-phase speed threshold being reached, the stator windings of the brushless motor 1204 are energize with the three-phase configuration and the brushless motor controller 1202 synthesizes a three-phase rotating magnetic field in the stator winding to continue to accelerate the rotor.

[00226] In step 2512, the brushless motor controller 1202 continues to monitor the rotor speed of the accelerating brushless motor 1204 to determine whether the target speed has been reached.

[00227] In step 2514, responsive to the target speed being reached, the brushless motor controller 1202 stops accelerating the rotor.

[00228] In some instances, the target speed will change to a value below the six- speed threshold. In step 2516, responsive to the rotor speed being below the six-speed threshold the brushless motor controller 1202 may synthesize a three-phase magnetic field in the coil windings 526.

[00229] In step 2518, responsive to the detection of the stop command, the brushless motor controller 1202 configures the coil windings 526 to implement a stop. In some embodiments, the coil windings may be configuration to implement a brake function. In certain embodiments, the coil winding may be configured to implement a reverse function. Otherwise the process is repeats starting with step 2502.

Advantages of Certain Embodiments

[00230] In sum, certain disclosed embodiments have several advantages when compared to conventional motors and generators. Surrounding the coils with magnets as described above creates more flux density and the forces are now all in the direction of motion which may create more torque, minimize vibration, and minimize noise - as compared to conventional electric motors where forces may try to pull the coil downwards or push it upwards (depending on the polarity), not in the direction of motion. As discussed above, most of the magnetic fields generated are in the direction of motion so there is little, if any, wasted field structure. Continuous torque and continuous power, therefore, are greatly increased. Furthermore, continuous torque density, continuous power density by volume, and continuous power density by weight are also increased when compared to conventional electric motors.

[00231] In certain embodiments, the equivalent full torque is available at start with no locked rotor current losses. The permanent magnet configuration has reduced inrush current at start.

[00232] In certain embodiments, the coil assembly may be compact and yet the coils are easily cooled because they are surrounded by an effective heat sink. Because there is no reason to overlap the coil windings, there is little, if any unwanted field induction - which also contributes to a more efficient design. One of the advantages of this configuration over conventional electric motors is that the end turns (in this case the radial section of the coils) are part of the “active section” of the invention. In conventional electric motors, the axial length of the copper conductor is the section that produces power. The end turns are a penalty, adding weight and losses, but not producing power because the end region fields are not effectively linking the end windings. However, in the above disclosed embodiments, the entire coil winding is effectively used to produce torque due to the side wall or axial magnets which are axially magnetized - efficiently utilizing the copper windings.

[00233] In the “DC” configuration, the motor may run independent of power line frequency or manufactured frequencies reducing the need for expensive pulse width modulated drive controllers or similar controllers.

[00234] The foregoing description of the embodiments of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many combinations, modifications and variations are possible in light of the above teaching. For instance, in certain embodiments, each of the above described components and features may be individually or sequentially combined with other wall portion, components or features and still be within the scope of the present invention, for instance:

[00235] In one embodiment, there may be a method of producing a current, the method characterized by: forming an area of magnetic concentration within a first radial segment defined in section by an outer magnetic cylinder wall portion having a first longitudinal length, an inner magnetic cylinder wall, a first magnetic side wall portion having a first radial length, and a second magnetic side wall portion having a second radial length, each wall portion having their like magnetic poles facing an interior of the first radial segment and the first longitudinal length is greater than either the first radial length or the second radial length, forming a second area of magnetic concentration within a second radial segment defined by an second outer magnetic cylinder wall portion having a first longitudinal length, a second inner magnetic cylinder wall portion, a third magnetic side wall portion having a first radial length, and a fourth magnetic side wall portion having a second radial length, each wall portion having their like magnetic poles facing away from an interior of second radial segment, positioning a coil within a slot formed by adjacent teeth of a coil assembly, rotating a shaft coupled to the coil assembly, rotating the coil through the first segment and extracting current in a first direction from the coil, rotating the coil through the second segment and extracting current in a second direction from the coil.

[00236] A method of producing a current, the method characterized by: forming an area of magnetic concentration within a first radial segment defined by an outer magnetic cylinder wall portion having a first longitudinal length, an inner magnetic cylinder wall, a first magnetic side wall portion having a first radial length, and a second magnetic side wall portion having a second radial length, each wall portion having their like magnetic poles facing an interior of the first radial segment and the first longitudinal length is greater than either the first radial length or the second radial length, forming a second area of magnetic concentration within a second interior cavity defined by an second outer magnetic cylinder wall portion having a first longitudinal length, a second inner magnetic cylinder wall portion, a third magnetic side wall portion having a first radial length, and a fourth magnetic side wall portion having a second radial length, each wall portion having their like magnetic poles facing away from an interior of the second radial segment, positioning a coil within a slot formed by adjacent teeth of a coil assembly, rotating a shaft coupled to the first radial segment and the second radial segment such that the first radial segment is rotated about the coil and current of a first direction is extracted from the coil, the second radial segment is rotated about the coil and current of a second direction is extracted from the coil. [00237] Additionally, undescribed embodiments which have interchanged components are still within the scope of the present invention. It is intended that the scope of the invention be limited not by this detailed description, but rather by the claims or future claims supported by the disclosure.

[00238] The abstract of the disclosure is provided for the sole reason of complying with the rules requiring an abstract, which will allow a searcher to quickly ascertain the subject matter of the technical disclosure of any patent issued from this disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.

[00239] Any advantages and benefits described may not apply to all embodiments of the invention. When the word "means" is recited in a claim element, Applicant intends for the claim element to fall under 35 USC 1 12(f). Often a label of one or more words precedes the word "means". The word or words preceding the word "means" is a label intended to ease referencing of claims elements and is not intended to convey a structural limitation. Such means-plus-function claims are intended to cover not only the structures described herein for performing the function and their structural equivalents, but also equivalent structures. For example, although a nail and a screw have different structures, they are equivalent structures since they both perform the function of fastening. Claims that do not use the word“means” are not intended to fall under 35 USC 1 12(f).