Hybrid Axial Flux Machines

While developing a consumer product line aimed at mass markets, a new class of pumps was invented, which then expanded into a new Platform Technology.

Hybrid Centrifugal Pump

N

S300 GPH @ 0’ 0 GPH @ 5’

13 Watts

Synchronous AC= 1800 RPM @ 60Hz

= 1500 RPM @ 50Hz

Impeller can rotate either direction

These are perhaps the most common simple pumps available. They haven’t changed since they were invented near the end of WWII. They don’t have much head pressure, they aren’t energy efficient, and you have no control beyond on-off.

Gear

Vane

Diaphragm

Diaphragm

Peristaltic

To overcome some of the limitations of centrifugal pumps we to turn to positive pressure pumps. !They come in a variety of styles. They can produce the pressures we need, but they use a separate motor. This adds expense and introduces potential problems, like shaft seals that can leak. !Some have brushed motors that will wear out, some are not energy efficient so they aren’t suitable for solar power. !We searched high and low for suitable pumps and came up empty handed, but we learned a great deal. !All of this basic research culminated in a fundamentally new way of making pumps. They are radically new, and radically useful.

Peristaltic

Positive Displacement Pumps

Hybrid Positive Displacement PumpsPatent Pending

This hybrid axial flux gear pump is only one of many variations of just one possible application of these basic inventions.

Exposed, Vented, Sealed, or Potted Stators

Axial field motors !(from Wikipedia)!Traditionally, the field has been applied radially- in and away from the rotation axis of the motor. However, some designs have the field flowing along the axis of the motor, with the rotor cutting the field lines as it rotates. !

Hybrid Motor / Driver

Gear Pumps, And More...

Patent Pending

!This allows for much stronger magnetic fields... This, in turn, gives the motor's power at lower speeds...

These machines have recently become mature and their high efficiency, power density and reliability has led to PM brushless machines successfully replacing d.c. commutator machines and cage induction machines in many areas.

!Axial Flux Permanent Magnet Machines 2nd Edition

Stepper Style

Same Stators & Rotors Different Wiring

Bipolar: 30˚ per step, 12 steps per revolution

Unipolar: 30˚ per step, 12 steps per revolution,

half-stepping @ 15˚ per step, 24 steps per revolution

Universal

Stators made with specialized powdered metal, having 4 Coils in a single layer on each side of a hybrid gear-rotor. A four pole stator socket. A circlip or retaining ring to hold the stator in the socket.

Patent Pending

Three Phase

6 Coils in 2 layers on a 6 pole stator, and a 6 pole stator socket. The same bobbins/coils fit both 4 & 6 pole stators. Same gear, same magnets, different pattern.

Patent Pending

Synchronous AC Drive

Shaft

= 600 RPM @ 60 Hz

= 500 RPM @ 50 Hz

Same 6 pole stator, socket, and bobbins-coils as 3 phase, now wired for synchronous drive. Same magnet pattern as stepper style. Roller Clutch Bearing to restrict rotation to a single direction.

Patent Pending

Roller Clutch Bearing

Dual Drive

Stepper, 3 Phase, or Synchronous

Patent Pending

Drive both gears to double the head pressure in a small package.

Hybrid Gear Pump

Stepper, 3 Phase, or Synchronous

Patent Pending

Scale the designs using suitable materials for larger models. Cast, Machined, Powdered Metal, or Heavy Duty Plastic.

Hybrid Vane Pump

Stepper, 3 Phase, or Synchronous

Patent Pending

Stators can be exposed, vented, sealed, or potted and submersible.

Hybrid Axial Flow Pump

Stepper, 3 Phase, or Synchronous

Patent Pending

Modularity

Create gear pumps, vane pumps, and turbine type axial flow pumps, and many other hybrid machines in a wide range of sizes, using an array of common components, with a variety of materials.

Patent Pending

Eccentric Planetary

Rotary

Swash-plate

Cam

Linear

Roller

Plus Sprockets, Toothed-Belt Pulleys, Friction-Rollers, And More…

Some Other Hybrid Rotors

Hybrid Axial Flux Machines

Coil Variables: • Wire Gauge • # of Turns •Applied Voltage

Stator Variables: • Diameter • 4 or 6 poles

Magnet Variables: • Material / Blend •Length of Magnet

Optimize With a Few Variables*

• Use standard materials and lengths of magnets for general purpose use • Customize magnet material and length of magnets when desired • Wind coils with appropriate gauge of wire as needed

* For Much Easier FEA Virtual Prototyping and Testing

Stock, Custom, Variants...

Rotor Bipolar Unipolar Universal 3 Phase Synchronous1.0” Stator X X X X X 1.5” Stator X X X X X2.0” Stator X X X X X2.5” Stator X X X X X3.0” Stator X X X X X

6 Volt X X X X X12 Volt X X X X X24 Volt X X X X X110 AC X220 AC XVented X X X X XSealed X X X X X

Submersible X X X X XPlastic X X X X X

Cast Metal X X X X XPowdered Metal X X X X X

Simple Driver X X X XSophisticated Controller X X X X XIntegrated Drive/Control X X X X X

Custom Options X X X X X

Thousands Of Possibilities

Patent Pending

Rotor Type

Drive Schemes

Stator Diameter

Voltage

Housing Options

Driver Options

Customization

Scale To Application

~ Diameter ~ Length ~ Volume

Smaller Lighter Less raw material Simple construction High Efficiency Permanent Magnet Rotor

The core of a hybrid axial flux vane compressor

Hybrid AC Compressor

Scale To Application

Patent Pending

Surprisingly small, lightweight and efficient

Solar Powered Pumping PV Panel Cooling

Solar Water Heaters Rainwater Harvesting

Livestock Watering Fountains/Statuary/Art

etc.

Automotive Pumps Engine Coolant

Auxiliary Coolant Inverter Coolant Battery Coolant

Heater Core Fuel Pump

Brake Actuator Power Steering

Fuel Cells DYNOX SCR

Automotive AC Electric

Hybrid Electric

General Pump Industry Food Processing

Beverages CPU Cooling

Chemical Transfer Dosing

Condensate Removal Vending Machines

etc.

Military

AerospaceAgricultural Pumps Livestock Watering Livestock Sprayers

Crop Sprayers Hydroponics

Irrigation etc.

Refrigerators ‘Dorm Size’ Residential

Commercial Industrial

etc.

General Air Conditioning Window Units

Central AC Heat Pumps

Commercial AC

Medical

Pumps &

Compressors

For more Information, to schedule a Webex, or to discuss the opportunities contact:

Steve M. Kube stevekube@gmail.com Clemmons, NC 27012 704-651-8078