Electric motor or generator

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ELECTRIC MOTOR OR GENERATOR and may be caused by Stresses resulting from magnetic forces during the operation of the motor or generator,

This is a continuation of application Ser. No. 08/774,946 mechanical Stresses resulting from mechanical clamping or filed on Dec. 27, 1996, now U.S. Pat. No. 5,731,649. otherwise fixing the magnetic core in place, or internal Stresses caused by the thermal expansion and/or expansion

BACKGROUND OF THE INVENTION due to magnetic Saturation of the amorphous metal material. The present invention relates generally to electric motors, Conventional magnetic cores are formed by laminating generators, and regenerative motors. The term regenerative Successive layers of core material together to form the motor is used herein to refer to a device that may be operated overall core. However, as mentioned above, amorphous as either an electric motor or a generator. More specifically, metal is difficult to cut or form easily. Therefore, in the past, the invention relates to an electric motor, generator, or amorphous metal cores have often been formed by rolling an regenerative motor including a Stator arrangement which amorphous metal ribbon into a coil with each Successive itself includes an electromagnet assembly having an amor layer of the material being laminated to the previous layer phous metal magnetic core made up of a plurality of 15 using an adhesive Such as an epoxy. When in use in an individually formed amorphous metal core pieces. The electric motor or generator, this laminated construction present invention also provides a control arrangement that is restricts the thermal and magnetic Saturation expansion of able to variably control the activation and deactivation of an the coil of amorphous metal material and results in high electromagnet using any combination of a plurality of acti internal Stresses. These Stresses cause magnetostriction that Vation and deactivation parameters in order to control the reduces the efficiency of the motor or generator as described Speed, efficiency, power, and torque of the device. above. Also, this construction places a layer of adhesive The electric motor and generator industry is continuously material iseach between coil of the core. Since amorphous metal

Searching for ways to provide motors and generators with example only a coupleprovided typically of mils as a very thin ribbon, for thick, a significant percentage increased efficiency and power density. For Some time now, of the Volume of the core ends up being adhesive material. it has been believed that motors and generators constructed 25 This volume of adhesive reduces the overall density of the using permanent Super magnet rotors (for example cobalt amorphous metal material within the laminated rare earth magnets and Neodymium-Iron-Boron magnets) therefore, undesirably reduces the efficiency of thecore, and core to and Stators including electromagnets with amorphous metal focus or direct the magnetic flux for a given volume of magnetic cores have the potential to provide Substantially overall core material.

higher efficiencies and power densities compared to con ventional motors and generators. Also, because amorphous for minimizinginvention

The present the provides a method and arrangement

Stresses on an amorphous metal magnetic metal cores are able to respond to changes in a magnetic core in an electric motor, generator, or regenerative motor. field much more quickly than conventional ferrous core This method and arrangement eliminates the need for lami materials, amorphous metal magnetic cores have the poten nating the various layers of the amorphous metal thereby tial to allow much faster field Switching within motors and 35 reducing the internal Stresses on the material and increasing generators, and therefore allow much higher Speed and the density of the amorphous material within the better controlled motors and generators than conventional core. Also, in order to take advantage of the highoverall ferrous cores. However, to date it has proved very difficult Switching capabilities of the amorphous metal magneticSpeed to provide an easily manufacturable motor or generator material, the present invention provides control methodscore and which includes amorphous metal magnetic cores. 40 arrangements that are able to variably control the activation

Amorphous metal is typically Supplied in a thin continu and deactivation of the electromagnet of an electric motor, ous ribbon having a uniform ribbon width. However, amor generator, or regenerative motor device including an amor phous metal is a very hard material making it very difficult phous metal magnetic core by using a combination of a to cut or form easily, and once annealed to achieve peak plurality of different activation and deactivation parameters magnetic properties, becomes very brittle. This makes it 45 in order to control the Speed, efficiency, torque, and power difficult and expensive to use the conventional approach to of the device.

constructing a magnetic core. This conventional approach typically involves cutting individual core layerS having a SUMMARY OF THE INVENTION desired shape from a sheet of core material and laminating AS will be described in more detail hereinafter, a device the layers together to form a desired overall magnetic core 50 Such as an electric motor, an electric generator, or a regen shape. The brittleness of amorphous metal also causes erative electric motor is disclosed herein. The device concern for the durability of a motor or generator which includes a rotor arrangement, at least one Stator utilizes amorphous metal magnetic cores. Magnetic cores arrangement, and a device housing for Supporting the rotor are Subject to extremely high magnetic forces which change arrangement and the Stator arrangement in the predeter at very high frequencies. These magnetic forces are capable 55 mined positions relative to one another. The device housing of placing considerable stresses on the core material which also Supports the rotor arrangement for rotation along a may damage an amorphous metal magnetic core. predetermined rotational path about a given rotor axis. The Another problem with amorphous metal magnetic cores is Stator arrangement has at least one energizable electromag that the magnetic permeability of amorphous metal material net assembly including an overall amorphous metal mag is reduced when it is Subjected to physical Stresses. This 60 netic core and an electric coil array which together define at reduced permeability may be considerable depending upon least one magnetic pole piece. The overall amorphous metal the intensity of the Stresses on the amorphous metal material. magnetic core is made up of a plurality of individually AS an amorphous metal magnetic core is Subjected to formed amorphous metal core pieces. The Stator arrange Stresses, the efficiency at which the core directs or focuses ment also includes a dielectric electromagnet housing for magnetic flux is reduced resulting in higher magnetic losses, 65 Supporting the electromagnet assembly Such that the mag reduced efficiency, increased heat production, and reduced netic pole pieces are positioned adjacent the rotational path power. This phenomenon is referred to as magnetostriction of the rotor arrangement. The dielectric electromagnet hous

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ing has core piece openings formed into the electromagnet Such that each of the pole pieces is positioned adjacent to a housing for holding the individually formed amorphous corresponding one of the different predetermined rotational metal core pieces in positions adjacent to one another So as paths. The two pole pieces are each individually formed to form the overall amorphous metal magnetic core. amorphous metal core pieces. Additional individually In one preferred embodiment, the rotor arrangement has formed netic amorphous metal core pieces form an electromag yoke magnetically coupling the two pole pieces to one at least one rotor magnet with north and South poles and the another Such that the core pieces together define the rotor arrangement has an arrangement for Supporting the C-shaped overall core.

rotor magnet for rotation about a given rotor axis Such that A method of making an amorphous metal magnetic core at least one of the magnet's poles is accessible along a predetermined rotational path about the given rotor axis. In for an electromagnet of a device Such as an electric motor, an electric generator, or a regenerative electric motor is also a preferred embodiment, the rotor magnet is a Super magnet. disclosed herein. The method includes the Step of forming a In some embodiments, the individually formed amor plurality of individually formed amorphous metal core phous metal core pieces are amorphous metal windings pieces, each having a desired core piece shape. A dielectric formed from a continueS ribbon of amorphous metal. 15 magnetic core housing including magnetic core piece open Preferably, the continuous ribbon of amorphous metal has a ings that define the desired overall magnetic core shape is substantially constant ribbon width. The individually formed provided. The plurality of individually formed amorphous amorphous metal core pieces may have a variety of croSS metal core pieces are assembled into the core piece openings Sectional shapes including a circle, an Oval, an egg shape, a of the dielectric magnetic core housing Such that the dielec toroidal ring, a triangle having rounded corners, and a tric core housing holds the core pieces adjacent to one trapezoid having rounded comers. Alternatively, the indi another So as to form the desired overall magnetic core vidually formed amorphous metal core pieces may be shape. In a preferred method, each core piece is wound into formed from individual Strips of amorphous metal material its final shape from a continuous ribbon of amorphous metal. Stacked in an associated core piece opening of a core piece In accordance with another aspect of the present housing. Also, in Some embodiments, any voids in the core 25 invention, a method and arrangement for controlling the piece openings of the electromagnet housing holding the rotational Speed and input/output power and torque of a amorphous metal core pieces are filled with a dielectric oil. device Such as an electric motor, an electric generator, or a Additionally, the amorphous metal core pieces may be oil regenerative electric motor is disclosed herein. The device impregnated. includes a rotor Supported for rotation along a predetermined In one embodiment, the Stator arrangement includes a rotor path about a given rotor axis. Preferably, the rotor plurality of electromagnet assemblies, each having a plural includes at least one permanent Super magnet. The device ity of pole pieces. Each of the pole pieces is an individually also includes a Stator having a plurality of dynamically formed amorphous metal core piece. Furthermore, at least activatable and deactivatable electromagnet assemblies (also one of the individually formed amorphous metal core pieces referred to herein merely as electromagnets) with amor is a toroidal ring forming an electromagnetic yoke magneti 35 phous metal magnetic cores. The electromagnets are spaced cally coupling each of the pole pieces to one another. The apart from one another adjacent to the predetermined rotor toroidal ring electromagnetic yoke includes an annular or path Such that movement of a particular point on the rotor other Such continuous Surface defined by one continuous (rotor point) from a given point adjacent one electromagnet edge of the continuous ribbon of amorphous metal after the (stator point) to a given point adjacent the next Successive ribbon of amorphous metal has been wound about itself. 40 electromagnet (stator point) defines one duty cycle. A posi Each of the pole pieces of the electromagnet assembly has tion detector arrangement determines the position and rota a first end (defined by one continuous edge of the ribbon) tional Speed of the rotor relative to the Stator at any given positioned adjacent the predetermined rotational path of the time in a duty cycle and produces corresponding Signals. A rotor magnet. Also, each of the pole pieces of the electro controller responsive to the Signals controls the activation magnet assembly has a second end (defined by the other 45 and deactivation of the electromagnets of the Stator using continuous edge of the ribbon) positioned adjacent the predetermined device control Settings Such that, for each annular Surface of the toroidal ring electromagnetic yoke. duty cycle, the controller is able to control any combination In another embodiment, the electromagnet of the Stator of a plurality of activation and deactivation parameters in arrangement includes a generally U-shaped overall amor order to control the Speed, efficiency, and input/output power phous metal magnetic core having two pole pieces. The two 50 and torque of the device.

pole pieces are each individually formed amorphous metal In a preferred embodiment, the activation and deactiva core pieces. An additional individually formed amorphous tion parameters include (i) the duty cycle activation time metal core piece forms an electromagnetic yoke magneti which is the continuous duration of time in which the cally coupling the two pole pieces to one another Such that electromagnet of the stator is activated (with either one the core pieces together define the U-shaped overall core. 55 polarity or the other) for each duty cycle, (ii) the start/stop In Still another embodiment, the arrangement Supporting points of the duty cycle activation time which are the times the rotor magnet Supports the rotor magnet Such that both the at which the duty cycle activation time Starts and stops north and the South poles of the rotor magnet are accessible during the duty cycle relative to the rotational position of the along different predetermined rotational paths about the rotor as it moves through the duty cycle from Stator point to given rotor axis. The electromagnet of the Stator arrange 60 the next adjacent Stator point, and (iii) the modulation of the ment includes a generally C-shaped overall amorphous duty cycle activation time which is the pulse width modu metal magnetic core having two pole pieces with each of the lating of the electromagnet by activating and deactivating pole pieces positioned adjacent to a corresponding one of the the electromagnet during what would otherwise be the predetermined rotational paths of the north and South poles continuous duty cycle activation time. of the rotor magnet. The overall magnetic core of the 65 In another embodiment, the position detector arrangement electromagnet assembly is a generally C-shaped overall includes an encoder disk Supported for rotation with the amorphous metal magnetic core defining the two pole pieces rotor and also includes an array of optical Sensors arranged

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S 6 in close proximity to the encoder disk. The encoder disk has FIG. 6 is a diagrammatic view of one embodiment of the a plurality of concentric tracks with Spaced apart position invention in which a windmill drives a generator designed in indicating openings which are actually through-holes in the accordance with the invention. disk. Each of the optical Sensors corresponds to and is FIG. 7 is a diagrammatic view of another embodiment of optically aligned with an associated one of the concentric the invention in which a turbine engine drives a generator trackS Such that each Sensor is able to detect the presence of designed in accordance with the invention. the position indicating openings defining its associated con centric track So as to be able to detect the position of the FIG. 8 is a perspective view of a second embodiment of rotor relative to the Stator. Preferably these openings are an overall amorphous metal magnetic core designed in sized and positioned to represent a digital byte of rotor accordance with the present invention. positional information with each track contributing one bit FIG. 9 is a perspective view of a third embodiment of an of the overall digital byte. In this way, during Startup of the overall amorphous metal magnetic core designed in accor motor/generator device, the position of the rotor can be dance with the present invention. precisely determined. FIG. 10 is a perspective view of a fourth embodiment of In still another embodiment, the controller further includes a counter arrangement capable of counting in 15 an overall amorphous metal magnetic core designed in accordance with the present invention.

increments of time which allow each duty cycle to be divided into a multiplicity of time periods which the con FIGS. 11A-H are diagrammatic perspective views of troller uses to control when to activate and deactivate the various embodiments of the individual amorphous metal electromagnet. core pieces having various croSS-Sectional shapes. In accordance with another aspect of the present FIG. 12 is a diagrammatic croSS-Sectional view of a invention, a method and arrangement for conditioning the multiphase device designed in accordance with the present electrical output of an electric generator driven by a input invention.

drive device is disclosed. The generator includes a Stator FIG. 13 is a diagrammatic plan View of a Stator arrange assembly having at least one dynamically activatable and ment of another embodiment of a multiphase device deactivatable Stator coil and a rotor assembly. A position 25 designed in accordance with the present invention. detector arrangement determines the position and rotational

Speed of the rotor assembly relative to the Stator assembly at DETAILED DESCRIPTION OF THE any given time and produces corresponding Signals. A PREFERRED EMBODIMENTS controller responsive to the Signals variably controls the activation and deactivation of the Stator coil Such that the Turning to the drawings, wherein like components are electrical output of the generator is conditioned to a desired designated by like reference numerals throughout the Vari electrical output without requiring the use of additional ous figures, attention is initially directed to FIGS. 1-3B. electrical power conditioning devices. In one embodiment, FIG. 1 illustrates a cross sectional view of a device 10 the input drive device is a wind mill. Furthermore, the designed in accordance with the present. Although device 10 controller may use a portion of the electrical power gener 35 will be referred to as an electric motor or an electric ated by the generator to drive the generator as an electric generator at various times throughout this description, it motor. The generator may be driven as an electric motor in should be understood that device 10 may take the form of a a way which reduces the amount of resistance the generator motor, a generator, an alternator, or a regenerative motor places on the input drive device or in a way which increases depending on the requirements of the application in which the amount of resistance the generator places on the input 40 the device is used. For purposes of this description, the term drive device. regenerative motor refers to a device that may be operated BRIEF DESCRIPTION OF THE DRAWINGS as either an electric motor or an electric generator. Also, although device 10 will in most cases be described as a DC

The features of the present invention may best be under brushless motor, it should be understood that it may take the stood by reference to the following description of the 45 form of a wide variety of other types of motors and/or presently preferred embodiments together with the accom generators and Still remain within the Scope of the invention. panying drawings in which: These other types of motorS and/or alternators/generators FIG. 1 is a diagrammatic cross-sectional view of a device include, but are not limited to, DC Synchronous devices, designed in accordance with the present invention including variable reluctance or Switched reluctance devices, and a rotor arrangement, a Stator arrangement having a Stator induction type motorS.

housing and an overall amorphous metal magnetic core 50 AS best shown in FIG. 1, device 10 includes a shaft 14, a made up of individually formed amorphous metal core rotor arrangement 16, a Stator arrangement 18, and a device pieces, and a control arrangement having an encoder disk. housing 20. Device housing 20 supports shaft 14 for rotation FIG. 2 is a diagrammatic plan view of the rotor arrange about the longitudinal axis of the Shaft using bearings 22 or ment of the device of FIG. 1. 55 any other Suitable and readily providable arrangement for FIG. 3A is an orthographic diagrammatic view of one Supporting a shaft for rotation. Rotor arrangement 16 is fixed embodiment of an overall amorphous metal magnetic core to shaft 14 for rotation with the shaft about the longitudinal forming part of the Stator arrangement of the device of FIG. rotational axis of shaft 14. Stator arrangement 18 is Sup 1. ported by device housing 20 Such that the Stator arrangement FIG. 3B is a diagrammatic cross-sectional view of the 60 is positioned adjacent the rotational path of the rotor stator housing of FIG. 1. arrangement.

FIG. 4 is a diagrammatic plan view of the encoder disk of Referring now to FIG. 2, which is a plan view of one the device of FIG. 1. preferred embodiment of rotor arrangement 16, rotor FIG. 5 is a graph illustrating various activation and arrangement 16 will be described in more detail. In this deactivation parameters which the control arrangement of 65 embodiment, rotor arrangement 16 is a disk or axial type the device of FIG. 1 may use to control the device of FIG. rotor including six radially spaced apart permanent Super 1. magnets 24a f(for example cobalt rare earth magnets), each

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having opposite ends defining north and South poles. Mag is a toroidal ring having an annular Surface 40 defined by one nets 24a-fare Supported for rotation about the axis of shaft continuous edge of the continuous amorphous metal ribbon 14 by a rotor disk 26 or any other Suitable arrangement Such wound to form toroidal ring core piece 36g. In either case, that the magnetic poles of magnets 24a–f are accessible for this embodiment, the continuous amorphous metal rib along two predetermined rotational paths about the shaft bon is not cut, etched, or otherwise machined other than axis and adjacent the rotor arrangement. They are oriented initially cutting the continuous ribbon of amorphous metal to relative to one another Such that on each side of the rotor the desired length required to form the desired core piece disk, the magnets present alternating north and South poles shape. Each of the cylindrical shaped core pieces 36a-f as shown in FIG. 2. forms a pole piece of overall core 36 with one end 37a of Although magnets 24a–f have been described as being each cylindrical core piece being positioned against annular permanent Super magnets, this is not a requirement. Surface 40 of toroidal ring shaped core piece 36g, and the Alternatively, the magnets may be other magnetic materials, other end 37b projecting out away from annular surface 40. or, in Some cases may be electromagnets. Also, although the Toroidal ring core piece 36g acts as a magnetic yoke rotor arrangement has been described as being a disk or axial preventing leakage of magnetic flux and magnetically cou type rotor, this is not a requirement. Instead, the rotor may 15 pling each of the cylindrical core pieces 36a-f take on a wide variety of Specific configurations Such as a FIG. 3B illustrates stator housing 28a apart from, but barrel or radial type rotor with the magnets being positioned designed to contain, core 36 of FIG. 3A. Note specifically on the outer circumference of the barrel or radial type rotor. the various core piece openingS 30 and coil openings 32. Although the rotor has been described as including Six Stator housing 28a also includes coolant openings 39 and magnets, it should be understood that the rotor may include wire raceway openings 41. Using coolant openings 39, a any number of magnets and Still remain within the Scope of coolant fluid may be circulated through Stator housing 28a the invention. And finally, although the rotor arrangement to prevent excessive heat buildup in Stator housing 28a, coil has been described as including magnets, this is not a array 38, and core 36. Coolant openings may be formed in requirement. For example, in the case of an induction motor, any appropriate location within the Stator housing in order to rotor arrangement 16 would not include magnets 24a–g. 25 provide cooling for the device. Wire raceway openings 41 Instead, as would be understood by those skilled in the art, are used to run wires which interconnect coil array 38. rotor disk 26 would be constructed from an iron based Although FIG. 3B illustrates one specific configuration of material or Some other magnetic material to form a magnetic the Stator housing which is designed to house the core pieces rotor core which is driven by a rotating magnetic field illustrated in FIG. 3A, it should be understood that the stator created by the Switching of the Stator arrangement. housing may take on a wide variety of configurations which As best shown in FIG. 1, in the embodiment being vary depending on the Specific core design.

described, Stator arrangement 18 includes two Stator hous As best shown in FIGS. 1, 3A, and 3B, individually ings 28a and 28b with the stator housings being positioned formed core pieces 36a–g are Supported within core piece adjacent opposite Sides of rotor arrangement 16. Stator openings 30 of stator housing 28a such that they are held in housings 28a and 28b are mirror images of one another, and 35 their respective positions relative to one another. Because therefore, only stator housing 28a will be described in detail. core piece openings 30 are formed in Stator housing 28a to Stator housing 28a is formed from a dielectric material such have the proper shape for Supporting each of the various as, but not limited to, a high Strength composite or plastic individually formed core pieces 36a-f, core pieces 36a-f material. Any appropriate material may be used to form the may be formed by winding the amorphous metal ribbon Stator housing So long as it is dielectric and able to properly 40 material without laminating the layers of the winding. This Support all of the associated components making up Stator allows each individually formed core piece to thermally arrangement 18. expand and/or expand due to magnetic Saturation, causing In accordance with the present invention, Stator housing the winding to slightly uncoil, without causing internal 28a has a plurality of openings including core piece open stress within the overall core or within any of the individu ingS 30 and coil openings 32 formed into the housing for 45 ally formed core pieces. This arrangement Substantially Supporting a dynamically activatable and deactivatable elec reduces the problems caused by magnetostriction described tromagnet assembly 34. The electromagnet assembly 34 in the background of the invention. Also, this arrangement includes an overall amorphous metal magnetic core 36 and eliminates the need to laminate the core pieces and therefore a coil array 38. Coil array 38 is supported in coil openings eliminates the volume of space within the overall core which 32. Also in accordance with the invention, Overall amor 50 is taken up by the laminating material. Because of this, a phous metal core 36 is made up of a plurality of individually greater amount of amorphous metal material is able to be formed amorphous metal core pieces 36a–g Some of which placed into a given volume which improves the efficiency at form magnetic pole pieces as best shown in FIG. 3A. Stator which a magnetic core is able to direct or focus magnetic housing 28a Supports electromagnet assembly 34 Such that flux. At the same time, each Stator housing holds the pole the pole pieces of the electromagnet assembly are held 55 pieces 36a–f in direct contact with yoke 36g so that the adjacent to one of the predetermined rotational paths of the entire core, from a functional Standpoint, approximates a magnetic poles of magnets 24a–f on rotor arrangement 16 as Single integrally formed core. Stator housing 28a may also best shown in FIG. 2. completely encase overall amorphous metal core 36 creating FIG. 3A illustrates the specific configuration of overall a Sealed enclosure which prevents corrosion of the core amorphous metal core 36 for the particular embodiment 60 pieces.

shown in FIG.1. Each individual core piece 36ag is formed In the embodiment shown in FIG. 1, any voids in core by winding a continuous ribbon of amorphous metal mate piece openingS 30 that are not filled by core pieces 36a–g are rial into the desired shape. In the case of core pieces 36a-f. filled with a dielectric oil 42 and core piece openings 30 are the core piece shape is a generally cylindrical shape Such sealed to maintain the oil within the voids. This oil filling of that the opposing continuous edges of each of these core 65 the core piece openings acts as a cushion to help prevent pieces define opposite ends 37a and 37b of the core piece. damage to the amorphous metal material as it is Subjected to However, in the case of core piece 36g, the core piece shape the large and varying magnetic forces associated with the

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motor. This oil filling also helps to thermally equalize the Still referring to FIG. 1, control arrangement 44 also Stator arrangements and may be used to improve the heat includes a position detector arrangement 48 for determining dissipating characteristics of the overall device. Also, amor the position and rotational Speed of rotor arrangement 16 phous metal core pieces 36a–g are oil impregnated. This relative to Stator arrangement 18 at any given time for each allows the windings of the amorphous metal core pieces to 5 duty cycle and for producing corresponding Signals. Detec more easily expand due to magnetic Saturation and thermal tor arrangement 48 includes an encoder disk 50 supported on expansion of the amorphous metal material further reducing shaft 14 for rotation with rotor arrangement 16. Detector Stresses that may cause magnetostriction. Although, the core arrangement 48 also includes an array of optical Sensors 52 piece openings described above are oil filled and the core positioned adjacent the encoder disk. pieces are oil impregnated, this is not a requirement. The 10 As illustrated in FIG. 4, which is a plan view of encoder invention would equally apply to devices which use mag disk 50, encoder disk 50 includes a plurality of concentric netic cores made up of individually formed amorphous tracks 54 with position indicating openings 56 formed into metal magnetic core pieces Supported in openings of a each of the tracks. In this embodiment, disk 50 includes six housing to form an overall amorphous metal magnetic core concentric tracks 54a–f Disk 50 is divided into three one shape regardless of whether or not the openings were filled 15 hundred and twenty degree arc, pie shaped Sections 58, each with oil and the core pieces were oil impregnated. of which are identical to one another. Each section 58 is Device 10 is a brushless, synchronous device in which the asSociated with a pie shaped Section of the rotor arrangement coils making up electromagnet coil array 38 within Stator extending from a given point on a first rotor magnet having housing 28a are all electrically connected Such that they are a particular polarity to a corresponding point on the next activated and deactivated at the same time. In the embodi- 20 Successive magnet having the same polarity (i.e. from one ment shown in FIG. 1, coil array 38 includes six pole piece South pole past a north pole to the next South pole). Inner coils, two of which are illustrated in FIG. 1 as coils 38a and track 54a has one long opening 56a extending half (a sixty 38d. Coil array 38 may be epoxied or otherwise fixed into degree arc) of the length of track 54a in each section 58. In position in order to add to the Overall Structural integrity of this case, each of these openings corresponds to one duty the Stator arrangement. Each coil is positioned around a 25 cycle of the device and the three openings together are corresponding one of core pieces 36a–f, two of which are aligned with every other one of the six rotor magnets (i.e. the illustrated in FIG. 1 as core pieces 36a and 36d. Coil array three magnets having the same polarity on each given Side 38 is wound Such that the projecting ends of the pole pieces of the rotor disk). Within each Section, each Successive track formed by magnetic core pieces 36a–f form alternating north has twice as many openings which are half as long as the and South poles when coil array 38 is activated. Toroidal ring 30 openings in the previous track. That is track 54b has two core piece 36g acts as a magnetic yoke redirecting the openings 56b within each section, track 54c has four open magnetic flux associated with the ends of core pieces 36a-f ings 56c and so on with the outside track having thirty two that are adjacent to toroidal ring core piece 36g to the openings, each having an arc of one and Seven eighths of a adjacent pole pieces of the opposite polarity. When the degree.

device is operated as an electric motor, Switching the direc- 35 Optical Sensor array 52 includes Six optical Sensors with tion of current flow through coil array 38 reverses the each Sensor corresponding to and positioned in optical polarity of each of the pole pieces of electromagnet assem alignment with one of the concentric tracks on encoder disk bly 34. As will be described in more detail hereinafter, in the 50. Array 52 is positioned adjacent encoder disk 50 such that case of a generator, Switching the way in which the elec optical Sensors detect the presence of openings 56. With tromagnets are connected to a load controls the power output 40 each of the optical Sensors providing one bit of information, and the condition of the electricity produced by the genera array 52 is able to provide controller 46 with a binary word tor. This arrangement allows the alternating north and South (a byte) which identifies the position of the rotor arrange poles of electromagnet assembly 34 of Stator arrangement 18 ment within less than a two degree arc. Using the most to controllably interact with the alternating north and South Significant bit, that is the Sensor associated with track 54a, poles of permanent magnets 24a–f of rotor arrangement 16. 45 controller 46 is also able to determine the location of the Device 10 also includes a control arrangement 44 for alternating north and South poles of the magnets Since the activating and deactivating coil array 38 with alternating openings 56a of track 54a corresponds to every other polarity. Control arrangement 44 includes a controller 46 magnet on the rotor disk as described above. which may be any suitable and readily providable controller Controller 46 also includes a counter arrangement 49 that is capable of dynamically activating and deactivating 50 capable of counting in increments of time which allow each electromagnet assembly 34 with varying polarity. duty cycle (sixty degree arc) to be divided into a multiplicity Preferably, controller 46 is a programmable controller of time periods or counts, for example, 1600 counts per duty capable of activating and deactivating electromagnet assem cycle when the device is rotating at a predetermined maxi bly 34 at a rate of Speed much higher than is typically done mum speed. This corresponds to one hundred counts for in conventional electric motors and generators. Because of 55 each opening 56f, or, in other words, one hundred times the the inherent Speed at which the magnetic field may be resolution provided by the encoder disk. For illustrative Switched in an amorphous metal core, for each duty cycle of purposes, for a high Speed motor capable of operating at the device, the stator arrangement of device 10 allows 20,000 RPM, this would require a counter arrangement or controller 46 to use any combination of a plurality of clock capable of operating at 3.2 million counts per Second activation and deactivation parameters to control the rota- 60 or a 3.2 MHZ clock. Although only one specific clock Speed tional Speed, power, and torque output of device 10. For has been described in detail, it should be understood that the purposes of this description, one duty cycle is defined as the present invention would equally apply regardless of the movement of a particular point of the rotor from a given Specific clock Speed of the counter arrangement. Stator point adjacent one electromagnet pole piece of the Controller 46 is arranged to be able to activate or deac Stator arrangement to a given Stator point adjacent the next 65 tivate electromagnet assembly 34 at any predetermined Successive electromagnet pole piece of the Stator count of counter arrangement 49. This provides extremely arrangement, as mentioned previously. precise control of the activation and deactivation of the

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electromagnets. Although the example of an operating Speed given duty cycle. The duty cycle activation time is indicated of 20,00 RPM is used, it is to be understood that this is not by the letter T in FIGS. 5A-C. The start/stop points of the an upper limit. Because of the extremely fast Switching duty cycle activation time are the times at which the duty capability of the amorphous metal Stator arrangement and cycle activation time starts (indicated by reference numeral the precise activation and deactivation control of the elec 60) and stops (indicated by reference numeral 62) during the tromagnets provided by the control arrangement described duty cycle relative to the rotational position of the rotor. AS above, motor and generator devices designed in accordance illustrated in FIG. 5B, the start/stop time may be changed with the invention are capable of providing extremely high while keeping the duty activation time T constant or it may speed devices with rotational speeds of 50,000 RPM or even be changed while, at the same time, changing the length of greater than 100,000 RPM. The present invention also duty activation time T. And finally, the modulation of the provides a Stator arrangement configuration and rotor duty cycle activation time is the pulse width modulating of arrangement configuration that are capable of withstanding electromagnet assembly 34 during the duty activation time the extreme centrifugal forces that would be generated by Tbetween its start and stop points. As illustrated in FIG. 5C, these extremely high Speed devices. this is done by activating and deactivating electromagnet In order to allow controller 46 to discretely detect the 15 assembly 34 during what would otherwise be the continuous presence of the openings of the various tracks in encoder duty cycle activation time T. While the pulse width modu disk 50, the openings in the various tracks are slightly lation is shown as equal ON and OFF pulses, the ON pulses Staggered relative to one another Such that the different may be different in duration than the OFF pulses. optical Sensors of array 52 are not trying to indicate the Furthermore, each Set of pulses can vary among themselves detection of the beginning of an opening for different tracks to provide a desired overall activation time within the time at the same precise time. This encoding configuration is T. In accordance with the invention, the Speed, efficiency, commonly referred to as gray code and is intended to and power and torque input/output of device 10 may be prevent errors by the controller caused by very slight inac controlled by using control arrangement 44 to activate and curacies in the locations of the position indicating openings. deactivate electromagnet assembly 34 using any combina Referring back to FIG. 1, now that the various compo 25 tion of these parameters, or any other predetermined acti nents making up device 10 have been described, the opera Vation and deactivation parameters in Some combination. tion of the device in various modes will be described in more When device 10 is stopped, controller 46 uses encoder detail. Because the amorphous metal magnetic core material disk 50 and optical sensor array 52 to determine the relative is able to Switch its magnetic field extremely quickly and position of rotor arrangement 16 relative to Stator arrange because control arrangement 44 is able to activate and ment 18. In the case of an electric motor, controller 46 uses deactivate electromagnet assembly 34 at extremely precise the position information to Start the rotation of the rotor times, control arrangement 44 of the present invention arrangement by energizing electromagnet assembly 34 Such allows controller 46 to use any combination of a plurality of that pole pieces 36 have the appropriate polarity to start the electromagnet assembly activation and deactivation param rotation of the motor in the desired direction. Controller 46 eters in order to control the Speed, efficiency, torque, and 35 activates and deactivates electromagnet assembly 34 Such power of the device. These parameters include, but are not that the polarity of each pole piece reverses for each Suc limited to, the duty cycle activation time, the Start/stop cessive duty cycle. Once the motor is rotating at a Sufficient points of the duty cycle activation time, and the modulation Speed, controller 46 only uses the Outer tracks of encoder of the duty cycle activation time. The activation and deac disk 50 to determine the rotational speed of the rotor tivation parameters will be described in more detail with 40 assembly relative to the Stator assembly for calibrating reference to FIGS. 5A-C, which are graphs showing the counter arrangement 49. Controller 46 continues controlling activation/deactivation Status of electromagnet assembly 34 device 10 by using counter arrangement 49 and the Signals for two consecutive duty cycles D1 and D2. produced by encoder disk 50 to select and use predetermined The electromagnet assembly is activated having alternat device control Settings which may be programmed into or ing north and South polarity for each of the pole pieces 45 otherwise provided to controller 46 to control the activation making up the electromagnet assembly. For any given Stator and deactivation of electromagnet assembly 34. Because pole piece, duty cycle D1 corresponds to the time it takes for control arrangement 44 is able to activate or deactivate the rotor assembly to rotate from a point where a north pole electromagnet assembly 34 at any one of the counts of of one of the rotor magnets is adjacent to and lined up top counter arrangement 49, control arrangement 44 is able to dead center with the given Stator pole piece to the time the 50 very precisely control the Speed, efficiency, torque, and South pole of the next Successive rotor magnet is adjacent to power of device 10 using any combination of the above and lined up top dead center with the given Stator pole piece. described activation and deactivation parameters. AS indicated by the reference letter N, the electromagnet The precision, Speed, and flexibility of control arrange assembly is activated during duty cycle D1 Such that the ment 44 allows a device designed in accordance with the given Stator pole piece acts as a north pole. Duty cycle D2 55 present invention to be used for a wide variety of applica corresponds to the time it takes for the rotor assembly to tions. Also, by using Super magnets in the rotor assembly rotate from the point where the south pole of the rotor and amorphous metal magnetic cores, the device is capable magnet at the end of duty cycle D1 is lined up top dead of very high power densities and very high rotational Speeds center with the given Stator pole piece to the time the north compared to conventional electric motors and generators. pole of the next Successive rotor magnet is lined up top dead 60 These advantages allow a device designed in accordance center with the given Stator pole piece. AS indicated by the with the present invention to be used in ways that have not reference letter S, the electromagnet assembly is activated been previously possible or practical using conventional during duty cycle D2 Such that the given Stator pole piece devices.

acts as a South pole. In a first example, one preferred embodiment of the As shown in FIG. 5A, the duty cycle activation time is the 65 invention is an electric motor for use in a numeric control continuous duration of time in which the electromagnet machine tool application in which multiple tools are driven assembly 34 of the Stator arrangement is activated for a using the same Spindle and chuck. In the case where the

Page 15

electric motor directly drives the Spindle and the motor and much wider range of wind conditions than is possible using Spindle are Supported for movement over a work Surface, the conventional generators.

Spindle and overall tool would not need to be constructed The power output of device 10 is controlled by activating nearly as heavily because of the light weight and high power and deactivating electromagnet assembly 34 as described density of the motor. Also, because of the flexibility of the above. Any combination of activation and deactivation control arrangement of the motor, the motor may be pro parameters including the duty cycle activation time, the grammed for a wide variety of Specific operations. For Start/stop points of the duty cycle activation time, and the instance, the tool may initially be used as a high Speed, modulation of the duty cycle activation time may be used to relatively low power router rotating at for example 20,000 control the power output of device 10. By controlling these RPM. Then, by driving the motor in the opposite direction, activation and deactivation parameters, a very wide range of the motor and Spindle may be Stopped very quickly So that power outputs may be achieved for any given sized device. a different tool may be automatically inserted into the chuck. Also, because device 10 may be driven in either direction as If, for example, the next operation is a lower Speed, but an electric motor by energizing electromagnet assembly 34 higher power requirement drilling operation, the control with the appropriate polarity for any desired fraction of time arrangement of the motor may be programmed to provide 15 during it's operation, the device is able to reduce or increase the desired Speed, efficiency, power, and torque output. the amount of force required to turn the device as a genera Using a motor in accordance with the present invention, a tor.extremely

Therefore, the device is able to act as a generator with much wider range of motor Speed, power, and torque Set anWhen wide range of power outputs. device 10 is acting as a generator, the flexibility tings are available compared to conventional motors. provided by control arrangement 44 also allows device 10 to In another application illustrated in FIG. 6, device 10 is be arranged to condition the power output of device 10 used as a generator which is driven by a windmill 100. In without requiring the use of additional power conditioning this situation, control arrangement 44 is configured to Switch devices. Using the example of the windmill application the way electromagnet assembly 34 is activated and deac illustrated in FIG. 6, as described above, control arrange tivated in order to vary the power generated by device 10 ment 44 is able to activate and deactivate electromagnet depending on the power input available from windmill 100. 25 assembly 34 in order to control the power output of device This arrangement allows the generator to operate in a much 10. Because of this control arrangement 44 is able to control wider range of operating conditions than is possible using the Speed at which the windmill operates. Also, control conventional generators. arrangement 44 is able to control the activation and deacti Typically windmill generators are configured to have a Vation parameters as described above. This allows control predetermined electrical output. AS the wind comes up, the arrangement 44 to be configured to activate and deactivate generator is not able to operate until the wind Speed reaches the electromagnet assembly such that the output of device 10 a minimum operating Speed. Since typical windmills are is conditioned to a desired electrical output without requir designed to operate at a point near the average wind speed ing the use of additional electrical power conditioning for the area in which they are installed, this means that the devices. This is done by controlling the speed of the device windmill is not able to generate any power when the wind 35 and activating and deactivating the electromagnet assembly is below the minimum operating Speed of the windmill. AS at the appropriate times to create an electrical output con the wind increases beyond the designed operating Speed, the ditioned to a desired electrical output. In the case where the windmill must be feathered or have a breaking mechanism output is desired to be pulsed DC, as would be the case when to waste Some of the wind energy in order to prevent the charging batteries, an Hbridge controller can convert the AC windmill from over Speeding. In Some cases, the windmill 40 output of the device to pulsed DC. This is known as “active must be shut down altogether in very high wind Situations to rectification'.

avoid damage or over heating of the breaking mechanism. As illustrated in FIG. 7, another application in which the Therefore, in high wind situations or very high wind inventive device is well Suited is a gas turbine driven Situations, much or all of the available wind energy goes to generator application. Because of the extremely high rota waste because the windmill generator is only able to gen 45 tional Speeds of turbine engines, conventional generators are erate its predetermined electrical output. typically connected to a turbine engine using reduction gears In accordance with the invention, device 10 may be that Substantially reduce the rotational Speed at which the designed to have a maximum power output which is more in generator is driven by the turbine engine. These reduction line with the high wind energy available to the windmill gear arrangements increase the cost of the overall System rather than the average wind energy. In this situation, when 50 and cause energy loses that reduce the overall efficiency of the wind is at it's average wind Speed, control arrangement the combination. In accordance with the present invention, 44 connects and disconnects electromagnet assembly 34 a generator designed as described above is directly driven by such that device 10 has a power output substantially lower a gas turbine without the use of reduction gears or any other than its maximum power output. In fact, in low wind arrangement for reducing the rotational Speed at which the Situations, device 10 may be used as an electric motor in 55 turbine engine drives the generator. As shown in FIG. 7, order to get the windmill Started. Once rotating at an device 10 is directly driven by turbine engine 200. Device 10 appropriate Speed, device 10 may be operated as a generator may also be used as a starter motor for the turbine engine. with a very low power output. AS the wind increases to AS also described above, because of the extremely high higher than average wind Speeds, control arrangement 44 Speed at which the amorphous metal magnetic core of device Simply activates and deactivates electromagnet assembly 34 60 10 is able to respond to changes in the magnetic field, and Such that the power output increases to match the energy because of the extremely fast Switching capabilities of input of the wind. In very high wind situations in which the control arrangement 44, device 10 is able to operate effec wind energy is even greater than the maximum power output tively at extremely high rotational Speeds. This allows of device 10, device 10 may be operated a certain fraction device 10 to be directly driven by turbine engine 200, and of the time as an electric motor driving the windmill in the 65 eliminates the need for any reduction gears or other arrange opposite direction to act as a brake. This overall configura ments for reducing the rotational Speed at which the turbine tion allows the windmill to operate and produce output in a engine drives device 10.

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The disk or axial type device configuration described C-shaped overall amorphous metal magnetic core 400, core above provides a compact overall package which may be pieces 400c-e form a magnetic yoke that magnetically designed to withstand extremely high centrifugal forces. couples their associated core pieces 400a and 400b. Also, in This allows a device of this configuration to operate at this embodiment, the Stator housing would be configured to extremely high rotational Speeds and therefore offer an Support all of the various core pieces in their respective extremely high power output for a given size device. In one positions to form the Six overall C-shaped magnetic cores. particularly interesting application, the device is contem AS described above with respect to the U-shaped cores, the plated to be used as an electric motor to directly drive a only difference between this embodiment and the embodi refrigeration unit turbo compressor at extremely high rota ment of FIG. 1 is that instead of all of the pole pieces on one tional speeds. These rotational speeds may be 50,000 to Side of the rotor arrangement being magnetically coupled by 100,000 RPM or more. By operating the turbo compressor the toroidal ring core piece, each pair of pole pieces formed at these rotational Speeds, the efficiency of the compressor is by associated core pieces 400a and 400b on opposite sides Substantially improved. Using conventional electric motors of the rotor arrangement are magnetically coupled. which operate at much slower Speeds, most or all of the FIG. 10 illustrates yet another possible configuration for efficiency gain associated with the high Speed turbo com 15 providing the magnetic core of the present invention. In this preSSor is lost to mechanical loses associated with the case the device takes the form of a barrel or radial type gearing necessary to achieve the high rotational Speed. By device rather than a disk or axial type device. In this directly driving the compressor with a high Speed motor configuration, a rotor assembly 500 would take the form of designed in accordance with the invention, the efficiency a barrel rather than a disk. In this example, if the device is losses associated with the conventional gear assembly are a DC brushless type motor, rotor assembly 500 would eliminated. This provides an overall arrangement that is included six rotor magnets 502 attached to the outer cir Substantially more efficient than conventional arrangements. cumferential edge of the rotor assembly. Alternatively, if the Although the overall amorphous metal magnetic core 36 device is an induction type motor, magnets 502 would not be of device 10 has been described as having an overall shape included and rotor assembly 500 would be made up of an of a toroidal ring with pole projections projecting out from 25 appropriately formed iron based material or other magnetic one of the annular Surfaces of the ring as illustrated in FIG. material core.

3A, this is not a requirement. Instead, the Overall amorphous The Stator arrangement of this barrel type embodiment metal magnetic core may take any desired shape and still fall includes only one overall amorphous metal core in the form within the Scope of the invention So long as the overall of a generally tubular shaped overall amorphous metal core amorphous metal core is made up of a plurality of individu 504. Core 504 is made up of a tubular shaped, individually ally formed amorphous metal core pieces which are Sup formed amorphous metal core piece 504a and six individu ported adjacent one another by a core housing. ally formed amorphous metal core pieces or teeth 504b.g. Referring to FIG. 8, the overall amorphous metal core Core piece 504a is formed by rolling a continuous ribbon of may take the form of U-shaped overall amorphous metal amorphous metal material of a desired width into the desired cores. In one specific embodiment, three Separate U-shaped 35 diameter tube shape. Core pieces 504b-g may be formed by overall cores 300 replace the toroidal ring configuration either Stacking individual Strips of amorphous metal material shown in FIG. 3A. Each core 300 is made up of three to form the desired core piece shape or alternatively may be individually formed amorphous metal core pieces 300a-c. formed by winding a continuous amorphous metal ribbon Core pieces 300a and 300b are cylindrical core pieces into a very elongated oval shape. In this embodiment, a similar to core pieces 36a–f of FIG. 3A. However, core 40 Stator housing 506 has core piece openings arranged Such pieces 300c are core pieces having an elongated oval croSS that each of core pieces 504b g are held adjacent to the inner Sectional shape. In this embodiment, the Stator housing surface of core piece 504a. The electromagnet coil array for would have core piece openings arranged Such that each pair this embodiment would be similar to that described above of core pieces 300a and 300b are held adjacent an associated for device 10. The only difference between the configuration one of core pieces 300c. The electromagnet coil array for 45 described above using the toroidal ring core piece and this this embodiment would be similar to that described above barrel or radial configuration is that, for the barrel for device 10. The only difference between the configuration configuration, the coils would be very elongated coils run described above using the toroidal ring core piece and the ning longitudinally parallel with the axis of the rotor assem U-shaped configuration is that the toroidal ring configuration bly and positioned around each of the core pieces or teeth magnetically couples all six of the pole pieces formed by 50 504b-g.

core pieces 36a-f, whereas, in the U-shaped configuration, Although the various core pieces have been described only each associated pair of pole pieces formed by core throughout the description as having specific cross-sectional pieces 300a and 300b are magnetically coupled. shapes, it should be understood that the invention is not FIG. 9 illustrates another possible configuration for pro limited to these Specific cross-sectional shapes. Instead, as Viding the magnetic core of the present invention. AS 55 illustrated in FIGS. 11 A-F, the individually formed core described above, device 10 of FIG. 1 includes two stator pieces may have any cross-sectional shape including a arrangements including overall amorphous metal cores 36, circle, an Oval, an egg shape, a toroidal ring, a triangle one on each side of rotor arrangement 16. FIG. 9 illustrates having rounded corners, or a trapezoid having rounded a generally C-shaped overall amorphous metal core 400 comers as illustrated by core pieces 510,512, 514,516,518, including five individually formed amorphous metal core 60 and 520 in FIGS. 11A-F respectively. pieces 400a-e. The two toroidal ring overall cores of FIG. Although the core pieces have been described as being 1 may be replaced with Six overall amorphous metal cores wound from a continuous ribbon of amorphous metal 400 positioned radially around the rotor arrangement. In this material, this is not a requirement. Alternatively, the core embodiment, Six core pieces 400a form pole pieces similar pieces may be formed by Stacking individually formed Strips to pole pieces 36a–f on one Side of the rotor arrangement. 65 or pieces of amorphous metal to form a core piece of a Core pieces 400b form corresponding pole pieces positioned desired shape Such as a rectangular core piece 522 or a on the other side of the rotor arrangement. For each trapezoidal cross-sectional shaped core piece 524, as illus

Page 17

trated in FIGS. 11G and 11H, or a wide variety if other formed amorphous metal core pieces 702a-S. A first core particular cross-sectional shapes. AS illustrated in these piece 702a of the nineteen core pieces is a toroidal ring core figures, the individual Strips may be Stacked atop one piece similar to core piece 36g shown best in FIG. 3. another with each piece being the same size and shape as Eighteen core pieces 702b-S are individually wound core indicated in FIG. 11G. Alternatively, the individual strips pieces having one end positioned adjacent toroidal ring core may be Stacked beside one another with various individual piece 702a thereby forming eighteen pole projections. Elec pieces having different sizes and shapes as illustrated in FIG. tromagnet assembly 700 also includes three separately con 11H. These various approaches allow a wide variety of trollable coil arrays 704a-c. Each of the separately control shapes to be formed. lable coil arrays is similar to coil array 38 of FIG. 1 with AS is known to those skilled in the art, when amorphous each array including a coil wrapped around every third metal material is produced, it typically has a particular consecutive one of core pieces 702b-S. With this direction along which magnetic flux will be directed most arrangement, each coil array corresponds to one of the efficiently. For a ribbon of amorphous metal material, this phases of a three phase device.

direction is typically either along the length of the ribbon or Although the device has been described above as a three acroSS the width of the ribbon. By using the appropriate 15 phase device, it should be understood that the device may approach described above to form each of the core pieces of alternatively be provided as a two phase device. In this case, an overall amorphous metal core, the individual core pieces overall amorphous metal core 702 would include thirteen may be formed Such that the amorphous metal material is core pieces rather than nineteen core pieces with twelve of always oriented Such that the magnetic flux is directed the core pieces forming pole pieces and one core piece through the pieces along the direction of the amorphous acting as the magnetic yoke as described above. Also, the metal material that most efficiently directs the magnetic flux. two phase device would include only two individually For example, in the case of the toroidal ring embodiment of controllable coil arrays. Furthermore, it is to be understood FIG. 3A, toroidal ring core piece 36g would be made by that the multiple phase devices are not limited to the toroidal winding an amorphous metal ribbon which has its most ring core configuration described above. Instead, the core efficient flux direction aligned along the length of the ribbon. 25 configuration may take on a wide variety of configurations However, each of pole pieces 36a–f would be formed by and still remain within the Scope of the invention. winding an amorphous metal ribbon which has its most Although the above described embodiments have been efficient flux direction aligned across the width of the ribbon. describe with the various components having particular This configuration aligns the amorphous metal material Such respective orientations, it should be understood that the that the magnetic flux is directed through the core along the present invention may take on a wide variety of Specific direction of the material that most efficiently directs the configurations with the various components being located in magnetic flux. a wide variety of positions and mutual orientations and Still Although the invention has been described as a single remain within the Scope of the present invention. For phase device in which all of the electromagnets of the Stator example, although each Stator arrangement of device 10 was assembly are activated Simultaneously, this is not a require 35 described as including Six pole pieces and the rotor was ment. AS would be clear to one skilled in the art, the device described as including six magnets, this is not a requirement. of the invention may also take the form of a multiphase Instead, the Stator arrangement may have any desired num device. FIG. 12 illustrates one approach to providing a ber of pole pieces and the rotor any number of magnets and multiphase electric motor 600. In this embodiment, three still remain within the scope of the invention. devices 10a-c designed as described above for device 10 are 40 Additionally, the present invention would equally apply to mounted in line on a common Shaft. Each of the devices a wide variety of electric motorS and generators So long as 10a-c is rotated twenty degrees relative to the previous the Stator arrangement of the device included an overall device. In other words, device 10b is rotated twenty degrees amorphous metal core made up of individually formed core relative to device 10a Such that each of the pole pieces of the pieces which are Supported in place by a dielectric housing. Stator arrangement in device 10b is fixed in a position twenty 45 These various generators and motors include, but are not degrees in advance of the corresponding pole pieces of the limited to, motors and generators of the DC brushleSS type, stator arrangement of device 10a. The same is true for device DC Synchronous type, variable reluctance or Switched reluc 10c relative to device 10b. Since the duty cycle of devices tance type, induction type, and many other types of 10a–C can extend through a sixty degree arc as described generators, motors, and alternators. Therefore, the present earlier, this configuration causes the three devices to be out 50 examples are to be considered as illustrative and not of phase with one another by one third of their duty cycle. restrictive, and the invention is not to be limited to the details Thus, the three devices 10a-c may be operated as an overall given herein, but may be modified within the scope of the three phase device with each of the devices 10a-c corre appended claims.

sponding to one phase. What is claimed is:

Alternatively, as illustrated in FIG. 13, a three phase 55 1. A device Selected from the group of devices consisting device may be provided by constructing a device which of an electric motor, an electric generator, and a regenerative includes a Stator arrangement having an electromagnet electric motor, the device including a rotor arrangement, at assembly 700 made up of individually formed core pieces least one Stator arrangement, and a device housing for and three Separately controllable coil arrayS. In this example, Supporting the rotor arrangement and the Stator arrangement the rotor assembly (not shown in FIG. 13) would still have 60 in predetermined positions relative to one another and for six rotor magnets as was the case for device 10 of FIG. 1. Supporting the rotor arrangement for rotation along a pre Similarly, the device includes two Stator arrangements with determined rotational path about a given rotor axis, the Stator one positioned on each side of the rotor arrangement as was arrangement comprising:

also the case for device 10 of FIG. 1. However, as shown in a) at least one energizable electromagnet assembly includ FIG. 13, which is a plan view of electromagnet assembly 65 ing an overall amorphous metal magnetic core and 700, this electromagnet assembly includes an overall amor electric coil array which together define at least one phous metal core 702 made up of nineteen individually magnetic pole piece, the overall amorphous metal

Page 18

magnetic core being made up of a plurality of indi c) the two pole pieces are each individually formed vidually formed amorphous metal core pieces, wherein amorphous metal core pieces, and at least one of the amorphous metal core pieces has a d) additional individually formed amorphous metal core shape Selected from a group of a circular disk, an egg pieces form an electromagnetic yoke magnetically cou shape, a triangle having rounded corners, a trapezoid pling the two pole pieces to one another Such that the having rounded corners, an Oval, a C-shape, a U-shape, core pieces together define the C-shaped overall core. and Said amorphous metal core pieces cooperating with 11. A device according to claim 1 wherein one another in forming part of Said electromagnet assembly, and a) the rotor arrangement is a barrel shaped rotor arrange b) a dielectric electromagnet housing for Supporting the ment having an outer circumferential Surface; electromagnet assembly Such that the magnetic pole b) the rotor arrangement includes Supporting means for pieces are positioned adjacent the rotational path of the Supporting at least one rotor magnet Such that the rotor arrangement, the dielectric electromagnet housing magnet eXtends along the outer circumferential Surface having core piece openings formed into the electro of the rotor arrangement generally parallel with the magnet housing for holding the individually formed 15 given rotor axis, and amorphous metal core pieces in positions adjacent to c) the overall magnetic core is a generally tubular shaped one another So as to form the Overall amorphous metal Overall amorphous metal magnetic core having its magnetic core. central longitudinal axis coinciding with the given rotor 2. A device according to claim 1 wherein the rotor axis, the overall core defining at least two magnetic arrangement includes at least one rotor magnet having north pole piece Such that each of the pole pieces extends and South poles, the rotor arrangement including means for radially inward toward the central axis of the overall Supporting the rotor magnet for rotation about a given rotor core, the pole pieces each being individually formed axis Such that at least one of the magnet's poles is accessible amorphous metal core pieces, the overall core includ along the predetermined rotational path about the given rotor ing an individually formed, tubular shaped, amorphous axis. 25 metal core piece forming an electromagnetic yoke 3. A device according to claim 1 wherein any Voids in the magnetically coupling the pole pieces to one another core piece openings of the electromagnet housing holding Such that all of the individually formed core pieces the amorphous metal core pieces are filled with a dielectric together define the generally tubular shaped overall oil. COC.

4. A device according to claim 1 wherein at least Some of 12. A device according to claim 2 wherein the rotor the individually formed amorphous metal core pieces are magnet is a Super magnet.

amorphous metal windings formed from a continueS ribbon 13. A device according to claim 1 wherein the device is a of amorphous metal. multiple phase device.

5. A device according to claim 4 wherein the continuous 14. A device according to claim 13 wherein the multiple ribbon of amorphous metal has a Substantially constant 35 phase device is made up of a plurality of discrete devices ribbon width. mounted in line on a common Shaft with each of the devices 6. A device according to claim 1 wherein at least one of being fixed to one another Such that the respective Stator the individually formed amorphous metal core pieces is arrangements of the plurality of devices are held in positions made up of a Stack of individual Strips of amorphous metal that are rotated a predetermined angle about the given rotor material cut to form a predetermined shape. 40 axis relative to one another.

7. A device according to claim 4 wherein the amorphous 15. A device according to claim 1 wherein the electro metal core pieces are oil impregnated. magnet housing further includes coolant openings formed 8. A device according to claim 5 wherein at least two of into the electromagnet housing for allowing a coolant fluid the individually formed amorphous metal pieces are cylin to be circulated through the housing.

drical pieces forming the two magnetic pole pieces of the 45 16. A device according to claim 1 wherein the electro electromagnet assembly. magnet housing further includes wiring raceway openings 9. A device according to claim 4 wherein the electromag formed into the electromagnet housing for containing wires net assembly of the Stator arrangement includes a generally which interconnect the coil array.

U-shaped overall amorphous metal magnetic core defining 17. A device according to claim 1 wherein the device is an two pole pieces, wherein the two pole pieces are each 50 induction motor.

individually formed amorphous metal core pieces, and 18. A Stator arrangement for use in a device Selected from wherein the Overall magnetic core includes an additional the group of devices including an electric motor, an electric individually formed amorphous metal core piece forming an generator, and a regenerative electric motor, the device electromagnetic yoke magnetically coupling the two pole including Said Stator arrangement, a rotor arrangement, and pieces to one another Such that the core pieces together 55 a device housing for Supporting the rotor arrangement and define the U-shaped overall core. the Stator arrangement in predetermined positions relative to 10. A device according to claim 4 wherein one another and for Supporting the rotor arrangement for a) the rotor arrangement includes Supporting means for rotation along a predetermined rotational path about a given Supporting at least one rotor magnet Such that both the rotor axis, the Stator arrangement comprising: north and the South poles of the rotor magnet are 60 a) at least one energizable electromagnet assembly includ accessible along different predetermined rotational ing an overall amorphous metal magnetic core and an paths about the given rotor axis, electric coil array which together define one or more b) the overall magnetic core is a generally C-shaped magnetic pole pieces, the overall amorphous metal overall amorphous metal magnetic core defining two magnetic core being made up of a plurality of indi pole pieces Such that each of the pole pieces is posi 65 vidually formed amorphous metal core pieces, wherein tioned adjacent to a corresponding one of the different at least one of the amorphous metal core pieces has a predetermined rotational paths, shape Selected from a group of a circular disk, an egg

Page 19

shape, a triangle having rounded corners, a trapezoid relationship to one another Such that (1) the first end of one having rounded corners, an Oval, a C-shape, a U-shape, of Said pole pieces is positioned adjacent to and in confront and Said amorphous metal core pieces cooperating with ing relationship with one of Said yokes while its Second end one another in forming part of Said electromagnet projects out therefrom in the direction of the other yoke, (2) assembly, and the first end of the other of Said pole pieces is positioned b) a dielectric electromagnet housing for Supporting the adjacent to and in confronting relationship with the other of electromagnet assembly Such that the one or more Said yokes while its Second end projects out therefrom in the magnetic pole pieces are positionable adjacent the direction of the one yoke, and (3) the opposite ends of the rotational path of the rotor arrangement, the dielectric yoke connecting member are adjacent Said confronting electromagnet housing having core piece openings yokes, respectively, whereby the core pieces define a formed into the electromagnet housing for holding the c-shaped configuration.

individually formed amorphous metal core pieces in 27. An amorphous metal core for use as part of a Stator positions adjacent to but unconnected from So as to arrangement which in turn can be used in a device Selected form the overall amorphous metal magnetic core. from the group of devices including an electric motor, an 19. A Stator arrangement according to claim 18 wherein 15 electric generator, and a regenerative electric motor, the Said core pieces include at least one pole piece having first device including Said Stator arrangement, a rotor and Second ends and a yoke which are held within Said arrangement, and a device housing for Supporting the rotor housing openings Such that the first end of Said pole piece is arrangement and the Stator arrangement in predetermined positioned adjacent to and in confronting relationship with positions relative to one another and for Supporting the rotor Said yoke and the Second end projects out therefrom. arrangement for rotation along a predetermined rotational 20. A stator according to claim 18 wherein said core path about a given rotor axis, the amorphous metal core pieces include a plurality of pole piece each having first and comprising:

Second ends and a yoke, all of which are held within Said a) a plurality of individually formed amorphous metal housing openings Such that the first end of each of Said pole core pieces including one or more thereof which Serve pieces is positioned adjacent to and in confronting relation 25 as a pole pieces when combined with cooperating ship with Said yoke and the Second end of each pole piece electric coils, wherein at least one of the amorphous projects out therefrom. metal core pieces has a Shade Selected from a group of 21. A Stator according to claim 20 wherein each of Said a circular disk, an egg shape, a triangle having rounded pieces is an amorphous metal winding formed from a corners, a trapezoid having rounded corners, an oval, a continuous ribbon of amorphous metal having opposite C-shape, a U-shape, and Said amorphous metal core edges Such that Said opposite edges form the first and Second pieces cooperating with one another in forming part of ends of the pole piece. an electromagnet assembly; and 22. A stator according to claim 21 wherein said yoke is an b) a dielectric electromagnet housing for Supporting the amorphous metal winding formed from a continuous ribbon core pieces in adjacent but unconnected relationship of amorphous metal having opposite edges which define 35 with one another Such that the one or more magnetic opposite yoke Surfaces and wherein the first end of each of pole pieces which are formed when combined with Said pole pieces is held by Said housing adjacent to and in cooperating electric coils are positionable adjacent the confronting relationship with one of Said yoke Surfaces. rotational path of the rotor arrangement, the dielectric 23. A Stator according to claim 22 wherein Said yoke is electromagnet housing having core piece openings shaped So as to define a toroidal ring. 40 formed into the electromagnet housing for holding the 24. A Stator according to claim 20 wherein at least Some individually formed amorphous metal core pieces in of the individually formed amorphous metal core pieces are Said adjacent but unconnected relationship with one made up of a Stack of individual Strips of amorphous metal another.

material cut to form a desired shape. 28. An amorphous metal core according to claim 27 25. A stator according to claim 20 wherein said core 45 wherein Said core pieces include at least one pole piece pieces include two and only two pole pieces which together having first and Second ends and a yoke which are held with Said yoke define a u-shaped configuration. within Said housing openings Such that the first end of Said 26. A Stator arrangement according to claim 18 wherein pole piece is positioned adjacent to and in confronting Said core pieces includes two pole pieces, each having first relationship with Said yoke and the Second end projects out and Second ends, two confronting yokes and a yoke con 50 therefrom.

necting member having opposite ends, all of which are held within Said housing openings in close but unconnected