Disc Version

Title: Reversible Continuously Spinning Transmission for Electric Vehicles

Specification: This application relates generally to a reversible torque transfer device. This transmission design may be used in many different applications. The example used for the illustrative purposes of this patent is a reversible clutch for electric vehicles. Extensive prior art exists in the field of vehicle transmissions. All of these designs are compatible with internal combustion engines (ICE). The evolution of the electric vehicle (EV) industry has presented a unique opportunity for the development of a transmission suitable for both the AC and DC electric motors. The power curve of the ICE motor is most efficient at 2-3K RPM. Current transmissions are designed to enable the motor to spin at this range regardless of the vehicle speed. This protects the motor from overheating at high RPM and from stalling at low RPM. It is important to note that the ICE motor continues to rotate when the vehicle is stopped and while shifting gears. The power curve for electric motors is much broader. Current AC motors perform well at 0-15K RPM. Standard EV powertrain designs eliminate the transmission and rely on a gear drive system to provide the correct ratio between motor RPM and wheel speed. The upside to this design is that it is simple and affordable. The down side is that the torque from the motor damages the internal gears to the point that they will fail unless replaced. In addition current gear drive systems require the motor to stop spinning when shifting from forward to reverse and while the EV is stopped for traffic, a red light or for a variety of reasons Spooling the EV motor from 0-15K RPM requires a large amount of energy. In addition it spikes the battery pack and greatly reduces the driving range of the vehicle. All of this is avoided with the introduction of the continuously spinning transmission (CST). The present disclosure illustrates a transmission design which enables the EV motor to spin while the vehicle is stopped or while the operator is shifting gears from forward to reverse. The benefit of the constant spin is that a rotating motor creates a flywheel effect due to centrifugal force. This force greatly reduces the amperage required to maintain the motor RPM and the motion of the EV. The primary advantage of this design is that the centrifugal force is converted into torque and therefor motion when the EV moves in either direction from a dead stop. This is a highly efficient method to overcome inertia. In a preferred embodiment, the CST housing has both an input and an output shaft. The input shaft is connected to the motor and the output shaft is connected to the wheel axels. The input and output shafts are separated by an internal clutch. The internal clutch may be a variety of styles including permanent magnet, electromagnetic or manual. In the preferred embodiment, the clutch is a composed of three separate disc plates. The center plate is composed of steel with a copper facing and is attached to the input shaft. The two outer plates are composed of steel and imbedded with permanent magnets. The two magnetic plates are connected to a paddle and shift rail. The paddles are designed to move the magnetic plates in the desired location. In the attached drawing, the magnetic plates are moved to the left for forward and to the right for reverse motion. As either plate is moved closer to the center plate they begin to rotate in unison with the center plate and shaft. They do not come into direct contact with the center plate. The magnetic force of the outer plates induces them to rotate with the copper plate. The left magnetic plate is connected to a chain or belt drive. This in turn rotates the output shaft and produces a forward momentum. The right magnetic plate is connected to a spur gear. This rotates the output shaft in the opposite direction and produces a reverse momentum. The benefit of this design is that it enables the electric motor to continuously rotate at all times. The clutch plates do not make physical contact therefor they do not suffer from friction or excess torque. In addition, the vehicle speed may be adjusted using the gap between the plates. In summary, I disclose a reversible, continuously spinning transmission for electric vehicles. This improvement over existing designs enables the electric motor to maintain rotation at all times. Continuous spinning of the motor while stopped or while shifting gears avoids the battery spike associated with current EV designs. A rotating motor creates a flywheel effect from the centrifugal force. This force is captured by the CST and converted into torque. This conversion provides substantial energy savings and greatly increases the travel range of the EV and the lifetime of the battery pack. The CST is suitable for all EV designs including cars, trucks, motorcycles and forklifts. 

Co-axial Version

Title: Reversible Continuously Spinning Transmission for Electric Motors Continuation for: Application # 15611634 filed 06/01/2017 Specification: This application relates generally to a torque transfer device. This transmission design may be used in many different applications. The example used for the illustrative purposes of this patent is a magnetic clutch for small electric motors. The current trend for power tools, lawn mowers, leaf blowers etc. is to incorporate battery powered electric motors. This improvement enables the product to be more energy efficient and to eliminate the need for connecting to an AC extension cord. The new cordless designs currently utilize long lasting Lithium- ion batteries and brushless motors. USP Application #15611634 describes a reversible plate style transmission suitable for large electric motors. This design is well suited for EV cars, trucks and forklifts where a reverse gear is a necessity and where the motor RPM’s are constantly changing. The size of the transmission for large motor applications is less critical then with small motor applications. In a preferred embodiment, this clutch is a composed of three separate disc plates. The center plate is composed of copper and is imbedded with permanent magnets and is attached to the input shaft. The two outer plates are composed of steel and imbedded with permanent magnets. The two outer magnetic plates are controlled by a paddle which is connected to a shift rail. The paddles are designed to move the magnetic plates in the desired location. As either plate is moved closer to the center plate they begin to rotate in unison with the center plate and shaft. They do not come into direct contact with the center plate. The magnetic force of the outer plates induces them to rotate with the copper plate. It is important to note that all of the plates contain the permanent magnets. The attraction between a permanent magnet and a regular steel plate diminishes quickly with increasing distance. This is due to the fact that the magnetisation in the steel plate decreases quickly. Two permanent magnets attract each other more with increasing distance, because the magnetisation in both magnets remains essentially the same. The present disclosure illustrates a transmission design which is suitable for small electric motors where space is at a premium. The motor shaft and the spinning component are coupled with the magnetic clutch which enables the motor to constantly spin at a preferred RPM. The benefit of the constant spin is that a rotating motor creates a flywheel effect due to centrifugal force. This force greatly reduces the amperage required to maintain the motor RPM and lengthens the run time between battery charges. In addition, the magnetic clutch protects the spinning component in the event of sudden impact with a large immobile object. For example when a drill bit encounters a large knot and the force of the P-factor transfers into the hands of the operator. This twisting effect can suddenly move the operator into a compromised position or injure his wrists. In another example the spinning blade on a lawn mower may strike a large object such as a rock and damage the blade or launch shards in and around the mower. This can be dangerous for both the operator and anyone or anything in the immediate area. The magnetic clutch allows the drill bit or mower blade to immediately disconnect from the motor shaft and to avoid the bad effects from a sudden impact. A majority of the cordless drills incorporate a planetary gear system to reduce the RPM and to control torque. This set of gears is expensive and adds a layer of complexity to the design and manufacture of the drill. It is possible to eliminate the planetary gears with the introduction of the magnetic clutch. The design of the magnetic clutch may include a variety of shapes and styles such as the plate configuration described in US Application #15611634. The magnetic discs are simple to manufacture and affordable. In a preferred embodiment for small motor applications the co-axial design is more suitable. The two magnetic units are cylinder shaped and interface as a piston and cylinder. The OD of the inner core is smaller than the ID of the outer core which enables the inner core to slide in and out of the outer core. The individual cores are lined with bar magnets with the correct polarity. The motor shaft is connected to the inner core and controls the rotation of the outer core. The outer core is connected to the driven member. The magnetic force is adjusted by the sliding movement and depth of the inner core. In summary, I disclose a continuously spinning magnetic transmission (CST) for small electric motors. This improvement over existing designs enables the electric motor to maintain rotation at all times. Continuous spinning of the motor avoids the battery spike associated with current cordless designs. A rotating motor creates a flywheel effect from the centrifugal force. This force is captured by the CST and converted into torque. This conversion provides substantial energy savings and greatly increases the cycle time and the overall lifetime of the battery pack. In addition the CST is designed to replace the planetary gear system incorporated into the majority of cordless drills. This is a significant benefit due to the cost savings and reduction in parts required for the manufacturing of the tool. The magnetic clutch provides a significant safety feature. The magnetic force allows the motor shaft to spin the driven member without a mechanical connection. This eliminates the dangerous effect created by sudden impact. The CST is suitable for all cordless designs including power tools, lawn mowers and leaf blowers.