IP Library › Granted Patent US 12,438,488
Granted Patent B2
US 12,438,488 · App. 18/392,057 · Granted Oct 7, 2025

Variable torque motor/generator/transmission

Inventors: James L. Bailey (Titusville, FL); Harley C. McDonald (Merritt Island, FL)
Assignee: Falcon Power, LLC
H02P25/188B60K6/26B60K6/48B63H21/14B63H21/20B63H23/10H02K3/28H02K7/183H02K16/04H02K19/16H02K21/024H02P31/00B60K2006/262B60K2006/4808B63H2021/202B63H2021/205H02K2213/09Y02T70/5236Y10S903/906
View Patent ↗
Loading inventors, assignments & file history…
Monitor This Case
Get email alerts when status or documents change.
Order Certified Copies
Most orders are placed with the USPTO same day — all within 24 business hours.
Order via The Patent Place →
Pre-filled with this patent's details
Quick Facts
Patent No.
US 12,438,488
App. No.
18/392,057
Granted
Oct 7, 2025
Kind
B2
Abstract

The present disclosure is directed to an electric generator and motor transmission system that is capable of operating with high energy, wide operating range and extremely variable torque and RPM conditions. In accordance with various embodiments, the disclosed system is operable to: dynamically change the output “size” of the motor/generator by modularly engaging and disengaging rotor/stator sets as power demands increase or decrease; activate one stator or another within the rotor/stator sets as torque/RPM or amperage/voltage requirements change; and/or change from parallel to series winding configurations or the reverse through sets of 2, 4, 6 or more parallel, three-phase, non-twisted coil windings with switchable separated center tap to efficiently meet torque/RPM or amperage/voltage requirements.

Claims (26)

1. A propulsion system comprising:

a propulsion device;

an engine to selectively power the propulsion device;

a variable torque motor/generator/transmission to selectively power the propulsion device, the variable torque motor/generator/transmission comprising:

a first stator and a second stator, wherein the second stator is spaced apart from the first stator, and

an interactive field element configured to translate so as to selectively engage at least one of the first stator, the second stator, or neither of the first stator nor the second stator;

an energy storage device to store energy for powering the variable torque motor/generator/transmission; and

a controller to selectively operate the propulsion system in a first mode where the variable torque motor/generator/transmission supplies power solely to the propulsion device, and a second mode where the engine supplies power to both the propulsion device and the variable torque motor/generator/transmission, where the variable torque motor/generator/transmission supplies energy for storage in the energy storage device when the propulsion system is operated in the second mode.

2. The propulsion system as recited in claim 1 , wherein the interactive field element is slidably coupled with a longitudinal support structure to translate along the longitudinal support structure parallel to its axis of rotation between at least one of: a first orientation where the first stator is engaged with the interactive field element, a second orientation where the second stator is engaged with the interactive field element, or a third orientation where neither the first stator nor the second stator is engaged with the interactive field element.

3. The propulsion system as recited in claim 1 , wherein at least one of the first stator or the second stator comprises at least one of an outer ring or an inner ring with respect to the interactive field element.

4. The propulsion system as recited in claim 1 , wherein the interactive field element comprises at least one of a permanent magnet or an electromagnet.

5. The propulsion system as recited in claim 1 , wherein the first stator comprises a first wire winding having a first winding configuration and the second stator comprises a second wire winding having a second winding configuration different from the first winding configuration.

6. The propulsion system as recited in claim 1 , wherein the longitudinal support structure comprises a central shaft with the first stator and the second stator of the stator support disposed around at least a portion of the central shaft.

7. The propulsion system as recited in claim 1 , further comprising at least a second interactive field element slidably coupled with a longitudinal support structure to translate along the longitudinal support structure parallel to its axis of rotation between the first stator engaged with the second interactive field element, the second stator engaged with the second interactive field element, and neither the first stator nor the second stator engaged with the second interactive field element.

8. The propulsion system as recited in claim 7 , further comprising at least a third interactive field element slidably coupled with the longitudinal support structure to translate along the longitudinal support structure parallel to its axis of rotation between the first stator engaged with the third interactive field element, the second stator engaged with the third interactive field element, and neither the first stator nor the second stator engaged with the third interactive field element.

9. The propulsion system as recited in claim 2 , further comprising an actuator configured to move the interactive field element between the first orientation, the second orientation, and the third orientation.

10. The propulsion system as recited in claim 9 , wherein the actuator comprises at least one of a solenoid, a linear motion screw, a pneumatic cylinder, or a hydraulic cylinder.

11. The propulsion system as recited in claim 1 , wherein each of the first and second stators includes a ring of cores circumscribing a central stator axis, wherein each phase of the ring of cores is wound with two or more non-twisted wires, in parallel with one another other, separated at a switchable center tap.

12. The propulsion system as recited in claim 11 , further comprising:

electronically controlled switches configured to selectively connect the two or more non-twisted wires in parallel or series.

13. The propulsion system as recited in claim 12 , wherein the electronically controlled switches are configured to connect the two or more non-twisted wires of each phase all in parallel, producing a first torque/speed.

14. The propulsion system as recited in claim 12 , wherein the electronically controlled switches are configured to connect the two or more non-twisted wires of each phase all in series, producing a second torque/speed.

15. The propulsion system as recited in claim 12 , wherein the two or more non-twisted wires include multiple sets of two wires, wherein the electronically controlled switches are configured to connect the two wires of each set in parallel and are configured to connect the multiple sets in series with one another, producing a third torque/speed different from all parallel and all series configurations of the two or more non-twisted wires.

16. The propulsion system as recited in claim 12 , wherein the two or more non-twisted wires include multiple sets of three wires, wherein the electronically controlled switches are configured to connect the three wires of each set in parallel and are configured to connect the multiple sets in series with one another, producing a fourth torque/speed different from all parallel and all series configurations of the two or more non-twisted wires.

17. The propulsion system as recited in claim 1 , wherein the propulsion system comprises a hybrid propulsion system.

18. The propulsion system as recited in claim 1 , wherein the engine comprises at least one of an internal combustion engine or a battery.

Continuity (10)
Continuation 17840148 · Jun 14, 2022
Continuation 17094475 · Nov 10, 2020
Continuation 16025134 · Jul 2, 2018
Continuation 15808188 · Nov 9, 2017
Continuation 15332824 · Oct 24, 2016
Division 14815733 · Jul 31, 2015
Provisional Application 62146725 · Apr 13, 2015
Provisional Application 62146694 · Apr 13, 2015
Provisional Application 62032468 · Aug 1, 2014
Related Publication 20240204706A1 · Jun 20, 2024
References Cited (126)
US 3401290A · Milton et al. · 1968 [cited by applicant]
US 3973137A · Drobina · 1976 [cited by applicant]
US 4027229A · Frink · 1977 [cited by applicant]
US 4093882A · Furuta · 1978 [cited by applicant]
US 4472673A · Miller · 1984 [cited by applicant]
US 4734604A · Sontheimer et al. · 1988 [cited by applicant]
US 4920293A · Kanda · 1990 [cited by applicant]
US 5019766A · Hsu et al. · 1991 [cited by applicant]
US 5189357A · Woodson et al. · 1993 [cited by applicant]
US 5614777A · Bitterly et al. · 1997 [cited by applicant]
US 5675203A · Schulze et al. · 1997 [cited by applicant]
US 5763977A · Shimasaki et al. · 1998 [cited by applicant]
US 5821660A · Anderson · 1998 [cited by applicant]
US 5831366A · Kern et al. · 1998 [cited by applicant]
US 5834872A · Lamb · 1998 [cited by applicant]
US 6005317A · Lamb · 1999 [cited by applicant]
US 6166469A · Osama et al. · 2000 [cited by applicant]
US 6211591B1 · Kowalski et al. · 2001 [cited by applicant]
US 6242832B1 · Lamb · 2001 [cited by applicant]
US 6337527B2 · Lamb · 2002 [cited by applicant]
US 6380648B1 · Hsu · 2002 [cited by applicant]
US 6492753B2 · Zepp et al. · 2002 [cited by applicant]
US 6555941B1 · Zepp et al. · 2003 [cited by applicant]
US 6737786B2 · Hsu · 2004 [cited by applicant]
US 6759780B2 · Liu et al. · 2004 [cited by applicant]
US 6841909B2 · Six · 2005 [cited by applicant]
US 7042128B2 · Zepp et al. · 2006 [cited by applicant]
US 7385332B2 · Himmelmann et al. · 2008 [cited by applicant]
US 7482903B2 · Kaumann et al. · 2009 [cited by applicant]
US 7497285B1 · Radev · 2009 [cited by applicant]
US 7549939B2 · Strauss et al. · 2009 [cited by applicant]
US 7804263B2 · Himmelmann et al. · 2010 [cited by applicant]
US 7863789B2 · Zepp et al. · 2011 [cited by applicant]
US 7965006B2 · Kang et al. · 2011 [cited by applicant]
US 8269389B1 · Somerville · 2012 [cited by applicant]
US 8415910B2 · Fulton · 2013 [cited by applicant]
US 8608521B1 · Snyder et al. · 2013 [cited by applicant]
US 9479037B2 · Bailey et al. · 2016 [cited by applicant]
US 10892700B2 · Bailey et al. · 2021 [cited by applicant]
US 20020163262A1 · Hsu · 2002 [cited by applicant]
US 20030094929A1 · Pendell · 2003 [cited by applicant]
US 20030137149A1 · Northrup et al. · 2003 [cited by applicant]
US 20050104469A1 · Zepp et al. · 2005 [cited by applicant]
US 20060121139A1 · Murb · 2006 [cited by applicant]
US 20070096581A1 · Zepp et al. · 2007 [cited by applicant]
US 20080116759A1 · Lin · 2008 [cited by applicant]
US 20080197730A1 · Himmelmann et al. · 2008 [cited by applicant]
US 20080264702A1 · Cheng · 2008 [cited by applicant]
US 20080265702A1 · Yeh · 2008 [cited by applicant]
US 20080272664A1 · Flynn · 2008 [cited by applicant]
US 20090160392A1 · Mularcik · 2009 [cited by applicant]
US 20090267434A1 · Park · 2009 [cited by applicant]
US 20100007225A1 · Platon et al. · 2010 [cited by applicant]
US 20100013346A1 · Peek · 2010 [cited by applicant]
US 20100109448A1 · Mamba et al. · 2010 [cited by applicant]
US 20100213778A1 · Knutson · 2010 [cited by applicant]
US 20100327791A1 · Casey · 2010 [cited by applicant]
US 20110227523A1 · Grantz · 2011 [cited by applicant]
US 20120086380A1 · Krieger et al. · 2012 [cited by applicant]
US 20120115662A1 · Han · 2012 [cited by applicant]
US 20120309242A1 · Haugland · 2012 [cited by applicant]
US 20120326553A1 · Peng et al. · 2012 [cited by applicant]
US 20140091746A1 · Fujishima et al. · 2014 [cited by applicant]
US 20140232233A1 · Fukushima et al. · 2014 [cited by applicant]
US 20140340013A1 · Li et al. · 2014 [cited by applicant]
US 20160020652A1 · Hunstable · 2016 [cited by applicant]
US 20160036308A1 · Bailey et al. · 2016 [cited by applicant]
CA 2652833A1 · 2010 [cited by applicant]
CN 2452804Y · 2001 [cited by applicant]
CN 101292411A · 2008 [cited by applicant]
CN 102079242A · 2011 [cited by applicant]
CN 102368644A · 2012 [cited by applicant]
CN 102647058A · 2012 [cited by applicant]
CN 102647139A · 2012 [cited by applicant]
CN 102842973A · 2012 [cited by applicant]
CN 103889754A · 2014 [cited by applicant]
DE 19960168A1 · 2001 [cited by applicant]
DE 102004041227A1 · 2006 [cited by applicant]
DE 102006020867A1 · 2007 [cited by applicant]
DE 102007018734A1 · 2008 [cited by applicant]
DE 102012022456A1 · 2014 [cited by applicant]
EP 1111762A2 · 2001 [cited by applicant]
EP 1265341A1 · 2002 [cited by applicant]
EP 1401087A1 · 2004 [cited by applicant]
EP 2306621A1 · 2011 [cited by applicant]
EP 2400656A2 · 2011 [cited by applicant]
JP S56129596A · 1981 [cited by applicant]
JP 2002262534A · 2002 [cited by applicant]
JP 2003111492A · 2003 [cited by applicant]
JP 2008155313A · 2008 [cited by applicant]
JP 2010213488A · 2010 [cited by applicant]
JP 2014506113A · 2014 [cited by applicant]
KR 20090060388A · 2009 [cited by applicant]
TW 505338U · 2002 [cited by applicant]
TW 517920U · 2003 [cited by applicant]
TW 201141042A · 2011 [cited by applicant]
TW 201444268A · 2014 [cited by applicant]
WO 8807782A1 · 1988 [cited by applicant]
WO 2007128742A1 · 2007 [cited by applicant]
WO 2015138766A1 · 2015 [cited by applicant]
WO 2016051456A1 · 2016 [cited by applicant]
Extended European Search Report for 21175446.0, dated Nov. 26, 2021. [cited by applicant]
Extended European Search Report for EP 15826799.7, dated Jun. 22, 2018. [cited by applicant]
Extended European Search Report for EP20177681.2, dated Oct. 22, 2020. [cited by applicant]
Extended European Search Report for Patent Application No. 13751926.0, dated Aug. 20, 2015. [cited by applicant]
Extended Supplementary European Search Report for European Application No. 17783121.1, dated Nov. 21, 2019. [cited by applicant]
Goudarzi, N. et al., “Aerodynamic and Electromagnetic Analysis of a Variable Electromotive-Force Generator for a Wind Turbine”, ASME 2012 International Mechanical Engineering Congress and Exposition, vol. 4, Dynamics, C… [cited by applicant]
https://duratracmotors.com/patents/. [cited by applicant]
https://duratracmotors.com/technical-papers/. [cited by applicant]
International Preliminary Report on Patentability for Application No. PCT/US2015/043296 dated Feb. 7, 2019. [cited by applicant]
International Preliminary Report on Patentability for Application No. PCT/US2017/027383 dated Oct. 16, 2018. [cited by applicant]
International Search Report and Written Opinion for PCT/US2015/043296, dated Oct. 23, 2015. [cited by applicant]
International Search Report and Written Opinion for PCT/US2017/027383, dated Jul. 25, 2017. [cited by applicant]
Nipp, Eckart, “Permanent Magnet Motor Drives with Switched Stator Windings”, Royal Institute of Technology, Department of Electrical Power Engineering Electrical Machines and Drives, Stockholm 1999, TRITA-EMD-9905, ISSN… [cited by applicant]
Notice of Reason for Rejection for Japan Application No. 2021-114252, dated Sep. 15, 2022. [cited by applicant]
Notice of Reason for Rejection in Japan for Patent Application No. 2021-114252, dated Jun. 13, 2023. [cited by applicant]
Office Action for Chinese Application No. 201780036470.5, dated Nov. 3, 2021. [cited by applicant]
Office Action for Taiwan Patent Application No. 104124994, dated Jul. 21, 2016. [cited by applicant]
Office Action from Taiwan Patent Application No. 106112419, dated Oct. 6, 2020. [cited by applicant]
Office Action in Europe for Application No. 21175446.0, dated Jan. 27, 2023. [cited by applicant]
Office Action in Taiwan for Application No. 110136696, dated Nov. 7, 2022. [cited by applicant]
Partial Supplementary European Search Report for EP 15826799.7, dated Feb. 19, 2018. [cited by applicant]
Reason for Rejection for Japanese Patent Application No. 2019-505130, dated Mar. 1, 2021. [cited by applicant]
Steiger, W. et al., “Directhybrid—a Combination of Combustion Engine and Electric Transmission,” 2006. [cited by applicant]
Examination Report from European Application No. 20177681.2, dated Feb. 12, 2025. [cited by applicant]
First Office Action from Chinese Application No. 202210863440.4, dated Jul. 16, 2025. [cited by applicant]