Understanding HVEMi configurations starts with Stages of expansion.

Stages 1, 2, 3 - Completing Stage 2 is the limit for efficient HVEMi motors WITHOUT regeneration. 

Stage 3 MUST include additional components, which includes regeneration.

Stage 1	Stage 2	Stage 3

Optimized coil stators and retail 2x3" disk magnets; 5 Sections - without regeneration - magnets are NOT aligned in this CAD image because it was a waste of time; the retail 2x3" disk magnets are used for visual aid.

Throughout this website I offer details for optimization, but I do not provide reasons for specific configurations.  The 5 Section color CAD image below will leave some with improper ideas about magnet field and flux interactions between stator coils in close proximity, assuming all coils are created equal.  Review everything.

The efficiency increases with each Stage 4 addition.  Just take a look at some of the images for reference.  The retail 2x3" disk magnets are used for layout and visual aid.  See below for animation.

The images display ONE Section, whereas the color HVEMi CAD image above displays 5 Sections.

After you work with and understand the Sections using the HVEMi Size Calculator, you are able to configure or size UP any HVEMi motor according to your requirements.  The size and strength of the shaft and Coil Row Assembly determines the maximum number of Sections or Core length.  From the standard HVEMi 3-Unit Motor the center shaft will provide the torque to drive external mechanisms in one direction; adding the lower right Stage 4 (3 rotors + 4 coils) will provide the reverse direction shaft with the same torque--balanced gearing.

While the above image demonstrates combining two HVEMi motors with less parts and improved efficiency, it also reveals the same expansion capabilities as below - unlimited.

The beauty of the design is that though I present attraction configurations, repulsion and other configurations work well (patent claims and optimized prototypes).  You CAN add as many additional Stage 4 Units as required when understanding the HVEMi Size Calculator.

Scalable 2-800 Usable HP

HVEMi Size Calculator is awesome

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The HVEMi wood frame prototype is presented as the example to follow for building and validating claims.  Since I am not provide step by step instructions for DIY applications, everything is presented for reference and assumes you have adequate knowledge or will obtain professional guidance.

Research and development companies, inventors and theorists have one thing in common--that is, they all require physical prototypes to prove what they claim.  Spending time on calculations without physical models to test each concept is a waste of time from my perspective.

I had developed interests in drafting and architecture (the manner in which things align), rebuilding motors (the manner in which things work), and magnetic fields (the manner in which the solar system revolves) in high school.  However, I was not interested in classroom studies and I was more interested in hands-on trial and error experience.  Now-a-days I can build or repair almost anything, including an entire house from the ground up.  But what I cannot understand is that brilliant people in the USA cannot guide our country effectively.

The wood frame HVEMi prototype is derived from my high school days, testing and presenting only one model.

The point of my personal frustration was the simple overlooked components within electric and combustion engines that would render a motor useless or greatly damaged.  Since I had my own money from working through high school, my motorcycles and cars always required some maintenance or repair.  I remember acquiring an old 1969 Toyota Corona with a blown engine.  I rebuilt the engine BUT did not change one heater hose, so when I drove to Los Angeles to visit some friends (at 17) while I was there the hose blew and the engine started knock'n...we towed it back to the Bay Area.  The car became a Dukes of Hazard off-road thrasher.  Backed in to another corner, it's time to focus on core motor concepts.

At that time of my life I was not trying to do anything but test ideas.  I have made many mistakes, but I never gave up until I was told too.  I guarantee that there are many wonderful inventions and developments not revealed to the public for control and financial reasons.  But for now, it is time to let HVEMi out of the bag.

Testing concepts

In high school I acquired parts and materials from Grand Auto Supply, old motors and various appliances.  The first theory was that multiple rotors can benefit from each other when conformed to create equalized magnetism, but not in terms of Halbach Array or many magnets positioned together in a circle that disrupts magnetic field strength.  On paper it did not seem that alignments would allow for rotation to break free without high current input, but this is where the HVEMi model proves to be correct.  (the most difficult task was making the gears)

The design on the left is not efficient... with 2 or 4 rotors squared... Either attracting or repelling mode the coils require high current input to either break or pull the rotation - OC linear alignment Of course, working with smaller magnets offers similar results but are very different than large magnets (2x2) The amount of torque (using hand or t-wrench) required to move magnets (attracting) toward dual 90-degree-alignment is very high, in addition once past 90-degree-alignment the pull force can break your wrist if not stop-protected.

HVEMi Beginnings

Whereas multiple rotors can be aligned with gears when attracting center rotor and each corresponding rotor is linearly aligned, will easily turn by hand.  Well, visually this does not make any sense because of the rotations: the center rotor CW and outside rotors CCW.  However, in this configuration the rotation starts with very low power input:

What I was originally after was to use less power to start the motor. Thus having available low RPM torque. Now it can be compared to electric motors with both generating and motoring modes, but it is more efficient.

Increased efficiency is also available through expansion of HVEMi Stages.  Whereas the above is Stage 1 and below is Stage 2.

Even as Stage 1 is non-obvious, Stage 2 and 3 with expansion is non-obvious as demonstrated. Visually Stage 2 looks like three Stage 1 units combined.  Well, I guess I will leave you with thinking there is no benefit for the combination. However, the efficiency increases!

Wood Frame Components

Always testing: alternator setup for load testing, duration and input - single center rotors (2x2 or 2x3)

Knowing the calculations is much different from visual and testing results.  However, reasons for COIL configuration is not fully disclosed but within the Optimizing Coils below some information is given.

The general purpose of deceptive prototypes are only understood when knowing the goals.

Have fun...wait until you see HVEMi optimized.

High voltage power supply, magnet gearing, custom stators and magnets...the above is the example of what you can do and how HVEMi will help you become self-reliant and energy independent.

The power supply is easy for most to create with basic knowledge.  Originally individual 12 for 12 switching, but I separated the source for 6 for 12 coils, high and low.  A Variac is excellent for regulating voltage and manual speed control.  The smaller caps are 350v 4.7uf - easy to change.  Using only the wire I had with me - okay - while pushing the limits of everything, which is amazing for what we learn.

Again, using the parts and materials I had acquired over the years, the gears were used before for different setups; whereas the 4 have the same pitch and 6 have the same but different pitch from the other 4.

The subsequent prototypes changed stator coils, spur gears 4 and then magnet gears, etc.

All you have to do is understand the difference between ONE 100 ohm air coil and ONE 100 ohm custom stator coil; with 50 watts input; 2x2" disk magnets.  This is the only test you can begin with and then realize what I have documented is base on AIR COILS.  1/2 HP (400 watts) output @ 600 watts input...break it down and do some math to really understand what is possible without brushless switching, etc.

  

Without much thought most people will be able to assess that open-air coils (below) do not offer total performance and efficient configurations.  So, why waste the time building these coils?  Well, I know the differences between what I am disclosing and proper stator coils, and I cannot give you everything without making you work for it...

However, never assume that I am promoting building HVEMi motors as described FOR manufacturers?

I have decided to disclose many key features in this presentation, limiting only final optimized versions.  As an engineer you may assess the electromagnetic field flux interaction between coils WHEN all coils are used as input is Not optimally positioned. So true.  For corresponding sections (coil-row) it is more efficient to increase spacing between coils at 50-75% of coil size for better INPUT performance.  For example from the below image, the two sections on the LEFT will have better performance over the two sections on the right WHEN separated. 

In addition, removing the second coil from the right from HVEMi prototypes the overall performance and efficiency increases (450 watts input @ 1/2 HP-400 watts output).  So, people not reading this far will not obtain this information.  The process is not always as clear to all people.  That is why I have mentioned to review all information on this website to gain insight into optimizing prototypes; it's not for everyone.

Regeneration testing using different coils!  Proving HVEMi concepts for expandable multiple rotor configurations for electric motors - definitely not looking the same as what I am presenting - and providing you the means to understand your energy independent future.

Since all my different prototype tests, while maintaining some level of security in many different locations, were not developed to show or appease others and any timeframe of completion was solely mine, the years of development was purposely guided by a 2012 plan of introduction.

Again, so why waste time building these coils and configurations?

All time is wasted when an invention is stolen prior to obtaining patent rights, to only benefit the thief.  However, to fully benefit the thief it must be stolen when the invention is finalized/completed.  When an invention is stolen with improper data the claims are more difficult to produce and present as validated, which will require additional resources to develop.

The responsibility for any size company developing new technology or pharmaceuticals include maintaining adequate measures taken to assure security while under development.  For this reason new developments, when possible, are allocated among several different divisions.  Individual inventors are without this option.

Testing custom stator coils and magnets provides the data for comparison over what is actually presented.  To maintain security and some measure of inaccurate efficiency while in Mexico, I used aluminum framing supports.

I used 1/8" x 1" aluminum framing, whereas I could have easily used 1/16" x 1/2".  I mention of this to prove that you do not have to be concerned about people stealing your HVEMi prototypes.  Since I am not from Mexico and did not know who I could trust, or who my wife might tell, presenting optimized versions would have been foolish.  When I speak to engineers now, we all assess levels of experience and knowledge in mechanical and electrical engineering.  If you do not know how the aluminum framing affects the performance and efficiency, then consider high school projects where you drop a small magnet down the center of a tube of copper.  What happens?  Induction.  Learn about it!

This aluminum framing decreases efficiency by 50%. (No, it wasn't a waste of my time...living and teaching in Mexico while with my young children was awesome...it was for maintaining focus)

Learn more about eddy currents and magnetic cores - know the difference between soft iron cores and air core coils.

Scaling down for small prototype testing is easy with Free software (see below for free files), but first you need to understand basic design features and how they relate to performance.  Without getting into magnetic flux, the focus below is to show magnet size references.

HVEMi Wood Frame Prototype Coil and Exact Positioning

Stage 1 wood frame 4 Sections prototype 1/2 HP output @ 600 watts input

The distance between center of shafts is 7.709"
The closest distance between rotating magnets is 2.433"
The white portion is reference to the rotation AND non-optimized magnetic field LOSS
Rotors at 90 degrees - it is noted that a iron ball surrounding magnets will have greater efficiency - ha
2x2" 3-outer rotors/shafts and 2x3" center rotor/shaft - N42 magnets
5/8" shaft w/ spacers; 3.75" ID coil; 100 ohm 26 AWG

HVEMi Custom / Retail Disk Magnet Coil Dimensions

Same power input; reconfigure stator air coils; air gap between magnet rotation to shaft size

The distance between center of shafts is 6.850"
The closest distance between rotating magnets is 1.019"
5.831" dia. Spherical and 2x3" Disk magnets; 1" hex shaft; 4.750" ID coil (free basic CAD file below)

Custom coil-stators and magnets - which would you rather use?

Prior to any consideration of soft iron cores or custom stators, creating coils is easy with 1/8" wall acrylic tubing.  Configuration differences include whether or not to use and attach ends to the spool; how you plan to fasten and secure the finished coil; time and cost; and, the field strength improvement without spool ends.

Again, this information is not for manufactured motors and only the process of prototype development.

Though I have had 200 watts per coil during short duration testing, I have never overheated or burnt up these coils with continuous 50 watts per coil.  There are calculating factors to determine maximum coil heat dispensation, to which is left for engineers and not for inexperienced hobbyists (custom stators, wire gauge, max amperes, etc.).

The ends of the spool (3/16" each shown) DO NOT need to be used; placing wax paper over ends prior to the wood holders seen in photos, use epoxy to seal the edges, and then wind.

Notice the teal-color tabs; these are molded along with the block assembly, but I can change this tab portion to hold another component depending on application.  Mechanical version shows each coil switched individually compared to one coil-row switched in series or parallel as an option, which will require high voltage power supplies. (What's the difference?)  Will two of the coils be used for regeneration?  Custom Stators/magnets.

Custom coil stators are positioned and held in place differently than what is shown below.

DuraForm® HST Composite SLS or SLA 3D Systems used for prototypes and low volume manufacturing is preferred before tooling.  The number of coils in one coil-row assembly is also the number of sections in HVEMi motors.  It's not just the strength of the assembly decreasing with length, but without robotic manufacturing the shafts/magnets/rotors placements would be very dangerous to handle; do not configure for more than 5 sections. (using large magnets)

Commutators next

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For Brushless Switching see Below - Optos

HVEMi Commutators being handmade is for prototype testing and not for continuous usage (unless in emergency conditions).  Of course, you understand high voltage sparks - jumps, so depending on your voltage the distance between the shaft and brushes is important to remember.  In most cases everything presented on this website limits voltage to under 300 VDC; under 140 VDC with load - PER 2 COIL/STATORS / ONE Switch

Manufactured commutators for mechanical versions may be available in the future, which will be much different than what is presented.

Below: 1" commutators double switching each coil (reverse positive high voltage every 180 degrees); when the magnet is at 10 degrees past OC...switch off at 175 degrees...carbon brush size determines positions.

RPM over 5,000 with two 1 1/2" disk x 1" magnets on 7/16" shaft.

Below: larger 5/8" shaft and commutators with 2x2" magnets (2 sections - 560 watts output @ 600 watts input - single center rotor - 2900 RPM)

If you make the brush switch housing with TAP Plastic - Quik-Cast Polyurethane, then you can use them for different setups.  The size of the carbon brush head determines switching positions.  Vacuum carbon brushes; HT epoxy for filler after square metal template was used to pour polyurethane, cut and sand

Now we are talking about making enough switches for 12 coils/stators individually switched, or two coils per switch.

Keep in mind that when you do NOT have access to a high voltage power supply, high voltage per coil can be regulated with a Variac and capacitors-bridge rectifier setup. (other components to regulate current)

Another HVEMi Prototype made abroad, so the carbon brushes were not all the same which caused me to individually form each hole rectangular shapes with epoxy for secure guides.  Terminal blocks rating 600 VDC / #18 wire rating 300 VDC...Load voltage under 75 VDC per coil/stator

Below left shows the wires coming through the back wall from duplicate commutator switches (not seen)

Below right shows the terminal strips connecting to the back duplicate commutators (not seen)

I used 1 1/2" copper tubing with 5/8" shaft; 1 5/8" (I forget) cuts for the wood setting; use plumbers putty at the base when pouring; I have used materials from TAP Plastic - Quik-Cast • Polyurethane Casting Resin System (I had a little left from CA that I took with me, along with parts)

Dremel cutting the separations; use 5-minute GEL Epoxy; use hose clamps to secure in place while cutting and to epoxy; table disk or belt sanding to smooth with no pits; notch out the metal collar before using the epoxy and shaft to center and affix to end.

Do you need to ask about HOW to switch the setup?  Well, each coil has, using the above setup, eight carbon brush switches.  The positive and ground need to be switched on and off every 180 degrees (or so).

Reed Relays

Below: Understanding power and voltage regulation will allow you to test other types of switching, but just so you know that 100 watt -1,000 volt reed switches, switching only one side of the coil will easily achieve 3500 RPM+torque

Another toy: Using older coils and two or three coils in the top larger coil,  older shaft with 2x2 magnets The center was producing AC (not at the air gap distance shown) 750 VDC HV power supply .25 amp (250v/coil)

Do you know why one-sided switching is a bad idea?  OF COURSE!  What happens between switching?  Double-sided/both sides switched is always more powerful, creating more torque...if you do not know what I am describing then consider that rotating magnets near coils create AC electricity.  So, if we are only switching 170^o of 360^o with VDC then the remainder is creating VAC.

This is by far the easiest test model to build, but I still prefer using reed relays and Optos after mechanical switching. Notice:  Small cube magnets, in two rows (#2 row for switching both sides-not recorded) Magnets epoxied to older com.. Hexagon shape wood framing .50" gap from reed switch Protection from Back EMF Voltage / Current Regulation

For Brushless Switching see Below - Optos

Rotors next

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Working with round shafts - reduce cost - balance concerns - increases labor

The magnets need to be secured on a flat surface, and there are many ways to accomplish the task.  Realizing the cost of each step is important for validation planning.  Unless you are ready to use square or hexagon shafts that cost $150-$175 for turning down the ends and/or using shaped collars where appropriate, using round shafts are sufficient.  Either way you still need to secure the magnets to the shaft.

HVEMi wood frame prototype uses the following 5/8" shafts and spacers.  However, when you understand the positioning of disk magnets, rotation and coil sizing you can also use retail bar magnets between disk magnets.  Instead of cut to size spacers, one length of shaft rod can be used.  I remember using 3/16" hardened steel pins.  More time for labor but less cost...

Position magnets ONE AT A TIME with great care, scuff magnets and align before using epoxy; the white/wood magnet spacing template is on top of 1/8" sheet metal to better secure and hold in place on work table. (2x2" disk magnets); each spacer is equally balanced. 

While working with extremely powerful magnets think ahead for everything you do.  Below, using a 2x2" angle bracket behind 1 1/4" sheet insulation to secure magnets WHEN attached to a shaft.  You need a secure place for moving shafts/rotors out of the way where you have plenty of space for movement with dangerous attraction accidents. DO NOT even get close to this with other magnets!

Filling gaps around spacers and then sealing the magnets:

Installing each rotor is very dangerous!  One miscalculation or misalignment will result in immediate injuries!

From the above wood frame prototype, the center rotor/shaft is locked into place where magnetic poles are parallel (90 degrees from attraction) to the next installed rotor. 

The above order in which parts are installed: Core Walls & Center Rotor (longer), 3 Coil-Rows, Rotors Next...

The distance from the left-side magnets on the rotor TO the left-side inside wall IS the actual CUT distance from the right-side magnets to the END of the shaft ON THE RIGHT SIDE.  The left side of shaft is installed through wall hole (without bearings) which will allow the right side to slide into place and moved into proper alignment.

As you may have noticed in the CAD image, the spacing between the coil and side wall is increased.

The bearings I used are sufficient but not for continuous usage, as well as many other components. 

Attaching magnets to a hexagon shaft; spring pins lock caps in place -  this is not the final version, but a good example for securing magnets with the ability to disassemble.  Understanding rotation and layout is easy with Free CAD software from eMachineShop.com, clearance is critical.  Real CAD image below.

From the above magnet-cap assembly, from a casting / molding perspective, it would be easier to position all the magnets with the spacers (forest-green) and THEN cast the unit as one; without the ability to disassemble.

Review notes about CAD next

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ALL CAD images and files were completed by me in less than 4 weeks, while busy with other things, so when you think of concepts, time, and waste just keep moving forward and we will find ourselves always creating.

Understanding rotation and layout is easy with Free CAD software from eMachineShop.com.

Prototype testing - using spur gears - calculating magnet rotation/coil spacing with: the distance between the center of shafts = spur gear pitch diameter (2 gears)

HVEMi concepts differs from multiple gears-rotors linearly aligned.  Free 4" pitch dia. gears eMachineShop file

Below: Dimensions CAD (left and right) ready for manufacturing is great, but don't forget simple calculating tools with eMachineShop software.

You can download the below file (eMachineShop-HVEMi-file) to use and reconfigure.  Of course, you need to download eMachineShop software first.  You can scale down, within the software, the file 25% for 1/4" shafts with 3/4 magnets.  If you screw up, without saving a backup file, just come back here and re-download the file.

After you check out eMachineShop.com and the free software, you might determine that it is NOT real CAD software and it is mainly used for their customers ordering parts.  They will be able to provide you quotes on framing walls and many parts.  I receive no credits for the mention or link.

If you are interested in ZWSoft.com ZW3D CAD software, it's a REAL CAD program on the market that can be used with a 30-day trial.

Brushless Switching next

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Mechanical Switching to Opto-Interrupters (CPU and single position timing w/ timing advance Later)

 

Above - Next stage after mechanical switching - real components, easy for most to implement, includes either reverse direction Opto or backup same direction...

• Socket Junction Modules Relays - M81714/60-20 Series II

• Transmissive Optical Sensor with Phototransistor Output TCST2103, TCST2202, TCST2300

• LV Transistors; HVEMi Parts - Handmade or Manufactured

Below Left: positioning optional switching (10k high voltage reed relays - 3 levels of 4) considers heat, HV spark gaps, LV wiring, and ease of access.  High voltage transistors are limited when considering switching multiple coil rows.

Above right: understanding Optos, resistors, transistors and regulating voltage/current are really not that difficult; one-sided switching; two coils; cellular phone 12v power supply; 60v 3A max power supply (using 21 VDC @ .55A) OR one 18 VDC cordless power drill battery = over 4,000 RPM+ See Videos

Above right:  I was teaching someone about Optos and the use of resistors by first using TWO cellular phone  power supplies; one 12v and one 5v; You can learn more online. (Just in case you were wondering, pulled out from the closet for the photo and video)

Opto-Interrupters and transistors are easy to implement; reed relays are just as easy.

As you can determine this is not an step by step instruction guide but free information overview -- experience required.

The HVEMi Size Calculator will help you understand where to start and what you can accomplish.

Is everything perfectly described or presented? No.  It will be a life-saver for many, but not for haters.

We all have our opinions, so make a list for the things I have done wrong and done right!  And then decide.

You came this far - so, I will personally help you - let me know how or get on the list for pre-ordering.