Innovative Engine-Generator for Vibration-Free Operation in Electric Vehicles, Hybrids, and Ultralight Aircraft
In the evolving world of electric vehicles (EVs), hybrids (REV and REEV) and ultralight aircraft (UL), there is a growing demand for increased range, efficiency, and reliability. One of the most common challenges in this area is extending the range of vehicles without compromising efficiency or comfort. This challenge is further complicated by vibrations and noise, which can adversely affect user comfort and the resilience of sensitive equipment. We present the Vibration-Free Range Extender, an engine-generator developed to address these issues and provide an innovative solution for electric vehicles, hybrids, and aircraft.
This page explores the basic technical and commercial aspects of our revolutionary engine-generator technology and examines how it stands out as an ideal alternative to traditional automotive range extenders and internal combustion engines. The unique Zero-Vibration design is critical to enhancing comfort and essential for applications involving highly precise optical and electronic instruments.
Solving the Vibration Problem
The main goal of the vibration-free Range Extender was to eliminate engine vibrations and reaction forces transmitted to the engine mounts. Through thorough analysis of the causes of vibrations, we designed an optimal solution. We created simulations (videos from the simulation are available on our YouTube channel: www.youtube.com/@KNOBGEAR) which confirmed the accuracy of our analysis. The result is an engine-generator that meets all initial requirements. This zero vibration motor-generator and range extender set a new standard for addressing vibrations and noise in electric vehicles, hybrids, ultralight aircraft, and unmanned vehicles such as drones, quadcopters, and multicopters.
Key Mechanisms for Achieving Zero Vibrations
Dynamic balancing of counterweights and symmetrical design: The engine-generator is designed with special dynamic balancing of the crankshafts and a symmetrical design to reduce both rotational and translational imbalances. This eliminates the typical vibrational forces generated during engine operation.
Zero Gyroscopic Moment
A key advantage of our solution is that it produces zero gyroscopic moment. This is achieved by using two equal masses rotating in opposite directions. It is well known that as the rotational speed of a mass—such as a flywheel or generator—increases, it generates a gyroscopic moment, which can negatively impact a vehicle’s maneuverability, aviation performance, and overall flight comfort. In extreme cases, large gyroscopic forces can even pose safety risks during emergency situations. Our design eliminates this issue entirely, as the opposing rotations cancel out each other’s gyroscopic effects. As a result, the system behaves similarly to a battery, without influencing the dynamics of the vehicle.
Efficiency and Performance Metrics
A key measure of any range extender, or engine-generator, is its efficiency in converting fuel to electrical energy. Our engine-generator solution surely does not disappoint. The design incorporates highly efficient modern components of contemporary internal combustion engines and generators. By eliminating balance shafts, we reduced the number of components, weight, and mechanical losses. The symmetrical construction ensures that the single synchronizing gear is minimally stressed, contributing to better mechanical efficiency and reduced fuel consumption.
Quiet and Reliable Operation
The vibration-free Range Extender excels with low noise levels. Due to the absence of vibrations, operational noise is significantly reduced and is quieter than traditional internal combustion engines used in range extenders.
Technical and Commercial Insights
Technical Advantages:
- No Vibrations: A key factor for sensitive environments, such as vehicles with highly precise instruments.
- No Gyroscopic Effect: One of the key factors is no gyroscopic effect.
- Flat and Lightweight Design: Small installation dimensions facilitates installation, especially where weight and space are limited.
- High Efficiency: Due to the absence of unnecessary balance shafts and components.
- Simple and Proven Design: By using standard motor parts, we ensure cost-effective development and proven durability.
- Global Patent Protection: Our solution is patent-protected in key global markets, ensuring its exclusivity and security.
Market Opportunities
The zero-vibration Range Extender has a wide range of applications, including electric vehicles, aviation, and the military industry. This technology is an ideal solution for extending the range of EVs, HEVs, REVs, and REEVs without added vibrations, making it a valuable addition for both luxury and commercial electric fleets. In aviation, especially in ultralight aircraft, air taxis, and multirotors, it is a quiet and lightweight alternative that improves user comfort and reduces the risk of damage to sensitive electronics. For precision instruments, the vibration-free design is an excellent choice.
Intellectual Property and Commercialization
The company holds worldwide patents on key innovations, including vibration elimination mechanisms. The business model focuses on licensing this technology to manufacturers in related industries and offers the sale of rights to use the patents.
Manufacturing and Production
The design is suitable for efficient mass production. The company is currently seeking partnerships with automotive and aviation manufacturers for further development of this technology.
Conclusion
The vibration-free engine-generator represents a significant step forward in the development of efficient, compact, and vibration-free range extenders. Its wide range of potential applications, combined with excellent features, performance, and patented design, positions it as a key technology in the future of electric vehicles and ultralight aircraft. It offers a unique solution to technical challenges and market needs. This engine-generator provides a unique and compelling solution for extending the operational range of vehicles without compromises on comfort or reliability.