Claims:WE CLAIM:
1. An axial flux magneto (100) for a two/three-wheeler vehicle, comprising:
a stator assembly (104) positioned towards an engine of the vehicle, wherein the stator assembly (104) comprises a base plate (406);
a core pack (402) mounted on the base plate (406), wherein the core pack further comprises a plurality of bobbins (404);
a stator coil is wrapped around the plurality of bobbins (404);
a rotor assembly (106) mechanically coupled to a vehicle crankshaft and co-axially positioned adjacent to the stator assembly (104), wherein the rotor assembly (106) comprises a boss (208);
a flywheel cup (204) is secured to the boss (208), wherein the flywheel cup comprises a plurality of pips (304) and a plurality of permanent magnets (206) separated by spacer ring,
wherein the plurality of permanent magnets (206) are mounted on the flywheel cup (204) in such a way wherein a face of the plurality of permanent magnets (206) are exposed to the stator winding to generate magnetic flux in axial direction; and
a pulser coil (602) affixed to the outer surface of Rotor assembly (208), wherein a pulser coil flux is generated during operation of the magneto.
2. The axial flux magneto as claimed in claim 1, wherein the plurality of pips (304) are circumferentially arranged on an outer surface of the flywheel cup (204) or boss (208) which are used by the pulser coil to generate timing signal for the ignition system.
3. The axial flux magneto as claimed in claim 1, wherein the pulser coil flux generated in the pulser coil (602) is cut by the plurality of pips (304), and wherein cutting of the pulser coil flux by the plurality of pips (304) generates an EMF in the said pulser coil (602) to initiate the ignition of the vehicle.
4. The axial flux magneto as claimed in claim 1, wherein the plurality of permanent magnets (206) are positioned at the inner base surface of the flywheel cup (204) with the help of spacer ring.
5. The axial flux magneto as claimed in claim 1, wherein the axial flux magneto (100) is configured to operate at speeds ranging between 800-14000 RPM.
6. The axial flux magneto as claimed in claim 1, wherein the axial flux magneto (100) is configured to generate output voltage ranging between 15-200 volts, and also generate electric current up to 22 Amperes.
7. The axial flux magneto as claimed in claims 5 and 6, wherein the axial flux magneto (100) is configured to generate different output voltage corresponding to the rotation speed also corresponding to the size, shape, material and number of the said axial flux magneto (100).

Dated 29th Day of July 2021

Priyank Gupta
Agent for the Applicant
IN/PA-1454
, Description:FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENT RULES, 2003

COMPLETE SPECIFICATION
(See Section 10 and Rule 13)
Title of invention:
AN AXIAL FLUX MAGNETO FOR A TWO/THREE-WHEELER VEHICLE
APPLICANT:
Varroc Engineering Limited.
An Indian entity having address as:
L-4, MIDC Waluj,
Aurangabad-431136,
Maharashtra, India

The following specification particularly describes the invention and the manner in which it is to be performed.

CROSS-REFERENCE TO RELATED APPLICATIONS AND PRIORITY
The present application does not claim priority from any other patent application.

TECHNICAL FIELD
The present subject matter described here, in general relates to a field of magneto for vehicles, more particularly for axial flux magneto for two/three-wheeler vehicles.
BACKGROUND
A magneto is an electromagnetic device, primarily used in vehicles, configured to convert mechanical energy to electrical energy using permanent magnets to produce alternating current. Further, a magneto comprises a stator and a rotor, wherein the stator comprises a plurality of windings and the rotor comprises a plurality of permanent magnets. Further, the rotor and stator are assembled in proximity to each other, such that the magnetic field from the permanent magnets pass through the core pack of the stator and induces current in the windings of the stator. Further, the rotor is coupled to an engine crankshaft, and wherein the crankshaft is configured to rotate the rotor. Since the rotor comprises the plurality of permanent magnets, rotation of rotor also causes rotation of permanent magnets over the stator to create rotating magnetic field. The rotation of the rotor causes change in magnetic field through the windings of the stator. According to Faraday’s Law of Electromagnetic Induction, when a conductor is placed in a varying magnetic field, the change in magnetic field induces electromotive force (EMF) within the conductor. Further, when the conductor is connected to a closed circuit, a current is induced which is known as the induced current. Similarly, due to the change in magnetic field cause by the rotor, the current gets induced in the windings of the stator. This induced current is used to drive the ac loads like head lamp and tail lamp of the vehicle Further, this induced current is rectified and regulated, and is used to charge the vehicle battery, the battery further drives the various electrical load of the vehicle. Magneto also generates signals which are used by the ignition circuit for the Spark timing.
Conventionally, radial flux magneto are commonly used in vehicles. However, it must be noted that radial flux magneto comprises a rotor embedded with permanent magnets surrounding a stator radially, i.e., perpendicular to the axis of a central shaft of the magneto. Further, the flux path of magnetic field lines is much longer, as the field lines goes from one pole of permanent magnets to the windings in the stator, and to the poles of permanent magnets. Further, the field lines travel through the second pole through an airgap, and again to the windings. Hence, this longer path generally decreases efficiency of the magneto. Further, radial-flux magneto also occupies larger spaces in the vehicle assembly.

Therefore, it is an utmost need of a magneto which is compact in size, as well as more efficient than the existing radial flux magneto.

SUMMARY
This summary is provided to introduce concepts related to axial flux magneto for a two/three-wheeler vehicle. This summary is not intended to identify essential features of the claimed subject matter nor is it intended for use in determining or limiting the scope of the claimed subject matter.

The present disclosure relates to an axial flux magneto for two/three-wheeler vehicle. Further, the axial flux magneto may comprise a stator assembly positioned near the engine of the vehicle. Further, the stator assembly may comprise a base plate, wherein the stator core is mechanically locked to the base plate. Further, the core pack may comprise a bobbin, wherein the bobbin may comprise a stator coil wound thereon. Further, the magneto may also comprise a pulser coil, wherein the pulser coil may be placed on the outer surface of the rotor assembly. Further, a pulser coil flux is generated in the pulser coil during operation of the axial flux magneto. Further, the axial flux magneto may comprise a rotor assembly, wherein the rotor is mechanically coupled to a vehicle crankshaft and may be co-axially positioned adjacent to the stator assembly. Further, the rotor assembly comprises a boss, wherein the boss is secured with a flywheel cup Further, the flywheel cup may also accommodate a plurality of permanent magnets. Further the spacer ring is placed which acts as a magnet separator. Further, the plurality of magnets may be arranged with the help of spacer ring on the inner circular base of the flywheel cup, so that the magnets face the stator winding to generate magnetic flux in axial direction i.e., parallel to the axis of a central shaft of the magneto. Further, the flywheel cup may comprise a plurality of pips, wherein the plurality of pips may be circumferentially arranged on the outer surface of the Rotor assembly.

BRIEF DESCRIPTION OF THE DRAWINGS
The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the drawings to refer like features and components.

Figure 1 illustrates an assembly of an axial flux magneto (100), as an embodiment of the present disclosure.

Figure 2 illustrates a sectional view 200 of the axial flux magneto (100), as an embodiment of the present disclosure.

Figure 3 illustrates an internal view (300) of the rotor assembly of the axial flux magneto (100), as an embodiment of the present disclosure.

Figure 4 illustrates internal view (400) of the axial flux magneto (100), as an embodiment of the present disclosure.

Figure 5 illustrates a complete assembly of the axial flux magneto (100), as an embodiment of the present disclosure.

Figure 6 illustrates a graph 600 between induced voltage and operating speed of the axial flux magneto (100), as an embodiment of the present disclosure.

Figure 7, illustrates another exemplary embodiment of the position of the pip in accordance with the present disclosure.

DETAILED DESCRIPTION
Reference throughout the specification to “various embodiments,” “some embodiments,” “one embodiment,” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “in various embodiments,” “in some embodiments,” “in one embodiment,” or “in an embodiment” in places throughout the specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments.

The present disclosure relates to an axial flux magneto (for two/three-wheeler vehicle. Further, the axial flux magneto (generator) may comprise a stator assembly, a rotor assembly, and a pulser coil, which will be illustrated in the following embodiment of the specification.

The axial flux magneto as disclosed in accordance with an exemplary embodiment is more efficient due to high power density, and light weight as stator weight is reduced. The efficient axial flux magneto as disclosed may comprise a rotor assembly mounted on a vehicle shaft. The rotor assembly may be configured to provide a rotating magnetic field. The rotor assembly may further comprise a plurality of permanent magnets with a trapezoidal shape. The plurality of magnets are mounted with the help of spacer ring on a flat surface of a flywheel cup. Further a boss is mechanically coupled to the flywheel cup.. Further the rotor may be rotated at different RMP values.

In accordance with the exemplary embodiment the axial flux magneto may further comprise a stator assembly. The stator assembly may be mounted on the engine case in front of the rotor. Further at different RPM values of the rotor the stator may be configured to induce different voltages. The stator assembly in accordance with the exemplary embodiment may further comprise of a core pack, stator windings, base plate and bobbin. In axial flux magneto the core pack may have slots and positioned in an axial direction (parallel to the axial of rotation).

In one embodiment, referring to Figure 1, which illustrates an assembly of an axial flux magneto (100). Further, the axial flux magneto (100) may comprise a central bore (102), a stator assembly (104), and a rotor assembly (106). Further, the stator assembly (104), as illustrated, may be assembled within the rotor assembly (106), and wherein the stator assembly (104) and the rotor assembly (106) may comprise a central bore (102). Further, central bore (102) of the rotor assembly (104) may encompass an internal combustion engine crankshaft, and therefore enable the rotor assembly to mechanically couple with the engine crankshaft. Further, a rotation of the engine crankshaft may rotate the rotor assembly (106), which may enable the rotor assembly (106) to generate a rotating magnetic flux. Further, the magnetic field flux may be generated in accordance to the rotation speed of the rotor assembly (106). Further, increase or decrease in rotation speed of the rotor may cause variation in magnetic field flux, and therefore may induce voltage in the stator.

In one embodiment, refer to Figure 2, which illustrates a sectional view (200) of the axial flux magneto (100), as an embodiment of the present disclosure. Further, the axial flux magneto (100) may comprise a stator (202), a flywheel cup (204), a plurality of permanent magnets (206), spacer ring and a boss (208). Further, it must be noted that the core pack (202) may be a member of the stator assembly (104). Further, it must also be noted that the flywheel cup (204), the plurality of permanent magnets (206) and the boss (208) may be a member of the rotor assembly (106). Further, as illustrated in the figure, the rotor assembly (106) and the stator assembly (104) may be assembled co-axially and adjacent to each other. Further, such arrangement offers constraint in overall size of the magneto, which may be lesser than that as compared to conventional radial flux magneto.

In one embodiment, refer to Figure 3, which illustrates internal view (300) of a rotor assembly (106) of the axial flux magneto (100), as an embodiment of the present disclosure. Further, as explained in previous embodiments, the rotor assembly (106) may comprise the central bore (102), the flywheel cup (204), the plurality of permanent magnets (206) separated by spacer ring and the boss (208).

In one embodiment, the rotor assembly (106) may comprise the flywheel cup (204). Further, the flywheel cup (204) may be a hollow cylindrical member closed at one end, wherein the closed end may be referred to as the base of the flywheel cup (204). Further, the base of the flywheel cup (204) is mechanically coupled to the boss Further, the base of the flywheel cup (204) may be configured to accommodate the plurality of permanent magnets (206). Further, the plurality of permanent magnets (206) may be arranged radially on the base of the flywheel cup (204) with the help of spacer ring. Further, the plurality of permanent magnets (206) may comprise trapezoidal-shaped magnets. In the same embodiment, the flywheel cup (204) may comprise a plurality of pips (304). Further, the plurality of pips (304) may be arranged circumferentially on the outer surface of the Rotor assembly (204). Further, the plurality of pips (304) may play a key role in generating ignition pulse for ignition of the vehicle, which may be illustrated in the successive embodiments.

In another embodiment, referring to Figure 4, which illustrates an internal view (400) of the stator assembly (104) of the axial flux magneto (100), as an embodiment of the present disclosure. Further, the stator assembly (104) may comprise a stator (202). Further, the stator (202) may comprise a base plate (406), a core pack (402), a bobbin (404), windings and a plurality of mounting holes (408). Further, the base plate (406) is mechanically locked to the core pack (402). Further, the core pack (402) may comprise the bobbin (404), and wherein the bobbin (404) may be configured to accommodate a coil winding. Further, the stator assembly (104) may be configured to assemble within the flywheel cup (204) (not shown in Figure 4). Further, the assembly of the stator assembly (104) within the flywheel cup (204) may enable the core pack (402) and the winding to(404) face the plurality of permanent magnets (206).

In a preferred embodiment, the plurality of permanent magnets (206) may face the core pack in axial direction, as illustrated. Further, since the poles of the plurality of permanent magnets (206) face the axial direction, the magnetic field flux from the plurality of permanent magnets (206) may pass axially through the stator assembly (104). Further, when the magnetic field flux varies, and since the axial flux magneto (100) is closed with the electric circuitry of the two/three-wheeler vehicle, an electric current may be induced in the winding of the stator assembly (104). Further, it must be noted, the position of the plurality of permanent magnet (206) may enable the plurality of permanent magnet (206) to transmit the magnetic field flux in axial direction, and therefore the path of transmission of the path of magnetic field flux may decrease. This decrease in the path of magnetic field flux may increase the power density as well as efficiency of the axial flux magneto (100), as compared to radial flux magneto. The stator material may be saved compared to radial flux magneto thus increasing the power density. Also, the losses are reduced by taking high slot fill factor. Further, since the electric current induced may be an alternating current (A.C.), the electric current induced may be rectified and regulated to a Direct current (D.C.) to charge the vehicle battery. Further, the D.C. current from the battery may be utilized by various accessories of the two/three-wheeler vehicle.

In another embodiment, referring to Figure 5, which illustrates a complete assembly of the axial flux magneto (100), as an embodiment of the present disclosure. Further, the axial flux magneto (100) may comprise a pulser coil (502), wherein the pulser coil (502) may be affixed on the outer surface of the rotor assembly (208). Further, it must be noted that the flywheel cup (104, 204) comprises the plurality of pips (310) used by the pulser coil (502). Further, the pulser coil (502) may also be referred to as a pickup coil, or a timing coil. Further, the pulser coil (502) may provide a timing signal in form of a pulse to an ignition control box of the vehicle (not shown in figures). In one embodiment, during operation of the axial flux magneto (100), the pulsar coil (502) may also generate a pulser coil flux. Further, during operation, the flywheel cup (204) may be configured to rotate, which may also rotate the plurality of pips (310) mounted thereon. Further, the plurality of pips may pass through a close proximity of the pulser coil (502). Further, the pulser coil flux may be configured to be cut by the plurality of pips (310). Further, when the plurality of pips (310) cut the pulser coil flux, a pulse may be generated. Further, this pulse may be transmitted to the ignition control box of the vehicle in the form of a timing signal, and therefore, ignition or various firing of the engine cylinder of the vehicle may be initiated. Further, when the gap (502) may pass through the pulser coil flux, no pulse may be generated. Further, the position may be referred to as Top Dead Center (TDC)/Bottom Dead Center (BDC) of the IC Engine Cylinder respectively.

Now, referring to Figure 6, which illustrates a graph (600) between induced voltage and operating speed of the axial flux magneto (100), as an embodiment of the present disclosure. Further, as explained earlier, since the poles of the plurality of permanent magnets (206) face the axial direction, the magnetic field flux from the plurality of permanent magnets (206) may pass axially through the stator assembly (104). Further, when the magnetic field flux varies, and since the axial flux magneto (100) is closed with the electric circuitry of the two/three-wheeler vehicle, an electric current may be induced in the winding of the stator assembly (104). Further, since the electric current induced may be an alternating current (A.C.), the electric current induced may be rectified and regulated to a Direct current (D.C.). Further, again referring to the graph (600), it must be noted that induced voltage increases linearly with the operating speed of the axial flux magneto (100), as the axial flux magneto (100) may be configured to induce voltage in accordance to the operating speed. Further, the speed at which the axial flux magneto (100) operate may range between 800-14000 revolutions per minute (RPM). Further, the axial flux magneto (100) may induce electric current up to 22 Amperes. Further, the axial flux magneto (100) may be configured to induce open circuit voltage in the ranges 12-200V.
Now referring to Figure 7, illustrates another exemplary embodiment of the position of the pip in accordance with the present disclosure. Further, the axial flux magneto (100) may comprise a pulser coil (502), wherein the pulser coil (502) may be affixed on the outer surface of the rotor assembly (208). Further, it must be noted that the boss (208) comprises the plurality of pips (310) used by the pulser coil (502). Further, the pulser coil (502) may also be referred to as a pickup coil, or a timing coil. Further, the pulser coil (502) may provide a timing signal in form of a pulse to an ignition control box of the vehicle (not shown in figures). In one embodiment, during operation of the axial flux magneto (100), the pulsar coil (502) may also generate a pulser coil flux. Further, during operation, the boss (208) may be configured to rotate, which may also rotate the plurality of pips (310) mounted thereon. Further, the plurality of pips may pass through a close proximity of the pulser coil (502). The pulser coil flux may be configured to be cut by the plurality of pips (310). Further, when the plurality of pips (310) cut the pulser coil flux, a pulse may be generated. This pulse may be transmitted to the ignition control box of the vehicle in the form of a timing signal.

Now, the aforementioned illustrated embodiments offer the following advantages over the Radial flux Magneto, which may include but are not limited to:
• The present disclosure provides a compact design of a magneto, which may be achieved using compact arrangement between rotor assembly and stator assembly.
• The present disclosure further provides higher efficiency due to axial flow of magnetic field flux.
• The present disclosure also possesses low weight and size, which may enable an ease of assembling within the two/three - vehicle.
The embodiments, examples and alternatives of the preceding paragraphs or the description and drawings, including any of their various aspects or respective individual features, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible.

The foregoing description shall be interpreted as illustrative and not in any limiting sense. A person of ordinary skill in the art would understand that certain modifications could come within the scope of this disclosure. The embodiments, examples and alternatives of the preceding paragraphs or the description and drawings, including any of their various aspects or respective individual features, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible.

Although implementations for the Axial flux Magneto have been described in language specific to structural features and/or methods, it is to be understood that the appended claims are not necessarily limited to the specific features or methods described. Rather, the specific features and methods are disclosed as examples of implementations for the Axial flux Magneto.