Kigaya TorqueHalo™ recovery skid
The high-value architecture captures an existing waste shaft, braking event, pressure drop, or curtailed turbine stream with commercial generator skids. A compact annular magnetic-spring coupler is optional: keep it only when measured downtime and maintenance savings exceed its energy penalty and installed cost.
Electrical array
One-machine operating point
Practical starting point: 24 outer magnets at 115 rpm is the highest tested speed before sustained hard-stop chatter began at 120 rpm. The sampled high-output button intentionally loads a 23-magnet impact-heavy stress case for comparison. Neither is a measured hardware optimum.
Classical-mechanics core: one horizontal rotor angle plus six co-rotating radial spring coordinates, with magnetic and elastic potential energy, rotor and pod inertia, viscous and Coulomb damping, transducer reaction, and event-resolved inelastic stops. Gravity is normal to the modeled motion plane, so the frame and bearings carry weight without adding in-plane drive energy. The magnetic curve is illustrative until fitted to a measured force–gap table. Rotating pods require secure retainers, a guard, dynamic balancing, and rated power transfer.
Series–parallel current architecture
This panel retains the original milliwatt modules as a benchmark. The facility planner above replaces enormous arrays of tiny transducers with a purpose-built modular generator bank.
Benchmark only: the existing transducer model remains useful for comparing motion, but it is not presented as a practical route to tens or hundreds of watts.
Waste-shaft recovery bank
Select the recoverable load and build it from serviceable commercial skids. The calculator works backward from electrical output to required waste-shaft power, generator torque, bus current, cooling, and economics. The six-arm animation remains a research coupler—not the power-producing architecture.
Calculating facility-scale requirements…
Build path: measured waste shaft → overrunning clutch → selectable straight-through bypass or sealed annular magnetic-spring torsional coupler → commercial three-phase PM generator skid → active rectifier → protected DC bus → certified inverter, transformer, switchgear, and site loads. No battery is assumed. A grid tie or full-power dump load must absorb rejected power.
Economic gate · project and optional coupler
Profit comes from capturing cheap energy that would otherwise be wasted. First test the whole recovery project. Then test the magnetic coupler separately against a straight-through generator; bypass it unless its measured reliability value pays for its losses and capital.
Calculating the source-to-load energy path…
Protected low-voltage auxiliary branch
The default case powers a small load from a limited DC/DC branch on the commercial bus. Switch to the tiny experimental array to see its measured milliwatt limitation without confusing it with the facility architecture.
Starting direct-load measurement…
This is an average-power and first-order ripple estimate—not a certified converter design. The practical branch needs isolation, fusing, current limiting, grounding, thermal protection, and the correct device protocol. It intentionally limits power before stepping the facility bus down to a touch-safe low voltage.
Ten-second array power trace
How to use this model
- Start with the load, then confirm measured waste-shaft power is actually available at the required speed and schedule. The magnets are not counted as a fuel source.
- Adjust each physical efficiency stage. The total is their product, so the calculator increases source power and cooling duty to pay for every loss.
- Select the largest serviceable commercial generator skid that fits the job. A 1 MW case can use two 500 kW skids instead of roughly 84 million milliwatt harvesters.
- Set the opportunity cost of the recovered input, electricity value, utilization, installed cost, and O&M. The project passes only if its payback is inside your selected limit.
- Test the optional magnetic ring separately: enter only measured avoided-downtime and maintenance savings. If its coupler-only payback fails, use the straight-through bypass.
- Use the DC-bus current to see why voltage and modular feeders matter. Final premises or grid connection requires certified equipment and an engineer-approved protection study.
- Use the six-arm animation only to study repulsive-force curves, spring motion, balance, and torque ripple. The plant architecture uses a sealed annular torsional ring with stationary generator coils.
- Switch to Release and coast, then reset. With no input, electrical loading and friction must bring every rotor to rest.
The huge tiny-module count appears because the present benchmark is only about milliwatts per machine. Millions of rectifiers, wires, bearings, retainers, and failure points destroy cost and reliability. The redesign converts power once in a commercial generator; the magnets and springs only smooth torque or protect the shaft.