Motors
​​​​​​​​​​Internal combustion engines are stripped of their heads, fuel connections and exhaust systems, which are replaced with an actuator covering each cylinder, a high pressure air tank that feeds the actuators, a low pressure air tank that captures the pressurized exhaust, and a compressor that intermittently recycles the air from the lower pressure tank to the main tank.The 300 bar air that drives the pistons is preserved for reuse and blow-by loss is replaced with pressurized ambient air, allowing the engine to be fully self-sustained, although semi-trucks can have their tank topped-up during scheduled shop maintenance.​​​The actuator works by having computer-controlled bursts of air inflate a bladder that flexes a diaphragm to put sustained pressure on the compressed air in the cylinder chamber which drives the pistons and turns the crankshaft, as is illustrated above.
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Wear Characteristics
The ACE system reduces piston ring wear by 50-70% and extends crankshaft life to 1.5-2 million miles (vs. 500 k-1 million for ICE) due to lower pressures (1200-950 PSI vs. 2000-3000 PSI) and temperatures (100-150° C vs. 1000-2000° C). These numbers are substantiated by actual findings that compressed-air engines (e.g., MDI AirPod prototypes) show 2–3 times longer piston/ring life than diesel engines due to lower pressures/temperatures, supporting the ACE’s potential for 2 million miles with normal maintenance. That extended life factor also means that maintenance intervals are less frequent and are significantly less expensive (e.g., actuator diaphragm replacement vs. Engine tear-down for piston/ring repair).
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​​​​​​​​​​​​​​​​​​​Generators
Any of the ACE motorscan easily be turned into an air-driven generator by simply connecting the driveshaft to that of a generator. The rule-of-thumb is that a motor can convert 60% of its horsepower into electricity and, by that standard, a 2-cylinder ACE-converted Harley-Davidson Ironhead engine can produce 33 kW of electricity, which is enough energy to power even the largest home and eliminate the electric bill. Our recommendation is that this motor-to-generator method be used in place of batteries to power electric cars and trucks and for homes and businesses in place of the power grid. Our water-driven generator is aimed for use where larger power capacity is needed such as industry, utilities, and AI Data Centers.​​The water-powered generator uses an axial-flow pump to circulate water through an enclosed piping system that includes an actuator acting as a pressure-transfer chamber (PTC) to energize the circulating water that flows into a turbine/generator. This hydroelectric generator system operates exactly like those in large pumped-storage systems, except that the Actutec generator is relatively compact and self-contained. These systems can scale up to 10 GW and can be located just about anywhere. What makes this system work is that the actuator simulates a tall column of water falling into the turbine when, in actuality, the pressure is caused by the bladder of the actuator flexing a diaphragm to transfer the simulated weight onto the turbine feed. Actutec generators produce clean energy 24 hours a day, 7 days a week, and never need refueling.
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PODS
Utility pods are a whole new concept in portable generators; they are configurable in terms of current and voltage and they don't need external fuel to operate. They are a form of electromagnetic actuators and are specifically a Linear free-Piston Generator (LFPG). Basically they are a foot long air-tight tube with a magnet (piston) inside and coil wrappings on the outside that produce electricity when excited.The respective tubes are called pods and each one produces 1 kW of usable power.These pods are clustered into structured groupings call frames and each frame can produce from 1 to 20 kW of output, with the ability to link multiple frames into a multi-frame configuration. Each frame has one control pod that determines the current type and voltage being output while starting/stopping and operation of the frame.
The e-bike battery assist is a single pod with the control features included. It, like the EV assist pod frame, keeps the bike's battery charged at 70-100% when riding, eliminating range anxiety.
The utility pod's piston travels back and forth within the tube at a cycle time of 60 Hz. The cylinder is pressurized at 20-50 bar and the piston, almost magically, moves practically fiction-free by riding on a thin cushion of air separating the piston and the cylinder walls. The compression of air halts the movement of the piston on one end and a gentle nudge of an electromagnetic coil sends it back in the other direction with the timing managed by the control pod.What makes the utility pod work is that the "nudges" only consume a small portion of the electricity generated when the piston traverses the sater coil windings, so the pod bleeds off some of that excess energy to power itself.
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