Motors (ICE Conversions)
​​​​​​​​​​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.​​​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 then drives the pistons and turns the crankshaft as is illustrated above.
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ACE motors use an enhanced alternator to produce their own electricity and so are able to operate fuel-free and extending a vehicle's range. The compressed air that drives the pistons does get depleted, but the system automatically regenerates that air while idling to keep the system topped up. ACE motors are capable of powering cars, trucks, trains, and medium sized marine vessels.
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Wear Characteristics
The actuator Controlled engine (ACE )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 motors can easily be turned into a fuel-free generator by using it to power an actual generator. Our power pods (below) are meant to cover uses in the 1-100 kW tange, while ACE generators are good for up to 1,000 kW, but, above that, it is best to use our hydroelectric generator. 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 13 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
Actutec Power 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 called a Linear Free-Piston Generator (LFPG). Basically they are a foot long air-tight tube with a magnetic piston inside and coil wrappings on the outside that produce electricity when excited. Each tube (pod) pod produces 1.25 kW of usable power. These pods are inserted into lattice structures called frames, and each frame can produce from 1 to 25 kW of output, with the ability to link multiple frames into a multi-frame configuration. Each frame has one control pod that manages the device, matching output to load.
The e-bike battery assist is a single pod with the control features imbeded. Just like the EV assist pod frame, it 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 moves practically fiction-free by riding on a thin cushion of air separating the piston and the cylinder walls. The compression of air within the chamber halts the movement of the piston on one end and a 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 stater coil windings, so the pod bleeds off some of that excess energy to power itself.
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