Apparatus for generating layout for additive manufacturing of electric drive device

Abstract

To support a layout process to create an electric motor in a process of additive manufacturing.SOLUTION: Disclosed is an apparatus 100 for generating a layout for additive manufacturing of an electric drive device for a disc rotor driven by a magnetic field. The apparatus 100 includes an input module 110 and a generating module 120. The input module 110 receives one or more input parameters from a user. The generating module 120 generates, from the one or more input parameters, a layout 200 of a plurality of coil structures 210, 220, ..., in which the plurality of coil structures generates the magnetic field by an electric current, and a layout of a control structure 300 in which the control structure is adapted to connect the plurality of coil structures 210, 220, ... with connectors 311, 312, 313 for a supply of the electric current, and to distribute the electric current to the plurality of coil structures 210, 220, ... to drive the disc rotor.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to an apparatus and method for generating layouts for additive manufacturing of electric drives, and more particularly to a procedure for producing additively manufactured electric drives supported by a parametric computer-aided design model. [Background technology]

[0002] Additive manufacturing can be used to create both the individual components of electronic circuits and the supporting structures. To assemble small-scale structures, such additive manufacturing devices (3D printers) need to deposit materials with significantly different physical properties in precise locations. An example of such a device is provided by a multi-material jetting printer. Such a printer can process metal or ceramic powders uniformly dispersed in a thermoplastic binder to form a liquid, which the printer can deposit with high precision in minute amounts.

[0003] An emerging application of this type of 3D ink printing is the additive manufacturing of printed circuit boards (PCBs), where the PCB substrate is created simultaneously with at least certain portions of the electronic components. This process allows for more complete connections between the components and the PCB substrate, as the combined structure is effectively cast as a single 3D construct.

[0004] As a step prior to the actual printing, this process requires the generation of a layout of the components to be placed in (and / or on) the support structure. The layout must then be converted into commands that the printer can follow. Ideally, the layout should include the characteristics of the printing process, including the properties of the materials used, or parameters of the configurations that the printer can achieve.

[0005] A specific example of such a process is directed to integrating an electric drive for a disk motor. In the current state of the art, an electric drive mounted on a conventional PCB can be surface-mounted or comprise multiple arrays of essentially triangular concentric wires conventionally printed on the surface of one or more layers, then stacked layer by layer to form the circuit board. This conventional printing method typically involves etching copper layers to create the wires. Electrical connections are then established between different PCB layers, with the wires on successive layers then being connected by vias, small-scale conductive paths drilled into the PCB, for each array of concentric wire outlines to form a coil structure. Electrical current flowing through the wires generates a magnetic field that drives a disk rotor supported on the surface of the PCB.

[0006] Conventional PCBs are typically designed using dedicated layout software, specifically a graphic design program for the functional specifications of integrated circuits, which receives user input. However, simply adapting such a program would eliminate many of the benefits that additive manufacturing using multi-material jet printers offers. This is especially true for creating coil arrays for electric drives, where 3D printers are expected to generate complete 3D coil structures rather than a stack of planar layers. Summary of the Invention [Problem to be solved by the invention]

[0007] Therefore, there is a need to support the layout process in order to create an electric motor using additive manufacturing processes. This involves the technical task of generating a feasible layout, a task that can be performed by additive manufacturing processes. [Means for solving the problem]

[0008] At least some of the above problems are solved by an apparatus according to claim 1, a method according to claim 8, a machine-readable storage device according to claim 10, a method for manufacturing an electric drive according to claim 11, and an electric drive according to claim 12. The dependent claims refer to further advantageous realizations of the subject matter of the independent claims.

[0009] The present invention relates to an apparatus for generating a layout for additive manufacturing of an electric drive for a disk rotor. The disk rotor is adapted to be driven by a magnetic field generated by the electric drive. The apparatus includes an input module configured to receive one or more input parameters from a user. The apparatus further includes a generation module configured to generate a layout of a plurality of coil structures from the one or more input parameters. The plurality of coil structures are adapted to generate a magnetic field by an electric current. The generation module is further configured to generate a layout of a control structure, the control structure being adapted to connect the plurality of coil structures with a connector for supplying an electric current and distribute the electric current to the plurality of coil structures to drive the disk rotor.

[0010] The additive manufacturing of electric drives includes, among other things, at least one electrically conductive material and one electrically insulating material. The two materials generally exhibit different properties for their use in additive manufacturing. When generating the layout, the generating module considers constraints that arise in the additive manufacturing of electric drives. These include, among other things, the achievable resolution of horizontal print layers and their respective vertical dimensions, as well as requirements such as the minimum distance between conductive parts of the electric drives to achieve adequate insulation. These constraints may depend on the technological layout (e.g., size and scale, configuration) of the devices used in additive manufacturing, but are particularly caused by different materials. The apparatus can be configured to incorporate constraints into the input module by limiting the possible values ​​of input parameters. The apparatus can further be configured to incorporate constraints into the generating module by imposing boundaries on certain parts of the layout (e.g., near conductive structures). The layout can also include data to be taken into account in the additive manufacturing process, such as waiting times after certain printing steps.

[0011] The input parameters specify the size and shape of the electric drive. Advantageously, the user only needs to provide a small number of input parameters (e.g., seven scalar values) to the input module. Based on the input parameters, the generation module generates a visual representation of the layout, i.e., configuration, of the electric drive.

[0012] The generation module and / or input module may be configured to ensure that the input parameters collectively result in a physically feasible layout. This may in particular rely on presenting to the user ranges of feasible values ​​for the input parameters. The range of one input parameter may depend on one or more user inputs for other input parameters.

[0013] A coil structure is a structure that is additively manufactured and effectively provides the function of a coil. When this description refers to a "coil," "wire," "line," or similar entity, it is understood that the respective structure is additively manufactured (e.g., rather than wound or unwound).

[0014] The generating module is advantageously adapted to generate a layout that allows the electric drive device to be fabricated together with a support structure, such as a PCB, in an additive manufacturing process, e.g., in a multi-material jetting printer. The support structure can comprise a dielectric material, e.g., plastic or a compound typically used as a substrate for PCBs. The support structure can fully or partially accommodate multiple coil structures and / or control structures. The generating module can also be configured to include other features in the shape of the support structure in the layout. The layout can, in particular, provide features, such as basins and / or support pins, that better adapt the support structure to support the disk rotor.

[0015] Optionally, the generation module is further configured to generate instruction data for the additive manufacturing device based on the layout of the plurality of coil structures and the layout of the control structure. While the layout may be a purely visual representation of an electrical drive, the generation module may be configured to convert the layout into instruction data, i.e., appropriate commands for operating the additive manufacturing device. The instruction data may in particular be output as electronic data.

[0016] In some cases, the additive manufacturing device is a multi-material jetting printer. In this case, the apparatus is configured with constraints resulting from the manufacturing method and materials used by the multi-material jetting printer. In some embodiments, the multi-material jetting printer uses conductive and dielectric inks that require specific margins, tolerances, and boundaries. The constraints are, among others: - the minimum distance in the horizontal printing plane (resolution), the minimum height of the printing layer, i.e. the resolution in the direction perpendicular to the horizontal plane, the maximum overall height of the object to be printed, i.e. the maximum distance in said perpendicular direction, - the maximum extent of the printed object in a given direction in the horizontal plane May include:

[0017] In particular, a particular resolution imposes constraints on the layout, as conductive parts, such as wires, must be kept a certain minimum distance apart to avoid interference. Printing inks, especially conductive inks, usually cannot be printed at an arbitrarily fine scale, which can further affect the achievable printing resolution.

[0018] Although assembly space for multi-material jetting printers is typically limited and miniaturization may be a focus of application, the layout device can also be configured for large motor layouts.

[0019] In some cases, the input parameters include one or more of the wire gauge or diameter of the wire comprising the coil structure; the pitch or inclination of the wire relative to a plane, such as a plane defined by a disk rotor; or the number of turns of the wire in a coil layer of the coil structure. The input parameters may further include a cross-sectional radius or diameter of each coil structure or at least one of the coil layers of each coil structure, where a coil layer may be provided, for example, by a wire spiral wrapping around the coil body of the coil structure. The input parameters may further include a distance between the coil structures or between at least one of the coil layers of each coil structure; the number of coil layers; and / or a distance between the coil layers of a coil structure.

[0020] According to an embodiment, the wires of the coil structure are inclined with respect to a major surface (e.g., of a printed circuit board utilized in an exemplary printed motor). Here, the term "inclined" can be understood as a continuous inclination with a predetermined inclination angle that defines a pitch (e.g., a constant angle or a constant pitch). This forms a spiral. Thus, according to an embodiment, the wires of the coil are not formed along a plane connected by vertical interconnects (vias), but along a spiral whose cross sections cannot be approximated by a flat surface.

[0021] In some cases, each coil structure includes one or more concentric wire spirals as coil layers, each wire spiral forming a coil layer around the coil body. Each coil layer has a triangular cross section with rounded corners (or allows for projection onto a triangle with rounded corners). The generation module can be configured to generate each wire spiral based on the projection of a circular spiral (i.e., a spiral projected onto a circle) onto the plane of the respective coil layer. This coil layer plane can be a lateral region of the coil body with a triangular base region, or more generally, with some advantageous non-rotationally symmetrical base region. The wire spirals are configured within that plane. In an embodiment, the height of the coil layer plane is given by the height of the round coil, which can be obtained by multiplying the number of turns by the pitch.

[0022] Advantageously, the projection is performed by a rotated projection line which is arranged parallel to the cross section of the coil layer and has an edge passing through the circular spiral at right angles to the center point of the cross section of the coil layer.

[0023] In an embodiment, the layout generation module includes, in a first step, generating a round coil, or more precisely, a circular spiral with the required diameter, pitch, and number of turns. This can be done, for example, by splining or sweeping, i.e., by generating a path and a cross section (for the wire to be projected) and essentially extruding the cross section along the path. A more complex shape of the wire spiral is then obtained in a second step, which includes projecting the circular spiral along a projection line that runs parallel to the cross section of the coil and perpendicular to the coil layer plane from the axis of the round coil, and rotating the projection line around said axis along the circular spiral. The projection can include further means for accurately generating the cross-sectional profile of the wire, in particular of the wire spiral; i.e., the term "projection line" is to be interpreted broadly.

[0024] An advantage of the method using rotated projection lines is that any wire spiral can be obtained by projecting it onto the corresponding coil layer plane. In another embodiment, the coil layer plane is, for example, a lateral surface of a body having a square or rectangular cross section. Another advantage is that the method requires relatively few input parameters, especially since it starts from a common base of a simple round coil structure.

[0025] Optionally, the generation module is configured to generate, for each coil structure, a connection between the respective ends of any two consecutive concentric wire spirals using a spline function. In one embodiment, the end point of a first wire spiral lies in a plane perpendicular to the longitudinal axis of the wire spiral. The end point of the first spiral is connected to the start point of a second spiral, thereby forming successive coil layers of the coil structure. This connection is generated by interpolating between the end point of the first spiral and the start point of the second spiral and applying a spline function confined to the plane. This form of connection between the first and second wire spirals can then be repeated for all coil layers of the coil structure.

[0026] In some cases, the coil structures are divided into pairs, and the control structure comprises, for each pair, wiring connecting the first member of the pair to the second member of the pair and to a connector for a power supply. The wiring is designed so that the coil structures generate, by means of a current, a time-varying magnetic field adapted to drive the disk rotor. In the current state of the art, several methods are known for realizing magnetic field driving of the disk rotor, and these methods can be implemented by the generation module.

[0027] An embodiment further relates to a method for generating a computer-aided design layout for additive manufacturing of an electric drive for a disk rotor adapted to be driven by a magnetic field, the method comprising: providing one or more input parameters; From one or more input dimensions, a layout of a plurality of coil structures, the plurality of coil structures being adapted to generate a magnetic field by an electric current; and - a layout of a control structure, the control structure being adapted to connect a plurality of coil structures with a connector for supplying current to the coil structures and to distribute the current to the plurality of coil structures in order to drive a disk rotor. generating a Includes.

[0028] Optionally, generating a layout of the plurality of coil structures includes, for at least one coil structure: generating a round wire helix (wherein the pitch and / or wire gauge and / or number of turns are determined from the provided input parameters); generating a rotational projection line parallel to a cross section of the coil body, where the coil body has a triangular cross section with rounded corners; projecting the round wire spiral onto a scaled surface of the coil body by a rotational projection line; Generating a connection between the ends of two consecutive concentric spirals by means of a spline function Includes.

[0029] The method may also be computer-implemented. Those skilled in the art will readily recognize that each step of the method may be performed by a programmed computer. Embodiments are also contemplated to encompass a program storage device, such as a digital data storage medium, that is machine-readable or computer-readable and encodes a machine-executable or computer-executable program comprising instructions that, when executed on a computer or processor, perform some or all of the steps of the aforementioned method.

[0030] An embodiment also relates to a method for manufacturing an electric drive for a disk rotor, the disk rotor being adapted to be driven by a magnetic field, the method including generating a layout by the apparatus described above.

[0031] The embodiment further relates to an electric drive for a disk rotor adapted to be driven by a magnetic field, the electric drive being manufactured by this method, i.e. in this case the manufacturing of the electric drive involves the generation of the layout shown above.

[0032] Key aspects of the present invention can be summarized as follows: the layout generated by the device allows for extremely compact printed motors; the motor can be printed directly into and / or on the surface of a PCB; no coil winding is required; in particular, it allows for the motor to be integrated into a PCB; the device provides a programmable mechanical computer-aided design (MCAD) model of an electric drive, thereby enabling the creation of a CAD model of a brushless DC disk motor according to parameters; the device allows for the input of disk motor input parameters such as wire diameter or thickness and RPM; the coil structure, as well as the wiring between them, is adapted to the given input parameters.

[0033] Advantages of the present invention include the semi-automatic creation of MCAD models of printed disk motors. The apparatus and method reduce the time required to create a CAD model of a disk motor and facilitate meeting dimensional requirements. Electric motors can be printed in or on PCBs in an extremely flat and compact form, achieving particularly fine conductor (wire) pitch and other 3D features not achievable with typical PCB configurations. In particular, the apparatus generates layouts that meet all requirements that are technically feasible, i.e., printable by a corresponding printing device, particularly a multi-material jetting printer.

[0034] Various embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0035] [Figure 1] 1 illustrates an embodiment of an apparatus for generating a layout for additive manufacturing of an electric drive according to the present invention; [Figure 2] FIG. 10 illustrates details of generating a layout for a coil structure from input parameters. [Figure 3]FIG. 10 details the step-by-step generation of a layout for a coil structure. [Figure 4] FIG. 10 shows further details of the step-by-step generation of a layout for a coil structure. [Figure 5] FIG. 10 illustrates a layout for multiple coil structures. [Figure 6] 10A and 10B are diagrams showing other aspects of the layout of a plurality of coil structures. [Figure 7] FIG. 10 is a diagram showing details of the layout of a control structure for wiring multiple coil structures. [Figure 8] FIG. 2 shows the layout of an electric drive. [Figure 9] 1 illustrates steps of a method for generating a layout for additive manufacturing of an electric drive. [Figure 10] FIG. 1 is a block diagram of one embodiment of a data processing system of the present invention for generating layouts for additive manufacturing of electrical devices. DETAILED DESCRIPTION OF THE INVENTION

[0036] Various examples will now be described in more detail with reference to the accompanying drawings, in which some examples are shown.

[0037] Thus, while the embodiments are susceptible to various modifications and alternative forms, the illustrative embodiments in the figures are described in detail herein. It is to be understood, however, that there is no intention to limit the embodiments to the particular forms disclosed, but rather that the embodiments are to cover all modifications, equivalents, and alternatives falling within the scope of the present disclosure.

[0038] The terminology used herein is for the purpose of describing illustrative examples only and is not intended to be limiting. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly dictates otherwise. It will be further understood that as used herein, the terms "comprises," "comprising," "includes," and / or "including" specify the presence of stated features, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof.

[0039] Unless otherwise specified, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the example belongs. It will be further understood that terms, e.g., terms defined in commonly used dictionaries, should be interpreted to have a meaning consistent with their meaning in the context of the relevant art, and will not be interpreted in an idealized or overly formal sense unless expressly defined herein.

[0040] FIG. 1 illustrates an embodiment of an apparatus 100 for generating a layout for additive manufacturing of an electric drive for a disk rotor, the disk rotor adapted to be driven by a magnetic field generated by an electric drive via an array of permanent magnets. The apparatus 100 includes an input module 110 configured to receive one or more input parameters from a user. The apparatus 100 further includes a generation module 120 configured to generate a layout 200 of a plurality of coil structures from the one or more input parameters. The plurality of coil structures 210, 220, etc. are adapted to generate a magnetic field for driving the disk rotor via an electric current. The generation module 120 is further configured to generate a layout of a control structure 300. The control structure is adapted to connect the plurality of coil structures 210, 220, etc. with connectors for supplying electric current and distribute the electric current to the plurality of coil structures.

[0041] In this embodiment, the layout 200 of the multiple coil structures includes six coil structures 210, 220,... arranged rotationally symmetrically around a common center 201. Each coil structure 210, 220,... includes an electrical conductor or wire that forms multiple concentric wire spirals as the coil layers of the respective coil structures 210, 220,... The coil body and each coil layer have a cross-section in the form of a triangle with rounded corners, such that each coil structure 210, 220,... is arranged in a plane that spans a 60° angle around the common center 201. The control structure layout 140 specifically connects the coil structures 210, 220,... on opposite sides of the common center 201. The multiple coil structures 210, 220,... may be wholly or partially contained within a support structure, particularly a dielectric composite, which may be the substrate of a printed circuit board (PCB).

[0042] The control structure layout 140 includes a wiring layout configured to sequentially supply current to the coil structures 210, 220,... so that the magnetic field generated by the coil structures 210, 220,... has a shape and time variation adapted to drive the disk rotor, which can be disposed on top of a support structure.

[0043] The apparatus can be configured to include support structure features in a layout that enables additive manufacturing of the support structure, the plurality of coil structures 210, 220, ..., and the control structure.

[0044] FIG. 2 shows how the apparatus 100 is configured to generate a layout for a coil structure 210 from input parameters.

[0045] Part (a) of the figure shows how the generation module 120 can generate a projection of the first wire spiral or coil layer 211 of the coil structure 210, where the projection has a triangular shape with rounded corners. The first coil layer 211 is located within a triangular region 212 of the cross-section of the electric drive. The triangular region 212 has a boundary including an apex located at a common center 201. At this apex, the boundary of the triangular region 212 involves a 60° angle. The cross-section of the complete electric drive can be further divided into triangular regions, each having a coincident apex located at the common center 201 and including respective additional coil structures 220, 230, ...

[0046] The input parameters include the radius r from the common center to the outer edge of the first coil layer 211. D , and the minimum distance d from the first coil layer 211 to the parallel edges of the boundary of the triangular region 212 D may include:

[0047] Part (b) of the figure shows the radius r of the curvature circle (osculating circle) applied to each corner of the first coil layer 211 as another input parameter. EThe figure shows how rounded corners of the first coil layer 211 can be obtained by specifying the radius r of the first coil layer 211. The circles of curvature shown are located at the vertices of the triangle 213, and the projections of the first coil layer 211 each have the same minimum distance r to the triangle 213. E The set of points with

[0048] Part (c) of the figure shows how some of the projections of further coil layers are positioned after defining the first spiral coil layer 211. For this task, the input parameters include the spiral distance d separating the projections of adjacent coil layers. H Other parameters include the wire gauge or wire diameter d W It can be said that:

[0049] FIG. 3 further illustrates how the apparatus 100 is configured to generate a layout for the coil structure 210 from input parameters.

[0050] As shown in part (a) of the figure, a circular spiral 214 (or round coil) can be generated. The circular spiral 214 has an axis perpendicular to the cross section (or projection) of the first spiral coil layer 211. To fix the radius of the circular spiral 214, the projection of the circular spiral 214, represented by a circle in the cross section, can be aligned with the projection of the first coil layer 211. The circular spiral 214 can then be defined by input parameters including the number of turns R and the pitch P.

[0051] Inserted on the left side of part (b) of the figure is a rotated projection line 205 that extends parallel to the cross section of the first coil layer 211, has an edge passing through the center point 206 of the cross section of the first coil layer 211, and passes through the circular spiral 214 at a right angle.

[0052] The right side of part (b) of the figure shows a coil layer surface 218 that includes the first coil layer 211 and extends in a direction perpendicular to the cross section of the first coil layer 211. The coil layer surface 218 can be generated as a surface that protrudes at a right angle from the projection of the first coil layer 211.

[0053] Part (c) of the figure shows that the circular spiral 214 is projected onto the coil layer plane 218. This can be achieved by an algorithm involving the rotational projection line 205.

[0054] Part (d) of the figure shows the first wire spiral / coil layer 211, generated as a result of the algorithm mentioned in the description of part (c). The number of turns R and pitch P of the circular spiral 214 also define the corresponding volume of the first coil layer 211.

[0055] FIG. 4 further illustrates how the apparatus 100 is configured to generate a layout for the coil structure 210 from input parameters.

[0056] Part (a) of the figure shows a projection of the first coil layer 211 and the outer second coil layer 211-2. The connection between the first coil layer 211 and the second coil layer 211-2 can be obtained by applying a spline function between the end point 215 of the first coil layer 211 and the start point 215-2 of the second coil layer 211-2.

[0057] As shown in part (b) of the figure, the second coil layer 211-2 can be obtained by first defining a second circular spiral 214-2 starting from a starting point 215-2 and including the same pitch P and number of turns R as the first coil layer 211.

[0058] As shown in part (c) of the figure, a second circular spiral 214-2 can then be projected to form a second coil layer 211-2 by an algorithm including a rotated projection line 205 (see FIG. 3).

[0059] 5 shows a projection of a layout 200 for multiple coil structures. The layout includes six coil structures 210, 220,... arranged symmetrically around a common center 201.

[0060] FIG. 6 illustrates another embodiment of a layout 200 for multiple coil structures. In some embodiments, the number of coil structures 210, 220,..., their arrangement within the regions, and the cross-section of the coil body can be predetermined. In other embodiments, a user can specify these data through input parameters. For example, the input module 110 can be configured to receive an even number specifying the number of regions, and the generation module 120 can be configured to adapt the shape of the coil structures 210, 220,... accordingly. Other embodiments are configured to provide cross-sectional options for the coil structures 210, 220,... (or coil layers or coil bodies) (e.g., essentially triangular or essentially circular), which may depend on the number of regions.

[0061] The generation module 120 and / or the input module 110 are advantageously configured to verify that the input parameters result in a physically sensible layout as a whole. The device 100 can provide an indication of the range of values ​​of the input parameters, for example via a display of the input module 110, or present the user with predefined choices of cross-sections of the coil structures 210, 220, .... The range of any one input parameter can be adapted depending on the values ​​already provided by the user for the other input parameters.

[0062] 7 shows details of the layout of a control structure 300 for wiring multiple coil structures 210, 220,.... After input parameters are provided by a user, a layout for wiring the coil structures 210, 220,... can be automatically generated. In this example, six coil structures 210, 220,... are connected in pairs, with each pair occupying opposite positions relative to a common center 201.

[0063] 8 shows the layout of the electric drive in cross-section through the coil structures 210, 220,... and parts of the layout of the control structure 300. The control structure connects the coil structures 210, 220,... in pairs, with each pair connected to a respective connector 311, 312, 313 for supplying current.

[0064] 9 illustrates steps of a method for generating a computer-aided design layout for additive manufacturing of an electric drive for a disk rotor adapted to be driven by a magnetic field. The method further includes step S110 of providing one or more input parameters. The method includes step S120 of generating, from the one or more input parameters, a layout 200 of a plurality of coil structures, where the plurality of coil structures 210, 220,... are adapted to generate a magnetic field by an electric current, and a layout 300 of a control structure, where the control structure is adapted to connect the plurality of coil structures 210, 220,... with connectors 311, 312, 313 for supplying electric current and distribute the electric current to the plurality of coil structures 210, 220,... to drive the disk rotor.

[0065] The step S120 of generating the layout 200 of the plurality of coil structures may include generating a circular spiral 214, 214-2 for each of the coil structures 210, 220, where the pitch P and / or wire gauge d W , and / or the number of rotations R is determined by input parameters. Step S120 may further include generating a rotated projection line 205 parallel to a cross section of the coil layer 210, where the coil layer 210 has a triangular cross section with rounded corners. Step S120 may further include projecting the circular spiral 214, 214-2 onto the coil layer plane 218 by the rotated projection line 205. Step S120 may further include generating a connection between respective ends (or end points and start points) 215, 215-2 of two consecutive coil layers 211, 211-2 by a spline function.

[0066] FIG. 10 shows a block diagram of one embodiment of a data processing system 400 (eg, a computer) for generating a layout for additive manufacturing.

[0067] The system includes a processor 402 and a memory 404 communicatively coupled to the processor 402 via an exemplary internal bus system 412. The memory 404 stores program code portions that, when executed, enable the processor 402 to perform the following functions: provide one or more input parameters through a providing unit 408; and generate a layout by a generating module 410 based on the one or more input parameters. The layout includes a layout of a plurality of coil structures, the plurality of coil structures adapted to generate a magnetic field by an electric current, and a layout of a control structure. The control structure is adapted to connect the plurality of coil structures with a connector for supplying an electric current and distribute the electric current to the plurality of coil structures to drive a disk rotor. Thus, the method of FIG. 9 can be implemented in this data processing system 400.

[0068] The generating (or computing) module 410 and / or the providing unit 408 may possibly be part of the processor(s) 402. The providing unit 408 may further include a transmitting unit (for output) and a receiving unit (for input) and may be realized by a network interface (e.g., for wired or wireless communication) available for communication or data exchange.

[0069] The description and drawings merely illustrate the principles of the disclosure, and it will thus be understood that those skilled in the art can devise various arrangements which, although not explicitly described or shown herein, embody the principles of the disclosure and are within the scope of the disclosure.

[0070] Furthermore, while each embodiment may stand on its own as an individual example, it should be noted that the defined features may be combined in various ways in other embodiments, i.e., a particular feature described in one embodiment may be realized in another embodiment, and such combinations are encompassed by the disclosure herein unless it is expressly stated that a particular combination is not intended.

[0071] Although the present invention has been illustrated and described in detail with reference to preferred embodiments, the present invention is not limited to the disclosed examples, and those skilled in the art can derive other modifications therefrom without departing from the scope of the present invention. Therefore, it is clear that there are multiple possible modifications. It is also clear that the embodiments mentioned as examples are merely practical examples that should not be considered as limiting the scope, applicability, or configuration of the present invention in any way. Indeed, the foregoing description and the illustrations enable those skilled in the art to implement the exemplary embodiments in concrete terms, and with knowledge of the disclosed inventive concepts, those skilled in the art can make various modifications, for example, with respect to the wavelength range of the sensor mentioned in the exemplary embodiments, the function or arrangement of individual elements, etc., without departing from the scope of the present invention, which is defined by the claims and their legal equivalents, such as other interpretations in the description. [Explanation of symbols]

[0072] 100 devices 110 Input Module 120 Generation Module 200 Coil structure layout 201 Common Center 205 Rotated Projection Line 206 Center point of coil structure (or coil layer or coil structure) 210, 220, 230, ... Coil structure 211, 211-2 Coil layer 212 Triangular area 213 Triangle 214, 214-2 circular spiral 215, 215-2 End / Start 218 Coil layer surface 300 Control Structure Layout 311, 312, 313 Connectors S110, S120 method steps

Claims

1. 1. An apparatus for generating a layout for additive manufacturing of an electric drive for a disk rotor adapted to be driven by a magnetic field, comprising: an input module configured to receive one or more input parameters from a user; From the one or more input parameters: a layout of a plurality of coil structures, said plurality of coil structures being adapted to generate said magnetic field by means of an electric current; and a layout of a control structure, said control structure being adapted to connect said plurality of coil structures with connectors for supplying said current and to distribute said current to said plurality of coil structures in order to drive said disk rotor; a generation module configured to generate Equipped with The apparatus, wherein each coil structure includes one or more concentric wire spirals as coil layers, and the generation module is configured to generate each wire spiral based on a projection of a circular spiral onto a coil layer plane and by a rotated projection line arranged parallel to the cross section of the wire spiral.

2. The apparatus of claim 1 , wherein the generation module is further configured to generate instruction data for an additive manufacturing device based on the layout of the plurality of coil structures and the layout of the control structure.

3. The apparatus of claim 2 , wherein the additive manufacturing device is a multi-material jetting printer.

4. The input parameters are: - wire gauge or wire diameter, - pitch or wire tilt, - number of turns, - the radius or diameter of the cross section of the coil structure or of the coil layers of the coil structure, the distance between the coil structures or between two coil layers of different coil structures, - the number of coil layers of the coil structure, - the distance between the coil layers of the coil structure The apparatus of claim 1 , comprising one or more of:

5. The device described in claim 1, wherein each wire spiral has a triangular cross section with rounded corners.

6. The apparatus of claim 5 , wherein the generation module is configured to generate, for each coil structure, a connection between each end of two consecutive concentric spirals by a spline function.

7. 2. The apparatus of claim 1, wherein the plurality of coil structures are grouped into pairs, and the control structure includes, for each pair, wiring coupling a first member of the pair to a second member of the pair and to the connector for power supply.

8. 1. A method for generating a layout for additive manufacturing of an electric drive for a disk rotor adapted to be driven by a magnetic field, comprising: providing one or more input parameters; From the one or more input parameters: a layout of a plurality of coil structures, said plurality of coil structures being adapted to generate said magnetic field by means of an electric current; and a layout of a control structure, said control structure being adapted to connect said plurality of coil structures with connectors for supplying said current and to distribute said current to said plurality of coil structures in order to drive said disk rotor; generating a Including, The step of generating the layout of the plurality of coil structures includes, for at least one coil structure: generating a circular spiral (wherein the pitch, and / or wire gauge, and / or number of turns are determined from said input parameters); generating a rotational projection line disposed parallel to a cross section of the coil layer; projecting the circular spiral onto a coil layer surface by the rotational projection line; generating a connection between each end of two successive coil layers by a spline function; A method comprising:

9. The method described in claim 8, wherein the coil layer has a triangular cross section with rounded corners.

10. A machine-readable storage device having stored thereon software code that, when executed by a data processing system, causes the data processing system to perform operations including: providing one or more input parameters; From the one or more input parameters: a layout of a plurality of coil structures, said plurality of coil structures being adapted to generate said magnetic field by means of an electric current; and a layout of a control structure, said control structure being adapted to connect said plurality of coil structures with connectors for supplying said current and to distribute said current to said plurality of coil structures in order to drive said disk rotor; and Including, A machine-readable storage device, wherein each coil structure includes one or more concentric wire spirals as coil layers, and each wire spiral is generated based on a projection of a circular spiral onto the coil layer plane by a rotated projection line arranged parallel to the cross section of the wire spiral.

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