Apparatus for generating layouts for additive manufacturing of electric drive systems

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 a method for generating a layout for additive manufacturing of an electric drive device, and particularly to a procedure for manufacturing an additively manufactured electric drive device that is supported by a parameter-based computer-aided design model.

Background Art

[0002] Additive manufacturing can be used to create both the individual components of an electronic circuit and the support structure. To assemble small-scale structures, devices (3D printers) for carrying out such additive manufacturing need to deposit materials with quite different physical properties at precise positions. An example of such a device is provided by a multi-material jet printer. Such printers are capable of processing metal or ceramic powder uniformly dispersed in a thermoplastic binder to form a liquid, and the printer is capable of depositing minute quantities of that liquid with high precision.

[0003] A new application of this type of 3D ink printing is the additive manufacturing of Printed Circuit Boards (PCBs), in which case the PCB substrate is created simultaneously with at least certain parts of the electronic components. This process allows the connection between the components and the PCB substrate to be made even more complete, as the combined structure is effectively cast as a single 3D construct.

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

[0005] A specific example of such a process involves integrating the electric drive unit for a disk motor. In modern technology, electric drive units mounted on conventional PCBs can be surface-mounted or include multiple arrays of essentially triangular, concentric wires printed conventionally on the surface of one or more layers, then stacked to form a circuit board. This conventional printing method typically creates the wires by etching layers of copper. Then, to form a coil structure, for each array of concentric wire shapes, the wires on consecutive layers are connected by vias, which are small conductive paths drilled into the PCB, establishing electrical connections between different PCB layers. The current flowing through the wires generates a magnetic field that drives the disk rotor supported on the PCB surface.

[0006] Conventional PCBs are typically designed using dedicated layout software, which in turn accepts user input, such as graphic design programs for the functional specifications of integrated circuits. However, simply adapting such programs negates many of the advantages that additive manufacturing using multi-material jet printers should offer. This is especially true for creating coil arrays for electric drive devices, where the 3D printer is expected to produce complete 3D coil structures rather than stacks of planar layers. [Overview of the project] [Problems that the invention aims to solve]

[0007] Therefore, in order to create electric motors in an additive manufacturing process, it is necessary to support the layout process. This includes the technical task of generating a feasible layout, i.e., a task that can be performed by the additive manufacturing process. [Means for solving the problem]

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

[0009] The present invention relates to an apparatus for generating layouts for additive manufacturing of electric drive units for disk rotors. The disk rotor is adapted to be driven by a magnetic field generated by the electric drive unit. The apparatus comprises an input module configured to receive one or more input parameters from a user. The apparatus further comprises a generation module configured to generate a layout of multiple coil structures from one or more input parameters. The multiple coil structures are adapted to generate a magnetic field by electric current. The generation module is further configured to generate a layout of a control structure, which is adapted to connect the multiple coil structures to connectors for supplying current and to distribute the current to the multiple coil structures in order to drive the disk rotor.

[0010] Additive manufacturing of electric drive units typically involves at least one conductive material and one electrically insulating material. The two materials generally exhibit different properties for their use in additive manufacturing. When generating a layout, the generation module is subject to constraints that arise in the case of additive manufacturing of electric drive units. These include, in particular, requirements such as the achievable resolution in the horizontal printing layers and their respective vertical directions, as well as the minimum distance between conductive parts of the electric drive unit to achieve adequate insulation. These constraints may depend on the technical arrangement of the device used in additive manufacturing (e.g., size and scale, configuration), but are particularly affected by the different materials. The device can be configured to incorporate constraints into the input module by limiting the possible values ​​of the input parameters. The device can further incorporate constraints into the generation module by providing boundaries in specific parts of the layout (e.g., near conductive structures). The layout may further include data considered in the additive manufacturing process, such as waiting times after specific printing steps.

[0011] The input parameters specify the size and shape of the electric drive unit. 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 unit.

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

[0013] A coil structure is a structure that is manufactured additively and effectively provides the function of a coil. Where this description refers to “coils,” “wires,” “lines,” or similar entities, each structure is understood to be manufactured additively (rather than, for example, being wound or drawn).

[0014] The generation module is advantageously adapted to generate a layout that allows for the creation of an electric drive unit together with a support structure such as a PCB in an additive manufacturing process, for example, in a multi-material jet printer. The support structure may include dielectric materials such as plastic or compounds typically used as substrates for PCBs. The support structure can house multiple coil structures and / or control structures, fully or partially. The generation module can also be configured to include other features of the support structure's shape in the layout. The layout may include features such as basins and / or support pins to better fit the support structure to support the disk rotor.

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

[0016] In some cases, the additive manufacturing device is a multi-material jet printer. In this case, the device is configured to have constraints arising from the manufacturing method and the materials used by the multi-material jet printer. In the examples, the multi-material jet printer uses conductive and dielectric inks that require specific margins, tolerances, and boundaries. The constraints are particularly: - Minimum distance (resolution) on the horizontal printing surface, - The minimum height of the printed 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 the vertical direction, - Maximum range of a printed object in a certain direction within the horizontal plane It may include.

[0017] In particular, conductive parts such as wires must maintain a minimum distance to avoid interference, thus imposing constraints on layout based on specific resolutions. Printing inks, especially conductive inks, typically cannot be printed at arbitrary fine scales, which can further impact the achievable printing resolution.

[0018] While the assembly space for multi-material jet printers is typically limited and miniaturization may be the focus of their use, layout equipment can also be configured for laying out large motors.

[0019] Depending on the circumstances, the input parameters may include one or more of the following: wire gauge or diameter of the wires constituting the coil structure; pitch; or inclination of the wires with respect to a surface, such as a surface defined by a disk rotor; or the number of turns of the wires in the coil layers of the coil structure. The input parameters may further include the radius or diameter of the cross-section of each coil structure or at least one of the coil layers of each coil structure, where the coil layers may be given, for example, by a wire helix enclosing the coil body of the coil structure. The input parameters may further include the distance between coil structures or between at least one of the coil layers of each coil structure; the number of coil layers; and / or the distance between the coil layers of a given coil structure.

[0020] According to an embodiment, the wire of the coil structure is inclined relative to the main surface (for example, of a printed circuit board used in an exemplary printed motor). Here, the term "inclined" can be understood as a continuous inclination at a predetermined inclination angle that defines a pitch (for example, a constant angle or a constant pitch). Thereby, a helix is formed. Therefore, according to the embodiment, the wire of the coil is not formed along surfaces connected by vertical interconnects (vias), but is formed along a helix of which each cross-section cannot be approximated by a flat surface.

[0021] In some cases, each coil structure includes one or more concentric wire helices as coil layers, and each wire helix forms a coil layer around the coil body. Each coil layer has a triangular cross-section with rounded corners (or allows projection onto a triangle with rounded corners). The generation module may be configured to generate each wire helix based on the projection of each coil layer of a circular helix (that is, a helix that projects onto a circle) onto a surface. This coil layer surface may be a lateral region of the coil body that has a triangular base region, or more generally, has several advantageous non-rotationally symmetric base regions. The wire helix is configured within that surface. In an embodiment, the height of the coil layer surface is given by the height of the rounded coil, which can be obtained by the number of turns multiplied by the pitch.

[0022] Advantageously, the projection is performed by a rotational projection line, which is arranged parallel to the cross-section of the coil layer and has an edge that passes through the center point of the cross-section of the coil layer and the circular helix at a right angle.

[0023] In an embodiment, the layout generation module includes generating, in a first step, a round coil, or more precisely, a circular spiral having the required diameter, pitch, and number of turns. This can be performed, for example, by splining or sweeping, i.e., generating a path and a cross-section (for the wire to be projected), and essentially extruding the cross-section along the path. Then, in a second step comprising projecting the circular spiral along a projection line that extends parallel to the cross-section of the coil and extends perpendicularly from the axis of the round coil to the coil layer plane, and rotating the projection line about said axis along the circular spiral, a more complex shaped wire spiral is obtained. The projection may in particular comprise further means for accurately generating the cross-sectional profile of the wire of the wire spiral, i.e., the term "projection line" is to be interpreted broadly.

[0024] The advantage of the method using a rotating projection line is that any wire spiral can be obtained by projecting onto the corresponding coil layer plane. In other embodiments, the coil layer plane is, for example, a side face of a body having a square or rectangular cross-section. Another advantage is that the method requires a relatively small number of input parameters, in particular since it starts from the common base of a simple round coil structure.

[0025] Optionally, the generation module is configured to generate, for each coil structure, a connection portion between respective ends of any two consecutive concentric wire spirals by means of a spline function. In an embodiment, the end point of the 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 the 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 said plane. This shape connecting the first wire spiral and the second wire spiral can then be repeated for all coil layers of the coil structure.

[0026] Depending on the circumstances, multiple coil structures may be divided into pairs, and the control structure includes wiring for each pair connecting the first member of the pair to the second member of the pair and a power supply connector. This wiring is designed to generate a time-varying magnetic field adapted so that the coil structure drives the disk rotor by electric current. At the current level of technology, several methods are known for achieving magnetic field drive of the disk rotor, and these methods can be implemented by a generation module.

[0027] The embodiment further relates to a method for generating a computer-aided design layout for the additive manufacturing of an electric drive for a disk rotor adapted to be driven by a magnetic field. This method is: A step of providing one or more input parameters, From one or more input dimensions, - A layout of multiple coil structures, wherein the multiple coil structures are adapted to generate a magnetic field by electric current, and - A layout of a control structure, wherein the control structure is adapted to connect multiple coil structures to connectors for supplying current to drive a disk rotor, and to distribute the current to the multiple coil structures. Steps to generate and Includes.

[0028] Depending on the case, the step of generating the layout of multiple coil structures may be performed for at least one coil structure: To generate a round wire helix (where pitch, and / or wire gauge, and / or rotation speed are determined from the provided input parameters), To generate a rotational projection line parallel to the cross-section of the coil body (where the coil body has a triangular cross-section with rounded corners), Projecting a round wire spiral onto a scaled surface of the coil body using rotational projection lines. The spline function generates a connection between the respective ends of two consecutive concentric helical bodies. Includes.

[0029] The method can also be implemented on a computer. It will be readily apparent to those skilled in the art that each step of the method can be performed by a programmed computer. Embodiments are also intended to include program storage devices, such as digital data storage media, that encode machine-readable or computer-readable machine-executable or computer-executable programs consisting of instructions, which, when executed by a computer or processor, perform some or all of the steps of the method described above.

[0030] The embodiment also relates to a method for manufacturing an electric drive for a disk rotor, wherein the disk rotor is adapted to be driven by a magnetic field, and the method includes the step of 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, wherein the electric drive is manufactured by this method, i.e., in this case the manufacture of the electric drive involves the generation of the layout shown above.

[0032] An important aspect of the present invention can be summarized as follows: Printed motors can be manufactured in extremely small size by the layout generated by the apparatus. The motor can be printed directly within and / or on the surface of a PCB. There is no need to wind coils. In particular, it becomes possible to integrate the motor into the PCB. The apparatus 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 apparatus allows input of input parameters of the disk motor, such as wire diameter or thickness and rotational speed. The coil structure, and the wiring between them, are adapted to the given input parameters.

[0033] The 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 CAD models of disk motors and make it easier to meet dimensional requirements. Electric motors can be printed in or on a PCB in an extremely flat and compact form, particularly the pitch of conductors (wires) and other 3D features that cannot be achieved with typical PCB configurations. In particular, the apparatus generates layouts that are technically feasible, i.e., printable by the corresponding printing device, especially by multi-material jet printers.

[0034] In the following, various embodiments of the present invention will be described with reference to the accompanying drawings, simply as examples. [Brief explanation of the drawing]

[0035] [Figure 1] This figure shows an embodiment of an apparatus for generating layouts for additive manufacturing of electric drive devices according to the present invention. [Figure 2] This figure shows the details of generating a layout for a coil structure from input parameters. [Figure 3]This figure shows the step-by-step generation details of the layout for the coil structure. [Figure 4] This figure shows further details of the step-by-step generation of the layout for the coil structure. [Figure 5] This is a diagram showing the layout for multiple coil structures. [Figure 6] This figure shows another configuration of the layout of multiple coil structures. [Figure 7] This figure shows the detailed layout of the control structure for wiring multiple coil structures. [Figure 8] This is a diagram showing the layout of the electric drive unit. [Figure 9] This figure shows the steps of a method for generating a layout for additive manufacturing of electric drive units. [Figure 10] This is a block diagram of one embodiment of the data processing system of the present invention for generating layouts for additive manufacturing of electrical devices. [Modes for carrying out the invention]

[0036] Next, we will explain various examples in more detail, referring to the attached diagrams that illustrate several real-world examples.

[0037] Therefore, while examples can take various forms of modification and substitution, this specification will describe in detail the exemplary examples shown in the figures. However, it should be understood that the examples are not intended to be limited to any particular form disclosed, but rather encompass all modifications, equivalents, and substitutions that fall within the scope of this disclosure.

[0038] The terms used herein are for illustrative purposes only and are not intended to be limiting. Where used herein, the singular forms “a,” “an,” and “the” are intended to include the plural form unless otherwise specified in the context. Where used herein, the terms “comprises,” “comprising,” “includes,” and / or “including” indicate the presence of the mentioned feature, step, action, element, and / or component, but do not preclude the presence or addition of one or more other features, steps, actions, elements, components, and / or groups thereof.

[0039] Unless otherwise specified, all terms used herein (including technical and scientific terms) have the same meaning as those generally understood by engineers in the field to which the examples belong. Terms, for example, those defined in commonly used dictionaries, should be interpreted in a way that is consistent with their meaning in the context of the relevant field, and it will be further understood that, unless explicitly specified herein, they should not be interpreted in an idealized or overly formal sense.

[0040] Figure 1 shows an embodiment of apparatus 100 for generating layouts for additive manufacturing of an electric drive for a disk rotor, the disk rotor being adapted to be driven by a magnetic field generated by the electric drive through an array of permanent magnets. Apparatus 100 comprises an input module 110 configured to receive one or more input parameters from a user. Apparatus 100 further comprises a generation module 120 configured to generate a layout 200 of a plurality of coil structures from one or more input parameters. The plurality of coil structures 210, 220, ... are adapted to generate a magnetic field for driving the disk rotor by 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, ... to connectors for supplying current and to distribute the current to the plurality of coil structures.

[0041] In this embodiment, the layout 200 of the multiple coil structures comprises six coil structures 210, 220, ... arranged rotationally symmetrically around a common center 201. Each coil structure 210, 220, ... contains a conductor or wire, which forms multiple concentric wire helices as coil layers of each coil structure 210, 220, ... The cross-section of the coil body and each coil layer is a triangular shape with rounded corners, and each coil structure 210, 220, ... is positioned in a region spanning a 60° angle around the common center 201 in plane. The layout 140 of the control structure connects the coil structures 210, 220, ... on opposite sides of the common center 201. The multiple coil structures 210, 220, ... may be contained, whole or partially, within a support structure, in particular in a dielectric composite material that can serve as a substrate for 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, ..., and to have a shape and time variation adapted to drive the disk rotor with the magnetic fields generated by the coil structures 210, 220, .... The disk rotor can be positioned on top of the support structure.

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

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

[0045] Part (a) of the figure shows how the generation module 120 can generate a projection of the first wire helix or coil layer 211 of the coil structure 210, the projection having the shape of a triangle 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 that includes a vertex located at a common center 201. At this vertex, the boundary of the triangular region 212 is at an angle of 60°. The cross-section of the complete electric drive can be further divided into triangular regions, each of which has a coincident vertex located at a common center 201 and includes further coil structures 220, 230, ...

[0046] The input parameter is 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 edge of the boundary of the triangular region 212. D It can include...

[0047] Part (b) of the figure shows the radius r of the curvature circle (contact circle) applied to each corner of the first coil layer 211 as another input parameter. EBy specifying this, it is shown how the rounded corners of the first coil layer 211 are obtained. The circles of curvature shown here are located at the vertices of triangle 213, and the projections of the first coil layer 211 are each at the same minimum distance r to triangle 213. E It can be determined as a set of points having [a certain characteristic].

[0048] Part (c) of the figure shows how some of the projections of further coil layers are positioned after the first helical coil layer 211 has been defined. For this task, the input parameter is the helical distance d separating the projections of adjacent coil layers. H It may include the wire gauge or wire diameter d. W It can be done this way.

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

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

[0051] On the left side of part (b) of the figure, a rotational projection line 205 is inserted, which 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 perpendicularly through the circular helical body 214.

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

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

[0054] Part (d) of the figure shows the first wire helix / coil layer 211, which is generated as a result of the algorithm mentioned in the explanation of part (c). The rotational speed R and pitch P of the circular helix 214 also define the corresponding quantities of the first coil layer 211.

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

[0056] Part (a) of the figure shows a projection view 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 endpoint 215 of the first coil layer 211 and the starting 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 helical body 214-2 that starts from the starting point 215-2 and has the same pitch P and the same rotational speed R as the first coil layer 211.

[0058] As shown in part (c) of the figure, the second circular helical body 214-2 can then be projected using an algorithm that includes a rotational projection line 205 (see Figure 3) to form the second coil layer 211-2.

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

[0060] Figure 6 shows another embodiment of layout 200 for multiple coil structures. In some embodiments, the number of coil structures 210, 220, ..., their arrangement within the region, and the cross-section of the coil body can be predetermined. In other embodiments, the user can specify this data by input parameters. For example, input module 110 can be configured to accept an even number specifying the number of regions, and accordingly, generation module 120 can be configured to adapt the shape of the coil structures 210, 220, .... Other embodiments are configured to provide a choice of cross-sections (essentially triangular or essentially circular, etc.) for the coil structures 210, 220, ... (or coil layers or coil bodies), which may depend on the number of regions.

[0061] The generation module 120 and / or input module 110 are advantageously configured to verify that the input parameters as a whole result in a physically reasonable layout. The device 100 can, for example, provide instructions about the range of values ​​for the input parameters via the display of the input module 110, or show the user a predetermined selection of cross-sections of the coil structures 210, 220, ... The range of any one input parameter can be adapted in accordance with values ​​already given by the user to the other input parameters.

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

[0063] Figure 8 shows the layout of the electric drive unit and the layout of the control structure 300, with cross-sections of the coil structures 210, 220, ... The control structure connects the coil structures 210, 220, ... in pairs, and each pair is connected to connectors 311, 312, and 313 for supplying current.

[0064] Figure 9 shows steps of a method for generating computer-aided design layouts 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. From one or more input parameters, the method includes step S120 of generating a layout 200 of a plurality of coil structures, wherein the plurality of coil structures 210, 220, ... are adapted to generate a magnetic field by electric current, and a layout of a control structure 300, wherein the control structure is adapted to connect the plurality of coil structures 210, 220, ... to connectors 311, 312, 313 for supplying electric current and distributing the electric current to the plurality of coil structures 210, 220, ... in order to drive the disk rotor.

[0065] Step S120, which generates a layout 200 of multiple coil structures, may include the step of generating circular helices 214, 214-2 for each of the coil structures 210, 220, ..., where pitch P and / or wire gauge d W The rotation speed R is determined by the input parameters. Step S120 may further include generating a rotational projection line 205 parallel to the 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 circular helical bodies 214, 214-2 onto the coil layer surface 218 by the rotational projection line 205. Step S120 may further include generating a connection between the respective ends (or start and end points) 215, 215-2 of two consecutive coil layers 211, 211-2 by a spline function.

[0066] Figure 10 shows a block diagram of one embodiment of a data processing system 400 (e.g., a computer) for generating layouts for additive manufacturing.

[0067] The system comprises a processor 402 and a memory 404 communicably connected to the processor 402 via an exemplary internal bus system 412. The memory 404 stores a program code portion, which, when executed, enables the processor 402 to provide the following functions: providing one or more input parameters through a providing unit 408, and generating a layout by a generating module 410 based on one or more input parameters. The layout includes a layout of a plurality of coil structures, adapted so that the plurality of coil structures generate a magnetic field by electric current, and a layout of a control structure. The control structure is adapted to drive a disk rotor by connecting the plurality of coil structures to connectors for supplying electric current and distributing the electric current to the plurality of coil structures. Thus, the method of Figure 9 can be implemented in this data processing system 400.

[0068] The generation (or calculation) module 410 and / or the supply unit 408 may optionally be part of one or more processors 402. The supply unit 408 may further include a transmission unit (for output) and a receiving unit (for input), and may be implemented by a network interface (e.g., for wired or wireless communication) available for communication or data exchange.

[0069] The description and drawings are merely illustrative of the principles of this disclosure. Therefore, those skilled in the art will understand that it is possible to devise various arrangements that embody the principles of this disclosure and fall within the scope of this disclosure, although these are not explicitly described or illustrated herein.

[0070] Furthermore, while each embodiment may stand independently as an individual example, it should be noted that various combinations of the defined features are possible in other embodiments; that is, a particular feature described in one embodiment may be realized in another. Such combinations are encompassed by the disclosures herein unless otherwise explicitly stated.

[0071] Although the present invention has been illustrated and described in detail by preferred embodiments, the present invention is not limited by the disclosed embodiments, and those skilled in the art can derive other modifications from them without departing from the scope of the 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 and should not be considered to limit the scope, applicability, or configuration of the present invention. Indeed, the foregoing description and the description of the drawings enable those skilled in the art to implement the exemplary embodiments in concrete terms, and they can use their knowledge of the conceptual nature of the disclosed invention to make various modifications, for example, with respect to the wavelength range of the sensors mentioned in the exemplary embodiments, the function or arrangement of individual elements, without departing from the scope of the invention as 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 Generating Modules 200 Coil Structure Layout 201 Common Center 205 Rotational projection lines 206 Center point of a coil structure (or coil layer or coil structure) 210, 220, 230, ... Coil structure 211, 211-2 coil layers 212 Triangular area 213 Triangle 214, 214-2 circular spiral 215, 215-2 End point / Start point 218 Coil layer surface 300 Layout of control structures 311, 312, 313 connectors Steps of method S110, S120

Claims

1. Apparatus for generating additive manufacturing layouts for electric drive units for disk rotors adapted to be driven by a magnetic field, An input module configured to receive one or more input parameters from the user, From the one or more input parameters mentioned above, - A layout of multiple coil structures, wherein the multiple coil structures are adapted to generate the magnetic field by an electric current, and - A layout for a control structure, wherein the control structure is adapted to drive the disk rotor by connecting the plurality of coil structures to connectors for supplying the current and distributing the current to the plurality of coil structures. A generation module configured to generate, Equipped with, Each coil structure comprises one or more concentric wire helices as coil layers, and the generating module is configured to generate each wire helice by rotational projection lines arranged parallel to the cross-section of the coil layer, based on the projection of a circular helix onto the coil layer surface.

2. The apparatus according to claim 1, wherein the generation module is further configured to generate command 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 according to claim 2, wherein the additive manufacturing device is a multi-material jetting printer.

4. The aforementioned input parameters are: - Wire gauge or wire diameter, - Pitch or wire angle, - Number of turns, - The radius or diameter of the cross-section of the coil structure or the coil layer of the coil structure, - The distance between coil structures or between two coil layers of different coil structures, - Number of coil layers in the coil structure, - Distance between coil layers in a coil structure The apparatus according to claim 1, comprising one or more of the following.

5. The apparatus according to claim 1, wherein each coil layer has a triangular cross-section with rounded corners.

6. The apparatus according to claim 5, wherein the generation module is configured to generate a connection between the respective ends of two consecutive concentric helical bodies using a spline function for each coil structure.

7. The apparatus according to claim 1, wherein the plurality of 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 the connector for power supply.

8. 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, The steps include providing one or more input parameters, From the one or more input parameters mentioned above, - A layout of multiple coil structures, wherein the multiple coil structures are adapted to generate the magnetic field by an electric current, and - A layout for a control structure, wherein the control structure is adapted to drive the disk rotor by connecting the plurality of coil structures to connectors for supplying the current and distributing the current to the plurality of coil structures. Steps to generate and Includes, The step of generating the layout of the plurality of coil structures is performed for at least one coil structure: To generate a circular helical body (where the pitch and / or wire gauge and / or rotational speed are determined from the input parameters), To generate rotational projection lines arranged parallel to the cross-section of the coil layer, The circular spiral body is projected onto the coil layer surface by the rotational projection line. The spline function generates a connection between the respective ends of two consecutive coil layers. Methods that include...

9. The method according to claim 8, wherein the coil layer has a triangular cross-section with rounded corners.

10. A machine-readable storage device storing software code, the software code being executed by a data processing system, causing the data processing system to perform an operation including, Providing one or more input parameters, From the one or more input parameters mentioned above, - A layout of multiple coil structures, wherein the multiple coil structures are adapted to generate a magnetic field by electric current, and - A layout for a control structure, wherein the control structure is adapted to connect the plurality of coil structures to a connector for supplying the current and to distribute the current to the plurality of coil structures in order to drive a disk rotor. To generate, Includes, A machine-readable memory device in which each coil structure comprises one or more concentric wire helices as coil layers, and each wire helice is generated by rotational projection lines arranged parallel to the cross-section of the coil layer, based on the projection of a circular helix onto the coil layer surface.

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