Systems and methods for magnetic field shaping in brushless direct current motors

Abstract

Systems and methods for magnetic field shaping in brushless direct current (BLDC) motors are disclosed. In some examples, the method includes forming a stator coil of a BLDC motor. The BLDC motor includes a rotor including a vessel mover disposed proximate the stator coil and including a magnetic structure. The stator coil includes windings comprising layers interconnected by intra-coil vias to form a continuous conductive path. The formation of the stator coil includes introducing variation(s) between two or more of the windings of two or more of the layers according to a desired magnetic field pattern. The stator coil is then driven by injecting a control signal to the conductive path to energize the stator coil, impart a directed force on the vessel mover to move the vessel mover in a direction of travel in accordance with the desired magnetic field pattern, and thereby commutate the BLDC motor.

Description

SYSTEMS AND METHODS FOR MAGNETIC FIELD SHAPING IN BRUSHLESS DIRECT CURRENT MOTORSCROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 649,878 entitled “SYSTEMS AND METHODS FOR MAGNETIC FIELD SHAPING IN BRUSHLESS DIRECT CURRENT MOTORS” filed on May 20, 2024, the disclosure of which is hereby incorporated by reference in its entirety for all purposes.FIELD

[0002] This technology generally relates to linear and rotary brushless direct current (BLDC) motors and, more particularly, to methods for and devices manipulating the geometry of stator coil windings in BLDC motors to achieve a desired or optimized magnetic field of the stator coils and thereby improve performance and efficiency of the BLDC motors.BACKGROUND

[0003] Multiphase linear and rotary brushless direct current (BLDC) motors are used in a variety of different types of deployments and disciplines. For example, BLDC motors are employed in vehicles (e.g., trains), wind turbines, spacecraft, nuclear reactor centrifuges, commercial building system components (e.g., magnetic bearings, elevators, lifts, fans, compressors, chillers, and pumps), household appliance system components (e.g.. lamps, chairs, sofas, beds, washing machines, rooms, and toys), and advertising system components (e.g., objects inside or above various frames), and in automation track systems to move objects, among many other use-cases.

[0004] In one example, liquid handler systems use automation track systems to move pucks coupled to vessels containing patient bodily fluid samples (e.g., blood, urine, spinal fluid) to various laboratory instruments for analysis. Liquid handler systems that are designed to dispense and process selected quantities of reagents, samples, or other liquids, can be adapted to analyze samples using, for example, immunoassay and / or clinical chemistry techniques. Such liquid handlers could be referred to as “analyzers” or “analyzer systems,” and can include a number of modules and a transport system to move samples between the various modules. It is desirable for liquid handler transport systems to move sample containers (e.g., reaction cuvettes, tubes, or vessels) in a smooth manner, avoid causing the sample containers to collide with each other, and otherwise prevent liquids from spilling from their containers during transport. In particular, liquid spills waste reagents and / or samples, which could potentiallyimpact the integrity of any tests being performed and can create obstructions that could impair the movement of subsequent sample containers.

[0005] Recently, there has been some development using coils embedded in the track surface to propel permanent magnet(s) in the base of a vessel mover. In particular, the coils in the track are selectively activated to apply a magnetic field to the magnet(s) in the vessel movers, synchronizing the fields to the movement of the magnet(s), causing movement along a plane. Conventionally, the coils are made of narrow-gauge wound copper wire. This approach is simple to construct, but is expensive, especially as the number of coils goes up to accommodate a large number of paths and the overall size of a laboratory' automation or other type of track system. Further, drive circuits are needed for the coils and Hall effect sensors may need to be placed near the track surface to detect the location and movement of the permanent magnet(s) of the vessel movers.

[0006] Synchronous activation of the coils creates a moving magnetic field that moves to / from adjacent planar coils along the row of coils. By synchronously activating groups of coils, a permanent magnet in the base of a vessel mover / carrier can be selectively propelled along a chosen path. Accordingly, the coils can be periodically spaced along the longitudinal axis of a track and individually commutated in a multiphase manner to adequately propel a vessel mover in a desired direction in a safe, predictable, quiet, and efficient manner. The primary benefits of using a linear coil drive include realization of high-fidelity analog current waveforms, lower force (torque) ripple, lower system electrical noise, reduced electromagnetic emissions, lower acoustic noise, greater control resolution for position and velocity, lower cost components, reduced difficulty to source components, reduced maintenance costs, and increase to useful life of the system.

[0007] A coil includes one or more turns, usually in a circular or cylindrical shape, of current-carrying wire designed to produce a magnetic field and includes related electrical resistance or inductance. Other common coil shapes include square, rectangular, hexagonal, octagonal, racetrack, and triangular, although coils can be any shape that includes completely- closed turns. A current through any conductor creates a circular magnetic field around the conductor due to Ampere's law. Coil shape can increase the strength of the magnetic field produced in a desired direction by a given current. The magnetic fields generated by the separate turns of wire all pass through the center of the coil and add (superpose) to produce a strong field in that location. The more turns of wire used, and / or the higher the current through the coil, the stronger the produced magnetic field. Conversely, a changing external magnetic flux induces a voltage in a conductor such as a wire, due to Faraday's law of induction. Theinduced voltage can be increased by winding the wire into a coil because the field lines intersect the circuit multiple times.

[0008] Coils can be incorporated into printed circuit boards (PCBs) or printed wiring boards (PWBs), which may be separate from a substrate of the wire windings of the coils, as multi-turn three-dimensional planar structures, such that they are spaced to efficiently impart force to move a vessel mover when commutated. PCB stator coil windings can be made lighter, smaller, and less noisy acoustically than wire-wound windings. Additionally, due to the lithographic techniques used in design and fabrication of PCBs, PCB stator coils are also more consistent across production units.

[0009] PCB stator coils take the form of a laminated sandwich structure of conductive and insulating layers in which each of the conductive layers is designed with an artwork pattern of traces, planes and other features etched from one or more sheet layers of copper laminated onto and / or between sheet layers of a non-conductive substrate. Electrical components may be fixed to conductive pads on the outer layers in the shape designed to accept the component's terminals, generally by means of soldering, to both electrically connect and mechanically fasten the components. Another manufacturing process adds vias or plated-through holes that allow interconnections between layers.

[0010] PCBs are used in nearly all electronic products, although alternatives include wire wrap and point-to-point construction, both once popular but now rarely used. PCBs require additional design effort to lay out the circuit, but manufacturing and assembly can be automated. Electronic design automation software is available to do much of the work of layout. Mass-producing circuits with PCBs is cheaper and faster than with other wiring methods, as components are mounted and wired in one operation. Large numbers of PCBs can be fabricated at the same time, and the layout has to be done only once. PCBs can also be made manually in small quantities, with reduced benefits.

[0011] PCBs can be single sided (i.e., one copper layer), double-sided (i.e., two copper layers on both sides of one substrate layer), or multi-layer (i.e., outer and inner layers of copper, alternating with layers of substrate). Multi-layer PCBs allow for higher component density because circuit traces on the inner layers would otherwise take up surface space between components. The rise in popularity of multilayer PCBs with more than two, and especially with more than four, copper planes was concurrent with the adoption of surface mount technology7. PCB's may be designed to accommodate thru-hole components, surface mount components, or both in hybrid applications.

[0012] Attempts have been made to improve BLDC motor efficiency by controlling the overall geometric shape of stator coils (e.g.. circular, racetrack, etc.) in BLDC motors and the position of the stator coils within BLDC motors. Despite these prior art efforts, a need remains for improving the efficiency of BLDC motors to reduce power consumption, lower heat dissipation, lower temperature rise, and produce less electrical emission (e.g., for regulatory purposes), among other deficiencies of current BLDC motor systems.SUMMARY

[0013] Described herein are systems and methods for purposely and predictively offsetting, displacing, interleaving, or otherwise controlling sub-surface stator windings within stator coils of BLDC motors to direct the magnetic field of the stator coils to impart improved or optimal thrust in a desired direction of travel for a vessel mover to thereby improve overall BLDC motor efficiency.

[0014] In one embodiment, the present disclosure is directed to a method for magnetic field shaping in BLDC motors that includes forming a stator coil of a BLDC motor. The BLDC motor includes a rotor including a vessel mover disposed proximate the stator coil and including a magnetic structure. The stator coil includes a plurality of windings each including one of a plurality of layers interconnected by a plurality of intra-coil vias to form a continuous conductive path. The formation of the stator coil in this example includes introducing one or more variations between two or more of the windings of two or more of the layers according to a desired magnetic field pattern. The stator coil is then driven by injecting a control signal to the conductive path to energize the stator coil, impart a directed force on the vessel mover to move the vessel mover in a direction of travel in accordance with the desired magnetic field pattern, and thereby commutate the BLDC motor.

[0015] In some examples, the method includes, to achieve the desired magnetic field pattern, introducing one or more of one or more geometric variations between the two or more of the windings, a lateral displacement in at least one direction of one or more portions of at least one of the two or more of the windings, an interleaving of at least a portion of the two or more of the windings, or an inversion of at least one of the two or more of the windings. In other examples, the introduction of the variations further includes varying, for the two or more of the windings of the two or more of the layers, an orientation, a trace width, a trace spacing, a trace curvilinear position, a trace shape, a wire gauge, or a spacing between the two or more of the layers.

[0016] In yet other examples, at least a portion of each of the plurality of the windings is formed above or below another portion of another one of the windings to thereby form a stack, the stator coil comprises a three-dimensional stator coil, and the formation further includes fabricating a printed circuit board (PCB), wherein the layers are printed on a substrate of the PCB. In some examples, the plurality7of windings are formed to be alternately laterally spaced and interdigitated. In some examples, the method further includes introducing another one or more variations between another two or more of the windings of another two or more of the layers to attenuate magnetic field emissions in one or more directions unaligned with the direction of travel.

[0017] In another embodiment, the present disclosure is directed to a method for manufacturing stator coils in BLDC motors. The method includes determining a desired magnetic field pattern to be generated by a stator coil of a BLDC motor. The BLDC motor includes a rotor includes a vessel mover disposed proximate the stator coil and the vessel mover includes a magnetic structure. The stator coil is designed to have one or more variations between a plurality7of windings of a plurality of layers of the stator coil. The one or more variations are configured to achieve the desired magnetic field pattern and the layers are interconnected by a plurality of intra-coil vias to form a continuous conductive path. The stator coil is then fabricated and configured to impart a directed force on the vessel mover to move the vessel mover in a direction of travel in accordance with the desired magnetic field pattern, and thereby7commutate the BLDC motor, when the stator coil is energized.

[0018] In some examples, the method further includes introducing one or more of one or more geometric variations betw een the tw o or more of the w inding, a lateral displacement in at least one direction of one or more portions of at least one of the two or more of the windings, an interleaving of at least a portion of the two or more of the windings, or an inversion of at least one of the tw o or more of the windings. In other examples, the method also includes varying, for the tw o or more of the windings, an orientation, a trace w idth, a trace spacing, a trace curvilinear position, a trace shape, a wire gauge, or a spacing betw een the tw o or more of the layers.

[0019] In yet other examples, at least a portion of each of the plurality of the windings is formed above or below7another portion of another one of the windings to thereby form a stack, the stator coil comprises a three-dimensional stator coil, and the method further includes fabricating a printed circuit board (PCB), wherein the layers are printed on a substrate of the PCB. In some examples, the plurality of windings are formed to be alternately laterally spaced and interdigitated. In some examples the method further includes introducing another one ormore variations between another two or more of the windings of another two or more of the layers to attenuate magnetic field emissions in one or more directions unaligned with the direction of travel.

[0020] In yet another embodiment, the present disclosure is directed to a transport system that includes a BLDC motor. The BLDC motor in some examples includes a stator including a plurality of conductive coils each including a plurality of windings of a plurality of layers interconnected by a plurality of intra-coil vias to form a continuous conductive path. One or more of the conductive coils includes one or more variations between two or more of the windings to achieve a desired magnetic field pattern. The BLDC motor in this example further includes a rotor including a vessel mover comprising a vessel mover disposed proximate the stator coil. The vessel mover includes a magnetic structure. The BLDC motor in this example further includes a control system including one or more of a hybridized movement control architecture or a processor and configured to drive the stator by injecting a control signal to the conductive path of one or more of the conductive coils to energize the one or more of the conductive coils and impart a directed force on the vessel mover to move the vessel mover in a direction of travel in accordance with the desired magnetic field pattern.

[0021] In some examples, the one or more variations include one or more geometric variations, a lateral displacement in at least one direction of one or more portions of at least one of the two or more of the windings, an interleaving of at least a portion of the two or more of the windings, or an inversion of at least one of the two or more of the windings. In other examples, the one or more variations are in orientation, trace width, trace spacing, trace curvilinear position, trace shape, wire gauge, or spacing between the two or more of the layers. In yet other examples, the transport system further includes a track configured to propel the magnetic structure. The track includes a plurality of multilayer PCBs arranged along a transport path, wherein each PCB has one or more of the conductive coils.BRIEF DESCRIPTION OF THE FIGURES

[0022] The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.

[0023] The accompany ing drawings, which are incorporated in and form a part of the specification, illustrate the embodiments of the invention and together with the written description serve to explain the principles, characteristics, and features of the invention. In the drawings:

[0024] FIG. 1 is a diagram of a track segment of a liquid handler system, in accordance with at least one aspect of the present disclosure;

[0025] FIG. 2 is a diagram of a vessel mover actuator, in accordance with at least one aspect of the present disclosure;

[0026] FIG. 3 is a top-view of a PCB coil in accordance with at least one aspect of the present disclosure;

[0027] FIG 4 is a cross sectional view of a printed circuit board (PCB) coil in accordance with at least one aspect of the present disclosure;

[0028] FIG. 5 is a top-view of a PCB coil track in accordance with at least one aspect of the present disclosure;

[0029] FIG. 6A is a top-view of a PCB coil track intersection in accordance with at least one aspect of the present disclosure;

[0030] FIG 6B is a cross sectional view of a PCB coil intersection in accordance with at least one aspect of the present disclosure;

[0031] FIG 6C is a cross sectional view of a PCB coil intersection in accordance with at least one aspect of the present disclosure;

[0032] FIG. 6D is a top-down x-ray view of a PCB coil track intersection in accordance with at least one aspect of the present disclosure;

[0033] FIG. 6E is a top-down x-ray view of another PCB coil track intersection in accordance with at least one aspect of the present disclosure;

[0034] FIG. 7 is a diagram of a liquid handler system including a vessel tracking system, in accordance with at least one aspect of the present disclosure;

[0035] FIG. 8 is a diagram of a dual-layer stator coil with serial interconnects in accordance with at least one aspect of the present disclosure;

[0036] FIG. 9 is a diagram of the magnetic field pattern emitted by the dual-layer stator coil of FIG. 8 in a standard, overlapping layout in accordance with at least one aspect of the present disclosure;

[0037] FIG. 10 is a diagram of a dual-layer stator coil with one layer inverted and serial interconnects in accordance with at least one aspect of the present disclosure:

[0038] FIG. 11 is a diagram of another dual-layer stator coil with the layers stacked, one layer inverted, and the layer including a geometric variance of the traces at one end in accordance with at least one aspect of the present disclosure;

[0039] FIG. 12 is a diagram of the one end with the geometric variance of the traces in one layer of the dual-layer stator coil of FIG. 11 in accordance with at least one aspect of the present disclosure;

[0040] FIG. 13 is a diagram of the magnetic field pattern emitted by the dual-layer stator coil of FIG. 11 in accordance with at least one aspect of the present disclosure;

[0041] FIG. 14 is a diagram of a three-layer stator coil with the intermediate layer inverted and shifted to result in interleaving of the intermediate layer traces in accordance with at least one aspect of the present disclosure;

[0042] FIG. 15 is a diagram of the magnetic field pattern emitted by the three-layer stator coil of FIG. 15 in accordance with at least one aspect of the present disclosure; and

[0043] FIG. 16 is a flowchart of a method for manufacturing and operating stator coils with desired magnetic field shaping in BLDC motors in accordance with at least one aspect of the present disclosure.DETAILED DESCRIPTION

[0044] Independent of the grammatical term usage, individuals with male, female or other gender identities are included within the term.

[0045] This disclosure is not limited to the particular systems, devices and methods described, as these may vary. The terminology used in the description is for the purpose of describing the particular versions or embodiments only and is not intended to limit the scope.

[0046] As used herein, the terms “algorithm,” “system,” “module,” “engine,” or “architecture,” if used herein, are not intended to be limiting of any particular implementation for accomplishing and / or performing the actions, steps, processes, etc., attributable to and / or performed thereby. An algorithm, system, module, engine, and / or architecture may be, but is not limited to, softw are, hardware and / or firmware or any combination thereof that performs the specified functions including, but not limited to, any use of a general and / or specialized processor in combination with appropriate software loaded or stored in a machine-readable memory and executed by the processor. Further, any name associated with a particular algorithm, system, module, and / or engine is, unless otherwise specified, for purposes of convenience of reference and not intended to be limiting to a specific implementation. Additionally, any functionality attributed to an algorithm, system, module, engine, and / or architecture may be equally performed by multiple algorithms, systems, modules, engines, and / or architectures incorporated into and / or combined with the functionality of another algorithm, system, module, engine, and / or architecture of the same or different type, ordistributed across one or more algorithms, systems, modules, engines, and / or architectures of various configurations.PCB-Based Automation Track Configurations

[0047] While examples of this technology are described and illustrated herein with reference to linear brushless direct current (BLDC) motors employed in automation track systems configured to transport vessel movers (e.g., pucks or sample carriers), the disclosed technology7is equally applicable to linear BLDC motors in other types of deployments, as well as rotary BLDC motors, as will be explained in more detail below. Accordingly, the linear BLDC motor of the automation track system disclosed herein is for exemplary purposes only, and other types of linear and rotary BLDC motors can advantageously be controlled using the back electromotive force (BEMF) signal extraction systems and methods of the disclosed technology.

[0048] Automation track systems can include a variety of different types of transport systems, including electro-magnetic drive systems, friction-based track systems, or conveyor belts. In one example, automation track systems can include a track having a plurality' of synchronously controlled electro-magnetic coils. The automation track can be configured to transport a vessel mover or other object, which typically consists of permanent magnet(s) whose field interacts with that generated by an electro-magnet coil array on the track. In these systems, the automation track is configured to move the vessel movers via synchronously controlled electro-magnetic coils that propel the vessel movers along the system’s track sections. Conventional electro-magnetically driven transport systems use metallic substrates for the automation track. Metallic substrates have several disadvantages, including cost and weight. Accordingly, exemplary automation track systems described herein include printed circuit board (PCB)-based substrates for the automation track. In these examples, each track segment can include one or more PCBs having coil arrays that are configured to electromagnetically actuate the vessel mover to transport the vessel mover.

[0049] In some embodiments, track sections are divided up into several coil boards. The coils can be formed in the copper layers of the PCB itself. In some embodiments coil boards are controlled by master boards and node controllers (also referred to herein as a traffic control unit). In some embodiments, each master board can control up to eight different coil boards. Meanwhile, a node controller is centralized. A single node controller can control the entire vessel mover track. In some embodiments, multiple distributed node controllers can be used for scalability. For example, in larger systems, multiple node controllers may be used, andcontrol of vessel movers can be handed off as they traverse different regions of the track. In some embodiments the components of the master boards can be integrated directly into the coil boards, allowing inclusion of drivers and magnetic coils on the same circuit board.

[0050] An automation track system can utilize a modular design whereby track components reside within modules and each module can easily be linked together to join the track segments by placing adjacent modules in proximity and linking them. Lids above track can be removed during installation or service to facilitate linking of tracks. In some embodiments, track sections are expanded by placing modules adjacent to one another and bolting the track sections of each module together forming a single multi-branching track system. Signaling cables can be daisy- chained together for ease of expanding control, although other methods for communicably coupling modules and / or track sections together can also be used in other examples.

[0051] In some examples, vessel movers ride between rails on a track surface. The rails can be aluminum or stainless-steel extrusions that also include vertical sides on the exterior of the track components underneath track surface. These extrusions can include brackets to easily bolt internal components to these side pieces to form a track unit. In some embodiments described herein, the track surface is a PCB and the PCB track surface can include one or more coatings or other components. At the bottom of the side components of rails resides a baseplate. The baseplate can be mounted to the modules containing track sections and provide support for the track system.

[0052] Beneath the track surface resides a series of coils in some examples. In some embodiments, coil boards are PCBs that include several coils, transverse to the direction of the track, and repeated in a longitudinal direction. In some embodiments, the coils are printed in a multi-layer PCB. Furthermore, in some embodiments, the coils can be printed directly in the layers of the coil boards, making the coil boards and coils one monolithic entity, and resulting in a relatively thin combination. In some embodiments, the coil boards receive a control signal to indicate the trajectory to apply to a vessel mover traveling along that coil board and a power source of 24 VDC. In some embodiments the PCB coil board itself forms the track (i.e., riding) surface. The coil boards include coils, motor drivers to drive those coils, and, optionally, one or more sensors to detect the presence of carriers traversing the track surface above the coil board by detecting the magnets of the vessel movers.

[0053] Thus, each of the segments that collectively comprise an automation track includes a plurality of coils that are activated, in sequence, to provide a linear motor in conjunction with magnets in the bottoms of vessel movers. Each coil is activated to provide a push or pull force on permanent magnet(s) placed in the bottom of each vessel mover. The speed at which coilsare activated in sequence determines the speed of the vessel mover on that section of track. Furthermore, vessel movers may be moved into a position and stopped at a predetermined location with high resolution by precisely modulating cunent within the coils and carefully controlling the commutation frequency at that location.

[0054] FIG. 1 shows an illustrative embodiment of a track segment 201 of an automation track system. As generally described above, the automation track system is configured to support one or more vessel movers 202 (also referred to as a "carrier’ or “sample earner”), which are configured to receive a vessel 204 (e.g., test tube) therein. The track segment 201 can include a riding surface 206, which is the upper surface of the track segment 201 that supports the vessel mover 202 thereon and along which the vessel mover 202 is transported between the modules or components (e.g., clinical analyzers) of the automation track system 200.

[0055] In some embodiments, the riding surface 206 can include an active region 207 that the vessel mover 202 is intended to move along. As shown, the active region 207 is the area corresponding to coils embedded in or below surface 206. The active region 207 can generally correspond to the medial portion of the riding surface 206, and the relative width of the region207 (as defined by the coils) is a design choice affected by the placement of magnets in the vessel mover 202. If any liquid contaminants are present on the active region 207, they could negatively impact or otherwise impair the movement of the vessel mover 202, as noted above. In some embodiments, the track segment 201 could include a PCB substrate, as generally described herein. Optionally, guide rails 21 1 can be used to help limit the lateral placement of vessel mover 202 relative to the track and active region 207.

[0056] Further, as shown in FIG. 2, the track system can include one or more coil arrays208 associated with each track segment 201. The coil arrays 208 can be configured to generate a magnetic field that interacts with a magnet 203 positioned within the base of the vessel mover 202. The coil arrays 208 and the vessel mover magnet 203 can collectively define a linear electromechanical actuator. By synchronously controlling the current in the coil arrays 208, the track system can propel the vessel movers 202 (and, thus, the vessels 204) across the track segments 201 to the desired module or other component of the system.PCB Printed Coils

[0057] Existing electromagnetic actuator topologies include a combination of conductive wire wound around a bobbin in curved shapes which are then augmented by mechanical diverter mechanisms comprising engagement arms and associated motors to guide vesselmovers off linear paths. These solutions are cumbersome to manufacture and suffer part to part inefficiencies due to the coil winding process and ability to assemble and align separate motor segments.

[0058] Some embodiments described herein instead utilize PCB manufacturing techniques in conjunction with movable vessel movers with bodies containing permanent magnets. A coupled electromagnetic device is created that is only possible due to the specific physics achievable within a PCB fabrication combined with mover and load constraints required by the application. A particular arrangement of artwork used to retain copper within the layer stack is prescribed which creates an exact relationship of resistance, inductance, and parasitic (floating) capacitance, which by design creates a specific relationship between factors optimized for the particular motion characteristics required by automation entities.

[0059] Spirals are formed on many PCB layers which are interconnected by vias through the substrate layer stack to create a coil with electrical properties that balance the thermal dissipation of copper losses with nominal and peak thrust forces required by the system. These interconnections are in some cases through the entire substrate stack and in others only connecting specific layers. The arrangement of spirals including but not limited to the width of copper, the separation from adjacent current carrying conductors, the exact shift of spirals between layers, the length of copper between coil terminations, the gap at the center of a spiral stack and the gap between adjacent spirals, as well as other design artifacts are all interdependent and optimized as a multi-objective solution.

[0060] The arrangement of spirals on each layer within the PCB layer stack creates sets of coils that enable electromagnetic forces to be produced in different directional axes. With coordinated switching of the coil layers, a coupled magnetic vessel mover 202 can then be motivated in different axes of motion with respect to the physical PCB. Motion may be along, across or a combination of more than one axis of the PCB substrate. Moreover, higher level routing between paths of travel may be achieved by designated motions such as performing 90 degree turns at the end of linear travel, a four- way diversion onto a perpendicular lane of travel, or continuation of a linear path without any mechanical assistance devices.

[0061] Some embodiments presented herein rely on physical contact between the static portion of the motor and the movable entities. Unlike typical linear motor designs there are no constraints on the motion of the moving parts relative to the stationary’ parts. In some embodiments, there are no contact guides, mechanical devices or bearings employed other than the normal friction that results from entities resting on the stationary PCB substrate. The friction resulting from the normal contacts are managed by material choices to minimize thefriction, whilst at the same time ensuring the life of the surfaces is sufficient for the intended system lifespan. Coating can be applied to the PCB substrate and / or the entity base (magnet and / or entity structure) to perform in concert as a pair achieving a specific regime of slip-stick friction that the automation track system uses for positioning of entities relative to the PCB substrate.

[0062] Furthermore, the manufacturing processes of PCB design yield extremely high- quality surfaces and tight geometric tolerances (variation typically <2% unit to unit) that enable a novel segment-to-segment alignment scheme to be achieved. Features and flexible material selections in the supporting structure align the separate PCB motor segments, which ensure seamless transfer of entities from one segment to another. The designs of the electromagnetic system, mechanical system, thermal systems and controller architecture described above are tightly coupled, each providing features and functionality to the other as part of the optimization that manifests the complete automation solution.

[0063] By using a PCB arrangement rather than winding insulated copper wire mechanically, any specific profile of the individual traces making up a coil can be created in design software. Coils can have a thickness dictated by the specific PCB manufacturing process selected, which may allow coils of any reasonable thickness to be used for each layer. Trace widths are dictated by the computationally created photoresist masks that are used during the photolithographic fabrication process. Thus, a total cross-section for each coil trace can be selected as part of the design process without complicating the manufacturing process. Similarly, the gaps between individual layers of spiral coil traces are dictated by the properties of the layers selected, including the thickness of core or prepreg layers and their dielectric properties. Within each layer, the gap between adjacent traces in a spiral can be selected in the printing mask. In contrast, traditional wound coils are limited to a single round profile of copper wire and the dielectric thickness for the wire that is wound around a bobbin.

[0064] Similarly, the exact shape of each coil spiral can be selected during the design process, resulting in a photoresist mask and resulting coil traces having the desired shape. Because a photolithographic fabrication process is used, there is generally no substantial penalty incurred by choosing one shape or another during the manufacturing process. This means that the outer profile of the windings can appear more rectangular to maximize the amount of copper used in the coils and the uniformity of the field. Any other design considerations can also influence the exact shape of the PCB spiral layers. Furthermore, individual spiral layers can have slightly different profiles and individual traces within each spiral can have different shapes, widths, etc. This allows coil design to be optimized to thedesired field parameters. Finally, because the PCB manufacturing process is controlled by a precise masking and etching process, repeatability between the different PCB boards can be easily achieved with high quality results.

[0065] FIG. 3 is a top view of a PCB coil 310, which can be one of the coils of the coil array 208 of FIG. 2, for example. The primary component of PCB coil 310 is a stack of spiral traces 314 in a multi-layer PCB. Spiral traces 314 can be printed on multiple layers of the PCB during the PCB fabrication process, with each layer referred to herein as a winding, to allow a greater number of turns of PCB coil 310. Spiral traces 314 can be printed in a clockwise or counterclockwise direction depending on the application. Each layer of spiral traces 314 can spiral inward or outward along a conductive path, which can differ between layers. Layers of spiral traces 314 can be interconnected to one another by vias 312 and 316. Vias include what will be referred to as intra-coil vias 316 that connect one end of a single layer of coil trace to one end of a coil trace in an adjacent layer, allowing one large stack of traces to form a single conductive coil. Vias also include what will be referred to as terminal vias that provide a conducting path to the top layer and bottom layer of a coil stack, allowing electrical connection to the terminals of stacked coil.

[0066] Multi-layer PCBs can be constructed using any applicable technique including by laminating alternating insulating layers with etched layers of copper (e.g., etched by masking and activating a photoresist layer that then allows the selective masking of copper when the copper layer is chemically etched). Vias are drilled and filled with a conductor (copper) to provide electrical paths between the etched copper layers. In general, coil 310 is an elongated coil having a long axis and a short axis. Adjacent coils are placed along a track such that an edge (right or left) of each coil intersected by the short axis is substantially parallel with an edge of each adjacent coil (such as shown in FIG. 6A). By arranging coils in this manner, within each PCB and by placing PCBs together, continuous groups of coils creating one or more continuous path for the magnetic vessel movers to move along are formed. That is, the coils are placed adjacent to one another in a horizontal plane defined by the PCB track surface, such that their longer sides are adjacent.

[0067] FIG. 4 is a conceptual illustration of the cross section of PCB coil 310, without the specific details of the insulator materials. Coil 310 is created by laminating layers 318, which are made up of etched copper layers and an insulating dielectric material such as fiberglass and resin core or prepreg sheets that are laminated in the presence of heat and vacuum. Virtually any number of layers 318 can be used, allowing any number of turns in printed coil to be created (the number of turns in each spiral times the number of layers of spirals gives the total turnsfor the printed coil 310). For example, a few hundred turns can be achieved by a dozen turns per spiral layer and twenty layers. The exact arrangement of traces within each spiral and how those traces are spaced relative to adjacent layers can be chosen to meet EMI or other specifications. In some embodiments, each conductive coil comprises at least twelve singlelayer spirals, and each spiral comprises at least twelve turns.

[0068] In the single-coil example shown in FIG. 4, the traces forming the spirals are shown in black, while the copper traces 320 that run from the spirals to vias 312 and 316 are illustrated separately for clarity. While vias are illustrated as overlapping in the two-dimensional cross section, the vias do not actually overlap, instead being formed in separate holes in the PCB. A top surface of the PCB provides a track surface for vessel movers 202. In some embodiments, a low friction surface, such as s high density polymer (HDPE, UHMWPE. or UHMW adhesive films), liquid photo-imageable solder mask (such as LP-40), or PTFE, is applied to the top surface after PCB manufacturing to facilitate smooth movement of a vessel mover 202.

[0069] FIG. 5 show s a series of parallel PCB printed coils 310. By printing these coils in parallel, they can be synchronously activated to create a moving magnetic field to drive the magnet 203 in the base of the vessel mover 202 in either direction along direction 322. Depending on design requirements, any suitable number of coils 310 can be printed on a single PCB board (also referred to herein as a coil board) and additional PCB boards can be placed adj acent to one another to create a track of any length. In this example, the demarcation between separate PCB boards is not shown. In some embodiments, six coils are printed per PCB board.

[0070] The example shown in FIG. 5 is a straightaway where symmetrically oval coils 310 are oriented in parallel. As explained below different arrangements can be created for curves and junctions, such as adding a trapezoidal component to the shape of the oval coils 310 and aligning adjacent coils 310 to have parallel edges. The specific aspect ratio of the coils 310, width and length, center size, overall shape, and spacing between coils 310 can be selected to create a linear synchronous motor (LSM) with desired physical properties.

[0071] FIG. 6A illustrates how an intersection that can be created using PCB printed coils 310. Unlike traditional bobbin-wound coils, PCB coils 310 are substantially thinner for the same number of turns. This means that two coils 310 can be stacked upon one another without moving the track surface substantially away from the edge surface of the coil 310. When a magnet 203 is spaced away from the surface of a spiral coil 310, the magnetic field diverges, and the field is less uniform and strong due to fringing effects. In particular, there is typically a square-law (l / rA2) relationship for magnetic field strength with respect to a magnet where r is the distance away from the energized coil 310. Therefore, it is desirable to keep the surfaceof the track as near to the top edges of the horizontally -laying coils 310 as possible. This is unachievable with traditional mechanical windings.

[0072] In the example illustrated in FIG. 6A, coils 310 are laid out in two intersecting directions, direction 322 as shown in FIG. 5 and perpendicular direction 324. Note that directions 324 and 322 need not be perpendicular, in some embodiments, as any intersection layout can be achieved using stacked coils 310. The arrangement shown in FIG. 6A can be logically grouped into two directional arrays or groups of coils 310. Coil group 328 is arranged horizontally along direction 322. Coil group 326 is arranged vertically in the page along direction 324. An intersecting group of coils 330 contains coils 310 of both sets, stacked on one another or interleaved with one another.

[0073] PCB coils 310A in group 326 can have substantially the same as or different characteristics from coils 310, depending on design requirements. To move the vessel mover 202, for example, from path 322 to path 324, the vessel mover 202 can be moved to the intersection at coils 330 by selectively and synchronously activating coils in set 328 to move the magnet 203 in the vessel mover 202 to the intersection. Once the magnet 203 has been moved to the intersecting group of coils 330. the coils within set 326 can be synchronously activated to move the magnet 203 along path 324. Alternatively, if the vessel mover 202 is not to turn at the intersection, the coils in group 328 will continue to synchronously activate. The specific direction in which the vessel mover 202 moves along path 322 or 324 is dictated by the order of synchronous activation of the coils 310.

[0074] Coil groups 326 and 328 form two paths of horizontally (in the plane of the PCB) adjacent coils 310. Each group provides a different direction of possible motion for vessel movers 202 propelled by the selective creation of a magnetic field within each direction group of coils 326 and 328. By overlapping parts of each coil group 326 and 328 below the PCB track surface, an intersection is formed, allowing the vessel mover 202 to selectively move between each directional group or continue the same path as the directional group of coils that propelled the vessel mover 202 to the intersection.

[0075] FIG. 6B shows a cross-section of the PCB layers used to create the stacked coils 310 and 310A in section 330. It should be appreciated that only six layers are shown for illustration purposes, but in practice many more layers would likely be used depending on the application. In this example, solid black windings 314A illustrate the topmost coil, while white windings 314B illustrate the windings in the bottom coil. Each coil 310 is created by stacking spirals that are electrically coupled through intra-coil vias 316, linked by copper traces 320. Terminal vias 312 provide terminal leads for a circuit to provide a current to each individualcoil. It should also be appreciated that while FIG. 6B shows individual windings of the two stacked coils 310 directly on top one another, the individual traces of the windings for each stacked coil 310 go in different directions and only have this stacked arrangement at the intersection of the individual traces. That is, there will be portions of each stacked coil 310 where the windings from the top-most coil are not directly atop the windings of the bottommost coil, as can be seen in FIG. 6D.

[0076] In some embodiments, the stacked coils of windings 314A-B are laminated into a single monolithic PCB board having several layers that is at least twice the number of layers of each coil 310. In some embodiments, stacked coils 310 can be created by creating two separate PCBs for each coil group and then stacking those PCBs. These stacked PCBs can be affixed to one another using any suitable fixation technique, such as epoxy or screws.

[0077] When stacked coils 310 are created using a single laminated PCB, it is also possible to interleave the windings of each coil 310 such that the top-most surface of each coil 310 is roughly adjacent to the surface of the PCB. Such an example is shown in FIG. 6C, where layers of windings 314A-B, each including a plurality of traces, are printed on interleaved laminated layers of the PCB. This requires slightly longer vias to connect the non-adjacent layers to form a single coil 310.

[0078] FIG. 6D is an x-ray view showing an exemplary' arrangement of stacked coils 310 to illustrate the individual traces and show how they intersect in the adjacent PCB layers. The arrangement of vias is merely conceptually illustrative. The specific arrangement of vias for stacked coils 310 in a monolithic multi-layer PCB would be carefully selected to avoid interfering with individual traces of the stacked spirals.

[0079] FIG. 6E is an x-ray view showing another exemplary arrangement of stacked coils 310 in which all of the coils 310 are in the same orientation when stacked (i.e.. not alternately flipped as illustrated in FIG. 6C) and interconnected in a continuous outside-to-inside manner. The coil 310 configuration illustrated in FIG. 6D allows an alternate means to control interleaving via geometry7and PCB trace routing as compared to that described and illustrated in more detail above. However, other methods for stacking, interleaving, interconnecting, and otherwise arranging coils 310 can also be used in other examples.Automation Track Apparatus

[0080] The synchronous activation of coils 310 can be selected according to a predetermined motion profile that sets maximum acceleration and / or maximum velocity constraints to limit vessel spilling, for example. That is, the exact location of the magnetic fieldcreated by the selection and activation of coils 310 can move according to a motion profile that accounts for acceleration and maximum velocity for the application. For example, the motion profile can slowly accelerate a vessel mover 202 to avoid spillage, moving the vessel mover 202 faster as it continues to accelerate. Similarly, as a vessel mover 202 approaches an intersection, such as a perpendicular intersection, the vessel mover 202 can slow down by applying a decelerating motion profile to a magnetic field, activating adjacent coils 310 in a decelerating manner. Motion profiles are typically achieved by sending controller signals to driver amplifiers under software control. Software modules monitor the motion of each vessel mover 202 and control the application of synchronous motor signals to the coils 310 to achieve a desired trajectory.

[0081] Electrical components (e.g., sensors, driver circuits, etc.) to assist the control and operation of the automation track can also be incorporated into PCB(s) and / or motor controller circuits can be placed on board(s). These can include linear current drivers, FPGAs, or processors that control amplifiers mounted to PCB(s) that provide a precise current to each individual coil 310. This allows the coils 310 to be activated synchronously according to a prescribed or desired motion profile. In some embodiments, the motor control and coil drivers are mounted on a separate PCB, electrically coupled to coils 310. In some embodiments, motor control components can be mounted on the underside of the PCB. This can present EMI challenges, so in some embodiments, motor control components are mounted on a separate board for intersection PCB boards, and other deployments for one or more of the electrical components can also be used in other examples.

[0082] As generally described above and shown in FIG. 7, automation track apparatus 250 can include one or more modules 252 (e.g., modules configured to process liquid samples in an exemplary deployment of the automation track apparatus 250 as a liquid handling system), a track system 200 interconnecting the various modules 252, vessel movers 202 that transport objects (e.g., liquid samples) between the various modules 252 along the track system 200, and coil array (s) 208 (e.g., of coils 310) associated with the track system 200 that is configured to drive the vessel movers 202. To drive the vessel movers 202. the coil array 208 is communicably coupled to a hybridized movements control architecture 300 of a control system 254 that also includes at least one processor 260 and memory 262, which can be communicably coupled together via a system bus, for example. Thus, the control system 254 is configured to control the coil array 208 to control the movement and routing of the vessel movers 202 along the track system 200, which in turn allows the vessel movers 202 to transport objects betweenthe modules 252 in particular sequences and with particular timings according to the system requirements.

[0083] The control system 254 can include hardware, software, firmware, or any combination thereof that is able to execute the described functions. In the illustrated example, the control system 254 includes the processor 260 coupled to a memory 262 storing instructions that, when executed by the processor 260, cause the control system 254 to execute one or more of the descnbed processes, steps, and / or functions described and illustrated herein. Thus, the processor 260 can be a central processing unit (CPU) or microprocessor, for example, and the memory can include any combination of random-access memory' (RAM), read-only memory (ROM), and / or FLASH memory', for example, and other ty pes of processors and / or memory can also be used in the control system 254 in other examples.

[0084] The hybridized movement control architecture 300, which is a circuit and / or related control software, can be configured to monitor the activity7of vessel movers 202 and / or control the selective application of synchronous currents to relevant coils 310 in the coil array 208. A linear current driver circuit that can be used to supply voltage to coils 310 to thereby commutate an associated BLDC motor is disclosed in U.S. Patent Application No. 63 / 549.979. which is hereby incorporated by reference herein in its entirety, although any' other type of driver circuit or drive modality' can also be used in other exemplary implementations of the technology' disclosed herein. The application of current to the coils 310 creates a magnetic field to propel the magnetic vessel movers 202 along the track system 200. The application of these currents can be done in accordance with a software-defined desired motion profile for the vessel mover 202 and can optionally be adapted based on real-time feedback from the BEMF device 256 to move the vessel movers 202 in accordance with a desired control scheme. Optionally, the control system 254 advantageously uses a BEMF signal directly measured and provided by a BEMF device 256 to more effectively and accurately compensate for the BEMF voltage in the commutation cycle, as described and illustrated in U.S. Patent Application No. 63 / 549,983, which is hereby incorporated by reference herein in its entirety7.

[0085] The automation track apparatus 250 can include any number of coil arrays 208, vessel movers 202, control systems 254. and / or BEMF devices 256 in other examples. For example, each of a plurality of control systems 254 can be communicably coupled to one of a plurality' of BEMF devices 256 and a plurality' of coil arrays 208, with those components collectively associated with one of a plurality of track segments that collectively comprise the track system 200, and other permutations and topologies can also be used.

[0086] Any number of the control systems 254 of the automation track apparatus 250 can be communicably coupled to a traffic control unit 264 that is configured to monitor the locations of the vessel movers 202 along the track system 200 and control the movement and / or routing of the vessel movers 202 accordingly by communicating with the various control systems 254 to cause the control systems 254 to selective energize or commutate coils 310 of the coil array 208.

[0087] In some examples, the control system includes a communication interface (not shown), which is communicably coupled to the traffic control unit 264 as well as, via a system bus for example, the processor 260, memory 262, and / or hybridized movement control architecture 300 of the control system 254. In some examples, the traffic control unit 264 is configured to communicate with the communication interface via a communication network (not shown), which can be a wired or wireless network that uses any communication protocol (e.g., Internet protocol (IP) or point-to-point over Ethernet), although other methods of communication between the traffic control unit 264 and one or more control systems 254 can also be used in other examples.Stator Coil Geometry and Magnetic Field Shaping

[0088] In some examples, the technology disclosed herein combines a linear electric BLDC motor with optimized stator coil windings based on geometry, placement, and use of interleaving, for example. The stator coil 310. also referred to herein as a conductive coil, may be configured to impart a highly directed force onto the vessel mover 202 in desired direction(s) of travel and to attenuate unwanted fields otherwise produced in off-axis directions (i.e., wasted energy and resulting in increased heat dissipation and electromagnetic interference (EMI)). While the examples described and illustrated below refer to three-dimensional (3D) PCB stator coils, the disclosed technology is equally applicable to conventional wire-wound and other types of stator coils that can be used in linear or rotary BLDC motors.

[0089] Referring to FIG. 8, a diagram of a dual-layer stator coil 800 with serial interconnects is disclosed. In this example, a first layer 802 is electrically coupled to a second layer 804 in a serial configuration to collectively form a conductive path. The second layer 804 can be stacked above the first layer 802 to form the stator coil 800. While a racetrack geometry' is disclosed in the examples described below', any other shape can be used for the windings that form the layers of a stator coil in other examples. Stacking the second layer 804 above the first layer 802 in this example results in a dual-layer stator coil 800 in which each of the layers 802, 804 have the same orientation and each layer’s respective traces coincide withother layers without interleaving, although other orientations can be used in accordance with desired magnetic field patterns, as will be explained in more detail below.

[0090] Referring to FIG. 9, a diagram of the magnetic field pattern emitted by the duallayer stator coil 800 of FIG. 8 in a standard, overlapping layout as described above with reference to FIG. 8 is disclosed. In this example, the magnetic field pattern emanates from the entirety of the surface of the stator coil 800 when the stator coil 800 is energized with a control signal as described in more detail above. While a 6 millimeter trace, 6 millimeter spacing, 5 millimeter interlayer gap, 1 oz Cu (1.37 millimeter), and 1.0A of current were used in this and other examples described and illustrated herein, any other values can be used for any of these parameters in other examples.

[0091] In the example illustrated in FIG. 9, each of the first and second layers 802. 804 of the stator coil 800 is in an oval configuration and the windings of each layer include traces collectively forming a racetrack configuration. Additionally, in this particular example, a cylindrical vessel mover 202 including a cylindrical magnetic 203 having a diameter 900 is to traverse the stator coil 800 in a direction of travel (e.g., in a straight section of track) aligned perpendicular to the major axis of the stator coil 800 as illustrated in FIGS. 1-2.

[0092] Thus, in this example, the magnetic field on either side of the path corresponding to the diameter 900 and direction of travel of the vessel mover 202 results from wasted or superfluous energy used to drive the stator coil 800. In other words, the magnetic field emitted by the stator coil 800 outside of the path corresponding to the diameter 900 and direction of travel of the vessel mover 202 does not impart a force on the vessel mover 202 that is useful for commutating the BLDC motor and transporting the vessel mover 202 in this linear BLDC motor example. In addition to the wasted energy that is not used to move the vessel mover 202, the stator coil 800 will dissipate heat in the areas associated with the superfluous magnetic field. However, as described and illustrated in detail below, the magnetic field can be manipulated to reflect a desired performance of the BLDC motor.

[0093] Referring to FIG. 10, a diagram of a dual-layer stator coil with one layer inverted and serial interconnects is disclosed. In this example, the stator coil 1000 includes a first layer 1002 and a second layer 1004 with a serial interconnection and the second layer 104 flipped or inverted. The second layer 1004 can be printed above the first layer 1002 in an example in which the stator coil 1000 is a PCB. With the inversion, the traces of each winding associated with each of the first and second layers 1002. 1004 will be substantially aligned in this example. The inversion is a variation that will impact the magnetic field pattern emitted by the stator coil 1000, as explained in more detail below.

[0094] To introduce another variation, and referring to FIG. 11, a diagram of another duallayer stator coil 1100 with the layers stacked, one layer inverted, and the layer including a geometric variance of the traces at one end is disclosed. The stator coil 1100 is dual layer with one layer inverted and each of the layers including a geometric variation of the respective associated traces at a first end of the stator coil 1100. Thus, the first end 1102 includes a partial overlap or interleaving in the traces associated with each layer whereas, at the second end 1104 of the stator coil 1100. the traces of each layer completely overlap or interleave.

[0095] Referring to FIG. 12, a diagram of the first end 1102 with the geometric variance of the traces of the dual-layer stator coil 1100 of FIG. 11 is disclosed. In the magnified representation of FIG. 12, the first end 1102 is illustrated by traces of a first layer 1200 and a second layer 1202 of the stator coil 1100. The traces of each of the first and second layers 1200 have a geometric variation from those disposed toward the second end 1104 that are curvilinear. In particular, the traces of the first and second layers 1200, 1202 have straight sections meeting at angles before returning to straight traves through the portion of the stator coil 1100 disposed between the first and second ends 1102, 1104. Dur to the second layer 1202 being inverted or flipped, there are substantial areas in which the traces of the first and second layers 1200. 1202 do not overlap, although the non-overlapping areas and variance and geometric shape can be introduced without inverting a layer in other examples.

[0096] More broadly, variations between two or more of the windings of two or more of the layers can be introduced in many ways with this technology in accordance with, or to achieve, a desired magnetic field pattern. For example, the trace width (e.g., linear or tapered), spacing (e.g., via wire gauge), weight, shape (e.g., mandrel), or curvilinear position can be varied. In other examples, interlayer spacing can be varied to achieve a desired magnetic field pattern, such as by varying the insulative buffer material used in the stator coil.

[0097] In other examples, a desired magnetic field pattern can be achieved with this technology via multi-layer winding with interleaving as the result of spiroidal asymmetry, multi-layer windings with interleaving as the result of laterally displayed or offset intermediate layers, and multi-layer winding with interleaving as the result of both spiroidal asymmetry and offsetting intermediate layers. In yet other examples, lateral displacement of interdigitated layers to control the magnetic field pattern generated by the energized stator coil can be used to impart a more highly directed force on the vessel mover 202 to more efficiently move the vessel mover 202 in the desired direction of travel, and other geometric and other variations can also be used in other examples.

[0098] Referring to FIG. 13. a diagram of the magnetic field pattern emitted by the duallayer stator coil of FIG. 11 is disclosed. As illustrated in FIG. 13. the magnetic field pattern is disposed only between the first and second ends 1102, 1104 and biased toward the first end 1102. Thus, the inversion of the layers toward the second end 1104 effectively attenuated or canceled the magnetic field emitted in that portion of the stator coil 1100 when the stator coil 1100 was energized. However, the geometric shape variance at the second end 1102 resulted in a magnetic field emitted by another portion of the stator coil 1100 despite the inversion of the layers, as illustrated in FIG. 13. Moreover, the electromotive force (EMF) of the magnetic field pattern was stronger in each dimension with the stator coil 1100 as compared to the duallayer stator coil 800 of FIG. 9. representing a more efficient energy' utilization, as reflected in Table 1 :Table 1

[0099] The magnetic field pattern imparts more force with the stator coil 1 100, but is biased toward the first end 1102, which may be advantageous in a curved section of a track in a linear BLDC motor implementation, for example. However, the stator coil 100 may not be desirable in a straight track section because it may be possible for the vessel mover 202 to move outside of the emitted magnetic field in an area in which no EMF could be applied (i.e., toward the first end 1104), and thereby remain in place or stuck without ability to continue to traverse the track.

[0100] Referring to FIG. 14, a diagram of a three-layer stator coil 1400 with the intermediate layer 1402 inverted and shifted (i.e.. laterally displaced) to result in interleaving of the intermediate layer traces is disclosed. In this example, 6 millimeter spacing in the traces for each layer is used and the intermediate layer 1402 is laterally displaced 12 millimeters so that a most external trace in the intermediate layer 1402 is non-overlapping and creating a radially overlapping coil pattern at the end 1404 of the stator coil 1400. Other types and magnitudes of lateral and other displacements, as well as coil patterns, can also be used in other examples.

[0101] Referring to FIG. 15, a diagram of the magnetic field pattern emitted by the three- layer stator coil 1400 of FIG. 14 is disclosed. In this example, the inversion and lateral displacement of the intermediate layer 1402 attenuated the magnetic field at the end 1404 ofthe stator coil 1400, for example. As illustrated below in Table 2, the EMF in several dimensions was greater with the stator coil 1400 than with a standard three-layer stator coil with no layers inverted or laterally displaced:Table 2

[0102] Thus, the configuration of the stator coil 1400 may be advantageous in examples in which the increased magnetic field strength is correlated vx i th direction of travel or with an otherwise desired magnetic field pattern. For example, with the more concentrated magnetic field spaced from the ends (i.e., the attenuated off-axis magnetic field at the ends), the stator coil 1400 may be more efficient (e.g., than another stator coil that does not reflect geometric or other variations between the layers) in a straight track section utilizing the vessel mover 202 and magnet 203, for example.

[0103] Referring to FIG. 16, a flowchart of a method for manufacturing and operating stator coils with desired magnetic field shaping in BLDC motors is disclosed. In step 1600 in this example, a desired magnetic field pattern to be generated by an energized stator coil of a BLDC motor is determined. The BLDC motor includes a rotor including a vessel mover disposed proximate the stator coil in this example, and the vessel mover includes a magnetic structure.

[0104] In one example, the determined desired magnetic field pattern is one that is in direction(s) beneficial to moving a vessel mover. Specifically, the desired magnetic field pattern can maximize the magnetic field in the direction of travel of a vessel mover and / or over a portion of the stator coil correlated with dimensions (e.g., diameter) of a magnetic structure of the vessel mover. Other t pes of desired magnetic field patterns can be determined in other examples and for other applications or implementations. Additionally, the desired magnetic field pattern as used herein contemplates attenuation of an undesired or off-axis magnetic field). Control of the magnetic field pattern generated by the energized stator coil facilitates improved efficiency and performance of the BLDC motor.

[0105] In step 1602, the stator coil is designed to have variation(s) between windings of layers of the stator coil in order to achieve the desired magnetic field pattern determined in step1600. The layers are interconnected by intra-coil vias to form a continuous conductive path, which can be energized to thereby impart a force on a magnetic structure proximate the stator coil. For example, if the determined desired magnetic field pattern is as illustrated in FIG. 15, then the stator coil can be designed with alternate layers inverted and offset or laterally displaced to introduce interleaving.

[0106] In other examples, geometric variations between two or more winding, a lateral displacement in at least one direction of portions of two or more windings, an interleaving of at least a portion of two or more windings, or an inversion of at least one winding can be introduced to generate the design in step 1602. In yet other examples, an orientation, a trace width, a trace spacing, a trace curvilinear position, a trace shape, a wire gauge, or a spacing between the two or more layers can be varied in the design generated in step 1602. Thus, in one particular example, the windings can be formed to be alternately laterally spaced and interdigitated and in yet another example, variation(s) between the windings of layers can be introduced to attenuate magnetic field emissions in one or more directions unaligned with the direction of travel of a vessel mover, for example. Other manipulations and variations can be employed in the design of the stator coil in step 1602 to achieve a desired magnetic field pattern of the stator coil.

[0107] In step 1604, the stator coil is fabricated according to the design generated in step 1602. The fabrication can be a PCB fabrication process in which the layers are printed on a substrate of the PCB, as explained in more detail above, although wire-wound and other types of stator coil fabrication processes can also be used in other examples. Irrespective of the fabrication process, at least a portion of each of the windings is formed above or below another portion of another one of the windings to thereby form a stack and a three-dimensional stator coil structure. Thus, in some examples, the fabricated stator coil is configured to impart a directed force on the vessel mover to move the vessel mover in a direction of travel in accordance with the desired magnetic field pattern, and thereby commutate the BLDC motor, when the stator coil is energized.

[0108] In step 1606, the stator coil is optionally driven by injecting a control signal to the conductive path formed by the interconnected windings of the layers of the stator coil in order to energize the stator coil. A plurality of stator coils may be energized individually or in groups (e.g., as a pair for two-phase control, as a triad for three-phase control). Additionally, a plurality of the same or different stator coils can collectively form a BLDC motor and any number of the stator coils can be energized serially or in parallel.

[0109] In some examples, the BLDC motor forms part of a transport system that includes the automation track apparatus 250 with the control system 254 that includes the hybridized movement control architecture 300, and / or processor 260, configured to drive the stator of the BLDC motor by injecting a control signal to the conductive path of one or more of the stator coils to energize the conductive coils and impart a directed force on the vessel mover 202 to move the vessel mover 202 in a direction of travel in accordance with the desired magnetic field pattern. In these examples, the transport system can further include a track system 200 configured to propel the magnet 203 and including a plurality of multilayer PCBs arranged along a transport path, with each PCB having one or more of the stator coils fabricated in accordance with step 1604.

[0110] Accordingly, with this technology, magnetic field can be shaped using variations in layers of stator coils in BLDC motors to improve the efficiency of the BLDC motors by focusing energy on generating EMF in a beneficial direction (e.g., a direction of travel). Thus, BLDC motors configured in accordance with the technology described and illustrated herein have lower heat dissipation, energy utilization, and produce less electrical emission.NON-LIMITING ILLUSTRATIVE EMBODIMENTS[OHl] The following is a list of non-limiting illustrative embodiments disclosed herein:

[0112] Illustrative embodiment 1. A method for magnetic field shaping in brushless direct current (BLDC) motors, the method comprising: forming a stator coil of a BLDC motor, wherein the BLDC motor comprises a rotor comprising a vessel mover disposed proximate the stator coil and comprising a magnetic structure, the stator coil comprises a plurality of windings each comprising one of a plurality of layers interconnected by a plurality of intra-coil vias to form a continuous conductive path, and the formation of the stator coil comprises introducing one or more variations between two or more of the windings of two or more of the layers according to a desired magnetic field pattern; and driving the stator coil by injecting a control signal to the conductive path to energize the stator coil, impart a directed force on the vessel mover to move the vessel mover in a direction of travel in accordance with the desired magnetic field pattern, and thereby commutate the BLDC motor.

[0113] Illustrative embodiment 2. The method of illustrative embodiment 1, further comprising, to achieve the desired magnetic field pattern, introducing one or more of one or more geometric variations between the two or more of the windings, a lateral displacement in at least one direction of one or more portions of at least one of the two or more of the windings,an interleaving of at least a portion of the two or more of the windings, or an inversion of at least one of the two or more of the windings.

[0114] Illustrative embodiment 3. The method of any one of the illustrative embodiments 1-2, wherein the introduction of the variations further comprises varying, for the two or more of the windings of the two or more of the layers, an orientation, a trace width, a trace spacing, a trace curvilinear position, a trace shape, a wire gauge, or a spacing between the two or more of the layers.

[0115] Illustrative embodiment 4. The method of any one of the illustrative embodiments 1 to 3, wherein at least a portion of each of the plurality of the windings is formed above or below another portion of another one of the windings to thereby form a stack, the stator coil comprises a three-dimensional stator coil, and the formation comprises fabricating a printed circuit board (PCB), wherein the layers are printed on a substrate of the PCB.

[0116] Illustrative embodiment 5. The method of any one of the illustrative embodiments 1 to 4, further comprising forming the plurality of windings to be alternately laterally spaced and interdigitated.

[0117] Illustrative embodiment 6. The method of any one of the illustrative embodiments 1 to 5, further comprising introducing another one or more variations between another two or more of the windings of another two or more of the layers to attenuate magnetic field emissions in one or more directions unaligned with the direction of travel.

[0118] Illustrative embodiment 7. A method for manufacturing stator coils in brushless direct current (BLDC) motors, the method comprising: determining a desired magnetic field pattern to be generated by a stator coil of a BLDC motor, the BLDC motor comprising a rotor comprising a vessel mover disposed proximate the stator coil, the vessel mover comprising a magnetic structure: designing the stator coil to have one or more variations between a plurality of windings of a plurality of layers of the stator coil, wherein the one or more vanations are configured to achieve the desired magnetic field pattern and the layers are interconnected by a plurality of intra-coil vias to form a continuous conductive path; and fabricating the stator coil, wherein the stator coil is configured to impart a directed force on the vessel mover to move the vessel mover in a direction of travel in accordance with the desired magnetic field pattern, and thereby commutate the BLDC motor, when the stator coil is energized.

[0119] Illustrative embodiment 8. The method of illustrative embodiment 7, further comprising introducing one or more of one or more geometric variations between the two or more of the winding, a lateral displacement in at least one direction of one or more portions ofat least one of the two or more of the windings, an interleaving of at least a portion of the two or more of the windings, or an inversion of at least one of the two or more of the windings.

[0120] Illustrative embodiment 9. The method of any one of the illustrative embodiments 7 or 8, further comprising varying, for the two or more of the windings, an orientation, a trace width, a trace spacing, a trace curvilinear position, a trace shape, a wire gauge, or a spacing between the two or more of the layers.

[0121] Illustrative embodiment 10. The method of any of claims 7 to 9, wherein at least a portion of each of the plurality of the windings is formed above or below another portion of another one of the windings to thereby form a stack, the stator coil comprises a three- dimensional stator coil, and the method further comprises fabricating a printed circuit board (PCB), wherein the layers are printed on a substrate of the PCB.

[0122] Illustrative embodiment 11. The method of any one of the illustrative embodiments 7 to 10, wherein the BLDC motor comprises a linear or rotary BLDC motor.

[0123] Illustrative embodiment 12. The method of any one of the illustrative embodiments 7 to 11. further comprising introducing another one or more variations between another two or more of the windings of another two or more of the layers to attenuate magnetic field emissions in one or more directions unaligned with the direction of travel.

[0124] Illustrative embodiment 13. A transport system, comprising a brushless direct current (BLDC) motor comprising: a stator comprising a plurality of conductive coils each comprising a plurality of windings of a plurality of layers interconnected by a plurality of intracoil vias to form a continuous conductive path, wherein one or more of the conductive coils comprise one or more variations between two or more of the windings to achieve a desired magnetic field pattern; a rotor comprising a vessel mover disposed proximate the stator coil, the vessel mover comprising a magnetic structure; and a control system comprising one or more of a hybridized movement control architecture or a processor and configured to drive the stator by injecting a control signal to the conductive path of one or more of the conductive coils to energize the one or more of the conductive coils and impart a directed force on the vessel mover to move the vessel mover in a direction of travel in accordance with the desired magnetic field pattern.

[0125] Illustrative embodiment 14. The transport system of illustrative embodiment 13, wherein the one or more variations: comprise one or more geometric variations, a lateral displacement in at least one direction of one or more portions of at least one of the two or more of the windings, an interleaving of at least a portion of the two or more of the windings, or an inversion of at least one of the two or more of the windings; or are in orientation, trace width,trace spacing, trace curvilinear position, trace shape, wire gauge, or spacing between the two or more of the layers.

[0126] Illustrative embodiment 15. The transport system any one of the illustrative embodiments 13 or 14, further comprising a track configured to propel the magnetic structure, the track comprising a plurality' of multilayer PCBs arranged along a transport path, each PCB having one or more of the conductive coils.

[0127] While various illustrative embodiments incorporating the principles of the present teachings have been disclosed, the present teachings are not limited to the disclosed embodiments. Instead, this application is intended to cover any variations, uses, or adaptations of the present teachings and use its general principles. Further, this application is intended to cover such departures from the present disclosure that are within known or customary practice in the art to which these teachings pertain.

[0128] In the above detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative embodiments described in the present disclosure are not meant to be limiting. Other embodiments may be used, and other changes may be made, without departing from the spirit or scope of the subject matter presented herein. It will be readily understood that various features of the present disclosure, as generally described herein, and illustrated in the Figures, can be arranged, substituted, combined, separated, and designed in a wide variety’ of different configurations, all of yvhich are explicitly contemplated herein.

[0129] Aspects of the present technical solutions are described herein with reference to flowchart illustrations and / or block diagrams of methods, apparatuses (systems), and computer program products according to embodiments of the technical solutions. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer readable program instructions.

[0130] These computer readable program instructions can be provided to a processor of a special purpose computer or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions / acts specified in the flowchart and / or block diagram block or blocks. These computer readable program instructions can also be stored in a computer readable storage medium that can direct a computer, a programmable data processing apparatus, and / or other devices to function in aparticular manner, such that the computer readable storage medium having instructions stored therein comprises an article of manufacture including instructions which implement aspects of the function / act specified in the flowchart and / or block diagram block or blocks.

[0131] The computer readable program instructions can also be loaded onto a computer, other programmable data processing apparatus, or other device to cause a series of operational steps to be performed on the computer, other programmable apparatus or other device to produce a computer implemented process, such that the instructions which execute on the computer, other programmable apparatus, or other device implement the functions / acts specified in the flowchart and / or block diagram block or blocks.

[0132] The flowchart and block diagrams in the figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various embodiments of the present technical solutions. In this regard, each block in the flowchart or block diagrams can represent a module, segment, or portion of instructions, which includes one or more executable instructions for implementing the specified logical function(s). In some alternative implementations, the functions noted in the blocks can occur out of the order noted in the figures. For example, two blocks shown in succession can, in fact, be executed substantially concurrently, or the blocks can sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and / or flowchart illustration, and combinations of blocks in the block diagrams and / or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts or carry out combinations of special purpose hardware and computer instructions.

[0133] A second action can be said to be “in response to'’ a first action independent of whether the second action results directly or indirectly from the first action. The second action can occur at a substantially later time than the first action and still be in response to the first action. Similarly, the second action can be said to be in response to the first action even if intervening actions take place between the first action and the second action, and even if one or more of the intervening actions directly cause the second action to be performed. For example, a second action can be in response to a first action if the first action sets a flag and a third action later initiates the second action whenever the flag is set.

[0134] The present disclosure is not to be limited in terms of the particular embodiments described in this application, which are intended as illustrations of various features. Many modifications and variations can be made without departing from its spirit and scope, as will be apparent to those skilled in the art. Functionally equivalent methods and apparatuses withinthe scope of the disclosure, in addition to those enumerated herein, will be apparent to those skilled in the art from the foregoing descriptions. It is to be understood that this disclosure is not limited to particular methods, reagents, compounds, compositions or biological systems, which can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting.

[0135] With respect to the use of substantially any plural and / or singular terms herein, those having skill in the art can translate from the plural to the singular and / or from the singular to the plural as is appropriate to the context and / or application. The various singular / plural permutations may be expressly set forth herein for sake of clarity.

[0136] It will be understood by those within the art that, in general, terms used herein are generally intended as ‘"open” terms (for example, the term ‘'including’' should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” et cetera). While various compositions, methods, and devices are described in terms of “comprising” various components or steps (interpreted as meaning “including, but not limited to”), the compositions, methods, and devices can also “consist essentially of’ or “consist of’ the various components and steps, and such terminology should be interpreted as defining essentially closed-member groups.

[0137] As used in this document, the singular forms “a,” “an.” and “the” include plural references unless the context clearly dictates otherwise. Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art. Nothing in this disclosure is to be construed as an admission that the embodiments described in this disclosure are not entitled to antedate such disclosure by virtue of prior invention.

[0138] In addition, even if a specific number is explicitly recited, those skilled in the art will recognize that such recitation should be interpreted to mean at least the recited number (for example, the bare recitation of “two recitations,” without other modifiers, means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C. et cetera” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (for example, “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and / or A, B. and C together, et cetera). In those instances where a convention analogous to “at least one of A, B, or C, et cetera” is used, in general such a construction is intended in the sense onehaving skill in the art would understand the convention (for example, “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and / or A, B, and C together, et cetera). It will be further understood by those within the art that virtually any disjunctive word and / or phrase presenting two or more alternative terms, whether in the description, sample embodiments, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase "‘A or B” will be understood to include the possibilities of “A” or “B” or '‘A and B.”

[0139] In addition, where features of the disclosure are described in terms of Markush groups, those skilled in the art will recognize that the disclosure is also thereby described in terms of any individual member or subgroup of members of the Markush group.

[0140] As will be understood by one skilled in the art, for any and all purposes, such as in terms of providing a written description, all ranges disclosed herein also encompass any and all possible subranges and combinations of subranges thereof. Any listed range can be easily- recognized as sufficiently describing and enabling the same range being broken down into at least equal halves, thirds, quarters, fifths, tenths, et cetera. As a non-limiting example, each range discussed herein can be readily broken down into a lower third, middle third and upper third, et cetera. As will also be understood by one skilled in the art all language such as “up to,” “at least,” and the like include the number recited and refer to ranges that can be subsequently broken down into subranges as discussed above. Finally, as will be understood by one skilled in the art, a range includes each individual member. Thus, for example, a group having 1-3 components refers to groups having 1, 2, or 3 components. Similarly, a group having 1-5 components refers to groups having 1, 2, 3, 4, or 5 components, and so forth.

[0141] Various of the above-disclosed and other features and functions, or alternatives thereof, may be combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art, each of which is also intended to be encompassed by the disclosed embodiments.

Claims

CLAIMSWhat is claimed is:1 . A method for magnetic field shaping in brushless direct current (BLDC) motors, the method comprising: forming a stator coil of a BLDC motor, wherein the BLDC motor comprises a rotor comprising a vessel mover disposed proximate the stator coil and comprising a magnetic structure, the stator coil comprises a plurality of windings each comprising one of a plurality of layers interconnected by a plurality of intra-coil vias to form a continuous conductive path, and the formation of the stator coil comprises introducing one or more variations between two or more of the windings of two or more of the layers according to a desired magnetic field pattern; and driving the stator coil by injecting a control signal to the conductive path to energize the stator coil, impart a directed force on the vessel mover to move the vessel mover in a direction of travel in accordance with the desired magnetic field pattern, and thereby commutate the BLDC motor.

2. The method of claim 1 , further comprising, to achieve the desired magnetic field pattern, introducing one or more of one or more geometric variations between the two or more of the w indings, a lateral displacement in at least one direction of one or more portions of at least one of the two or more of the windings, an interleaving of at least a portion of the two or more of the windings, or an inversion of at least one of the two or more of the windings.

3. The method of claim 1, wherein the introduction of the variations further comprises varying, for the two or more of the windings of the two or more of the layers, an orientation, a trace width, a trace spacing, a trace curvilinear position, a trace shape, a wire gauge, or a spacing between the tw o or more of the layers.

4. The method of claim 1, wherein at least a portion of each of the plurality of the windings is formed above or below another portion of another one of the windings to thereby form a stack, the stator coil comprises a three-dimensional stator coil, and the formation comprises fabricating a printed circuit board (PCB). wherein the layers are printed on a substrate of the PCB.

5. The method of claim 1, further comprising forming the plurality of windings to be alternately laterally spaced and interdigitated.

6. The method of claim 1, further comprising introducing another one or more variations between another two or more of the windings of another two or more of the layers to attenuate magnetic field emissions in one or more directions unaligned with the direction of travel.

7. A method for manufacturing stator coils in brushless direct current (BLDC) motors, the method comprising: determining a desired magnetic field pattern to be generated by a stator coil of a BLDC motor, the BLDC motor comprising a rotor comprising a vessel mover disposed proximate the stator coil, the vessel mover comprising a magnetic structure; designing the stator coil to have one or more variations between a plurality of windings of a plurality of layers of the stator coil, wherein the one or more variations are configured to achieve the desired magnetic field pattern and the layers are interconnected by a plurality of intra-coil vias to form a continuous conductive path; and fabricating the stator coil, wherein the stator coil is configured to impart a directed force on the vessel mover to move the vessel mover in a direction of travel in accordance with the desired magnetic field pattern, and thereby commutate the BLDC motor, when the stator coil is energized.

8. The method of claim 7, further comprising introducing one or more of one or more geometric variations between the two or more of the windings, a lateral displacement in at least one direction of one or more portions of at least one of the two or more of the windings, an interleaving of at least a portion of the two or more of the windings, or an inversion of at least one of the two or more of the windings.

9. The method of claim 7, further comprising varying, for the two or more of the windings, an orientation, a trace width, a trace spacing, a trace curvilinear position, a trace shape, a wire gauge, or a spacing between the two or more of the layers.

10. The method of claim 7, wherein at least a portion of each of the plurality of the windings is formed above or below another portion of another one of the windings to therebyform a stack, the stator coil comprises a three-dimensional stator coil, and the method further comprises fabricating a printed circuit board (PCB). wherein the layers are printed on a substrate of the PCB.

11. The method of claim 7, wherein the BLDC motor comprises a linear or rotary BLDC motor.

12. The method of claim 7, further comprising introducing another one or more variations between another two or more of the windings of another two or more of the layers to attenuate magnetic field emissions in one or more directions unaligned with the direction of travel.

13. A transport system, comprising a brushless direct current (BLDC) motor comprising: a stator comprising a plurality7of conductive coils each comprising a plurality of windings of a plurality of layers interconnected by a plurality of intra-coil vias to form a continuous conductive path, wherein one or more of the conductive coils comprise one or more variations between two or more of the w indings to achieve a desired magnetic field pattern; a rotor comprising a vessel mover disposed proximate the stator coil, the vessel mover comprising a magnetic structure; and a control system comprising one or more of a hybridized movement control architecture or a processor and configured to drive the stator by injecting a control signal to the conductive path of one or more of the conductive coils to energize the one or more of the conductive coils and impart a directed force on the vessel mover to move the vessel mover in a direction of travel in accordance with the desired magnetic field pattern.

14. The transport system of claim 13, wherein the one or more variations: comprise one or more geometric variations, a lateral displacement in at least one direction of one or more portions of at least one of the two or more of the windings, an interleaving of at least a portion of the two or more of the windings, or an inversion of at least one of the tw o or more of the windings; or are in orientation, trace width, trace spacing, trace curvilinear position, trace shape, wire gauge, or spacing between the two or more of the layers.

15. The transport system of claim 13, further comprising a track configured to propel the magnetic structure, the track comprising a plurality of multilayer printed circuit boards (PCBs) arranged along a transport path, each PCB having one or more of the conductive coils.

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