Flat DC Electric Machine Radial Currents Axial Flux
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Solution Overview
Problem
Existing axial flux motors are limited in power delivery and torque speed curves, and often require commutators and brushes, which can lead to wear and tear, while also being thicker than desired for certain applications.
Innovation Solution
The design employs radial currents interacting with axial magnetic flux, eliminating the need for commutators and brushes by using a metallic ring and ball-bearing assemblies for electrical connections, allowing for thin, efficient, and smooth motion in flat dc electric machines suitable for micro-motors to electric vehicles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If commutators and brushes are used in axial flux motors, then electrical connections can be established, but wear and tear occurs reducing reliability
Solution Approach 1:
The patent extracts and eliminates the commutator and brush components from the motor design. By using radial conductors that extend beyond the rotor surface, electrical connections are made directly to the conductor ends without requiring sliding contact components, thus removing the source of wear and tear while maintaining electrical connectivity.
Solution Approach 2:
The patent replaces the mechanical sliding contact system (brushes and commutators) with a direct electrical connection system. The radial conductors protrude from the rotor and connect directly to stationary electrical contacts, substituting the mechanical wear-prone system with a static electrical connection that eliminates friction and arcing.
2Power
If conventional axial flux motor designs are used, then power delivery can be achieved, but the motor thickness is greater than desired
Solution Approach 1:
The patent transitions from conventional cylindrical motor geometry to a flat disc geometry with radial conductors. By arranging conductors radially from the center outward and using axial magnetic flux, the motor achieves power delivery in a planar configuration that significantly reduces thickness while maintaining effective active material volume.
Solution Approach 2:
The patent changes the geometric parameters of the motor design by using radial conductors with specific length and angular spacing, along with axial magnetic flux density distribution. These parameter changes enable the motor to achieve desired power output in a thinner profile by optimizing the arrangement and dimensions of the radial conductors within the axial flux field.
3Object-generated harmful factors
If pancake motor design is used, then smooth motion is achieved, but power delivery is limited
Solution Approach 1:
The patent applies local quality by varying the angular spacing and length of radial conductors at different positions around the rotor. This non-uniform distribution of conductor properties allows optimization of torque production in specific regions while maintaining overall smooth operation, achieving both reduced torque ripple and enhanced power delivery through localized conductor characteristics.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enhances power-to-weight ratio, reduces torque ripple, and eliminates wear issues, enabling efficient and smooth operation in a variety of applications from micro-motors to electric vehicle motors with improved power delivery and reduced maintenance.
Implementation Method 1
The present invention of flat dc electric machine is based, in the preferred embodiments, on the interaction of radial currents with an axial magnetic flux
Data Source
AI summary
Various implementations of a dc electric machine based on interaction of radial currents with axial magnetic field are described herein. A set of mechanisms are described to implement the concepts resulting in flat dc electric motor/generator with or without brushes and no commutator. In a preferred embodiment of a dc electric machine, conventional brush is replaced with a roller type of mechanism to make electrical contacts. The dc electric machines described herein, use relatively low voltage power source for their operation. In preferred embodiments, axial magnetic field is generated by either a permanent disc magnet or electromagnet. The unique design described herein makes it possible to produce micro-motors either on a chip or a printed circuit board (PCB). Unique designs of a motorized wheel are described herein which helps implement a simpler but more capable Electric Vehicle (EV) and allows for frictionless braking system.