Modular VFD Enclosure for PCB Stator Axial Flux Machines
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Solution Overview
Problem
Existing axial field rotary energy devices and variable frequency drive (VFD) systems face challenges with increasing size and weight as power ratings increase, requiring different parts and tooling, and lack a standardized VFD enclosure that can be coupled to enclosures of varying sizes.
Innovation Solution
A VFD integrated system with a modular VFD enclosure that maintains a consistent size regardless of power rating, featuring a separate enclosure for the VFD with IP54 or IP55 protection, allowing for easy attachment to different-sized axial field rotary energy devices, and includes features for heat dissipation, selective access, and visual status indication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the size of the axial field rotary energy device increases as a function of power rating, then the power output increases, but the size of the VFD enclosure increases at the same rate
Solution Approach 1:
The VFD enclosure is segmented into modular components with standardized dimensions. The enclosure is divided into a control module housing and a power module housing that can be independently configured. This segmentation allows the VFD to maintain a consistent base enclosure size while accommodating different power ratings through modular component arrangements rather than scaling the entire enclosure volume with power output.
Solution Approach 2:
A universal VFD enclosure design is implemented that can accommodate multiple power ratings (5hp, 7.5hp, 10hp, 15hp) using the same base enclosure dimensions. The enclosure incorporates universal mounting features, standardized component footprints, and scalable internal layouts that allow a single enclosure type to serve multiple power levels, eliminating the need for different enclosure sizes for different power ratings.
2Power
If the size of the axial field rotary energy device increases as a function of power rating, then the power output increases, but the overall weight of the system increases
Solution Approach 1:
The VFD system is segmented into modular components that can be independently manufactured and assembled. This segmentation allows for optimized material selection and weight distribution across different modules, enabling the system to achieve higher power output without proportionally increasing overall weight through efficient component placement and structural design.
Solution Approach 2:
The enclosure design utilizes parameter changes in material density and structural thickness rather than increasing overall volume. By optimizing wall thickness, material selection, and structural reinforcement locations based on actual load requirements for each power rating, the system achieves necessary strength and protection while minimizing weight increase relative to power output improvements.
3Power
If different sized VFD enclosures are used for different power ratings, then each machine can be optimized for its specific power level, but different parts and tooling are required for manufacturing
Solution Approach 1:
A universal VFD enclosure platform is designed with standardized dimensions, mounting features, and component layouts that can accommodate multiple power ratings. This universality allows the same enclosure mold, fastening systems, sealing components, and assembly tooling to be used across 5hp, 7.5hp, 10hp, and 15hp models, significantly reducing manufacturing complexity and part variety while still allowing optimization for each power level through internal component arrangement.
4Ease of manufacture
If a standardized VFD enclosure is used across different power ratings, then manufacturing is simplified and volume is reduced, but the enclosure must accommodate varying internal component layouts
Solution Approach 1:
The VFD enclosure is segmented into standardized zones and modules with defined mounting interfaces. This segmentation allows different internal component layouts for various power ratings to be accommodated within the same external enclosure by reconfiguring modular components within predefined zones, maintaining manufacturing simplicity while providing adaptability for different power levels.
Data Source
AI summary
A system has an axial field rotary energy device with a housing, an axis and a rotor with a shaft, bearings, rotor disks and permanent magnets. A printed circuit board (PCB) stator is between the rotor disks to define an air gap on each side thereof. A variable frequency drive (VFD) assembly has a VFD housing and first pads coupled to inductors to facilitate heat removal from the inductors. A concave cradle is coupled to a ferromagnetic core and has a same contour as an outer surface of the ferromagnetic core. A second pad is coupled to a rectifier module. A third pad is coupled to switching devices and has pins to align the switching devices with the third pad. Standoffs are coupled to the VFD housing to support a first printed circuit board assembly (PCBA). A second PCBA is mounted to a shield plate above the first PCBA.