Motor PCB Coil Routing to Reduce Eddy Current Losses
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Solution Overview
Problem
Existing electric motors face challenges in efficiently connecting coils to printed circuit boards (PCBs) due to the risk of magnetic alternating fields inducing eddy currents, which can lead to significant losses and inefficiencies.
Innovation Solution
The solution involves routing connecting lines in multiple planes transverse to the axial direction, splitting sections of these lines into electrically insulated sub-lines, and using a printed circuit board with specific configurations to minimize eddy current formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the printed circuit board is positioned near the stator to achieve compact design and improve connectivity, then the ease of manufacture and assembly is improved, but eddy currents are induced in the connecting lines due to magnetic alternating fields
Solution Approach 1:
The connecting lines are segmented into multiple parallel sub-lines (e.g., three sub-lines per connecting line) that are electrically insulated from each other in the region exposed to magnetic alternating fields. This segmentation disrupts the formation of large eddy current loops while maintaining electrical connectivity, thereby reducing eddy current losses without compromising the compact design or assembly-friendliness of the printed circuit board.
Solution Approach 2:
The connecting lines have different structural configurations in different regions: in the region exposed to magnetic alternating fields, they are split into multiple insulated sub-lines to minimize eddy currents; in other regions, they maintain their conventional structure for optimal electrical connectivity. This local differentiation allows the design to simultaneously achieve compactness and reduce energy losses.
2Device complexity
If connecting lines are routed in a single plane for simplicity, then the device complexity is reduced, but eddy current formation is exacerbated due to larger loop areas
Solution Approach 1:
The connecting lines are routed in multiple planes (e.g., first plane, second plane, third plane) rather than a single plane. This multi-planar routing reduces the area of eddy current loops by distributing the current paths in three-dimensional space, thereby reducing eddy current losses. The sub-lines are arranged in different planes and electrically connected at their ends, maintaining functionality while reducing complexity compared to conventional single-plane routing.
3Ease of manufacture
If the printed circuit board uses conventional connecting line configurations, then the manufacturing process is simplified, but significant energy losses occur due to eddy currents
Solution Approach 1:
The connecting lines are manufactured as multiple parallel sub-lines with electrical insulation between them in the magnetic field exposure region. This segmentation can be integrated into conventional printed circuit board manufacturing processes using standard techniques for creating multiple conductive traces, thereby maintaining manufacturing simplicity while dramatically reducing eddy current losses through the disrupted current paths.
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 significantly reduces eddy current losses and enhances the assembly-friendliness and cost-effectiveness of coil connections in electric motors.
Implementation Method 1
the positioning of the printed circuit board near to the stator entails the risk of magnetic alternating fields acting on the current-carrying conductors and eddy currents being induced in the lines
Data Source
AI summary
An electric motor, at least having a stator and an annular rotor which are arranged next to one another along an axial direction; wherein the stator has a plurality of stator teeth which are arranged next to one another along a circumferential direction and which each extend along the axial direction At least one coil has at least one turn is arranged on each stator tooth, wherein the at least one turn is electrically conductively connected to a printed circuit board. The printed circuit board is arranged on an end side of the stator and next to the stator along the axial direction. The printed circuit board comprises a plurality of electrical connecting lines via which the at least one turn of each coil is connected at least to other turns or to an electrical connection of the motor.