PCB Alternator Integrated with Flywheel Magnets
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Solution Overview
Problem
Small engine control systems rely on separate wound alternators and starters, which are inefficient and require additional components, leading to increased complexity and weight.
Innovation Solution
An engine control system incorporating a flywheel with magnets and a printed circuit board (PCB) alternator, where the rotating magnetic field induces current through coils on the PCB, generating electrical energy and enabling integrated starting mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate wound alternators and starters are used, then reliable energy generation and starting functions are achieved, but device complexity and weight increase
Solution Approach 1:
The patent combines the alternator and starter functions into a single integrated unit. The flywheel serves dual purposes: as a rotational inertia component for the engine and as a stator for the alternator. The PCB alternator integrates both energy generation and starting control functions, eliminating the need for separate wound alternators and starters, thus reducing component count while maintaining reliability
Solution Approach 2:
The flywheel is designed with magnets embedded in it, allowing it to function both as a traditional flywheel for engine operation and as a magnetic field source for the alternator. The PCB alternator serves multiple functions: generating electrical energy during engine operation and providing electronic starting capability, making the system more versatile without adding components
2Reliability
If separate wound alternators and starters are used, then complete engine control functions are achieved, but weight increases
Solution Approach 1:
The patent merges the heavy wound alternator and separate starter components into a single lightweight PCB alternator system. The PCB construction with integrated coils and circuitry replaces traditional wound magnetic components, dramatically reducing weight while maintaining complete engine control functions for both energy generation and electronic starting
Solution Approach 2:
The patent replaces traditional mechanical wound alternators and electromagnetic starters with a PCB-based electronic system. The PCB alternator uses printed circuit board traces as coils and electronic control circuits, substituting heavy mechanical and electromagnetic components with lightweight electronic components, thereby reducing overall system weight while preserving full control functionality
3Device complexity
If integrated PCB alternator with flywheel is used, then device complexity and weight are reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent merges the alternator coils directly onto the PCB substrate in close proximity to the flywheel magnets. This integration allows for precise alignment to be built into the PCB manufacturing process itself, where coil trace positions can be accurately controlled during PCB fabrication, thereby managing precision requirements through manufacturing process control rather than mechanical assembly
4Power
If traditional wound alternator is used, then adequate power generation is achieved, but efficiency and compactness decrease
Solution Approach 1:
The patent replaces the traditional wound alternator with a PCB alternator that uses printed circuit board traces as coils. This electronic construction eliminates mechanical losses associated with traditional wound components, improving efficiency. The direct integration of the PCB alternator with the flywheel reduces mechanical clearance and improves magnetic coupling, further enhancing efficiency while maintaining adequate power generation capability
Solution Approach 2:
The patent changes the physical parameters of the alternator by using PCB trace geometry instead of traditional wire winding. This allows for optimized coil configurations, tighter tolerances, and better magnetic field utilization, improving the efficiency of energy generation. The PCB construction also enables more compact winding patterns and better thermal management, contributing to overall system efficiency
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 solution simplifies the engine control system, reduces weight, and enhances efficiency by integrating energy generation and starting functions within a compact design, improving power output and reducing component count.
Implementation Method 1
Power is generated by the flywheel rotating and causing the magnetic fields associated with the number of magnets to induce a current through the coils integrated into the printed circuit board
Data Source
AI summary
An engine control system includes an engine, crankshaft, and a flywheel. The flywheel is coupled to the crankshaft of the engine and includes a number of magnets arranged axially along a first side. The system further includes a printed circuit board including a number of coils integrated into the circuit board. The printed circuit board is positioned such that a first face of the printed circuit board is positioned parallel to the first side of the flywheel. Power is generated by the flywheel rotating and causing the magnetic fields associated with the magnets to induce a current though the coils integrated into the printed circuit board.