PCB Axial Field Motor Stator Panels for Modular Manufacturing
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Solution Overview
Problem
Conventional axial air gap brushless motors with layered disk stators are large, difficult to manufacture, and expensive, while axial field electric devices using PCB stators are not modular, leading to a need for cost-effective and modular improvements.
Innovation Solution
A modular axial field rotary energy device with a housing containing a stator assembly composed of axially-stacked stator panels and a rotor assembly with magnets, where each stator panel consists of a single electrical phase and is connected through conductive traces on printed circuit boards, allowing for efficient current flow and modular design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional layered disk stators with wire interconnections are used, then the motor can be manufactured with traditional methods, but the device becomes large and difficult to manufacture
Solution Approach 1:
The patent replaces traditional mechanical wire winding and interconnection systems with printed circuit board (PCB) technology. The PCB stator uses standardized PCB fabrication processes to create conductive traces that replace hand-wound coils and complex wire interconnections, dramatically simplifying manufacturing while reducing device size and complexity
Solution Approach 2:
The patent changes the fundamental manufacturing parameters from traditional motor winding techniques to PCB fabrication parameters. This includes using photolithography, etching, and automated PCB assembly processes instead of manual wire winding, transforming the manufacturing approach to achieve both simplicity and compactness
2Ease of manufacture
If PCB stators are used to reduce size and simplify manufacturing, then manufacturing ease improves, but the designs become complicated and expensive
Solution Approach 1:
The patent divides the stator into multiple discrete PCB panels that can be independently manufactured and then assembled. Each PCB panel is a separate, standardized component that simplifies the design of individual units while allowing flexible configuration when assembled, reducing overall design complexity
Solution Approach 2:
The patent creates universal PCB panel designs that can be used across different motor configurations and applications. The standardized PCB panels serve multiple functions and can be adapted to various requirements, reducing design complexity through reuse and standardization
3Power
If PCB stators with multiple coil configurations are used, then electrical performance improves, but manufacturing cost and complexity increase
Solution Approach 1:
The patent merges multiple coil functions into integrated PCB circuits where conductive traces on the PCB perform the functions of multiple separate coils. The PCB layout allows multiple electrical phases and coil configurations to be implemented as unified circuit patterns, improving electrical performance while reducing manufacturing complexity through integration
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
The solution provides a cost-effective and modular design with improved manufacturing efficiency and performance by ensuring consistent circumferential spacing between magnets and efficient current flow through interconnected coils, reducing complexity and costs.
Implementation Method 1
A rotor assembly including a plurality of rotors can be rotatably mounted within the housing on opposite axial ends of the stator assembly. The rotors can be mechanically coupled together. Each rotor can include magnets having leading and trailing edges.
Implementation Method 2
Each stator panel comprises a respective printed circuit board (PCB) having a respective plurality of coils that are electrically conductive and interconnected within the respective PCB. The respective PCB can be configured so that an electrical current that flows through any one of the respective plurality of coils likewise flows through all of the respective plurality of coils
Data Source
AI summary
An axial field rotary energy device can include a housing having an axis. A stator assembly is mounted to the housing and has stator panels that are axially-stacked and discrete panels from each other. Each stator panel includes a respective printed circuit board (PCB) having respective coils that are electrically conductive and interconnected within the respective PCB. In addition, a rotor assembly including rotors is rotatably mounted within the housing on opposite axial ends of the stator assembly. The rotors can be mechanically coupled together. Each rotor can include magnets having leading and trailing edges. The trailing edge of one magnet and the leading edge of an adjacent magnet can be parallel to each other to define a consistent circumferential spacing, relative to the axis, between adjacent ones of the magnets.