PCB Stator Axial-Flux Motor With Modular VFD Packaging
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Solution Overview
Problem
Existing axial field rotary energy devices and VFD systems face challenges with increasing size and weight as power ratings increase, leading to complexities in manufacturing and a need for a VFD package that occupies a consistent volume regardless of power rating.
Innovation Solution
The integration of a VFD system with a modular enclosure that maintains the same size or volume across different power ratings, coupled with an axial field rotary energy device featuring a printed circuit board stator and rotor disks with magnets, allows for flexible mounting and efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the size of the axial field rotary energy device increases to accommodate higher power ratings, then the power output is improved, but the size of the VFD enclosure increases at the same rate, leading to increased overall weight and volume
Solution Approach 1:
The VFD enclosure is segmented into modular components with standardized dimensions. The enclosure is divided into functional sections (power processing section, control section, heat dissipation section) that can be independently designed and assembled. This modular approach allows the VFD to maintain a consistent base enclosure size while accommodating different power ratings through internal component configuration rather than external scaling.
Solution Approach 2:
A universal VFD enclosure design is implemented that can accommodate multiple power ratings (5hp, 7.5hp, 15hp, etc.) without requiring different enclosure sizes. The enclosure incorporates standardized mounting features, flexible internal component layouts, and scalable electrical architectures that allow the same physical enclosure to house VFDs of varying power capacities through internal configuration rather than external dimension changes.
2Power
If the size of the axial field rotary energy device increases to accommodate higher power ratings, then the power output is improved, but the overall weight of the system increases
Solution Approach 1:
The VFD system is segmented into modular functional units (rectifier module, inverter module, control module, heat sink) that can be independently optimized for weight. Each module uses standardized mounting and connection interfaces, allowing lightweight design without compromising structural integrity. The segmentation enables selective placement of high-density components and strategic distribution of weight throughout the enclosure.
Solution Approach 2:
The VFD enclosure and internal components utilize composite material strategies to reduce weight while maintaining strength and thermal management capabilities. The enclosure may use high-strength, low-weight alloys or composite structures. Internal components such as heat sinks and mounting brackets employ material selections that optimize the strength-to-weight ratio, reducing overall system weight without sacrificing durability or thermal performance.
3Power
If different power ratings require different VFD enclosure sizes, then the power processing capability is optimized, but the manufacturing complexity increases and standardization is reduced
Solution Approach 1:
A universal enclosure platform is designed with standardized dimensions, mounting features, and assembly procedures that serve all power ratings. The same enclosure shell, fastening systems, cable access points, and mounting brackets are used across 5hp, 7.5hp, 15hp, and other power ratings. This universality simplifies manufacturing by allowing production lines to produce a single enclosure type that accommodates multiple power levels through internal component variation rather than external dimension changes.
Solution Approach 2:
The system accommodates different power ratings by changing internal parameters (component power ratings, electrical configurations, thermal management specifications) rather than external physical dimensions. The enclosure maintains constant geometric parameters while the internal electrical and thermal parameters are adjusted to match different power requirements. This approach allows standardized manufacturing of the enclosure while still optimizing for different power processing capabilities through internal configuration.
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 manufacturing by maintaining a consistent VFD enclosure size, reduces overall weight and volume of the system, and enables flexible mounting to different-sized axial field rotary energy devices, while also providing effective heat management and protection against environmental factors.
Implementation Method 1
an axial field rotary energy device having a printed circuit board (PCB) stator coaxial with rotor disks having respective magnets
Implementation Method 2
The VFD enclosure can have features to capture and dissipate the heat generated by components such as MOSFETs, rectifier bridges and inductors
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.