PCB Stator Axial Flux Motor With Modular VFD Packaging
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Solution Overview
Problem
Existing axial field rotary energy devices with variable frequency drives (VFDs) face challenges in size and weight scalability, as the VFD enclosure size increases with the device's power rating, leading to increased manufacturing complexity and weight, necessitating a solution for a VFD package that occupies a consistent volume regardless of power rating.
Innovation Solution
The integration of a VFD system with a printed circuit board (PCB) stator and a clam shell enclosure allowing for adjustable air gaps and modular VFD enclosures providing IP54 or IP55 protection, featuring heat dissipation and selective access for maintenance, and adaptable to various axial field rotary energy device sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the VFD enclosure size is increased to accommodate higher power ratings, then the power handling capability is improved, but the overall system weight and manufacturing complexity increase
Solution Approach 1:
The VFD system is divided into separate functional modules: power processing components (rectifier, inverter, DC bus) are integrated with the rotary energy device, while control electronics are housed in a separate control unit. This segmentation allows the main VFD enclosure to remain compact while still handling high power through the distributed architecture.
Solution Approach 2:
The modular VFD enclosure is designed with universal mounting features and standardized interfaces that allow it to accommodate different power ratings through configuration rather than physical resizing. The same enclosure structure can serve multiple power levels by adjusting internal component arrangement.
2Power
If the VFD enclosure size is increased to accommodate higher power ratings, then the power handling capability is improved, but the manufacturing complexity increases
Solution Approach 1:
The VFD system is divided into separate functional modules: power processing components (rectifier, inverter, DC bus) are integrated with the rotary energy device, while control electronics are housed in a separate control unit. This segmentation allows the main VFD enclosure to remain compact while still handling high power through the distributed architecture.
Solution Approach 2:
The design uses standardized parameters and dimensions for the VFD enclosure that remain constant across different power ratings. By changing only the configuration of internal components rather than the enclosure dimensions, manufacturing processes remain consistent while accommodating varying power requirements.
3Weight of stationary object
If the VFD enclosure is made compact with consistent volume, then the weight is reduced, but the adaptability to different power ratings becomes more difficult
Solution Approach 1:
The VFD enclosure incorporates adjustable and reconfigurable elements such as removable mounting brackets, adjustable component positions, and flexible cable management systems. These dynamic features allow the same compact enclosure to be adapted to different power ratings without requiring physical resizing.
Solution Approach 2:
The modular VFD enclosure is designed with universal mounting features and standardized interfaces that allow it to accommodate different power ratings through configuration rather than physical resizing. The same enclosure structure can serve multiple power levels by adjusting internal component arrangement.
4Ease of repair
If the VFD enclosure provides full access for maintenance, then the ease of repair is improved, but the protection from environmental factors deteriorates
Solution Approach 1:
The VFD enclosure is divided into multiple accessible sections or panels that can be opened independently to access specific components. This segmented access design allows maintenance personnel to reach critical components without compromising the sealed integrity of the entire enclosure, maintaining IP54/IP55 protection while enabling repairs.
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 enables a compact and adaptable VFD system that maintains consistent volume across different power ratings, simplifying manufacturing and reducing weight, while ensuring reliable operation and easy maintenance.
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
a variable frequency drive (VFD) to operate when connected to a 60 or 50 Hz alternating current (AC) source
Data Source
AI summary
A system can include an axial field rotary energy device with an axis of rotation and a rotor coaxial with the axis and having a shaft, bearings, rotor disks that are coaxial and permanent magnets on each rotor disk. A printed circuit board (PCB) stator is located between the rotor disks to define an air gap on each side of the PCB stator. An enclosure has two enclosure sections with an inspection port. Bearing caps and bearings are mounted to the rotor. A variable frequency drive (VFD) assembly is coupled to the axial field rotary energy device. The VFD has a flexible conduit that extends between the VFD housing and the axial field rotary energy device. The flexible conduit can adapt to different sizes of axial field rotary energy devices.