PCB Stator Axial Field Drive With Universal VFD Enclosure
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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 power rating, requiring different parts and tooling, and resulting in increased volume and weight.
Innovation Solution
A modular VFD integrated system where the VFD enclosure maintains a constant size regardless of the power rating of the axial field rotary energy device, featuring a separate enclosure for the VFD with mounting features for various device sizes, and incorporating features for water and dust protection, heat management, and selective access to electronic components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the VFD enclosure size increases with power rating to accommodate higher power axial field rotary energy devices, then the system can handle higher power ratings, but the overall volume and weight of the system increases
Solution Approach 1:
The VFD enclosure is designed as a universal standardized size that can accommodate multiple power ratings (5hp, 7.5hp, 10hp, 15hp) through configurable internal mounting structures. The enclosure serves multiple functions: housing VFD electronics, providing heat dissipation pathways, offering IP54/IP55 protection, and accommodating different power ratings without requiring size changes. This multi-functionality resolves the contradiction by maintaining constant volume while handling variable power requirements.
Solution Approach 2:
Instead of changing the physical dimensions of the VFD enclosure with power rating, the invention changes internal parameters such as component layout, mounting configuration, and heat dissipation pathway design. The enclosure volume remains constant while internal arrangements are optimized for different power levels, thereby resolving the contradiction between power handling capability and volume.
2Power
If the VFD enclosure size increases with power rating to accommodate higher power axial field rotary energy devices, then the system can handle higher power ratings, but the overall weight of the system increases
Solution Approach 1:
The standardized VFD enclosure weight remains constant across different power ratings because the enclosure itself does not change size. The universal design allows the same enclosure to serve multiple power ratings, thereby resolving the contradiction between power handling capability and weight.
Solution Approach 2:
The system is segmented into modular components where the VFD enclosure is a separate, standardized module that does not scale with the axial field rotary energy device size. This segmentation allows the enclosure weight to remain constant while the device power rating varies, resolving the contradiction.
3Power
If different sized VFD enclosures are used for different power ratings, then each power rating can be optimized, but different parts and tooling are required for manufacturing
Solution Approach 1:
By designing a universal VFD enclosure that can accommodate multiple power ratings, the invention eliminates the need for different enclosure parts and tooling for manufacturing. The same enclosure design, tooling, and assembly processes can be used across all power ratings, significantly simplifying manufacturing while still supporting different power levels through internal configuration adjustments.
4Reliability
If the VFD enclosure is sealed for protection, then water and dust ingress is prevented, but access to electronic components for maintenance is restricted
Solution Approach 1:
The VFD enclosure is segmented into multiple access points or removable panels that allow maintenance personnel to access specific electronic components without compromising the overall sealed structure. This segmentation enables both high protection levels (IP54/IP55) and ease of repair by allowing selective access to components that require maintenance.
Solution Approach 2:
The invention introduces intermediary access mechanisms such as sealed removable panels or maintenance ports that act as mediators between the sealed enclosure and the external environment. These intermediaries allow component access for maintenance while maintaining the protective sealing when closed, resolving the contradiction between protection and accessibility.
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.