PCB Stator Axial Flux Motor With Integrated VFD Cooling
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Solution Overview
Problem
Conventional electric commutated motors (ECMs) and brushless direct current (BLDC) motors are not easily integrated with variable frequency drives (VFDs) due to their traditional radial flux configurations, limiting their operational flexibility and efficiency, especially when operating with direct connection to an alternating current (AC) electrical source.
Innovation Solution
The development of an axial field rotary energy device system that incorporates a printed circuit board (PCB) stator, permanent magnets, and a VFD integrated within a common enclosure, allowing for efficient operation and cooling of both the motor and the VFD.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional radial flux PM motors are used with separate VFD connections, then motor operation is reliable, but integration with VFD is complex and operational flexibility is limited
Solution Approach 1:
The patent merges the motor and VFD into a single integrated unit called an electric commutated motor (ECM). The VFD components are built into the motor housing, eliminating the need for separate external VFD connections. This integration directly resolves the technical contradiction by improving adaptability and versatility while reducing system complexity through consolidation of components.
2Adaptability or versatility
If axial flux PM motors with PCB stator are used, then integration with VFD is improved, but heat management becomes more challenging
Solution Approach 1:
The patent converts the harmful heat generated by both the motor and VFD into a beneficial cooling solution. A cooling system with fans and heat sinks is integrated into the ECM housing, using the same enclosed space that previously trapped heat. The cooling airflow paths are designed to efficiently remove heat from both components, transforming the heat management challenge into an effective thermal control system.
3Productivity
If motor and VFD are integrated in common enclosure, then operational efficiency is improved, but cooling requirements increase
Solution Approach 1:
The patent implements a multi-functional cooling system that serves both the motor and VFD components simultaneously. The same cooling airflow paths, fans, and heat sinks are used to cool both integrated components, rather than requiring separate cooling systems for each. This universal cooling approach maintains high operational efficiency while avoiding the increased complexity that would result from separate cooling systems.
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 improved integration and operational efficiency of axial flux ECMs with VFDs, enhancing their ability to operate effectively with AC electrical sources and providing effective cooling mechanisms to manage heat generation.
Implementation Method 1
a PCB stator and rotors having respective permanent magnets (PM). The rotors can rotate about the axis relative to the PCB stator
Implementation Method 2
a cooling system can be integrated within the enclosure and configured to cool the axial field rotary energy device and the VFD
Data Source
AI summary
An axial field rotary energy device or system includes an axis, a PCB stator and rotors having respective permanent magnets. The rotors rotate about the axis relative to the PCB stator. A variable frequency drive (VFD) having VFD components are coupled to the axial field rotary energy device. An enclosure contains the axial field rotary energy device and the VFD, such that the axial field rotary device and the VFD are integrated together within the enclosure. In addition, a cooling system is integrated with the enclosure to cool the axial field rotary energy device and the VFD.