PCB Stator Axial Flux Motor With Universal VFD Packaging

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Solution Overview

Problem

Existing axial field rotary energy devices and variable frequency drive systems face challenges with increasing size and weight as power ratings increase, requiring different parts and tooling, and necessitate a VFD package that maintains a consistent volume and weight regardless of power rating.

Innovation Solution

A system comprising an axial field rotary energy device with a PCB stator and a VFD assembly, featuring a clam shell enclosure with adjustable air gaps, interchangeable VFD enclosures, and a flexible conduit to accommodate different sizes, along with a VFD housing that maintains consistent dimensions across varying power ratings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If the VFD enclosure size increases to accommodate higher power ratings, then the power handling capability is improved, but the weight and volume of the system increase

Engineering Contradiction:

Improvepower handling capabilityVSAvoidVFD enclosure weight

Core Design Contradiction:

PowerVSWeight of stationary object

Solution Approach 1:

The patent implements a universal VFD enclosure design that can accommodate multiple power ratings (5hp, 7.5hp, 10hp, 15hp) through modular component arrangements. The same physical enclosure housing is used across different power ratings, with internal component placement and conduit routing adapted to fit each configuration, eliminating the need for separate enclosures for each power level.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The VFD system is divided into modular components including the enclosure housing, flexible conduit sections, and interchangeable internal components. This segmentation allows the same enclosure to be configured for different power ratings by rearranging or replacing specific internal elements without changing the overall enclosure size or weight.

Inventive Principle:

Principle #1Segmentation

2Power

If the VFD enclosure size increases to accommodate higher power ratings, then the power handling capability is improved, but the volume of the system increases

Engineering Contradiction:

Improvepower handling capabilityVSAvoidVFD enclosure volume

Core Design Contradiction:

PowerVSVolume of stationary object

Solution Approach 1:

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system employs flexible conduit sections that can be routed and positioned dynamically to accommodate different internal configurations within the same enclosure volume. The flexible conduit allows adaptability in routing paths without requiring additional space, enabling the same enclosure to serve multiple power ratings efficiently.

Inventive Principle:

Principle #15Dynamics

3Power

If different power ratings require different VFD enclosure sizes, then the power handling capability is optimized, but the manufacturing complexity and tooling requirements increase

Engineering Contradiction:

Improvepower handling capabilityVSAvoidmanufacturing simplicity

Core Design Contradiction:

PowerVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system accommodates different power ratings by changing internal parameters such as component placement, conduit routing lengths, and mounting positions within the same enclosure, rather than changing the enclosure itself. This allows manufacturing to use a single enclosure template while adapting internal configurations for different power levels.

Inventive Principle:

Principle #35Parameter changes

4Power

If different power ratings require different VFD enclosure sizes, then the power handling capability is optimized, but the system weight increases

Engineering Contradiction:

Improvepower handling capabilityVSAvoidsystem weight

Core Design Contradiction:

PowerVSWeight of stationary object

Solution Approach 1:

Inventive Principle:

Principle #6Universality (Multi-functionality)

5Weight of stationary object

If the VFD enclosure size is reduced to a fixed size, then the weight and volume are reduced, but the adaptability to different power ratings must be maintained

Engineering Contradiction:

ImproveVFD enclosure weightVSAvoidadaptability to different power ratings

Core Design Contradiction:

Weight of stationary objectVSAdaptability or versatility

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Inventive Principle:

Principle #15Dynamics

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 system achieves a compact and modular design that simplifies manufacturing, reduces weight, and provides consistent performance across different power ratings while ensuring effective heat dissipation and protection against contaminants.

Implementation Method 1

a flexible conduit configured to adapt to different sizes of axial field rotary energy devices

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

an axial field rotary energy device having a printed circuit board (PCB) stator and rotor disks with permanent magnets

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentEP4535625B1Modular axial field rotary energy device with PCB stator and variable frequency drive system

Publication Date: 2026.04.29 INFINITUM ELECTRIC INC

Figure 1~3
Figure 4A~4B
Figure 4C~4D

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.