PCB Stator Axial Flux Motor With Modular VFD Enclosure Scaling
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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, 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 axial field rotary energy device's power rating, featuring a separate enclosure with IP54 or IP55 protection, selective access for cable connection, and heat dissipation capabilities, allowing for interchangeable mounting on various device sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the VFD enclosure size increases with the device's power rating, then the axial field rotary energy device can handle higher power, but the volume and weight of the system increase
Solution Approach 1:
The system is divided into two independent modules: the axial field rotary energy device and the VFD enclosure. The VFD enclosure is designed as a separate, standardized unit that can be independently sized and then coupled to different device sizes, breaking the direct proportional relationship between device power and VFD volume.
Solution Approach 2:
A single standardized VFD enclosure design is created that can serve multiple power ratings (5 hp, 7.5 hp, 10 hp, 15 hp) through universal mounting features and adaptable cable access points. This universal enclosure replaces the need for multiple size-specific enclosures.
2Power
If the VFD enclosure size increases with the device's power rating, then the axial field rotary energy device can handle higher power, but the weight of the system increases
Solution Approach 1:
The system is divided into two independent modules: the axial field rotary energy device and the VFD enclosure. The VFD enclosure is designed as a separate, standardized unit that can be independently sized and then coupled to different device sizes, breaking the direct proportional relationship between device power and VFD volume.
Solution Approach 2:
A single standardized VFD enclosure design is created that can serve multiple power ratings (5 hp, 7.5 hp, 10 hp, 15 hp) through universal mounting features and adaptable cable access points. This universal enclosure replaces the need for multiple size-specific enclosures.
3Power
If different parts and tooling are required for different device sizes, then each power rating can be optimized, but the manufacturing complexity increases
Solution Approach 1:
A single standardized VFD enclosure design is created that can serve multiple power ratings (5 hp, 7.5 hp, 10 hp, 15 hp) through universal mounting features and adaptable cable access points. This universal enclosure replaces the need for multiple size-specific enclosures.
Solution Approach 2:
The VFD enclosure incorporates adaptable features such as adjustable cable access points and flexible mounting configurations that can accommodate different device sizes without requiring custom tooling or parts, enabling a static enclosure design to serve dynamic manufacturing needs.
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.