Segmented PCB Stator Layout for Modular Axial Field Motors
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Solution Overview
Problem
Conventional axial field rotary energy devices with PCB stators are complex, expensive, and not modular, making them difficult to manufacture and costly.
Innovation Solution
A modular axial field rotary energy device design featuring a rotor with a magnet and a stator composed of multiple PCB segments, each with a single electrical phase, where PCB layers are spaced apart and connected via vias to form a continuous coil configuration, enhancing manufacturing efficiency and reducing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional axial air gap brushless motors with layered disk stators are used, then the motor structure is established, but the motor becomes relatively large and difficult to manufacture
Solution Approach 1:
The stator is divided into multiple discrete PCB segments that can be manufactured separately and then assembled together. Each PCB segment contains specific coil windings and can be produced using standard PCB manufacturing processes, significantly simplifying the overall manufacturing complexity compared to traditional layered disk stators.
Solution Approach 2:
Traditional mechanical wire winding and interconnection methods are replaced with PCB-based electrical connections. The coil windings are created using standard PCB trace and via technologies, eliminating complex manual winding operations and reducing manufacturing difficulty.
2Ease of manufacture
If PCB stators are used in axial field electric devices, then the device structure is defined, but the design becomes complicated and relatively expensive
Solution Approach 1:
The PCB stator is segmented into multiple independent PCB boards, each handling specific phases or coil groups. This segmentation allows for standardized design modules that can be reused and simplified manufacturing processes while maintaining the overall device functionality.
Solution Approach 2:
The PCB segments are designed with universal connection interfaces and standardized mounting patterns, allowing the same basic design to be used across different device configurations. This universality reduces design complexity and enables economies of scale in manufacturing.
3Ease of manufacture
If traditional stator designs are used, then the motor functions, but it is not modular and difficult to manufacture
Solution Approach 1:
The stator is constructed from multiple independent PCB segments that can be manufactured separately using standard PCB processes and then assembled together. This segmentation enables modular manufacturing, improving production efficiency and allowing for easier assembly and maintenance.
Solution Approach 2:
The modular PCB segment design allows individual segments to be replaced or upgraded independently without requiring replacement of the entire stator assembly, improving maintenance efficiency and enabling component-level optimization.
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 design improves manufacturing ease and reduces costs while maintaining performance by utilizing a modular structure with efficient coil connections, allowing for cost-effective production of axial field rotary energy devices.
Implementation Method 1
PCB layers are spaced apart and connected via vias to form a continuous coil configuration
Implementation Method 2
axial field rotary energy device can include a rotor comprising an axis of rotation and a magnet; and a stator coaxial with the rotor
Implementation Method 3
rotor comprising an axis of rotation and a magnet; and a stator coaxial with the rotor
Data Source
AI summary
An axial field rotary energy device can include a rotor comprising an axis of rotation and a magnet. In addition, a stator can be coaxial with the rotor. The stator can include a plurality of stator segments that are coupled together about the axis. Each stator segment can include a printed circuit board (PCB) having a PCB layer comprising a coil. Each stator segment also can include only one electrical phase. The stator itself can include one or more electrical phases.