Segmented Stator Design for Large Axial Field Machines
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Solution Overview
Problem
The size limitations of one-piece printed circuit board (PCB) stators in rotary energy devices restrict the production of large axial field machines, making them costly due to higher labor and material expenses in lower volume facilities.
Innovation Solution
A segmented stator design using multiple layers of printed circuit board power and series conductor layers arranged in an annular array, with daughter PCBs for electrical connections between segments, allowing for larger diameter machines and cost-effective high-volume manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a one-piece printed circuit board stator is used, then manufacturing simplicity is maintained, but machine size is limited and costs increase for large diameter machines
Solution Approach 1:
The stator is divided into multiple segments that can be manufactured separately using standard PCB fabrication processes and then assembled together to form the complete stator assembly. This allows large diameter machines to be constructed from smaller, manufacturable components while maintaining the benefits of PCB-based manufacturing.
2Strength
If a one-piece printed circuit board stator is used, then structural integrity is maintained, but manufacturing cost increases for large diameter machines due to lower volume facilities
Solution Approach 1:
By segmenting the stator, each individual segment can be manufactured in high-volume facilities using automated PCB processes, achieving economies of scale. The segments are then joined together with appropriate fastening and electrical connection mechanisms to restore structural integrity for the complete assembly.
3Length of stationary object
If segmented stator design is used, then large diameter machine production becomes cost-effective, but manufacturing complexity increases due to multiple assembly steps
Solution Approach 1:
The stator is divided into multiple segments that can be manufactured separately using standard PCB fabrication processes and then assembled together to form the complete stator assembly. This allows large diameter machines to be constructed from smaller, manufacturable components while maintaining the benefits of PCB-based manufacturing.
Solution Approach 2:
Daughter printed circuit boards are used as intermediary components to provide electrical connections between adjacent stator segments. These daughter boards simplify the electrical interconnection process and provide a standardized interface for assembling the segmented stator structure.
Data Source
AI summary
An axial rotary energy device including a segmented stator assembly having a plurality of segments arranged in an annular array. Each stator segment is constructed by stacking a plurality of PCB power conductor layers and a plurality of PCB series layers. Each layer having radial conductors extending from an inner via to an outer via. The vias electrically connect selected radial conductors of the series conductor layer and power conductor layer. Each power conductor layer includes a pair of positive and negative terminal vias for one phase of the electric current connected to selected outer vias. A daughter PCB layer electrically connects two adjacent segments together by having a first portion electrically connected to a negative terminal via located in one segment and a second portion electrically connected to a positive terminal via located in an adjacent segment together with a current conductor electrically connecting the two terminal vias together.