Stator Module Connector Design for Planar Drive Thermal Management
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Solution Overview
Problem
Planar-drive systems face challenges with high resistance losses and heating issues in stator modules due to high-power drive currents, which affect the efficiency and reliability of rotor movement in electric planar-drive systems.
Innovation Solution
A stator module design featuring a power module and a stator assembly connected via a connector with contact pins, allowing for a mechanically rigid and thermally flexible connection, enabling efficient transfer of drive currents while minimizing heat dissipation challenges through a cross-shaped arrangement and press-fit connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If high-power drive currents are generated to transmit sufficient force to the rotor, then the driving force is improved, but resistance losses and heating of the stator increase
Solution Approach 1:
The stator is divided into multiple independent stator modules, each with its own power module and connector. This segmentation allows the system to distribute high-power drive currents across multiple modules, reducing resistance losses in each individual module while maintaining sufficient driving force overall.
Solution Approach 2:
The connector extends in an elongated manner along both the first and second directions, creating a two-dimensional connection arrangement. This dimensional approach allows for optimized current distribution paths and reduces resistance losses by spreading the electrical load across multiple contact pins arranged in a grid-like pattern.
2Force
If high-power drive currents are generated to transmit sufficient force to the rotor, then the driving force is improved, but heating of the stator increases
Solution Approach 1:
The stator is divided into multiple independent stator modules, each with its own power module and connector. This segmentation allows the system to distribute high-power drive currents across multiple modules, reducing resistance losses in each individual module while maintaining sufficient driving force overall.
Solution Approach 2:
Different regions of the stator module are designed with different properties - the connector region is designed for optimal electrical connection and heat dissipation, while the stator assembly region is optimized for magnetic field generation. This local differentiation allows for better thermal management in high-current areas.
3Stability of the object's composition
If the power module and stator assembly are mechanically fastened rigidly, then structural stability is improved, but thermal expansion and contraction are constrained
Solution Approach 1:
The connector serves as a flexible intermediate element between the power module and stator assembly. While providing mechanical fastening and electrical connection, the connector's elongated structure with multiple contact pins allows for controlled flexibility, accommodating thermal expansion and contraction without creating excessive stress on the rigid components.
Solution Approach 2:
The mechanical connection between power module and stator assembly is made dynamically adaptable through the connector design. The connector can adjust its mechanical properties to allow for thermal movement while maintaining structural integrity, transitioning between rigid and flexible states as thermal conditions change.
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 solution provides a stable and efficient means to drive the rotor in multiple directions with reduced thermal issues, allowing for independent control of power modules and improved heat dissipation, enhancing the overall performance and reliability of the planar-drive system.
Implementation Method 1
a driving force is exerted onto the rotor by current-carrying conductors magnetically interacting with drive magnets of a magnet arrangement
Implementation Method 2
The power module and the stator assembly are each plate-shaped. The power module is mechanically fastened to the stator assembly by the connector
Data Source
AI summary
A stator module for driving a rotor of an electrical planar-drive system comprises a power module, a stator assembly arranged on a top surface of the power module, and a connector. The power module is embodied to provide drive currents for driving the rotor. The stator assembly comprises coil conductors electrically connected to the power module via the connector for charging with the drive currents. The power module and the stator assembly each have a plate-shaped embodiment. The power module is mechanically fastened to the stator assembly by the connector. The stator assembly comprises a contact structure with contact holes arranged side by side, and the power module comprises a connecting arrangement with further contact holes arranged side by side. The connector comprises contact pins arranged side by side to engage in the further contact holes of the connecting arrangement, and in the contact holes of the contact structure.