3D printed axial flux motor

MOTORPRINTER - Best Electric Machine

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MOTORPRINTER is a patented 3D Printer for the just-in-time additive manufacture of the highest performance electromagnetic axial-flux cores with integral frame and winding assemblies for low or high frequency, high power electric motors, generators, and transformers (i.e., electric machines).

MOTORPRINTER uniquely layers readily available materials that are optimally pre-manufactured to be ultra price-performance enhanced: 1) for the electric machine magnetic core component, such as ultrathin, high performance amorphous metal or nanocrystalline metal ribbon that provides 10x the permeability and 80% lower core loss than electrical steels but with similar flux saturation, 2) for the integral structural frame component, such as high performance structural building materials, and 3) for the multiphase winding component, such as high performance shaped magnetic wire.   In contrast, layering material of all other 3D Printers is optimally pre-manufactured to be price-performance compatible with the 3D Printer and not for the product being manufactured. As a result, a practical electric motor 3D Printer has never materialized until MOTORPRINTER.

MOTORPRINTER eliminates the high capital equipment, offshored oppressed labor, and large facility costs of traditional century old, assembly line electric machine manufacture with a portable, scalable, low waste, non-smokestack, compact, remotely controlled, additive manufacturing footprint (e.g., shipping container).

MOTORPRINTER is essential for manufacturing high power, high frequency magnetics (e.g., transformers) with the highest performance magnetic materials: a) for leveraging the switching speed, high temperature performance of wide bandgap semiconductors, b) for facilitating high efficiency and compact power conditioning, c) for automatic frequency and phase translation, such as only provided by a position dependent flux high frequency transformer of Brushless Real Time Emulation Control (BRTEC), and d) for implementing the only symmetric synchronous electric machine system, called SYNCHRO-SYM.

MOTORPRINTER is a patented “method” for rapidly and additively manufacturing ultrahigh performance, low or high frequency, high power axial-flux electric motor, generator, and transformer cores (i.e., axial-flux “electric machine” cores) of any programmable size or power rating: 1) with readily available, environmentally friendly, and optimally pre-manufactured layering materials that are exclusively made for the performance of the electric machine product, such as ultrathin nanocrystalline, amorphous, or electrical steel ribbon, magnet wire, and structural materials, instead of traditional layering materials that are specifically manufactured for compatibility with the 3D Printer, 2) with perfectly aligned slots and internal channels of any programmed shape (for containing windings, permanent magnets, reluctance saliencies, etc.), 3) without damaging the delicate attributes of the pre-processed high performance materials, such as amorphous metal ribbon, 4) without the extraneous time and cost of secondary or post-process operations, such as Blanchard grinding for a precision flat air-gap surface, 5) without tool wear, and 6) with winding and integral frame assemblies from inexpensive, readily available, optimally pre-manufactured, high performance magnet wire and structural steel, aluminum, or composite building materials, instead of the traditional inventory of pre-designed and pre-ordered casted components.

NOTE: Electric machines, which include compact and efficient high frequency transformers, are the essential backbone components of the entire electricity infrastructure. Furthermore, magnetic core material with high flux saturation limits, high permeability, and low core loss that can be conveniently manufactured into high power, high frequency magnetic cores is essential. Evolving material science is improving nanocrystalline or amorphous metal ribbons for high power, high frequency cores while preserving low loss, high flux saturation, and high permeability but still, manufacturing of moderately complex transformer cores with these materials has not been practical. Also, soft magnetic composite materials, such as ferrite, show low permeability, low flux saturation limits, or are difficult to structurally form in the large size factor for high power applications. As the only empirically proven laminated object manufacturing (LOM) 3D Printer with solid amorphous or nanocrystalline metal ribbon, the patented MOTORPRINTER is an essential enabler of the smart electricity infrastructure.

NOTE: As a patented “method,” which protects the manufacturing IP and more importantly, the product manufactured with the IP, MOTORPRINTER will democratize the distributed manufacture of electric machines by mitigating unfair trade practices, such as offshoring for low cost oppressed labor, and by conveniently localizing and scaling rapid just-in-time electric machine manufacturing at the research facility, at the boutique motor manufacturing facility, or at the traditional OEM manufacturing facility.

NOTE: Unlike all other 3D Printers, which utilize specially pre-manufactured raw materials to be specifically compatible with the 3D Printer without regard to the product being 3D Printed, MOTORPRINTER rapidly 3D Prints axial flux electric machines just-in-time by directly using readily available pre-manufactured materials with the lowest cost and highest performing electromagnetic and structural properties for the highest electric machine efficiency and smallest size, such as amorphous metal ribbon.

NOTE: Although virtually the entire base of rotating electric machine manufacturing is devoted to the radial-flux form (or rotor cylinder inside a stator cylinder form) because of traditional manufacturing technology limitation, the axial-flux form of electric machine (or adjacent stator and rotor disks) has been shown to reduce copper utilization by 13-14% and iron utilization by 21.5-32.5%, while providing higher torque density and finer air-gap depth control without rotor and stator surface contention during over speed but requires a more robust frame and bearing assembly.

NOTE: The axial-flux formfactor provides a non-obstruction outside-to-inside winding approach for automation of any winding style with the potential for orthocyclic winding fill factor (e.g., 90%). In contrast, the radial-flux inside-to-outside winding approach is not friendly to automated winding, except for the hairpin winding style, which may provide a high fill factor (e. g., 90%) and efficiency at low speeds. MOTORPRINTER’s axial-flux formfactor at least neutralizes any perceived advantages of hairpin windings, while providing rapid, just-in-time additive electric machine manufacture.

NOTE: Under design control of BEM’s computer aided design tool (BEM-CAD), MOTORPRINTER simultaneously 3d-Prints the high frequency power magnetic core of the electronic power conditioner conveniently integrated into the annulus of the low frequency axial-flux electric machine core for another level of electric machine system power density. In contrast, all others electric motor manufacturers place the entire power electronic real-estate, which includes the high frequency magnetics, of the so-called smart motor system in a separate box chassis mounted on the outside of the electric motor frame.

NOTE: Where other electric machine manufacturers traditionally repackage and manufacture their me-too asymmetric electric machine system from the same off-the-shelf core stamped laminations, castings, etc. , BEM is just-in-time, additively manufacturing the only symmetric synchronous doubly-fed electric machine system, called SYNCHRO-SYM, with its patented 3D Printer of amorphous metal axial-flux electric machine cores with integral frame and winding assemblies, called MOTORPRINTER.

MOTORPRINTER performance with amorphous metal ribbon has been empirically studied and successfully proven through the formulation, orchestration, and coordination of BEM with the original inventor, the foundry of amorphous metal ribbon (i.e., Metglas), and several fiber laser companies (e.g., IPG Photonics). More information can be found in the MOTORPRINTER whitepaper and a study by Metglas. Also, BEM developed a Computer Aided Design tool (BEM-CAD) for the design and programming of MOTORPRINTER manufacture of axial flux electric machine cores with integral frame, bearing bezel, and winding assembly.

It follows that being compatible with available, highly optimized, premanufactured layering material, MOTORPRINTER fabrication, integration, and manufacturing operation has no risk without the customary engineering solution.

PRODUCT → WHITE PAPERS:

THE NEED FOR 3D PRINTING OF AIRPLANE ELECTRIC MACHINES

▷ brushless permanent magnet motor design with axial flux 3d models 【 STLFinder 】

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Tags: Motor PCB new technology

At first I just wanted to make a very small drone. But I quickly realized that there was a limiting factor in my design, namely the size and weight of the engine. Even a small motor is still a discrete device and needs to be connected to all other electronic components and structural components. So I started to wonder if there was a way to combine these components and reduce the quality a bit.

My inspiration comes from how some radio systems use antennas made from copper wires on a printed circuit board (PCB). Can I use something similar to create a strong enough magnetic field to drive a motor? I decided to see if electromagnetic coils made from PCB tracks could be used to make axial flow motors. In an axial flow motor, the electromagnetic coils that form the motor stator are mounted parallel to the disc-shaped rotor. Permanent magnets are built into the rotor disk. The stator coil is driven by alternating current to rotate the rotor.

The first task is to make sure that I can generate enough magnetic flux to spin the rotor. Designing a flat helical coil and running current through it is very easy, but I limited my motor diameter to 16mm so that the diameter of the entire motor would be comparable to the diameter of the smallest completed brushless motor. 16mm means I can fit a total of 6 coils under the rotor disc, with about 10 turns per coil. Ten turns is not enough to generate a large enough magnetic field, but it is easy to make multilayer printed circuit boards these days. By printing in stacked spools (with spools on each of the four layers), I can get 40 turns per spool, enough to turn the rotor.

As the design progressed, a more serious problem arose. To keep the motor rotating, the dynamically changing magnetic field between the rotor and stator must be synchronized. In a typical AC driven motor, this synchronization occurs naturally due to the arrangement of the brushes connecting the stator and rotor. A brushless motor requires a control circuit that implements a feedback system.

In the brushless motor I made before, I measured the back EMF as feedback for speed control. The reason for back EMF is that a rotating motor is like a small generator generating a voltage opposite to the voltage used to drive the motor in the stator winding. Reverse EMF induction can provide feedback information about how the rotor is turning and allow the control circuit to synchronize the coils. But in my PCB motor, the back emf is too weak to use. To this end, I installed a Hall effect sensor that can directly measure the change in the magnetic field to measure the speed of the rotor and its permanent magnet rotating above the sensor. This information is then entered into the engine control circuit.

To make the rotor itself, I turned to 3D printing. At first I made a rotor, mounted it on a separate metal shaft, but then I started printing a fixing shaft as an integral part of the rotor. This simplifies the physical components down to a rotor, four permanent magnets, a bearing, and a circuit board that provides the coils and structural support.

I received my first electric motor quickly. Tests show that it can generate 0.9g/cm static torque. It wasn't enough to reach my original goal of making a motor built into a drone, but I realized that this motor could still be used to move a small and cheap robot -wheels on the ground, so I insisted on researching (the engine is usually one of the most expensive parts on a robot). This print motor can run from 3.5 to 7 volts, although it gets quite hot at higher voltages. At 5V, its operating temperature is 70°C, which can still be controlled. It consumes about 250 mA of current.

I've been working hard at the moment on increasing engine torque (you can follow the research progress I keep posting on Hackaday. https://hackaday.io/project/39494-pcb-motor). By adding a ferrite sheet to the back of the stator coil to hold the coil's magnetic field lines, I can nearly double the torque. I am also working on other prototypes with different winding configurations and more stator coils. Also, I was trying to use the same technology to build an electric PCB actuator that could drive a 3D printed slider sliding over a row of 12 coils. Also, I'm testing a flexible PCB prototype that uses the same printed coil for an electromagnetic drive. My goal - even if I can't build a small drone that can fly in the sky - is to start building robots with smaller and simpler mechanical structures than existing robots.

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