US 11,929,657 B1
Modular axial field rotary energy device with PCB stator and enhanced variable frequency drive system
Zachary Thomas Radkey-Pechacek, Leander, TX (US); John Mitchell Wilson, Cedar Park, TX (US); George William Vogel, Jr., Cedar Park, TX (US); Shriram Pushparaj Patil, Richmond, TX (US); Randal A. Lee, Austin, TX (US); and Paulo Guedes-Pinto, Round Rock, TX (US)
Assigned to INFINITUM ELECTRIC INC., Round Rock, TX (US)
Filed by INFINITUM ELECTRIC, INC., Round Rock, TX (US)
Filed on Sep. 27, 2023, as Appl. No. 18/373,644.
Int. Cl. H02K 5/06 (2006.01); H02K 5/02 (2006.01); H02K 11/00 (2016.01); H02K 11/33 (2016.01)
CPC H02K 5/06 (2013.01) [H02K 5/02 (2013.01); H02K 11/0094 (2013.01); H02K 11/33 (2016.01); H02K 2211/03 (2013.01)] 14 Claims
OG exemplary drawing
 
1. A system, comprising:
an axial field rotary energy device having:
an axis of rotation;
a rotor coaxial with the axis and having a shaft, bearings, rotor disks that are coaxial, permanent magnets on each rotor disk, and the permanent magnets on each rotor disk face toward each other;
a printed circuit board (PCB) stator located axially between the rotor disks to define an air gap on each side of the PCB stator between the PCB stator and each of the rotor disks;
a housing having two housing sections with at least one of the housing sections having an inspection port oriented radially, relative to the axis, and aligned with the PCB stator and the air gaps between the PCB stator and the rotor disks, such that the inspection port provides a direct line of sight to the air gaps; and the system further comprises:
a variable frequency drive (VFD) assembly comprising:
a VFD housing having:
first pads coupled to inductors to facilitate heat removal from the inductors;
a concave cradle coupled to a ferromagnetic core, the concave cradle has a same contour as an outer surface of the ferromagnetic core, and the concave cradle facilitates heat removal from the ferromagnetic core;
a second pad coupled to a rectifier module to facilitate heat removal from the rectifier module;
a third pad coupled to switching devices to facilitate heat removal from the switching devices, the third pad having pins to align the switching devices with the third pad, and spring clips to retain and apply uniform pressure to the switching devices; and
fourth pads with wire loops coupled to cables;
standoffs coupled to the VFD housing to support a first printed circuit board assembly (PCBA) comprising a rectifier module, a DC bus module, and an inverter module;
a second PCBA mounted to a shield plate above the first PCBA, and the second PCBA comprises:
an input/output (I/O) and communication module; and
light emitting diodes (LEDs) that indicate status;
mounting brackets coupled to the VFD housing and configured to be mounted to axial field rotary energy devices of different sizes;
a flexible conduit connects the VFD housing to the axial field rotary energy device; and
a safety barrier that provides selective access to power and communication terminals;
a main cover coupled to the VFD housing and having a seal that engages a first raised edge on the VFD housing; and
an access cover coupled to the main cover comprising:
a seal that engages a second raised edge on the main cover; and
light pipes aligned with the LEDs.