6 components 5 styles 12 variants

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Information about 6 components 5 styles 12 variants

Published on September 27, 2015

Author: SteveK8

Source: slideshare.net

1. 6 Components - 5 Styles -12Variants - Endless Possibilities As shown so far, by simply rearranging the same set of 4 core components we can create different styles of motors. Core components include: magnets, 4 pole stators, 6 pole stators, and bobbin wound coils (wire and a bobbin). In the present context a bobbin wound coil is considered a single component. The coils may be wired or connected differently for different styles of motor, and they may or may not use different numbers of turns of different gauges of wire to better suit different purposes, but in the present context a bobbin wound coil is considered a single component regardless of those differences. Three motor styles have been disclosed so far: Stepper, 3 phase, and Synchronous. We could include three possible styles of stepper motor; bipolar, unipolar, and universal and then we could say we can create 5 styles of motor using the same core components. However, presently we’ll consider the Stepper as one basic style of motor, having three variants. Upon further investigation we find a fourth basic styles of motor can be added to the lineup, again using the same core components. I’m not going to disclose details of this fourth style just yet, but it is simple, robust and the fundamentals of it are well known. Now, if we make a slight modification to one of our core components and add one small inexpensive part we can create a fifth basic style of motor. Again, I don’t intend to disclose details at this time, but it too is simple, robust, and while the fundamentals of this fifth style are well known, it is a simpler configuration than any previous design that I’m aware of. With regards to driving these five basic styles of motor all but one of them can be driven directly from AC current at any available frequency. Stepper motors require some form of PWM to run, and the circuitry can be simple or sophisticated. Some applications of these motors will require rotor position sensors, and others will not. Adding rotor position sensing technology increases the sophistication and cost of the motor and driver, but they offer benefits that can outweigh the added costs. On the other hand, for applications that do not need rotor position sensing, like most pumping applications for example, being able to omit sensor technology means creating a more robust design. Fewer parts = fewer potential problems. Using PWM we can mimic line frequencies to run any motor that can run directly off of power mains and we can control the speed, and other aspects of the motor as well. We can get quite creative here. For instance, we could even drive a 3 phase motor like a stepper motor. We could run our synchronous motor as a stepper that runs in only one direction. We could drive our fourth and fifth (undisclosed) styles of motors in unusual ways too. Page of1 2

2. I have not examined all of the possible combinations in great detail, but if we add to our five basic styles of motors all the variants of stepper styles, we come up with about 12 styles of motors that might be created using 6 core components. Again, I haven’t spent a lot of time analyzing how the variants of stepper style drive schemes could be used in each of the basic motor styles. So, by simply rearranging 6 core components we can create 5 basic styles of motor and 12 variants. We can then multiply the above with perhaps 10 different voltage ratings to get 120 different motors using the same 6 core components. That’s a pretty good return on investment in tooling, and it minimizes the parts needed to be kept in inventory. So far we have not discussed components used in hybrid machines. If we introduce just 10 possible rotor combinations, i.e. material and function, our 120 possible motors becomes 1,200 possible hybrid motors. If we introduce just 10 possible combinations of materials and functions for the housings, the options jump to 120,000 variations. If we have 10 sizes, or sets of core components (a superset?) the number of possible options skyrockets to 1.2 million. In reality we could tweak the rotor and housing designs endlessly, making the possible combinations based on the same superset of 60 core components unlimited. This where users customize rotors and housings to suit their specific applications and use these hybrid axial flux motors to drive them. It’s relatively easy and inexpensive to design and manufacture rotors and housings in low, medium or high volume.The core components on the other hand require specialized engineering using fairly expensive software. Also, the core components while being relatively low cost to produce in high volume are cost prohibitive to produce in low volume. The keys then to getting these hybrid axial flux machines used across the boards in unlimited variations is to create a representative number of hybrid machines from a superset of core components and empower others to incorporate the machines, and the core components into their own designs. Show people how to design with hybrid machines using online examples, templates, and by making prototype kits available for designers, inventors, artisans, and engineers. The core components can then find their way into all manner of products, from children’s toys to household appliances, office machines, automotive, medical, military, aerospace applications and more. All based on 6 core components and 5 basic motor styles. stevekube@gmail.com Page of2 2

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