A stator serves as the heart of an electronic motor. This equipment is usually made of iron and it goes around a stationary part. The weight of a stator accounts for two-thirds of a motor. In order to reduce the weight of the stator, professionals recommended making the stator from a PCB.
Over the years, the PCB stator has gained a lot of popularity. The unique benefits and advanced performance of this stator makes contributed to its widespread use. Also, it is a better choice compared to conventional copper wound machines. Furthermore, the PCB rotor motor technology is beneficial for several applications. It offers effective solutions in some applications, thereby contributing to the performance of these systems.
There are several questions yet to be answered about the PCB stator motor. How does this equipment impact electronics and what is the difference between the stator and conventional copper wound machines? This article provides answers to all these questions.
What is a PCB Stator Motor?
The printed circuit board stator motor features conductive traces. Rather than the conductive traces, copper wires were used in conventional machines. With the PCB stator design, it was easier to precisely place conductive traces. Therefore, this contributed to the increased efficiency and enhanced performance of the PCB stator motor.
The use of copper wires in conventional machines has its limitations. To prevent such limitations, the PCB stator integrated the circuit board technology to maximize copper placement in the stator. In this case, the copper is only placed where it is required. As a result, we now have more efficient machines that only require a proportion of the copper.
PCB stators are available in a wide range of sizes and shapes. Therefore, it is well-suited for many applications. In a PCB stator, the copper coils are directly etched on the circuit board. The use of copper coils reduced the weight and size of stators.
Asides from reducing the weight and size by half, copper coils helps in getting rid of cogging, eddy current losses, torque ripple, and stator hysteresis. In the long run, this leads to an improved efficiency across many load conditions. Furthermore, the PCB stator makes automation much easier during the manufacturing process.
Specialized winding machines are often needed for the production of conventional copper wound stators. These machines are very expensive and complex to operate. On the other hand, PCB stator manufacturing doesn’t need these machines. This makes PCB stator a cost effective option.
Benefits of PCB Stator Motor
The PCB stator motor offers a durable and compact solution for a number of applications. With several benefits, this equipment has been found useful in high-performance applications.
Efficiency
One of the factors that contribute to the popularity of the PCB stator motor is its efficiency. It can produce a more powerful magnetic field due to its less resistance. PCB stators don’t need much energy to function well. With this, the battery life in devices can be longer.
Size and weight
Since PCB stators don’t have big metal components, they are lighte weight and very small in size. Therefore, they are suitable for use in applications where weight and space are a major concern.
Durability
Epoxy coating and metal laminations can cause mechanical failure in equipment. The absence of these things in a PCB stator motor helps to reduce the risk of damage and mechanical failure in stators. Furthermore, PCB stators are less prone to environmental factors and corrosion.
Precision control
This is one of the best benefits a PCB stator motor offer. It gives the user a better control of the operation of the motor. Also, this is beneficial for applications that need good motor control. Such applications include drones and robotics.
Better Flexibility
In order to achieve increased flexibility, a PCB stator is a much better choice than a copper wound stator. This is because you can place copper where it is required in a board. Also, you can construct PCB in several shapes.
Quiet Operation
PCB stator motors have fewer moving parts which makes them quiet while working. Also, they don’t vibrate while in operation.
Sustainability
PCB stator needs only a small fraction of copper and produce motors that use less energy. The motor design’s sustainability increases due to the PCB stator.
The Working Principle of a Stator
Every generator or motor features a stator. The stator is a heavy iron that comprises copper wire. The iron copper stator has been replaced by the PCB stator. There is a low amount of copper present in the PCB stator. This resulted in smaller and lighter weight stator.
Generally, a stator has a 3-phase supply which helps to produce the rotary magnetic field. However, this function will change according to machines such as generator, motor, and devices powered by fluids. The stator produces a rotary magnetic field in the motor. In a generator, the rotary magnetic field is changed into electric current. The stator directs how fluid flows to the rotating part of the system in fluid powered devices.
Eddy current losses are one of the problems associated with stators. However, there are ways to prevent or reduce such problem. The stator can be designed with quality alloy steel laminations. For a conventional wire wound stator, the integral parts of include the outer frame, core, and windings.
The PCB stator technology helped to create axial flux electric motor for electrification. With more development in the PCB stator technology, much has been achieved.
What is the Difference Between the PCB Stator and Traditional Electric Motor?
The PCB stator has replaced the use of the traditional electric motor. In a PCB stator motor, there are no copper winding and external iron. In this case, a single circuit board comprises copper circuit. This helps to minimize the loss of energy that occurs due to the core.
Furthermore, the PCB stator motor enables sensors and some electronic components to be directly installed on the circuit board. As for traditional electric motors, the components are mounted separately. The PCB stator ensures better efficiency than a regular electric motor. In terms of weight, there is a difference between the PCB stator and traditional electric motor. The PCB stator has a lower weight compared to the traditional type.
Due to the reduced weight of the PCB stator, it can get rid of torque ripple. Furthermore, the PCB enhances the insulation properties of the copper. This helps to prevent any possible short circuits or other failure. One of the benefits of the PCB stator is its cost effectiveness. It is a cheaper alternative to the traditional electric motor.
There is noise reduction and extension of the drive system lifespan. PCB stator motor has been used in applications ranging from medical pumps to robotics. Thermal dissipation is a major concern when it comes to the utilization of PCB stator. PCB stator has more surface ratio than a copper wire stator. Therefore, this enables better thermal dissipation.
With a larger surface ration, there is better thermal dissipation; hence, less copper is needed. Some of the key benefits of using PCB stator are cost reduction, reliability, greater efficiency, and weight reduction.
Functions of a Stator
There are many uses of a stator. A stator plays functional roles in a wide array of applications.
- A stator acts as a field magnet in a motor. This function is according to the rotating electromotive device.
- It is also used in a motor to provide a magnetic field
- It transforms the revolving magnetic field to electric current when used in a generator
- The stator creates motion by interacting through the armature.
- It directs the fluid flow to the rotary system when used in fluid-powered devices.
PCB Stator Manufacturers
ECM PCB Stator Technology
This company’s innovation has eliminated the use of copper winding in conventional electric motors. Its ultra-thin stator offers enhanced efficiency at minimized environmental impact. ECM PCB stator can withstand extreme environments. This lightweight stator provides no cogging and noise. Their PCB stator design is beneficial to the electric motor industry.
Infinitum Electric
The objective of Infinitum Electric is to develop high-end stator technology for smarter electric generators and motors. Its PCB stator technology is developed to provide unmatched durability and efficiency. The company which was founded in 2016 has been able to achieve great improvement in the operations of PCB stator. Also, their PCB stator has no copper windings which are usually present in the regular electric motors.
Conclusion
For more than several decades, electric motors have continued to evolve. Before the PCB stator came into the picture, the bulky copper wire stators were commonly in use. In such stators, the copper interacts with the magnet to create speed and torque. However, these stators need copper wire winding.
The PCB stator motor is a better alternative to the traditional electric motor. For better flexibility, a PCB stator is better than a copper wound stator. We have discussed every vital detail about the PCB stator in this article. Also, we compared the PCB stator with the copper wound stator.
