Introducing the Field Modulation Motor with
The Team Who is we? George Bennett Optimal Motion, Inc. Dan Jones Incremotion Associates, Inc. Carl Copeland Floor 36, Inc. 2
Introducing the Field Modulation Motor 3
What is a Field Modulation Motor? It's a motor design with a unique, 3D magnetic path consisting of: A flux stator A field stator A central rotor 4
Field Modulation Motor What is Novel? Magnetic Design The Twin Stators Field stator with permanent magnets Provides consistent BEMF & motive forces Creates optimal gap condition (even with 4 air gaps) Flux stator Can greatly vary with minimal impact Provides materials flexibility modulates field stator s motive forces on rotor 5
Field Modulation Motor What is Novel? Magnetic Design The Twin Stators Magnetically Isolated Stator Assemblies 3 arrays of 12 stators Full magnetic isolation Modular, swappable stator assemblies 6
Field Modulation Motor What is Novel? Magnetic Design The Twin Stators Magnetically Isolated Stator Assemblies Central Rotor Ultralight design Impermeable, non-magnetic composite support structure materials Minimal permeable material Very low inertia 7
Field Modulation Motor What is Novel? Magnetic Design Multiple Phases Magnetic Isolation allows for individual positioning of stators Stators connected to form 12 phases per array Wired for 6 3-phase motors on a common shaft But Why 3 arrays? 8
Field Modulation Motor What is Novel? Magnetic Design Multiple Phases Mechanical Torque Balancing 36 stator x 11 rotor configuration 0.9 position steps, 0.45 half steps Imperceptible detent torque Uniquely unaffected by load or saturation Ultra-smooth stepping easily damped Extremely good acoustics 9
The Field Modulation Motor Culminating in the Field Modulation Stepper Motor 10
Where we started from Over 6 years of intense R&D, we hired 6 firms to assist in optimization, FEA and simulation development. We burned through 4 FEA solutions and 3 simulations. Data was inaccurate, prototypes disappointing & progress illusive. Partnered with Incremotion & Optimal Motion on 7 th iteration. 11
What we discovered Traits so unique; leading experts were laid waste, highly advanced FEA software platforms and techniques are rendered useless. No current FEA system or simulation successfully modeled it. A custom simulation had to be built from the empirical data. Custom controls and electronics had to be developed to measure it. 12
What we got Unique resonant power generator system Highly reliable for remote applications Switches loads without contactors Each load is fully isolated Full short protection Low RPM, high power direct drive (no gearbox) Prototype can handle 160 HP High performance, high power stepper. And More to come 13
The Resonant Generator How it works 14
Field Modulation in a Stepper Motor 6 Parallel motors at 12 poles gives 0.909 degrees/step Size starts with standard size 42, size 85 is quite usable Ultra-smooth motion No cogging torque 3 phase operation can be easily damped Lower inertia, better time constants Ultra-low acoustics 15
Unique Traits of Architecture as Motor High power/speed stepper Infinitesimally low detent torque Very strong restoring force & powered position holding Trapezoidal waveform Ideal 6 step operation (half steps) Linear micro-stepping (no sine tables) Excellent Direct Drive performance Ultra-low inertia High phase count Excellent low speed torque Optimal direct drive with high torque No complex vector control needed 16
Trapezoidal Back EMF Very steep transitions Good position holding Easy drive 2 coils in series cancel odd harmonics 17
Variable Holding Torque Slope 18
Projected Parameters 19
18 Phase Driver Electronics That s a lot of phases to control! Needs a small FPGA A 24 transistor drive circuit is under development Are the controls more expensive? Each is ¼ the rating of a conventional 3 phase motor Efficiency goes up Parts volume goes up Size goes down Form factor improves flatter layouts Wire costs are the same ($/lb.) 20
Unique Architecture High Power Near Zero Detent Torque Direct Drive 3 Phase Operation Low Acoustics Scalability Size, Speed, Power & Precision The Field Modulation Motor 21
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