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E-Circuit Motors

Advantages

High Operating Efficiency
ECM acquired license rights to ~90% efficient variable speed motor technology. In less than 18 months ECM has advanced the technology to ~95% efficiency.  ECM believes these numbers are Game Changing for many current applications and enabling for many more.

Superior Torque Density – Low Mass
ECM machines produce the same torque with less than half the mass (Nm/kg) of many competing designs.

Thermal Performance
Even high-efficiency motors and generators face challenges in removing heat, particularly when operating 24/7.  ECM has developed and validated a novel design to effectively remove heat. ECM has filed a utility patent and patent art searches suggest that ECM will obtain broad patent protection.

Computer-automated Stator Design
E-Circuit motor’s proprietary software automatically and effortlessly translates E-Circuit motor design specifications to production-ready drawings (Gerber Files) that can be manufactured world-wide.   This reduces a months-long design process using generic CAD tools to a few seconds of computer time.  The software also integrates all new efficiency enhancing design features proprietary to E-Circuit Motors.

Computer-automated Optimization
The optimization of E-Circuit Motor designs to meet a customer’s specifications via our proprietary software is a crucial feature.  This process can be done interactively with a customer to quickly generate multiple designs to meet their varied requirements.  In the past printed circuit board motors designs were produced by hand with the aid of a spreadsheet calculator driven by the experience and intuition of a few people.  Numerous prototypes were required to obtain real-world performance meeting specifications.  E-Circuit motors has developed accurate motor optimization software that integrates with our existing stator design program.  The modeling framework supporting this tool is being perfected using data from each round of E-Circuit prototypes, and trial versions of this software that can be used by any member of technical staff is being perfected now.

 

Simple Componentry
ECM motors consist of a housing unit, and rare earth magnets on each side of a printed circuit board (“PCB”) manufactured stator. Eddy current losses and resistance losses are minimized through ECM’s patent pending design innovations.

Quality of Motion
With no steel in the stator all cogging is eliminated (i.e. no flux reversals).

Robust Manufacturing Process
ECM’s stator is manufactured using the same advanced technologies used in PCB production. Using proprietary in-house design and optimization software ECM is able to electronically transfer stator design files directly to the PCB manufacturer.  Once the stator is etched or “printed” on each layer, they are stacked, pressed, drilled, and plated. This highly automated process is ubiquitous, low cost and prone to fewer errors (if any).

Systems Design
The flexibility of the ECM design often eliminates the mechanical losses associated with a gearbox, and leverages the higher efficiencies at lower operating speeds enabled by permanent magnet rotor excitation.

Power Electronic Integration
ECM motors (like all BLDC motors) require the use of power electronics to affect variable speed control. ECM has produced and tested a stator design for operation under sensor-less control. This design eliminates placed components and associated manufacturing costs required for prior designs. It also integrates seamlessly with the latest control topologies.

Durability
End turn insulation failure is a primary mode of failure in all traditional motors.  ECM machines have windings that are completely constrained and encapsulated – including the end turns.  PCBs have been run through HALT (highly accelerated life test) thermal, vibration, and cycle testing with impressive results. Materials designed for extreme environments can be incorporated into an ECM machine for the harshest conditions.