A method and arrangement is disclosed herein for making a stator with 3D printed end turns. The stator includes a stator lamination stack with semi-closed slots. Straight I-pin wire segments are housed in the slots of the stator lam stack and form the in-slot segments of a stator winding arrangement. The end turns of the winding arrangement are provided by a conductive material that is 3D printed material at both axial ends of the straight I-pins. The end turns result in a winding arrangement with diamond coils that are inter-locked. The 3D printing of the end turns makes the winding arrangement possible, as the winding arrangement is configured such that it cannot be inserted into the lamination stack in a radial direction (i.e., via any slot openings at the inner diameter or outer diameter).

A method and arrangement is disclosed herein for making a stator with 3D printed end turns. The stator includes a stator lamination stack with semi-closed slots. Straight I-pin wire segments are housed in the slots of the stator lam stack and form the in-slot segments of a stator winding arrangement. The end turns of the winding arrangement are provided by a conductive material that is 3D printed material at both axial ends of the straight I-pins. The end turns result in a winding arrangement with diamond coils that are inter-locked. The 3D printing of the end turns makes the winding arrangement possible, as the winding arrangement is configured such that it cannot be inserted into the lamination stack in a radial direction (i.e., via any slot openings at the inner diameter or outer diameter).

An axial field rotary energy system has a housing and rotors with an axis of rotation that are rotatably coupled to the housing. Each rotor includes a magnet. A stator assembly is located axially between the rotors and coupled to the housing. The stator assembly has a printed circuit board (PCB). The PCB includes a plurality of layers, and each layer has coils. A shaft is coupled to the rotors and the housing. The shaft can dispense a liquid coolant between the rotors and stator assembly. The housing can include a sump to collect the liquid coolant.

An axial field rotary energy system has a housing and rotors with an axis of rotation that are rotatably coupled to the housing. Each rotor includes a magnet. A stator assembly is located axially between the rotors and coupled to the housing. The stator assembly has a printed circuit board (PCB). The PCB includes a plurality of layers, and each layer has coils. A shaft is coupled to the rotors and the housing. The shaft can dispense a liquid coolant between the rotors and stator assembly. The housing can include a sump to collect the liquid coolant.

A manipulator arm for a robot, including a printed circuit board motor and a transmission, the printed circuit board motor including a multi-layer board having at least one first solenoid coil with flat coils lying vertically on top of each other, the flat coils being connected electrically in series or in parallel, two vertically adjacent coils being orthogonally offset to each other in each case such that, in a cross-section perpendicular to the surface of the multi-layer board, conducting track portions of the one flat coil are arranged in partial overlap vertically with two conducting track portions of the other flat coil. A robot having at least one manipulator arm of this type and the use of a printed circuit board motor in a manipulator arm of a robot are also provided.

A manipulator arm for a robot, including a printed circuit board motor and a transmission, the printed circuit board motor including a multi-layer board having at least one first solenoid coil with flat coils lying vertically on top of each other, the flat coils being connected electrically in series or in parallel, two vertically adjacent coils being orthogonally offset to each other in each case such that, in a cross-section perpendicular to the surface of the multi-layer board, conducting track portions of the one flat coil are arranged in partial overlap vertically with two conducting track portions of the other flat coil. A robot having at least one manipulator arm of this type and the use of a printed circuit board motor in a manipulator arm of a robot are also provided.

A coil substrate according to an embodiment includes an insulating layer; a first coil pattern portion disposed on one surface of the insulating layer; a second coil pattern portion disposed on the other surface of the insulating layer; and a pad portion disposed on the one surface of the insulating layer and connected to the first coil pattern portion, wherein the first coil pattern portion includes: an inner coil pattern portion; and an outer coil pattern portion spaced apart from the inner coil pattern portion at a predetermined interval and disposed outside the inner coil pattern portion, wherein the pad portion is disposed between the inner coil pattern portion and the outer coil pattern portion.

A coil substrate according to an embodiment includes an insulating layer; a first coil pattern portion disposed on one surface of the insulating layer; a second coil pattern portion disposed on the other surface of the insulating layer; and a pad portion disposed on the one surface of the insulating layer and connected to the first coil pattern portion, wherein the first coil pattern portion includes: an inner coil pattern portion; and an outer coil pattern portion spaced apart from the inner coil pattern portion at a predetermined interval and disposed outside the inner coil pattern portion, wherein the pad portion is disposed between the inner coil pattern portion and the outer coil pattern portion.

Rotary motors incorporating flexible printed circuit boards are described. A motor may include a stator assembly and a rotor assembly co-radially arranged with the stator assembly and configured to rotate relative to the stator assembly. At least one of the stator assembly and the rotor assembly may include a flexible printed circuit board having a base layer and a plurality of conductive elements formed on the base layer.

Rotary motors incorporating flexible printed circuit boards are described. A motor may include a stator assembly and a rotor assembly co-radially arranged with the stator assembly and configured to rotate relative to the stator assembly. At least one of the stator assembly and the rotor assembly may include a flexible printed circuit board having a base layer and a plurality of conductive elements formed on the base layer.