SINUSOIDAL WAVE FORMS AND
ZERO COGGING

Motors integrated with ECM’s technology have a superior quality of motion compared to conventional machines.

• No out-of-plane forces on the stator as a result
of applied torque
• Perfectly loaded in the in-plane, stiff direction
• No tendency for the design to encourage
buckling or plate deflections

DURABILITY & HALT

• Proven durability
• ECM motors have been run through HALT
testing with impressive results
• Thermal, vibration, cycling
• Durable design:
• Less moving parts
• Fully encapsulated windings
• Durable material: FR-4
• FR-4 is a composite of glass fiber
• Like carbon fiber composite, it compares well
to standard materials, especially when loaded
correctly
• FR-4 is used in military applications, including
missile/rocket PCB’s

DESIGN FEATURES AND CYCLE TIME

PrintStator, ECM’s PCB stator design and
optimization software, reduces design cycle time
and improves design flexibility.

• PCB Stator Design
• Hollow shaft capability of motor and drive —
through hole design
• Allows media, electrical or mechanical
components to be guided through the motor
cavity
• Potential to integrate fan/fluid pump within
motor cavity
• Compact integration with harmonic/planetary
drive torque multipliers
• PrintStator: Design and Optimization Software
• Significantly reduces design cycle time
• Quickly transforms customer application
requirements into an optimized motor
design that’s ready for rapid prototyping and
commercial production

EFFICIENT POWER CONSUMPTION,
EXTENDED BATTERY LIFE

PrintStator’s optimization capabilities create
machines with efficiencies >90%.

• PrintStator allows for the targeted
reduction of resistance and eddy current losses
• Optimizing copper geometries and thickness in
PCB stators
• PrintStator has the ability to optimize/restrain
all other parameters for the most optimal
efficiency result

A SUSTAINABLE, COST-EFFECTIVE
SOLUTION

Increased efficiency and decreased materials
contribute greatly to ECM’s sustainability
initiatives as well as its emphasis on cost-
effectiveness.

• Up to 80% less raw materials
• PrintStator optimizes magnet and steel mass
• PCB Stators require significantly less copper
than conventional motor windings
• Highly efficient motors consume less power and
have a reduced carbon footprint
• ECM’s patented stator design optimizes copper
geometries and winding patterns, delivering
superior efficiency at a reduced cost and
environmental impact.

FORM FACTOR

PCB Stators integrate into remarkably thin,
compact, lightweight motors and generators.

• Up to 70% lighter
• Up to 80% less raw materials
• Fewer steel components, simpler part
geometry
• Drastically thinner
• Planar form factor
• Motor envelope increases in size radially
• Remains axially thin, even at large power
ratings

EFFECTIVE THERMAL FEATURES

A thermal design which has a continuous copper path from the parts of the stator, where losses originate, to the interface to the case. This is possible due to utilizing portions of the PCB copper that do not carry current.

• Can be shaped and function as “heat pipes”
• These non-hollow “heat pipes” are using the
copper to conduct the heat from the center of
the stator to the outside edge, where the stator
is clamped into the case and the heat can be
rejected to ambient

MORE TORQUE WITH LESS MASS

ECM’s characteristic form factor and PrintStator’s design capabilities result in extremely torque dense machines.

• PrintStator optimizes copper geometries and
winding patterns, delivering superior torque
• ECM motors scale radially rather then axially,
producing motors with superior torque in a
reduced volume

PCB STATOR MANUFACTURING

• Very reliable and cost-effective production
• No manual copper winding
• Ability to design and print stators at any of
numerous circuit board printers across the globe
• Utilizes Gerber Files that are ubiquitously
utilized by the printed circuit board
manufacturing industry

ELECTROMAGNETIC AND ACOUSTIC
NOISE

Correctly controlled, ECM machines eliminate
harmonics from leads (electromagnetic) and
winding structures (acoustic).

• Harmonics do not excite mechanical modes in
the motor because it’s not used as a filter
• Forces acting on stator winding can initiate
vibration, causing acoustic noise and reliability
problems
• ECM coils are fully encapsulated in composite
structure, eliminating this problem
• In conventional motors, cogging torque is
produced, resulting in vibration and acoustic
noise
• Lack of iron in ECM stators results in smooth
torque, eliminating cogging and mechanical
excitation of attached structures as a source
of noise