The Flywheel Storage System has transitioned to a continuous, high-density PCB-based Stator Track. This architecture converts the entire 4.7m circumference into a high-performance Linear Synchronous Motor (LSM), enabling active magnetic levitation and precise power extraction/injection at any point along the track.
The 4.7m loop is now constructed as a continuous hexagonal tunnel comprised of modular Aluminum-Monocoque PCB panels.
- Design: Each hexagonal face is an aluminum-backed PCB panel. The six panels are precision-machined at 120° angles to mate directly, forming a rigid, self-supporting hexagonal tunnel.
- Structural Sealing: The aluminum backing serves as both the structural mating surface and the thermal heat sink. High-temperature O-rings or structural thermal adhesives at the joints ensure vacuum-tight integrity for the liquid cooling circuit.
- Winding: Flat-pancake coils are printed directly on the inner layer of the PCB (multi-layer, 2 oz copper) in a continuous 3-phase A-B-C pattern across the entire track.
- Cooling Integration: The aluminum backing of each PCB panel features precision-milled channels. When assembled, these form a continuous liquid-cooling circuit integrated directly into the stator structure.
¶ 3. Power and Phase Timing
- Voltage Range: 48V to 400V.
- Peak Capacity: Scalable up to 25 kW per meter of track.
- Phase Timing: Real-time synchronization is achieved via integrated Hall Effect sensors on the PCB panels, allowing the inverter to dynamically adjust frequency to match the rotor's Halbach magnet arrays at any velocity.
| Parameter |
Value |
Note |
| Coil Architecture |
Continuous PCB LSM |
Track-wide active control. |
| Structural Basis |
Aluminum-Monocoque |
Panels act as structure and heat sink. |
| Cooling |
Integrated Milled Channels |
Aluminum-backed fluid circulation. |
| Sensors |
Integrated Hall Effect Arrays |
Distributed real-time tracking. |