The Flywheel Storage System now utilizes a continuous hexagonal tunnel constructed from precision-machined, aluminum-backed PCB panels. This guide details the fabrication and assembly of this monocoque structure.
| Item |
Description |
Purpose |
| Aluminum-backed PCB Panels |
Multi-layer PCB + 5mm Al-backing |
Structural panels with printed coils. |
| Machining Jig |
Precision CNC Fixture |
Ensures exact 120-degree mating angles. |
| Structural Thermal Adhesive |
High-strength, thermally conductive |
Bonds panels and seals cooling channels. |
| Cooling O-Rings |
Viton (High-Temp) |
Seals the integrated cooling circuit. |
| Assembly Bolts |
Titanium |
Fastens the monocoque panels together. |
The stator module is a self-supporting hexagonal segment.
- Corner/Facet: The six PCB panels form the facets. The beveled aluminum edges mate to form the vertices of the hexagon.
- Integrated Cooling: Milled channels in the aluminum backing of each panel form a continuous conduit when mated.
- Structural Integrity: The assembly is self-supporting, requiring minimal external bracing.
- CNC Machining: The edges of the aluminum-backed PCB panels are precision-milled at 120° angles to ensure flush, pressure-tight mating surfaces.
- Channel Milling: Cooling channels are milled into the outer (aluminum) side of each panel.
- Coil Check: Electrical continuity and insulation resistance tests are performed on the printed coils.
- Mating: Panels are positioned in a precision jig to form the hexagonal shape.
- Sealing: O-rings are placed in the gasket grooves between panels.
- Fastening: Titanium bolts fasten the panels together, compressing the O-rings to seal both the cooling circuit and the structure.
- Adhesive: A structural, thermally conductive adhesive is applied to mating faces for additional rigidity and thermal bridging.
- Angle Tolerance: Mating bevels must be exactly 120.0° (+/- 0.05°).
- Seal Integrity: The integrated cooling circuit must hold 150 psi without pressure loss.
- Structural Rigidity: The monocoque assembly must have zero detectable flex under specified loading.