用印刷电路板技术打造微型高扭矩电机，突破微机器人关节空间限制。
High Torque Density PCB Axial Flux Permanent Magnet Motor for Micro Robots
- 采用HDI工艺的多层印刷电路绕组，提升铜填充率
- 19mm直径、5mm厚电机实现45%铜填充率，扭矩密度创纪录
- 适合对体积和扭矩有极致要求的微机器人关节设计
准直接驱动（QDD）正改变足式与机械臂机器人的传动方式，通过去除高减速比齿轮箱实现更紧凑的结构，但对低速大扭矩电机提出严苛要求，尤其在薄盘状关节空间内。轴向磁通永磁（AFPM）电机满足几何与扭矩需求，但当外径缩小至20mm以下时，传统绕线定子铜填充率低，导致电阻升高、连续扭矩受限。本文提出一种微尺度AFPM电机，利用先进IC基板高密度互连（HDI）技术实现印刷电路板（PCB）绕组。48层定子由四个12层HDI模块堆叠而成，仅19mm直径、5mm厚，达到45%的铜填充率，创下该尺寸下的新纪录。通过全面电磁与热分析优化设计，并完成原型机制造与实验验证。
原文摘要 · Abstract (English)
Quasi-direct-drive (QDD) actuation is transforming legged and manipulator robots by eliminating high-ratio gearboxes, yet it demands motors that deliver very high torque at low speed within a thin, disc-shaped joint envelope. Axial-flux permanent-magnet (AFPM) machines meet these geometric and torque requirements, but scaling them below a 20mm outer diameter is hampered by poor copper fill in conventional wound stators, inflating resistance and throttling continuous torque. This paper introduces a micro-scale AFPM motor that overcomes these limitations through printed-circuit-board (PCB) windings fabricated with advanced IC-substrate high-density interconnect (HDI) technology. The resulting 48-layer stator-formed by stacking four 12-layer HDI modules-achieves a record 45\% copper fill in a package only 5mm thick and 19mm in diameter. We perform comprehensive electromagnetic and thermal analyses to inform the motor design, then fabricate a prototype whose performance characteristics are experimentally verified.
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