Infinitum Electric - Experts & Thought Leaders

Driving motors with precision and energy efficiency is a top priority for many industries, from process control to building and HVAC to industrial automation at any scale. Motors keep the world turning. Motors present inherent challenges, consuming both raw materials and energy, existing as one of the most power-hungry, as well as heaviest, devices in the automation world. New EC Aircore Motors Being devoted to new possibilities in the electric motor industry, Texas-based manufacturer Infinitum has launched the newest version of its Aircore EC motor lineup. These motors redefine the boundaries of the machines that thousands of engineers use daily. power and torque density The new motor lineup, with a 20% reduction in weight over the previous EC generation These air-core motors provide high power and torque density in a flat structure devoid of the copper-clad ferrous cores of traditional motor stator windings. The new motor lineup, with a 20% reduction in weight over the previous EC generation, is designed for use in commercial and industrial HVAC pump and fan applications, material handling, and any other motor application with relatively low power demands. Why Air Core? Typical electric motors rely on copper windings wrapped around iron cores, distributed around the stationary outside shell of the motor, called the stator. These cores hold the magnetic field induced by the current in the windings, strengthening the transfer of the magnetic force to the rotor, which moves the load. Disadvantages The iron cores can also be subject to eddy currents, which convert some of the magnetic field While this works well for the conversion of electrical energy into mechanical motion, the strategy holds some disadvantages. Motors are notoriously large and heavy, especially for high-power applications; that iron core is by no means a lightweight material! The iron cores can also be subject to eddy currents, which convert some of the magnetic field into a wasteful, heat-generating electrical path, reducing the motor’s efficiency. Printed circuit board (PCB) The concept of Infinitum’s Aircore EC motors is built around a stator that consists of a printed circuit board (PCB). This flat design, lacking the solid iron core, reduces the size and weight dramatically. PCB designs are also more resistant to overheating failure in this flat design, leading to longer life and greater reliability. Air-core motor catalog Since the PCB is a bit more limited in magnetic field capacity, Infinitum’s air-core motor catalog contains motors from 3-15 HP. These motors are suitable for medium and relatively low-power applications but are perhaps not yet a proper substitute for many large motors in use currently. Benefits for Engineers VFD includes support for Modbus RTU and TCP/IP, BACnet, as well as digital and analog I/O common to most VFDs The EC motors from Infinitum include an integrated VFD, with communication protocols and software that make the installation and commissioning much easier. Specifically, the VFD includes support for Modbus RTU and TCP/IP, BACnet, as well as digital and analog I/O common to most VFDs. I-con The commissioning software, I-con, provides access to tuning and operating parameters, access to custom drive sequences for standard operations, and configuration control for integration into a larger control system (such as communication and addressing parameters). The software also allows monitoring of real-time data to verify power consumption, temperature, and vibration for extended motor health and emissions data. The EC motor lineup is all compatible with 3-phase power supply systems, ranging from 415-575 volts for markets in the US and Canada. Looking Forward in Motor Technology Over the many generations of technology, motors have resolutely stood as a testament to the working power of AC electricity. Due to the massive power requirements to move heavy loads, it’s no wonder these devices consume more power than any other industrial load. Innovations like this latest generation of the Aircore EC motor by Infinitum prove that many advances are yet to be made in the area of motion systems, increasing the reliability, efficiency, and lifetime of these important devices. 

The use of axial flux motors is gaining traction across industries, particularly in the electric motor space. Axial flux motors or pancake motors are mechanically configured to provide specific advantages when compared to ubiquitous radial flux motors. By design, the space between the rotor and stator (described in technical terms as the direction of magnetic flux between the two) in an axial flux motor is aligned parallel to the axis of rotation.  radial flux motors Its counterpart, the radial flux motor, is named for the magnetic field generated by the stator windings that moves radially across the air gap between the stator and rotor and induces a torque that turns the rotor. Despite the ubiquity of radial flux motors, both types offer characteristic strengths and weaknesses, depending on the application. The magnetic field generated by the stator windings that moves radially across the air gap According to Infinitum’s chief strategy officer, Bhavnesh Patel, axial flux propulsion is gaining ground in the EV space due to specific design form factors that allow the motor to sustainably power passenger and commercial electric vehicles. Axial flux motors, he said, are touted for their ability to generate more torque and power density than radial flux motors, and occupy less space based on the configuration.   Aircore Motor Topology is Different Patel told Machine Design during a one-on-one briefing that Infinitum will roll out the next generation of its axial flux motor (Aircore EC motor) at the AHR Expo in Chicago (January 22-24, 2024).  Aircore EC is a high-efficiency motor designed to sustainably power commercial and industrial applications—such as HVAC fans, pumps, and data centers—with less energy consumption, reduced emissions, and reduced waste.  Covered by 43 issued patents and 48 pending patents, the new motor replaces the heavy, copper wound iron stator found in traditional motors with a lightweight, printed circuit board (PCB) stator that is 10 times more reliable, 10% more efficient, and 50% smaller and lighter, noted Infinitum’s briefing notes. Author's quote A stator is essentially copper wire wrapped around iron; you can run current through that copper" Every motor is built around a stator and rotor. “A stator is essentially copper wire wrapped around iron; you can run current through that copper and it creates a magnetic field,” explained Patel.  “The innovation that we have is that we eliminated the iron within that stator and, instead of using copper wire, we etched the copper on multiple layers of a printed circuit board. And that results in a number of benefits.” PCB stator design In mobility applications, for example, PCB stators offer promising performance and efficiency benefits due to superior heat mitigation and high power density. Another distinguishing factor is that it uses 66% less copper than conventional motors, Patel said. Replacing the iron core with a PCB stator has further resulted in a reduction in mechanical losses, greater efficiency gains, and noise and vibration reductions.  With the PCB stator design, said Patel, the motor can achieve up to four to five times the current density of a conventional, liquid-cooled motor using a liquid cooling technique that allows the coolant to be in direct contact with the stator, mitigating heat across a larger surface area, enabling high overload capability and extended life. Combination of Motor and VFD The combination motor and variable frequency drive or VFD is an explanatory characteristic The startup characterized the Aircore EC motor system as an integrated variable frequency drive that delivers upwards of 93% system efficiency, as well as class-pioneering power and torque density in a low-footprint package that is 20% lighter than the previous version.  The combination motor and variable frequency drive or VFD (“essentially the electronics that drive the motor”) is a defining feature. The advantage of combining the two components, according to Patel, is that Infinitum was to “software-define the motor.” In other words, through firmware, the OEM can tell the motor exactly what operating point it needs to operate at. (For instance, 10 HP, or 9 HP, or 7 HP, and so forth.) UL compliance rating Motors typically come off the shelf with a NEMA sticker and UL compliance rating. “The UL sticker will say, for example, a 10 HP, 1800 RPM motor will draw 12 amps,” explained Patel. But this presents a limitation, he said, because it denotes the only operating point at which one can modulate the speed. “That means that the machine designer or equipment builder will have to make sure their wiring size is designed for 12 amps, that every one of the motors can support 12 amps, that the circuit breakers have to be designed around 12 amps, the transformers and overload relays and everything else upstream has to be designed for 12 amps,” Patel said. Motor with the VFD  But the UL sticker reflects that the motor now is drawing a lower input current" But developing a combo solution—motor with the VFD—has meant that the design engineer has more flexibility. “If the customer’s operating point is something other than 10 HP—let’s say it’s a 1,200 RPM application—we can actually tell the motor that its max speed is 1,200 RPM,” said Patel. “But the UL sticker reflects that the motor now is drawing a lower input current. So, instead of 12 amps at 1,200 RPM, now you might be drawing only six amps. And your wiring size can now be reduced.” Reduction in the capital costs There are cost savings to be had in large facilities, too. By one estimation a typical data center relies on 500 motors in their HVAC systems. For Microsoft or Amazon, or any entity building a data center with more than 1,000 motors, this could be a significant reduction in the capital costs of building that facility.  “The upfront cost is reduced just because they use that technology,” pointed out Patel. “There is operational cost reduction because we’re using less energy to provide the same amount of cooling, and so there’s longer-term operational savings.” Target Application: HVAC Infinitum is rolling out its latest PCB stator motor with specific market segments in mind Infinitum is rolling out its latest PCB stator motor with specific market segments in mind, said Patel during the briefing with Machine Design. “We looked out into the market and we said, there’s a lot of places motors are used—everything from a dishwasher motor to 40 motors in a single electric vehicle,” Patel said. “Think about the car windows and the windshield wipers and the fan—there are a whole bunch of the motors there. The point being, there’s a lot of applications this could potentially go into, but we decided to narrow it down to HVAC to start with, industrial second and then mobility third. And within each segment, we found a very receptive audience. Think about most HVAC systems that are running almost 24/7, and so efficiency and sustainability is key for many of these applications,” he said. Cooling and Heating Market Calls Backing from key investors is part and parcel of Infinitum’s success story. The start-up reported last year that it had secured $185 million in Series E funding to expand the company, increase production to meet customer demand and drive decarbonization in the industrial sector. Industrial automation juggernaut Rockwell Automation signed an agreement with Infinitum last year and is helping the startup break into the industrial space—specifically material handling applications. “Think again about an Amazon distribution center or UPS facility,” said Patel. “They have hundreds of motors on those conveyor systems. Rockwell today supplies a lot of the VFDs that drive those conveyors with our technology, combining the VFD—the electronics, essentially—and the motors to drive those conveyor systems." Global HVAC market size Global axial flux motor need size is cast to grow from $150.3 million in 2022 to $395.5 million by 2032 Startups like Infinitum are impacted by global economic trends. The global axial flux motor market size is projected to grow from $150.3 million in 2022 to $395.5 million by 2032, at a compound annual growth rate (CAGR) of 10.1%, according to Spherical Insights. The global HVAC market size was estimated at $16.4 billion in 2022 and is expected to grow to $22.1 billion by 2028 and with a CAGR of 5.10% during the forecast period 2023-2028, according to a Market Data Forecast. Infinitum’s decision Patel said market size is an important rationale for Infinitum’s decision to focus on commercial HVAC as a core market. Potential applications for the technology are wide-ranging and may include process compressors, conveyors, pumps, fans, blowers, coolers, compressors, crushers, chippers, and grinders. Analysts report electric motors will see strong expansion across industries, such as automotive (which is predicted to dominate) and HVAC (systems that manage heating and cooling in industrial and commercial buildings). These industries will expand due to investments in product development. 

At the AHR Expo, Infinitum, creator of the sustainable air-core motor, unveiled the next generation of its award-winning Aircore EC, a high-efficiency motor system designed to sustainably power commercial and industrial applications, such as HVAC fans, pumps, and data centers with less energy consumption, reduced emissions, and reduced waste.  Key features Infinitum’s latest generation Aircore EC motor system features an integrated variable frequency drive and delivers upwards of 93% system efficiency, as well as class-pioneering power and torque density in a low-footprint package that is 20% lighter than the previous version, with new features for easier installation and serviceability. The Aircore EC motor system is available immediately in four standard frame sizes ranging from 3-15 HP at 415V, 460V, and 575V for the Canadian and US markets. In addition, Infinitum will be releasing a heavy-duty version of the Aircore EC suitable for pump and more demanding fan applications.  Additional features Additional features of the Aircore EC motor system include:  Custom Nameplating: Allows customers to match an application’s exact HP/RPM specifications for reduced energy, electrical, and wiring costs  Flexible Mounting: Compact form factor enables a variety of horizontal, vertical, and peripheral mounting options Controls: Optional IoT capabilities and Infinitum’s I-con motor control software ensure continuous monitoring and reporting of carbon emissions, energy consumption, heat, and vibration for optimal energy management, performance, and predictive maintenance Communication: Support for a wide variety of communication protocols, including MODBUS RTU, Analog, MODBUS IP, BACnet MS/TP, and more Serviceability: User alerts identify specific problems for faster resolutions; a removable access panel allows for easier access to terminals, connectors, and programming ports Compact with IE5 efficiency Infinitum’s custom nameplating capability is an extremely powerful offering as it can drastically lower overall capital" “Infinitum’s Aircore EC product is unique in the industry and opens design possibilities for a wide variety of use cases. Its compact form factor enables direct mounting options which can limit additional cost associated with installation,” said Blake Griffin, analyst, Interact Analysis. “In addition to achieving IE5 efficiency, Infinitum’s custom nameplating capability is an extremely powerful offering as it can drastically lower overall capital investment associated with large motor-driven systems. This benefit cannot be understated when considering installations of motors can reach the hundreds or thousands in projects within sectors like data centers and commercial buildings.” Space and energy savings “Infinitum’s Aircore EC motors are a key component of our APL-DP-EC Series of plenum fans for air handling units, which are recognized for their space and energy savings and commonly used to cool data centers,” said Don Barkley, HVAC Sales Manager of Canarm. “Infinitum motors can be used to build fan arrays that offer high reliability and redundancy for data centers, while the motor’s modular design requires less labor for installation and allows for easier maintenance. We look forward to taking advantage of the latest features in this new version of Aircore EC.”  Decarbonization advantages The next evolution of our Aircore EC motor system pushes the boundaries of efficiency and sustainability" Infinitum’s technology was recently highlighted in the 2024 Global Cleantech 100 report for its ability to achieve deeper building decarbonization by boosting the efficiency of HVAC hardware that is enhanced by the motor system’s software to allow for granular control and preference-setting. “Designed with a greener future in mind, the next evolution of our Aircore EC motor system pushes the boundaries of efficiency and sustainability even further,” said Ben Schuler, founder and CEO, of Infinitum. “The combination of lighter materials, higher efficiency, and power density, and design for serviceability and reusability give our new Aircore EC motor the advantage to power the world’s most energy-intensive applications with less energy, emissions, and waste.” motor’s modular design The Infinitum Aircore EC motor replaces the heavy, copper wound iron stator found in traditional motors with a lightweight, printed circuit board (PCB) stator that is 10x more reliable. When compared to conventional motors, it is 10-65% more efficient, 50% smaller and lighter, and uses 66% less copper. The motor’s modular design allows for housing, rotors, and stators to be reused multiple times to serve future generations. The Aircore EC motor system is covered by 43 issued patents and 48 pending patents and is IP-65 rated.