A cross flux permanent magnet linear motor based trolley bus

Abstract

The application discloses a suspended rail car based on a transverse magnetic flux permanent magnet linear motor, which comprises a frame, a transverse magnetic flux permanent magnet linear motor unit and a control system; the transverse magnetic flux permanent magnet linear motor unit comprises a main load-bearing structure, a first mover iron core, a second mover iron core, a winding, a connecting piece and a plurality of permanent magnets; the first mover iron core is in a U shape, connecting heads are arranged at two end portions, and the connecting heads are respectively clamped in two U-shaped long grooves; the permanent magnets are uniformly distributed in two second gaps; the winding is horizontally sleeved on the first mover iron core; the winding, the first mover iron core and the second mover iron core form a closed magnetic circuit; and the main load-bearing structure is horizontally located in a space surrounded by the first mover iron core and the two U-shaped long grooves and is connected with the second mover iron core through the connecting piece. The application not only can improve the carrying efficiency and precision, but also can reduce the energy consumption and maintenance cost, and is very important for meeting the needs of modern industry for efficient, reliable and economical carrying equipment.

Description

Technical Field

[0001] This invention belongs to the field of permanent magnet linear motor technology, specifically relating to a suspended rail tram based on a transverse flux permanent magnet linear motor. Background Technology

[0002] In the field of heavy materials handling, especially in applications requiring high precision and efficiency, traditional gantry crane systems are often challenged by their design and operational limitations. These systems largely rely on complex mechanical transmission mechanisms and electric motors, resulting in low efficiency, high energy consumption, complex maintenance, and high costs. Furthermore, the operational stability and precision of traditional gantry cranes are limited by their mechanical structure and transmission systems, which is particularly pronounced in demanding industrial applications.

[0003] With the rapid development of industrial automation and intelligent manufacturing, the demand for more efficient, reliable, and easy-to-maintain material handling equipment has increased dramatically. Especially in fields such as precision manufacturing, large equipment assembly, and automated logistics, the limitations of traditional gantry cranes have become a major obstacle to improving production efficiency and reducing operating costs.

[0004] The emergence of transverse flux permanent magnet linear motor technology offers new possibilities for solving these problems. Compared with traditional motors, transverse flux permanent magnet linear motors can directly convert electrical energy into linear motion without the need for complex mechanical transmission systems, thereby improving energy efficiency and reducing energy consumption and maintenance requirements. However, effectively integrating this linear motor technology into gantry crane systems to fully utilize its advantages and overcome the limitations of existing technologies remains a technical challenge. Summary of the Invention

[0005] Technical problem to be solved: Traditional gantry cranes rely on complex mechanical transmission systems, which are not only inefficient and costly to maintain, but also have limited adaptability to the operating environment. To address these problems, this invention proposes a suspended rail trolley based on a transverse flux permanent magnet linear motor, which can not only improve handling efficiency and accuracy, but also reduce energy consumption and maintenance costs. This is crucial for meeting the needs of modern industry for efficient, reliable and economical handling equipment.

[0006] Technical solution:

[0007] A suspended rail tram based on a transverse flux permanent magnet linear motor, the suspended rail tram comprising a frame, a transverse flux permanent magnet linear motor unit, and a control system;

[0008] The frame includes a support frame and a track located above the support frame. The track includes two horizontal frames and two U-shaped long slots arranged in opposite directions on the two frames, with a first gap between the two U-shaped long slots. The transverse flux permanent magnet linear motor unit is mounted on the U-shaped long slots, so that the U-shaped long slots serve as the stator of the permanent magnet linear motor.

[0009] The transverse flux permanent magnet linear motor unit includes a main load-bearing structure, a first mover core, a second mover core, windings, connectors, and several permanent magnets.

[0010] The first moving core is U-shaped, with connectors at both ends that are respectively engaged in two U-shaped slots, and there is a second gap between the first moving core and the horizontal frame; the plurality of permanent magnets are evenly distributed in the two second gaps, and the N pole and the S pole are alternately arranged.

[0011] The winding is horizontally sleeved on the first moving core; the second moving core is horizontally located in the first gap and connected to two U-shaped long slots; the winding, the first moving core, and the second moving core form a closed-loop magnetic circuit;

[0012] The main load-bearing structure is horizontally located within the space enclosed by the first moving core and two U-shaped long slots, and is connected to the second moving core via a connector.

[0013] The control system and the transverse flux permanent magnet linear motor unit adopt a model predictive control method, which controls the transverse flux permanent magnet linear motor unit by adjusting the three-phase voltage to minimize the value function.

[0014] Furthermore, the two ends of the main load-bearing structure are welded to the inner side of the first moving core.

[0015] Furthermore, the second moving core is connected to the connector.

[0016] Furthermore, the bottom of the main load-bearing structure is provided with rollers, which carry the first moving core horizontally along the frame.

[0017] Furthermore, at least one first groove in the same direction as the U-shaped long groove is provided on the opposite surface of the horizontal frame. The bottom of the first groove is provided with a first ball hole. The two ends of the second moving iron core are respectively located in the two first grooves, and the top of the second moving iron core is provided with a first ball. The first ball is located in the first ball hole and moves along the first ball hole.

[0018] Furthermore, at least one second groove in the same direction as the U-shaped long groove is provided on the inner side of the U-shaped long groove. A second ball hole is provided at the bottom of the second groove. A second ball is installed at the relative position of the connector. The second ball is located in the second ball hole and moves along the second ball hole.

[0019] Furthermore, the winding is made of copper; the first mover core, the second mover core, and the frame are made of steel; the main load-bearing structure is made of aluminum alloy; and the permanent magnet is made of neodymium iron boron.

[0020] Furthermore, the control system employs a model predictive control method to control the transverse flux permanent magnet linear motor unit; the control process includes the following steps:

[0021] The continuous-time model of the transverse flux permanent magnet linear motor unit is constructed as follows:

[0022] Voltage equation:

[0023]

[0024] Electromagnetic force equations:

[0025]

[0026] Dynamic equations:

[0027]

[0028] The voltage equation, electromagnetic force equation, and dynamic equation are discretized using Euler methods to establish a discretized state-space model:

[0029] x(k+1)=A d x(k)+B d u(k)

[0030] in:

[0031]

[0032]

[0033] The value function for the predictive control model is:

[0034]

[0035] Where V A V B V C It refers to the voltages of phases A, B, and C; I A ,I B ,I C It represents the current in phases A, B, and C; R A ,R B ,R C These are the resistances of phases A, B, and C; L A ,L B ,L C The inductances of phases A, B, and C are: N = (N-1) / ( ... dIt is resistance; x(k) is the state vector at step k; x(k+1) is the predicted value of the state vector at step k; A d B is the coefficient matrix of the state vector; d It is the coefficient matrix of the input vector; It is the derivative of the state vector at step k; I A (k), I B (k), I C (k) represents the values ​​of phase A, phase B, and phase C at step k, respectively; u(k) is the control input vector at step k; V A (k), V B (k), V C (k) represents the input values ​​of phase A, phase B, and phase C at step k; n is the prediction time domain; q1 is the weight of displacement error; q2 is the weight of velocity error; r1, r2, and r3 are the weights of currents in phase A, phase B, and phase C; and Ts is the sampling time.

[0036] Beneficial effects:

[0037] First, the overhead rail trolley based on a transverse flux permanent magnet linear motor of the present invention aims to overcome the limitations of traditional gantry cranes in terms of operating efficiency, energy consumption, stability and maintenance costs. The present invention utilizes transverse flux technology and permanent magnet materials to achieve a highly efficient force transmission method, improve the operating efficiency and response speed of the system, and reduce energy loss, thereby reducing operating costs.

[0038] Secondly, the overhead trolley based on a transverse flux permanent magnet linear motor of the present invention improves the stability and safety of the gantry crane through optimized motor design and control algorithm, ensuring good handling performance under various working conditions.

[0039] Third, the overhead rail trolley based on the transverse flux permanent magnet linear motor of the present invention extends service life and reduces maintenance requirements by reducing mechanical wear parts, thereby making the gantry crane system more economical and efficient.

[0040] Fourth, the overhead trolley based on a transverse flux permanent magnet linear motor of the present invention provides stable support and guidance for the gantry crane through its frame structure, ensuring precise control and alignment of the entire system. It also features interfaces for mounting the linear motor and the transport device. The transport device, which can be a hook, clamp, or other tool, interacts directly with the items to be transported, enabling precise control of the lifting, moving, and placing processes.

[0041] Fifth, the overhead rail trolley based on a transverse flux permanent magnet linear motor of the present invention significantly improves operating efficiency, reduces energy consumption, and enhances system stability and safety. Compared with traditional gantry crane systems, it has high adaptability and flexibility, and can meet the needs of different working environments and handling requirements. It has obvious advantages in terms of economy, efficiency and reliability, and provides an innovative solution for the automation and intelligence of industrial handling operations. Attached Figure Description

[0042] Figure 1 This is a schematic diagram of the single-phase structure of the motor of the present invention.

[0043] Figure 2 This is a schematic diagram of the main magnetic circuit of the single-phase structure of the motor of the present invention.

[0044] Figure 3 This is an exploded view of the single-phase structure of the motor of the present invention.

[0045] Figure 4 This is a schematic diagram illustrating the motion principle of the motor slide rail ball bearings according to the present invention.

[0046] Figure 5 This is a schematic diagram of the three-phase structure of the motor of the present invention.

[0047] Figure 6 This is a schematic diagram of the gantry crane structure of the present invention.

[0048] Explanation of reference numerals in the attached diagram: 1. Winding; 2. First moving core; 3. Main load-bearing structure (welded to the moving core); 6. Stator (also the frame of the gantry crane); 7. Rollers of the main load-bearing structure; 8. Second moving core (welded to the connecting piece, as part of the main magnetic circuit); 9. Connecting piece located between the main load-bearing structure and the second moving core; 10 and 11 are both ball holes of the moving core (first ball hole and second ball hole). Detailed Implementation

[0049] The following embodiments are provided to enable those skilled in the art to more fully understand the present invention, but do not limit the invention in any way.

[0050] This invention discloses a suspended rail tram based on a transverse flux permanent magnet linear motor. The suspended rail tram includes a frame, a transverse flux permanent magnet linear motor unit, and a control system.

[0051] The frame includes a support frame and a track located above the support frame. The track includes two horizontal frames and two U-shaped long slots arranged in opposite directions on the two frames, with a first gap between the two U-shaped long slots. The transverse flux permanent magnet linear motor unit is mounted on the U-shaped long slots, so that the U-shaped long slots serve as the stator of the permanent magnet linear motor. Figure 6 This is a schematic diagram of the gantry crane structure of the present invention.

[0052] See Figures 1 to 3 The transverse flux permanent magnet linear motor unit includes a main load-bearing structure, a first mover core, a second mover core, windings, connectors, and several permanent magnets.

[0053] The first moving core is U-shaped, with connectors at both ends that are respectively engaged in two U-shaped slots, and there is a second gap between the first moving core and the horizontal frame; the several permanent magnets are evenly distributed in the two second gaps, and the N pole and S pole are alternately arranged.

[0054] The winding is horizontally sleeved on the first moving core; the second moving core is horizontally located in the first gap and connected to two U-shaped long slots; the winding, the first moving core, and the second moving core form a closed-loop magnetic circuit;

[0055] The main load-bearing structure is horizontally located within the space enclosed by the first moving core and two U-shaped long slots, and is connected to the second moving core via connectors;

[0056] The control system and the transverse flux permanent magnet linear motor unit achieve optimal control by adjusting the three-phase voltage to minimize the value function. Specifically, minimizing the value function effectively reduces displacement and speed errors, and minimizes the three-phase voltage (i.e., energy consumption), thus achieving the dual goals of high-precision control and low energy consumption.

[0057] The two ends of the main load-bearing structure are welded to the inner side of the first moving core. This design ensures a stable connection between the load-bearing structure and the moving core, effectively improving the structural strength and stability of the entire system. This connection method allows for more direct and efficient force transmission, reducing potential energy losses in intermediate stages and thus improving overall work efficiency.

[0058] The second mover cores are connected together via connectors. This connection method not only simplifies the assembly process but also improves the modular design of the system, making maintenance and replacement more convenient and faster. The advantage of modular design lies in its ability to quickly respond to different operational needs; by replacing or adjusting specific modules, functions can be expanded or adjusted, greatly improving the system's flexibility and adaptability.

[0059] Rollers are installed at the bottom of the main load-bearing structure, carrying the first moving core horizontally along the frame. This design utilizes the low-friction characteristics of the rollers to significantly reduce energy consumption during horizontal movement and ensure smooth and precise movement. The use of rollers enables heavy-duty structures to move easily and smoothly, reducing the need for driving force. Furthermore, since rolling friction is lower than sliding friction, this also reduces system wear and maintenance costs.

[0060] At least one first groove, aligned with the U-shaped long groove, is provided on the opposite surfaces of the horizontal frame. A first ball bearing hole is provided at the bottom of each first groove. The two ends of the second mover core are located within the two first grooves, and a first ball bearing is provided at the top of the second mover core. The first ball bearing is located within and moves along the first ball bearing hole. This design allows the mover core to move smoothly and precisely within the horizontal frame, effectively reducing friction and improving the overall transmission efficiency of the system. The use of balls significantly reduces frictional resistance, thereby achieving higher transmission efficiency and precision, while also reducing heat generation and component wear caused by friction.

[0061] The inner surface of the U-shaped groove has at least one second groove aligned with the U-shaped groove. A second ball bearing hole is located at the bottom of the second groove. A second ball bearing is mounted at a corresponding position on the connector, positioned within and moving along the second ball bearing hole. This design allows the second ball bearing to slide smoothly within the groove, further reducing system resistance and improving the structure's motion flexibility and control precision. The smooth movement of the ball bearing within the groove ensures that the system maintains high-precision motion control even under high loads, while simultaneously reducing the energy consumption of the drive system and improving operational stability and reliability. Figure 4 This is a schematic diagram illustrating the motion principle of the ball bearings in the motor slide rail of the present invention. The balls in the slider roll on the track, creating rolling friction, thereby reducing frictional resistance. When the slider moves, the balls circulate within the track, supporting the smooth movement of the slider.

[0062] Figure 5 This is a schematic diagram of the three-phase structure of the motor of the present invention. The three-phase structure is an extension of the single-phase structure, with the main load-bearing part being a single unit, and the rest being the same.

[0063] In selecting materials for each structural component, the primary considerations were motor efficiency and structural strength. For example, the windings are made of copper; the mover core, ball bearings, and gantry crane frame are made of steel; the main load-bearing components are made of aerospace-grade aluminum alloy; and the permanent magnets are made of neodymium iron boron. The frame structure is constructed using high-strength materials, ensuring the system's stability and durability in various industrial environments. This frame not only provides support for the entire system but is also specially designed to allow the mover components to move smoothly along the stator, enabling precise object handling.

[0064] The mover component is the key power source of the system, comprising windings, a mover core, and a main load-bearing structure resembling a small cart to reduce friction and improve smoothness of movement, along with related accessories. Preferably, a dedicated motor can also be equipped on the main load-bearing structure to control the vertical movement of the object. Through precise control of the two motors, the system can achieve fine-tuning of the position of the transported object, meeting high-precision handling requirements. This design not only improves the efficiency of the handling process but also increases operational flexibility.

[0065] The stator of the transverse flux linear motor works in conjunction with the mover to generate a powerful linear driving force through efficient transverse flux. The stator employs specially designed permanent magnet materials and a magnetic circuit layout to maximize magnetic field utilization efficiency, thereby improving the overall driving efficiency and response speed of the system. Specifically, this invention utilizes Model Predictive Control (MPC) to control the transverse flux permanent magnet linear motor. MPC predicts the future state of the system in real time and optimizes the control input according to a set objective function, thereby minimizing displacement error, velocity error, and energy consumption. This control strategy can handle multivariable and constrained problems in the system, providing high-precision control and significantly improving the system's operational efficiency and energy efficiency.

[0066] The following is the mathematical modeling process for this transverse flux permanent magnet linear motor:

[0067] The continuous-time model of the motor is as follows:

[0068] Voltage equation:

[0069]

[0070] Electromagnetic force equations:

[0071]

[0072] Dynamic equations:

[0073]

[0074] After Euler discretization of the above equations, the discretized state-space model is established as: x(k+1)=A d x(k)+B d u(k)

[0075] in:

[0076]

[0077] Finally, the value function for model predictive control was designed as follows:

[0078]

[0079] Where VA V B V C It refers to the voltages of phases A, B, and C; I A ,I B ,I C It represents the current in phases A, B, and C; R A ,R B ,R C These are the resistances of phases A, B, and C; L A ,L B ,L C The inductances of phases A, B, and C are: N = (N-1) / ( ... d It is resistance; x(k) is the state vector at step k; x(k+1) is the predicted value of the state vector at step k; A d B is the coefficient matrix of the state vector; d It is the coefficient matrix of the input vector; It is the derivative of the state vector at step k; I A (k), I B (k), I C (k) represents the values ​​of phase A, phase B, and phase C at step k, respectively; u(k) is the control input vector at step k; V A (k), V B (k), V C (k) represents the input values ​​of phase A, phase B, and phase C at step k; n is the prediction time domain; q1 is the weight of displacement error; q2 is the weight of velocity error; r1, r2, and r3 are the weights of currents in phase A, phase B, and phase C; and Ts is the sampling time.

[0080] The control system consists of hardware and software, and is responsible for receiving user commands, processing system feedback, and adjusting motor operation to achieve efficient material handling operations.

[0081] The above are merely preferred embodiments of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should be considered within the scope of protection of the present invention.

Claims

1. A suspended tram based on a transverse flux permanent magnet linear motor, characterized in that, The overhead rail trolley includes a frame, a transverse flux permanent magnet linear motor unit, and a control system; The frame includes a support frame and a track located above the support frame. The track includes two horizontal frames and two U-shaped long slots arranged in opposite directions on the two frames, with a first gap between the two U-shaped long slots. The transverse flux permanent magnet linear motor unit is mounted on the U-shaped long slots, so that the U-shaped long slots serve as the stator of the permanent magnet linear motor. The transverse flux permanent magnet linear motor unit includes a main load-bearing structure, a first mover core, a second mover core, windings, connectors, and several permanent magnets. The first moving core is U-shaped, with connectors at both ends that are respectively engaged in two U-shaped slots, and there is a second gap between the first moving core and the horizontal frame; the plurality of permanent magnets are evenly distributed in the two second gaps, and the N pole and the S pole are alternately arranged. The winding is horizontally sleeved on the first moving core; the second moving core is horizontally located in the first gap and connected to two U-shaped long slots; the winding, the first moving core, and the second moving core form a closed-loop magnetic circuit; The main load-bearing structure is horizontally located within the space enclosed by the first moving core and two U-shaped long slots, and is connected to the second moving core via a connector. The control system and the transverse flux permanent magnet linear motor unit adopt a model predictive control method, which controls the transverse flux permanent magnet linear motor unit by adjusting the three-phase voltage to minimize the value function.

2. The overhead rail tram based on a transverse flux permanent magnet linear motor according to claim 1, characterized in that, The two ends of the main load-bearing structure are welded to the inside of the first moving core.

3. The overhead rail tram based on a transverse flux permanent magnet linear motor according to claim 1, characterized in that, The second moving core is connected to the connector.

4. The overhead rail tram based on a transverse flux permanent magnet linear motor according to claim 1, characterized in that, The bottom of the main load-bearing structure is equipped with rollers, which carry the first moving iron core to move horizontally along the frame.

5. The overhead rail tram based on a transverse flux permanent magnet linear motor according to claim 1, characterized in that, At least one first groove in the same direction as the U-shaped long groove is provided on the opposite surface of the horizontal frame. A first ball hole is provided at the bottom of the first groove. The two ends of the second moving iron core are respectively located in the two first grooves, and a first ball is provided at the top of the second moving iron core. The first ball is located in the first ball hole and moves along the first ball hole.

6. The overhead rail tram based on a transverse flux permanent magnet linear motor according to claim 1, characterized in that, The inner side of the U-shaped long groove is provided with at least one second groove in the same direction as the U-shaped long groove. The bottom of the second groove is provided with a second ball hole. The second ball is installed at the relative position of the connector. The second ball is located in the second ball hole and moves along the second ball hole.

7. The overhead rail tram based on a transverse flux permanent magnet linear motor according to claim 1, characterized in that, The winding is made of copper; the first mover core, the second mover core, and the frame are made of steel; the main load-bearing structure is made of aluminum alloy; and the permanent magnet is made of neodymium iron boron.

8. The overhead rail tram based on a transverse flux permanent magnet linear motor according to claim 1, characterized in that, The control system employs model predictive control to control the transverse flux permanent magnet linear motor unit; the control process includes the following steps: The continuous-time model of the transverse flux permanent magnet linear motor unit is constructed as follows: Voltage equation: Electromagnetic force equations: Dynamic equations: The voltage equation, electromagnetic force equation, and dynamic equation are discretized using Euler methods to establish a discretized state-space model: x(k+1)=A d x(k)+B d u(k) in: The value function for the predictive control model is: Where V A V B V C It refers to the voltages of phases A, B, and C; I A ,I B ,I C It represents the current in phases A, B, and C; R A ,R B ,R C These are the resistances of phases A, B, and C; L A ,L B ,L C The inductances of phases A, B, and C are: N = (N-1) / ( ... d It is resistance; x(k) is the state vector at step k; x(k+1) is the predicted value of the state vector at step k; A d B is the coefficient matrix of the state vector; d It is the coefficient matrix of the input vector; It is the derivative of the state vector at step k; I A (k), I B (k), I C (k) represents the values ​​of phase A, phase B, and phase C at step k, respectively; u(k) is the control input vector at step k; V A (k), V B (k), V C (k) represents the input values ​​of phase A, phase B, and phase C at step k; n is the prediction time domain; q1 is the weight of displacement error; q2 is the weight of velocity error; r1, r2, and r3 are the weights of currents in phase A, phase B, and phase C; and Ts is the sampling time.

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