Linear motor

Abstract

A linear motor including a stator assembly, an armature mechanically coupleable to a test body configured to be moved relative to the stator assembly by operation of the linear motor, and a suspension system configured to facilitate movement of the armature relative to the stator assembly along an axis of movement without physically touching the armature during movement. Additionally disclosed are a multi-phase linear motor, a linear motor having an armature including an array of planar magnets, and a linear motor having a magnetic damping system.

Description

[Technical Field]

[0001] (Related Applications) This application is a non-provisional patent application claiming priority to U.S. Provisional Patent Application No. 62 / 795,273, filed January 22, 2019, entitled "Linear Motor," which is incorporated herein by reference.

[0002] FIELD OF THE INVENTION The present invention relates generally to materials testing systems, and more particularly to linear motors for materials testing systems. [Background technology]

[0003] Linear motors are typically utilized in materials testing systems. In these systems, the linear motors are coupled to a test piece. Moving part It is known to use electricity and magnetism to create back and forth motion within a moving assembly. Moving part and Moving part The suspension system may be "frictionless" in that it may be arranged and configured to operate without sliding or rolling contact between the suspension system and the vehicle. Moving part Flexural suspension structures for driving a vehicle are known, such as that described in US Pat. No. 6,405,599. Moving part These flexible suspension structures, to which the components are directly physically attached, are designed to bend based on the material properties and bendable nature of the suspension structure. Moving part Restricting movement of Moving part As it moves from the center position due to the electromagnetic force, it bends from the suspension structure. Moving part resistance to increases.

[0004] Thus, a linear motor having frictionless characteristics, as well as its method of use and assembly, would be well received in the art. Summary of the Invention

[0005] In one exemplary embodiment, the test apparatus includes a stator assembly and a test body mechanically coupleable to the stator assembly and configured to be moved relative to the stator assembly by operation of a linear motor. Moving part And while moving Moving part relative to the stator assembly along the axis of movement without physically touching the Moving part and a suspension system configured to facilitate movement of the vehicle.

[0006] Additionally or alternatively, the suspension system of the test apparatus may include: Moving part to the suspension system without sliding or rolling contact between the Moving part at least one air bushing configured to allow movement of the

[0007] Additionally or alternatively, the suspension system of the test apparatus includes a frame body having a first opening extending along a first axis parallel to the axis of movement, the at least one air bushing being located within the first opening; Moving part includes a first air bushing shaft extending into the first opening.

[0008] Additionally or alternatively, the at least one air bushing of the test apparatus includes a first air bushing located proximate a first end of the first opening and a second air bushing located proximate a second end of the first opening.

[0009] Additionally or alternatively, the frame body of the test apparatus includes a second opening extending along a second axis parallel to the axis of movement; Moving part includes a second air bushing shaft extending into the second opening, the second opening including a third air bushing located proximate a first end of the second opening and a fourth air bushing located proximate a second end of the second opening.

[0010] Additionally or alternatively, at least one air bushing of the test device is positioned within the first opening in the frame body such that some movement is permitted between the air bushing and the frame body.

[0011] Additionally or alternatively, at least one air bushing of the test apparatus is removably mounted within the first opening of the frame body with an interference fit.

[0012] Additionally or alternatively, at least one air bushing of the test apparatus has a hollow cylindrical shape, and the first air bushing shaft is a cylindrical shaft having a radius that is 3 to 5 microns smaller than the inner radius of the at least one air bushing.

[0013] Additionally or alternatively, the stator assembly of the test apparatus includes a first coil subassembly and a second coil subassembly; Moving part is located and extends between the first coil subassembly and the second coil subassembly, Moving part includes a magnet frame having a plurality of permanent magnets disposed thereon, a first air bushing shaft extending parallel to the magnet frame, and a top end plate and a bottom end plate connecting the first and second air bushing shafts to the magnet frame such that a first space extends parallel to the axis of movement between the first air bushing shaft and the magnet frame, and a second space extends parallel to the axis of movement between the second air bushing and the magnet frame; and the test apparatus includes a first coil subassembly, a second coil subassembly, and a Moving part The at least one air bushing may be disposed in a cooling system configured to cool the at least one of the coils.

[0014] Additionally or alternatively, the test equipment Moving part includes a specimen shaft extending from at least one of the top end plate and the bottom end plate, and a fifth air bushing surrounds the specimen shaft.

[0015] In another exemplary embodiment, a linear motor includes a stator assembly configured to receive power and a rotor adjacent to the stator assembly and configured to move relative to the stator assembly when the stator assembly receives power. Moving part And while moving Moving part relative to the stator assembly along the axis of movement without physically touching the Moving part and a suspension system configured to facilitate the movement of ions.

[0016] Additionally or alternatively, the linear motor suspension system may include: Moving part to the suspension system without sliding or rolling contact between the Moving part at least one air bushing configured to allow movement of the

[0017] Additionally or alternatively, the suspension system of the linear motor includes a frame body having a first opening extending along a first axis parallel to the axis of movement, the at least one air bushing being located within the first opening; Moving part includes a first air bushing shaft extending into the first opening.

[0018] Additionally or alternatively, the at least one air bushing of the linear motor includes a first air bushing located proximate a first end of the first opening and a second air bushing located proximate a second end of the first opening.

[0019] Additionally or alternatively, the frame body of the linear motor includes a second opening extending along a second axis parallel to the axis of movement; Moving part includes a second air bushing shaft extending into the second opening, the second opening including a third air bushing located proximate a first end of the second opening and a fourth air bushing located proximate a second end of the second opening.

[0020] Additionally or alternatively, at least one air bushing of the linear motor is positioned within the first opening in the frame body such that some movement is permitted between the air bushing and the frame body.

[0021] Additionally or alternatively, at least one air bushing of the linear motor is removably mounted within the first opening of the frame body with an interference fit.

[0022] Additionally or alternatively, at least one air bushing of the linear motor has a hollow cylindrical shape, and the first air bushing shaft is a cylindrical shaft having a radius that is 3 to 5 microns smaller than the inner radius of the at least one air bushing.

[0023] Additionally or alternatively, the stator assembly of the linear motor includes a first coil subassembly and a second coil subassembly; Moving part is located and extends between the first coil subassembly and the second coil subassembly, Moving part includes a magnet frame having a plurality of permanent magnets disposed thereon, a first air bushing shaft extending parallel to the magnet frame, a top end plate and a bottom end plate connecting the first and second air bushing shafts to the magnet frame such that a first space extends parallel to the axis of movement between the first air bushing shaft and the magnet frame, and a second space extends parallel to the axis of movement between the second air bushing and the magnet frame, and the linear motor includes a first coil subassembly, a second coil subassembly, and a Moving part The at least one air bushing may be disposed in a cooling system configured to cool the at least one of the coils.

[0024] In another exemplary embodiment, a method includes: a stator assembly; Moving part and providing a suspension system, receiving power by a stator assembly, and moving along an axis after receiving power by the stator assembly. Moving part The rotor is moved back and forth relative to the stator assembly, and during this movement Moving part Without physically touching the Moving part and supporting the vehicle with a suspension system.

[0025] In another exemplary embodiment, a testing apparatus includes a polyphase linear motor including a stator assembly and a test body mechanically coupleable to a test specimen configured to be moved relative to the stator assembly by operation of the polyphase linear motor. Moving part and, Moving part and supports the stator assembly. Moving part 1. A suspension system configured to control movement of a vehicle, comprising: Moving part and a suspension system configured to operate without sliding or rolling contact between the suspension system.

[0026] Additionally or alternatively, the polyphase linear motor of the test device is a three-phase linear motor.

[0027] Additionally or alternatively, the stator assembly of the test apparatus includes a first coil subassembly and a second coil subassembly; Moving part is located and extends between the first coil subassembly and the second coil subassembly, Moving part has a plurality of permanent magnets disposed thereon.

[0028] Additionally or alternatively, the first coil subassembly of the test apparatus is a laminated magnetic core including multiple poles around which multiple vertically arranged windings are wound to create the first coil stack, and the second coil subassembly is a laminated magnetic core including multiple poles around which multiple vertically arranged windings are wound to create the second coil stack.

[0029] Additionally or alternatively, the magnetic core of the first coil assembly of the test device includes six poles and six vertically arranged windings, the magnetic core of the second coil assembly includes six poles and six vertically arranged windings, the top and fourth windings of each of the first and second coil stacks are connected to a first phase of a three-phase linear motor, the second and fifth windings of each of the first and second coil stacks are connected to a second phase of the three-phase linear motor, and the third and sixth windings of each of the first and second coil stacks are connected to a third phase of the three-phase linear motor.

[0030] Additionally or alternatively, a gap is positioned between each of the multiple vertically arranged windings of the first and second coil stacks of the testing apparatus, and the material testing apparatus further comprises at least one cooling duct configured to provide cooling air through the gap positioned between each of the multiple vertically arranged windings of the first and second coil stacks.

[0031] Additionally or alternatively, each of the plurality of poles of the test fixture includes a coil bobbin having integral cooling fins disposed thereon, the integral cooling fins extending through the windings and into the gaps between the windings.

[0032] Additionally or alternatively, the test apparatus further includes potting material located within each gap, and at least one heat pipe embedded within the potting material of each gap, the at least one heat pipe configured to transfer heat from the plurality of vertically arranged windings of the first and second coil stacks.

[0033] Additionally or alternatively, the test apparatus further includes at least one cooling fin attached to each heat pipe, the at least one cooling fin configured to facilitate heat transfer.

[0034] Additionally or alternatively, the test equipment Moving part The stroke is at least 70 mm.

[0035] Additionally or alternatively, the suspension system of the test apparatus may include: Moving part each of the first and second coil assemblies is located between the first side frame and the second side frame; the suspension system further includes an upper mounting plate for attachment to each of the first and second side frames and the first and second coil assemblies; and the suspension system is further attached to each of the first and second side frames and the first and second coil assemblies.

[0036] Additionally or alternatively, the first and second side frames of the test apparatus each have an I-shaped cross-section, the first cooling duct is attached to the first side frame such that a space located between the top and bottom of a first side of the I-shaped cross-section of the first side frame defines an air path, the second cooling duct is attached to the first side frame such that a space located between the top and bottom of a second side of the I-shaped cross-section of the first side frame defines an air path, the third cooling duct is attached to the second side frame such that a space located between the top and bottom of a first side of the I-shaped cross-section of the second side frame defines an air path, and the second cooling duct is attached to the second side frame such that a space located between the top and bottom of a second side of the I-shaped cross-section of the second side frame defines an air path.

[0037] In another exemplary embodiment, a linear motor includes a multi-phase stator assembly, the multi-phase stator assembly including at least one stack having a plurality of cores, the stack being proximate to the multi-phase stator assembly and configured to move relative to the multi-phase stator assembly when power is applied to the multi-phase stator assembly. Moving part a multi-phase stator assembly including: Moving part and for the multiphase stator assembly Moving part 1. A suspension system configured to control movement of a vehicle, comprising: Moving partand a suspension system configured to operate without sliding or rolling contact between the suspension system and the vehicle.

[0038] Additionally or alternatively, the linear motor is a three-phase linear motor and the multi-phase stator assembly is a three-phase stator assembly.

[0039] Additionally or alternatively, the multi-phase stator assembly of the linear motor includes a first coil subassembly and a second coil subassembly; Moving part is located and extends between the first coil subassembly and the second coil subassembly, Moving part includes a plurality of permanent magnets disposed thereon.

[0040] Additionally or alternatively, the first coil subassembly of the linear motor is a laminated magnetic core including multiple poles around which multiple vertically arranged windings are wound to create the first coil stack, and the second coil subassembly is a laminated magnetic core including multiple poles around which multiple vertically arranged windings are wound to create the second coil stack.

[0041] Additionally or alternatively, the magnetic core of the first coil assembly of the linear motor includes six poles and six vertically arranged windings, the magnetic core of the second coil assembly includes six poles and six vertically arranged windings, the top and fourth windings of each of the first and second coil stacks are connected to a first phase of the three-phase linear motor, the second and fifth windings of each of the first and second coil stacks are connected to a second phase of the three-phase linear motor, and the third and sixth windings of each of the first and second coil stacks are connected to a third phase of the three-phase linear motor.

[0042] Additionally or alternatively, a gap is located between each of the plurality of vertically arranged windings of the first and second coil stacks of the linear motor, and the material testing apparatus further comprises at least one cooling duct configured to provide cooling air through the gap located between each of the plurality of vertically arranged windings of the first and second coil stacks.

[0043] Additionally or alternatively, the linear motor Moving part The stroke is at least 70 mm.

[0044] Additionally or alternatively, the method may include providing a multi-phase stator assembly and a rotor adjacent to the multi-phase stator assembly. Moving part and a suspension system; receiving power by a multi-phase stator assembly; and after receiving power by the multi-phase stator assembly, Moving part moving the rotor back and forth along a movement axis relative to the multi-phase stator assembly; Moving part to the multiphase stator assembly so that there is no sliding or rolling contact between the Moving part By controlling the movement of Moving part and supporting the suspension system.

[0045] In another exemplary embodiment, the test apparatus includes a stator assembly and a test body mechanically coupleable to the test body configured to move relative to the stator assembly by operation of a linear motor. Moving part in response to a magnetic field generated by the stator assembly: Moving part an array of flat magnets configured to generate movement in Moving part and, Moving part and supports the stator assembly. Moving part 1. A suspension system configured to control movement of a vehicle, comprising: Moving part and a suspension system configured to operate without sliding or rolling contact between the linear motor and the suspension system.

[0046] Additionally or alternatively, the test equipment Moving part is a magnet that Moving part from the first side and the opposite side Moving part The magnet frame includes a plurality of permanent magnets disposed therein so as to be exposed from the second side of the magnet frame.

[0047] Additionally or alternatively, the array of the test fixture includes two rows of flat tile magnets arranged with alternating polarities.

[0048] Additionally, or alternatively, the flat tile magnets of each of the first and second arrays of the test fixture are oriented in a skewed manner such that the bottom and top edges of each of the flat tile magnets are not perpendicular to the side edges of the flat tile magnets. Moving part Can be attached to.

[0049] Additionally or alternatively, each of the two arrays of the test fixture includes 14 flat tile magnets.

[0050] Additionally or alternatively, the stator assembly of the test apparatus includes a first coil subassembly and a second coil subassembly; Moving part is located and extends between a first coil subassembly and a second coil subassembly, the first coil subassembly including a plurality of poles around which a plurality of vertically arranged windings are wound to create a first coil stack, and the second coil subassembly including a plurality of poles around which a plurality of vertically arranged windings are wound to create a second coil stack.

[0051] Additionally or alternatively, an array of flat magnets may be used in the testing device. Moving part , extending along a first length that is longer than the second lengths of the first and second coil stacks.

[0052] Additionally or alternatively, the test equipment Moving partincludes a magnet frame having a first side proximate to a first coil assembly and a second side opposite the first side proximate to a second coil assembly; Moving part further includes a first bushing shaft, a second bushing shaft, a top end plate, and a bottom end plate, and the top end plate and bottom end plate connect the first and second air bushing shafts to the magnet frame such that a first space extends parallel to the movement axis between the first bushing shaft and the magnet frame, and a second space extends parallel to the movement axis between the second air bushing shaft and the magnet frame.

[0053] Additionally or alternatively, the test equipment Moving part The stroke is at least 70 mm.

[0054] Additionally or alternatively, each of the flat magnets of the test device includes a thickness of between 10 mm and 22 mm, and each of the flat magnets is a permanent neo magnet.

[0055] In another exemplary embodiment, the linear motor includes a stator assembly configured to receive power and a test body mechanically coupleable to the stator assembly configured to move relative to the stator assembly when the stator assembly receives power. Moving part in response to a magnetic field generated by the stator assembly Moving part an array of planar magnets configured to induce movement in Moving part and, Moving part and supports the stator assembly. Moving part and a suspension system configured to control the movement of the suspension system. Moving part and the suspension system.

[0056] Additionally or alternatively, the linear motor Moving part is a magnet that Moving part from the first side and the opposite side Moving parta magnet frame having a plurality of permanent magnets disposed therein so as to be exposed from the second side of the magnet frame;

[0057] Additionally or alternatively, the linear motor array includes two rows of flat tile magnets arranged with alternating polarities.

[0058] Additionally, or alternatively, the flat tile magnets of each of the first and second arrays of the linear motor are arranged in a skewed manner such that the bottom and top edges of each of the flat tile magnets are not perpendicular to the side edges of the flat tile magnets. Moving part Can be attached to.

[0059] Additionally or alternatively, each of the two arrays of the linear motor includes 14 flat tile magnets.

[0060] Additionally or alternatively, the stator assembly of the linear motor includes a first coil subassembly and a second coil subassembly; Moving part is located and extends between a first coil subassembly and a second coil subassembly, the first coil subassembly including a plurality of poles around which a plurality of vertically arranged windings are wound to create a first coil stack, and the second coil subassembly including a plurality of poles around which a plurality of vertically arranged windings are wound to create a second coil stack.

[0061] Additionally or alternatively, an array of flat magnets may be used to form the linear motor. Moving part , extending along a first length that is longer than the second lengths of the first and second coil stacks.

[0062] Additionally or alternatively, the linear motor Moving part includes a magnet frame having a first side proximate to a first coil assembly and a second side opposite the first side proximate to a second coil assembly; Moving partfurther includes a first bushing shaft, a second bushing shaft, a top end plate, and a bottom end plate, and the top end plate and bottom end plate connect the first and second air bushing shafts to the magnet frame such that a first space extends parallel to the movement axis between the first bushing shaft and the magnet frame, and a second space extends parallel to the movement axis between the second air bushing shaft and the magnet frame.

[0063] Additionally or alternatively, the linear motor Moving part The stroke is at least 70 mm.

[0064] In another exemplary embodiment, a method includes: providing a stator assembly having an array of flat magnets disposed thereon in proximity to the stator assembly; Moving part and a suspension system; receiving power from a stator assembly; exposing an array of flat magnets to a magnetic field generated by the stator assembly; and Moving part the forward and backward movement of the magnets is produced by a flat array of magnets; Moving part to the multiphase stator assembly so that there is no sliding or rolling contact between the Moving part By controlling the movement of Moving part and supporting the suspension system.

[0065] In another exemplary embodiment, the testing device includes a linear motor mechanically coupleable to a stator assembly and a test body configured to move relative to the stator assembly upon operation of the linear motor. Moving part and a linear motor including a stator assembly supporting the moving part and Moving part 1. A suspension system configured to control movement of a vehicle, comprising: Moving part and a suspension system configured to operate without sliding or rolling contact between the linear motor and the suspension system, and when power is disconnected to the linear motor, Moving partand a magnetic damping system configured to absorb kinetic energy of the movement of the

[0066] Additionally or alternatively, the magnetic damping system of the test device may include: Moving part a magnet array disposed on a frame of a suspension system parallel to the axis of movement of the linear motor, the magnet array being configured to Moving part and the magnet array is configured to absorb kinetic energy of the movement of Moving part The linear motor is configured to provide damping during operation to improve control of the movement of the linear motor.

[0067] Additionally or alternatively, the magnet array of the magnetic damping system of the test device may be Moving part The magnet array is separate from the magnets used to create the movement of Moving part Extends parallel to the axis of movement of Moving part The magnetic field is positioned adjacent to the conductive, non-magnetic surface of the magnetic field.

[0068] Additionally or alternatively, a gap of less than 1 cm may be provided between the magnet array and the test device. Moving part between the conductive and non-magnetic surfaces.

[0069] Additionally or alternatively, the linear motor of the test fixture is a three-phase linear motor, and the magnetic damping system is configured to simultaneously short out power to each of the three phases.

[0070] Additionally or alternatively, the stator assembly of the test apparatus includes a first coil subassembly and a second coil subassembly, the first coil subassembly including a plurality of poles around which a plurality of vertically arranged windings are wound to create a first coil stack, and the second coil subassembly including a plurality of poles around which a plurality of vertically arranged windings are wound to form a second coil stack.

[0071] Additionally or alternatively, a test device for the first coil subassembly and the second coil subassembly immediately after the power is shorted Moving part The movement of Moving part The magnet is configured to generate an electromagnetic force that generates a current and a force that resists the movement of the magnet.

[0072] Additionally or alternatively, the magnetic damping system of the test device may include: Moving part adjacent to the first side of Moving part a first magnet array disposed on a frame of the suspension system parallel to the axis of movement of the Moving part adjacent to the second side of Moving part a second magnet array disposed on the frame of the suspension system parallel to the axis of movement of the

[0073] Additionally or alternatively, the first and second magnet arrays of the magnetic damping system of the test apparatus may be driven by linear motors. Moving part The first magnet array is separate from the magnets used to generate the motion of Moving part Extends parallel to the axis of movement of Moving part a second magnet array positioned adjacent to the first conductive non-magnetic surface of the Moving part Extends parallel to the axis of movement of Moving part the first and second arrays of magnets being positioned adjacent to a second conductive non-magnetic surface when power is disconnected to the linear motor; Moving part The device is configured to absorb the kinetic energy of the movement of the object.

[0074] Additionally or alternatively, each magnet in the magnet array of the test fixture is a flat tile permanent neo magnet.

[0075] In another exemplary embodiment, the linear motor includes a stator assembly configured to receive power and a test body mechanically coupleable to the stator assembly configured to move relative to the stator assembly when the stator assembly receives power. Moving part and, Moving part and supports the stator assembly. Moving part1. A suspension system configured to control movement of a vehicle, comprising: Moving part and a suspension system configured to operate without sliding or rolling contact between the magnetic damping system and the suspension system, wherein when power is disconnected to the linear motor, the magnetic damping system Moving part It is configured to absorb the kinetic energy of movement.

[0076] Additionally or alternatively, the magnetic damping system of the linear motor may include: Moving part a magnet array disposed on a frame of a suspension system parallel to the axis of movement of the linear motor, the magnet array being configured to Moving part The device is configured to absorb the kinetic energy of the movement of the object.

[0077] Additionally or alternatively, the magnet array of the magnetic damping system of the linear motor may be Moving part The magnet array is separate from the magnets used to generate the movement of Moving part Extends parallel to the axis of movement of Moving part The magnetic field is positioned adjacent to a conductive non-magnetic surface of the magnetic field.

[0078] Additionally or alternatively, a gap of less than 1 cm may be provided between the magnet array and the linear motor. Moving part The magnetic field exists between the conductive and non-magnetic surfaces.

[0079] Additionally or alternatively, the linear motor is a three-phase linear motor and the magnetic damping system is configured to simultaneously short-circuit power to each of the three phases.

[0080] Additionally or alternatively, the stator assembly of the linear motor includes a first coil subassembly and a second coil subassembly, the first coil subassembly including a plurality of poles around which a plurality of vertically arranged windings are wound to create a first coil stack, and the second coil subassembly including a plurality of poles around which a plurality of vertically arranged windings are wound to form a second coil stack.

[0081] Additionally or alternatively, the first coil subassembly and the second coil subassembly of the linear motor immediately after the power is shorted Moving part The movement of Moving part The magnet is configured to generate an electromagnetic force that generates a current and a force that resists the movement of the magnet.

[0082] Additionally or alternatively, the magnetic damping system of the linear motor may include: Moving part adjacent to the first side of Moving part a first magnet array disposed on a frame of the suspension system parallel to the axis of movement of the Moving part adjacent to the second side of Moving part a second magnet array disposed on the frame of the suspension system parallel to the axis of movement of the

[0083] Additionally or alternatively, the first and second magnet arrays of the magnetic damping system of the linear motor may be Moving part The first magnet array is separate from the magnets used to generate the movement of Moving part Extends parallel to the axis of movement of Moving part a second magnet array positioned adjacent to the first conductive non-magnetic surface of the Moving part Extends parallel to the axis of movement of Moving part the first and second magnet arrays being positioned adjacent to a second conductive non-magnetic surface of the linear motor when power is disconnected to the linear motor; Moving part The device is configured to absorb the kinetic energy of the movement of the object.

[0084] In another exemplary embodiment, a method includes: a stator assembly; Moving part receiving power by a stator assembly; and after receiving power by the stator assembly, Moving part Moving the back and forth, Moving partto the stator assembly so that there is no sliding or rolling contact between the suspension system and the Moving part By controlling the movement of Moving part The linear motor is supported by a suspension system, power to the stator assembly is cut off, and when power is cut off, the linear motor is damped by a magnetic damping system. Moving part and a method for absorbing the kinetic energy of movement of a body.

[0085] The above and further advantages of the present invention may be better understood by referring to the following description in conjunction with the accompanying drawings, in which like reference numerals indicate like elements and features in the various drawings. For clarity, not every element may be labeled in every drawing. Also, the drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the invention. [Brief explanation of the drawings]

[0086] [Figure 1] FIG. 1 illustrates a perspective view of a linear motor, according to one embodiment. [Figure 2] 2 illustrates a cutaway view of the linear motor of FIG. 1 taken at arrow AA, according to one embodiment. [Figure 3] FIG. 2 illustrates a perspective view of the linear motor of FIG. 1 showing cooling ducts, according to one embodiment. [Figure 4] FIG. 4 illustrates a perspective view of a first side frame of the linear motor of FIGS. 1 and 3 revealing the top surface, according to one embodiment. [Figure 5] FIG. 4 illustrates a perspective view of a second side frame of the linear motor of FIGS. 1 and 3 revealing the underside, according to one embodiment. [Figure 6] 6 illustrates a perspective view of a frame subassembly including the first and second side frames of FIGS. 4 and 5 connected between upper and lower plates oriented to expose the upper side, according to one embodiment. [Figure 7] FIG. 7 illustrates a perspective view of the frame subassembly of FIG. 6 oriented to reveal its underside, according to one embodiment. [Figure 8] FIG. 5 illustrates a perspective cutaway view of the first side frame of FIG. 4 showing two air bushings disposed within the vertical openings, according to one embodiment. [Figure 9] FIG. 4 shows a perspective view of the moving part of the linear motor of FIGS. 1 and 3, according to one embodiment. [Figure 10] 10 shows a perspective view of the magnet frame of the moving part of FIG. 9 according to one embodiment. [Figure 11] 11 shows an enlarged perspective view of a portion of the magnet array of the magnet frame of FIG. 10 according to one embodiment. [Figure 12] FIG. 4 illustrates a perspective view of a coil subassembly of the linear motor of FIGS. 1 and 3, according to one embodiment. [Figure 13] FIG. 13 illustrates a side view of a portion of the coil subassembly of FIG. 12 according to one embodiment. [Figure 14] FIG. 13 illustrates a perspective view of a coil bobbin with integrated cooling fins of the coil assembly of FIG. 12 according to one embodiment. [Figure 15] FIG. 13 illustrates a perspective view of the coil subassembly of FIG. 12 with heat pipes and additional cooling fins, according to one embodiment. [Figure 16] FIG. 4 illustrates an electrical schematic diagram of a three-phase motor of the linear motor of FIGS. 1 and 3, according to one embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0087] DETAILED DESCRIPTION OF THE INVENTION Embodiments of the present invention provide numerous advancements within the art of testing systems, and more particularly, frictionless material handling systems. As used herein, a frictionless material testing system includes: A) a moving part ( Moving partA material testing system configured to operate without contact (sliding, rolling, etc.) between A) a moving part, B) a suspension system supporting the moving parts, etc. Material testing systems, including the frictionless material testing systems described herein, may be configured to exert a back-and-forth linear force and / or motion on a material, device, apparatus, or other object under test. Frictionless material testing systems have been found to have superior reliability, sensitivity, and cleanliness compared to systems that operate with sliding or rolling contact.

[0088] Prior art frictionless material testing systems have traditionally been limited in stroke range due to the moving parts coupled to the test specimen and the suspension system, as known concepts for creating controlled movement between them require mounting a magnet carrier between flexible suspension components. When one or more magnets held by the magnet carrier are exposed to a magnetic field created by a single-phase linear motor, the flexible suspension component bends. While this configuration is frictionless (i.e., the bending flexible suspension component does not impart any contact-based friction), the range of movement is limited by the material properties of the flexible suspension component.

[0089] The present invention provides a frictionless materials testing system with an increased stroke range. The system described herein comprises: Moving part It is not necessary to directly connect any flexible suspension components between the suspension system and the flexible suspension support. Rather, embodiments of the present invention allow for movement relative to the suspension system that is not directly connected to any flexible suspension support. Moving part Includes:

[0090] Embodiments of the present invention include a materials testing system that includes a multi-phase linear motor with a stack of multiple cores configured to provide a desired longer stroke distance. For example, the present invention includes a materials testing system that includes a three-phase linear motor, where each phase of the motor controls one or more windings or coils in the stack of coils. The multiple phases allow for testing over a greater vertical stroke distance than is achievable with a single-phase motor. Moving part can provide control of

[0091] The embodiments described herein provide a method for moving a motor over a greater stroke distance without sliding friction. Moving part supported by an air bushing suspension system to control the movement of Moving part The present invention relates to a frictionless material testing system. Moving part When the air bushing suspension system is powered by a linear motor, the air bushing suspension system is driven by magnetic attraction. Moving part Prevent bending or twisting of Moving part and the one or more stator assemblies.

[0092] An embodiment of the present invention is a magnetic Moving part A magnetic field for integration with a linear motor having a stator assembly including one or more stacks of coils for moving a magnetic field. Moving part Embodiments of the present invention include using an array of diagonally arranged flat tile magnets. Moving part The magnet Moving part and a magnet array extending through the magnet frame so as to be exposed on two opposing sides or surfaces of the stator coil stack, each of the two opposing sides or surfaces being proximate to a respective stator coil stack.

[0093] Further described herein is a frictionless materials testing system having a stopping or braking system that includes a magnetic damping system for providing damping when the frictionless materials testing system is stopped. Moving partto generate a force that slows down the Moving part In embodiments using a multi-phase linear motor, an embodiment of the frictionless materials testing system includes a system configured to simultaneously disconnect or short-circuit power to each phase.

[0094] A cooling approach for cooling the linear motor of a frictionless materials testing system is further described. The cooling system described herein utilizes recycled air supplied to the air bushing of the suspension system to cool components of the linear motor, such as the windings or coils. Another novel approach to embodiments of the cooling system of the present invention includes utilizing a coil bobbin with fins to optimize heat removal, and a heat pipe extending from the gap located between the windings of the coil stack, with additional cooling fins attached thereto.

[0095] The present teachings will now be described in more detail with reference to exemplary embodiments thereof, as illustrated in the accompanying drawings. While the present teachings are described in conjunction with various embodiments and examples, it is not intended that the present teachings be limited to such embodiments. On the contrary, the present teachings encompass various alternatives, modifications, and equivalents, as will be appreciated by those skilled in the art. Those skilled in the art with access to the teachings herein will recognize additional implementations, modifications, and embodiments, as well as other fields of use, that are within the scope of the disclosure described herein.

[0096] References in the specification to "one embodiment" or "an embodiment" mean that a particular feature, structure, or characteristic described in connection with an embodiment is included in at least one embodiment of the teachings. References to particular embodiments within this specification do not necessarily all refer to the same embodiment.

[0097] Referring now to the drawings, Figure 1 shows a perspective view of a materials testing machine 10 including a linear motor 100 according to one embodiment. Moving part200, a suspension system 300, and a stator assembly 400. Moving part 200 includes an output shaft 210 extending from a bottom end that is mechanically coupleable to a test specimen (not shown). Moving part 200, and thereby output shaft 210, is configured to be moved back and forth by operation of linear motor 100 along axis of movement 500, as described herein. Moving part The stroke length of 200 may be greater than 70 mm in one embodiment. Moving part The stroke length of 200 may be greater than 80 mm, 90 mm, or 100 mm. The materials testing machine 10 may be configured with any necessary stroke length to adequately perform a test on a given specimen or material.

[0098] The suspension system 300 includes: Moving part Supporting 200, Moving part 200 and the suspension system 300. Moving part 200 along the axis of movement 500. Moving part 200 may be configured to apply a force to the specimen, inducing either a motion or a mechanical stress (or both) along the axis of movement 500 .

[0099] Linear motor 100, Moving part 200, suspension system 300, and stator assembly 400 are shown in more detail in subsequent figures. The mechanical attachment between output shaft 210 and the test specimen may be conventional. For example, the configuration of the test specimen may depend on the particular material test to be performed. The test specimen may be considered to be any material, component, jig, fixture, device, etc.

[0100] Moving part200 may be a magnetic device having a magnet array 212 positioned or otherwise arranged within a magnet frame 214. Although not shown, the magnet array 212 may include Moving part 200 extends through the magnet frame 214 on the opposite side. Moving part Only one side of the 200 is shown, Moving part 200 may be geometrically symmetrical or substantially symmetrical about a first plane of symmetry that extends parallel to both the axis of movement 500 and a horizontal axis 510 perpendicular to the axis of movement, as shown. Moving part 200 may also be magnetically and geometrically symmetrical or substantially symmetrical about a second plane of symmetry extending parallel to the axis of movement 500 and a second horizontal axis 520 that is perpendicular to the axis of movement and further perpendicular to the first axis of movement.

[0101] Moving part 200 is held in place by a suspension system 300 that includes a first side frame 310 and a second side frame 312. The first and second side frames 310, 312 Moving part The suspension system 300 is configured to support the Moving part 200 therein (e.g., the first and second openings shown in FIGS. 6 and 7). Moving part The suspension system 300 further includes a top mounting plate 314 and a bottom mounting plate 316 for mounting, connecting, or otherwise mounting the first and second side frames 310, 312 and the stator assembly 400. The suspension system 300 may include a structure (e.g., first and second side frames 310, 312) that includes openings 395, 397, although other embodiments are contemplated. The coil stack in the stator assembly 400 is located between the first side frame 310 and the second side frame 312. The suspension system 300 further includes a top mounting plate 314 and a bottom mounting plate 316 for attaching, connecting, or otherwise mounting the first and second side frames 310, 312 and the stator assembly 400.

[0102] In the illustrated embodiment, the linear motor 100 is a three-phase linear motor. Figure 2 shows a cutaway view of the linear motor 100 of Figure 1 taken along arrow AA, according to one embodiment. The linear motor 100 includes a first coil subassembly 414 having a first coil stack 410; Moving part and a second coil subassembly 416 having a second coil stack 412 housed within the stator assembly 400 adjacent two opposing sides of the magnet array 212 exposed on either side of the magnet frame 214 of the stator assembly 400. Upon receiving power, the coil stack of the stator assembly 400 Moving part Provides 200 movement.

[0103] The first coil subassembly 414 includes a first laminated magnetic core 422 having six separate poles 418a, 418b, 418c, 418d, 418e, and 418f wound with six separate windings 420a, 420b, 420c, 420d, 420e, and 420f, respectively, that create the first coil stack 410. Similarly, the second coil subassembly 416 includes a second laminated magnetic core 422 having six separate poles 424a, 424b, 424c, 424d, 424e, and 424f wound with six separate windings 426a, 426b, 426c, 426d, 426e, and 426f, respectively, that create the second coil stack 412. As shown, the first phase A is connected from the top to the upper winding 420a, 426a of each of the first and second coil stacks 410, 412, along with a fourth winding 420d, 426d. The second phase B is connected from the top to the second winding from the top 420b, 426b of each of the first and second coil stacks 410, 412, along with a fifth winding 420e, 426e. The third phase C is connected from the top to the third winding from the top 420c, 426c of each of the first and second coil stacks 410, 412, along with a sixth winding 420f, 426f.

[0104] As shown, each of the magnets in magnet array 212 includes an opposite or counter polarity relative to its immediately adjacent magnets. Specifically, magnet array 212 includes 14 rows of two magnets each. Other embodiments may include more or fewer than 14 rows of two magnets each. For example, shorter stroke versions of linear motor 100 may include 13, 12, 11, 10 or fewer magnet pairs. Longer stroke versions of linear motors may include 15, 16, 17, 18, 19, 20 or more magnet pairs. This three-phase configuration allows for: Moving part generating a magnetic field that interacts with the magnet array 212 of 200; Moving part The suspension system 300 moves up and down (i.e., back and forth) along a translation axis 500. The magnet array 212 may be positioned closely to each of the first and second coil stacks 410, 412 within a predetermined gap tolerance. The gap span may be maintained at a tight tolerance to prevent the magnet array 212 from being attracted to one or the other of the first and second coil stacks 410, 412 during operation as much as possible. While it may be impossible to create perfectly equal gaps between each side of the magnet array 212 and the coil stacks 410, 412, the lateral stiffness of the suspension system 300 may be configured to support lateral forces created by slightly uneven gaps. The lateral stiffness of the suspension system 300, including air bushings (described in more detail below), may be high enough to offset any lateral forces caused by uneven gaps.

[0105] The illustrated embodiment includes a three-phase linear motor with a three-phase stator assembly 400. Moving part The principles described herein relating to 200, suspension system 300, and stator assembly 400 may be incorporated into a single-phase linear motor, or any other multi-phase linear motor. Although it has been discovered that a three-phase system is capable of achieving a higher stroke length than a single-phase system in applications where stroke length is not critical, a single-phase linear motor may also be used without departing from various embodiments of the present invention.

[0106] FIG. 3 illustrates a perspective view of the linear motor 100 of FIG. 1 , showing cooling ducts 318, 320, and 322 according to one embodiment. The cooling ducts 318, 320, and 322 may be removably attachable features to each of the first and second side frames 310 and 312 of the suspension system 300. As shown, the first cooling duct 318 is attached to the front of the first side frame 310, and the second cooling duct 320 is attached to the rear of the first side frame 310. Similarly, the third cooling duct 322 is shown attached to the front of the second side frame 312. Although hidden, a fourth cooling duct may be attached to the rear of the second side frame 312. Each of the cooling ducts 318, 320, and 322 may provide a passageway for air to travel therethrough. To facilitate the circulation, recirculation, and / or blowing of air through the cooling ducts 318, 320, 322, fans 324, 326, 328 are shown attached to each cooling duct 318, 320, 322, respectively.

[0107] 4 and 5, FIG. 4 illustrates a perspective view of the first side frame 310 of the linear motor 100 of FIGS. 1 and 3 with the upper surface 330 exposed, according to one embodiment. FIG. 5 illustrates a perspective view of the second side frame 310 of the linear motor 100 of FIGS. 1 and 3 with the lower surface 332 exposed, according to one embodiment. The first and second side frames 310, 312 may be symmetrical components having the same dimensions and characteristics. In other embodiments, the first and second side frames 310, 312 may each include one or more unique features, dimensions, etc. (not shown).

[0108] The first and second side frames 310, 312 of the suspension system 300 may be dimensioned to support air flow from the ducts 318, 320, 322 into gaps located between each of the windings 420a, 420b, 420c, 420d, 420e, 420f, 426a, 426b, 426c, 426d, 426e, 426f of the stator assembly 400 and / or over the magnets of the magnet array 212. To accomplish this, the first and second side frames 310, 312 may each include an I-shaped cross-section. Accordingly, the first and second side frames 310, 312 each include an upper portion 340, 342, respectively, a middle portion 344, 346, respectively, and a lower portion 348, 350, respectively. 3, the cooling ducts 318, 320, 322 are attached between the top and bottom of the I-shaped cross section such that the first and second side frames 310, 312 define an air passage from the cooling ducts 318, 320, 322 to the stator assembly 400 and / or magnet array 212. In other embodiments, the shape of the first and second side frames 310, 312 may be more solid than in the embodiment shown and may include openings, slots, ports, etc. to facilitate air flow.

[0109] 4 and 5, first side frame 310 includes a first opening 334 having an air bushing 336a disposed therein, and second side frame 312 includes a second opening 338 having another air bushing 336b disposed therein. First and second openings 334, 338 are cylindrical openings having circular cross-sections configured to receive cylindrical air bushings 336a, 336b (hereinafter generally referred to as air bushings 336), respectively. However, in other embodiments, openings of other shapes are contemplated. For example, triangular or rectangular openings may be used in first and second side frames 310, 312 having arrays of opposing flat bearings rather than utilizing cylindrical air bushings 336 without departing from the scope of the various inventive concepts described herein.

[0110] When the power to the linear motor 100 is cut off, each of the first and second side frames 310, 312 Moving part 200. The magnetic damping system further includes a magnetic damping system configured to absorb kinetic energy from the movement of the magnetic damping system. Specifically, the magnetic damping system includes: Moving part 200. The magnetic damping system is shown as two arrays of magnets 380a, 380b, one disposed on each of the first and second side frames 310, 312 parallel to the axis of motion 500 of the linear motor 100. In addition to absorbing kinetic energy when power is removed, the magnetic damping system may be configured to reduce instability and make the linear motor 100 more stable. For example, during normal operation, the magnetic damping system may be tuned by adjusting the gap or by using a different number or type of magnets to provide optimal damping for improved system control.

[0111] While FIG. 4 clearly shows a first array of magnets 380a disposed on the first side frame 310, the second side frame 312 includes a second array of magnets 380b (more clearly shown in FIG. 6). Each magnet in each of the arrays of magnets 380a, 380b is shown as a flat tile permanent neo-magnet. These arrays of magnets 380a, 380b are used to rotate the linear motor 100. Moving part To generate 200 moves Moving part Each of the arrays of magnets 380a, 380b is separate from the magnet array 212 utilized by linear motor 100 when assembled and operational. Moving part 200 extends parallel to the axis of movement 500 Moving part 200. A small gap (e.g., less than 1 cm, less than 5 cm, or less than 25 cm) separates each of the arrays of magnets 380a, 380b from the adjacently positioned magnets (shown more clearly in FIG. 10 and described below). Moving part 200. The first and second arrays of magnets 380a, 380b are Moving partUtilizes eddy currents induced by the movement of 200 conductive, non-magnetic surfaces to resist movement and thereby move during standstill Moving part The number of magnets shown in each of the first and second arrays of magnets 380a, 380b is 12, although more or fewer magnets may be provided. Each of the arrays of magnets 380a, 380b includes a single row of magnets vertically disposed on the magnet retention surfaces 382a, 382b of the first and second side frames 310a, 310b, respectively. The magnet retention surfaces 382a, 382b are configured to provide a damping effect to the linear motor 100 when assembled and in operation. Moving part 200. Alternatively, the first and second side frames 310a, 310b may be vertically sized protrusions extending from the respective surfaces of the first and second side frames 310a, 310b adjacent to each other.

[0112] The top and bottom surfaces of the first and second side frames 310, 312 may each include one or more alignment pins 352, 354. For example, the top surface 330 of the first side frame 310 includes a first alignment pin 352 to facilitate attachment between the first side frame 310 and the top plate 356. The bottom surface 332 of the second side frame 312 is shown to include a second alignment pin 354 to facilitate attachment between the second side frame 312 and the bottom plate 358. While only the top surface of the first side frame 310 and the bottom surface 332 of the second side frame 312 are shown, it should be understood that alignment pins may also be included on the bottom surface of the first side frame 310 and the top surface of the second side frame 312. The upper and lower surfaces of each of the first and second side frames 310, 312 may further include, for example, threaded openings 360 for receiving attachment mechanisms such as threaded screws, bolts, or the like, for attaching the first and second side frames 310, 312 to the upper and lower plates 356, 358.

[0113] The first and second side frames 310, 312 each include two air supply openings 384 for each air bushing 336 configured to be disposed within the first opening 334 and second opening 338, respectively. The air supply openings 384 may be configured to supply forced air from an air source (not shown) to the air bushings 336. The air supply openings 384 may be configured to directly receive air or may be configured to receive a tube, pipe, or other device configured to pass air therethrough. The first and second side frames 310, 312 further include three pressure relief openings 386 for each bushing configured to be disposed within the first opening 334 and second opening 338. The air supply openings 384 and pressure relief openings 386 are shown in FIG. 7 and described in more detail below.

[0114] Figure 6 shows a perspective view of a frame subassembly 370 including the first and second side frames 310, 312 of Figures 4 and 5 connected between upper and lower plates 356, 358 oriented to expose the upper sides 362, according to one embodiment. Figure 7 shows a perspective view of a frame subassembly 370 including the first and second side frames of Figures 4 and 5 connected between upper and lower plates 356, 358 oriented to expose the lower sides 364, according to one embodiment. The upper and lower plates 356, 358 are configured to attach the first and second side frames 310, 312 together and also provide mounting locations for attaching the first and second coil stacks 410, 412 of the stator assembly 300. Accordingly, the upper and lower plates 356, 358 may include various openings, e.g., threaded, to receive mounting screws, bolts, or other mechanisms for assembling the frame subassembly 370, or for further attaching the frame subassembly 370 to other components (not shown) of the materials testing system 10.

[0115] The upper and lower plates 356, 358 may each include multiple x,y location openings 368a, 368b, 368c and clocking slots 366a, 366b, 366c to facilitate assembly. The x,y location openings 368a, 368b, 368c may be circular openings to receive circular pins, which can prevent movement between the plates 356, 358 and the side frames 310, 312 through which the pins extend. The clocking slots 336a, 336b, 336c are elongated along the direction of movement, which can provide some movement between the plates 356, 358 and the side frames 310, 312 through which the pins extend.

[0116] To assemble the linear motor 100 and its frame subassembly 370: Moving part After linear motor 100 is placed within frame subassembly 370, pins may be inserted into x,y location openings 368b, 368c and clocking slots 336b, 336c, respectively, of lower plate 358. Pins may then be inserted into x,y location openings 368a and clocking slot 366a of upper plate 356. Once the pins are placed through clocking slots 336a, 336b, 336c and x,y location openings 368a, 368b, 368c, a method of assembling linear motor 100 includes energizing air bushings 336 within first and second vertical openings 334, 338. This air pressure, in conjunction with the limited movement provided by clocking slots 366a, 366b, 366c, may align the system, after which the upper and lower plates 356, 356 may be fully tightened with bolts, screws, or the like.

[0117] Each of the upper and lower plates 356, 358 may include the same dimensions and characteristics. For example, each of the upper and lower plates 356, 358 may include: Moving part Two shafts configured to receive the shaft therein Moving part When assembled, the first opening 334 of the first side frame 310 may include shaft openings 394a, 394b, 394c, and 394d. Moving partThe second opening 338 of the second side frame 312 is aligned with the shaft openings 394a, 394c. Moving part Shaft openings 394b, 394d align to provide left and right collective vertical openings that extend through each of top plate 356, each of first and second side frames 310, 312, and bottom plate 358. Each of the collective vertical openings extends along an axis parallel to axis of movement 500.

[0118] No. 1 Moving part An opening 395 extends between the openings 394a, 394b in the top plate 356 and a corresponding second Moving part An opening 397 extends between openings 394c, 394d in lower plate 358. Moving part The openings 395 and 397 are Moving part Accept it internally, Moving part An upper bump stop 390a is shown extending from the upper plate 356, and a lower bump stop 390b extends from the lower plate 358. The bump stops 390a, 390b Moving part The bump stops 390a, 390b may provide a physical boundary for the movement of 200. The bump stops 390a, 390b may be made of a soft elastomeric material, such as an FKM elastomer, to slow deceleration.

[0119] The top plate 356 is shown to include first and second stack mounting surfaces 392a, 392b. Similarly, the bottom plate 358 is shown to include third and fourth stack mounting surfaces 392c, 392d. The stack mounting surfaces 392a, 392b provide a surface upon which the first coil stack 410 is mounted. Similarly, the stack mounting surfaces 392c, 392d provide a surface upon which the second coil stack 412 is mounted. Accordingly, the stack mounting surfaces 392a, 392b, 392c, 392d each include a plurality of openings that may be configured with threads to receive screws, bolts, or the like. The dimensions by which the stack mounting surfaces 392a, 392b, 392c, 392d extend into the top and bottom plates 356, 358 determine the extent to which the stack mounting surfaces 392a, 392b, 392c, 392d move. Moving part200 and the first and second coil stacks 410, 412 may be precision machined to provide the desired gap distance.

[0120] 8 illustrates a perspective cutaway view of a first side frame 310 showing two air bushings 336a, 336c disposed within the vertical opening 334 of the first side frame 310, according to one embodiment. While only the first side frame 310 is shown cut away in FIG. 8 to reveal the two air bushings 336a, 336c within the vertical opening 334, the second side frame 312 may similarly further include two air bushings 336. Thus, the following description of air bushings 336a, 336c is applicable to the two air bushings 336 located within the second side frame 312.

[0121] As shown, the first air bushing 336a of the first side frame 310 is located proximate a first upper end of the opening 334, and the second air bushing 336b is located proximate a second lower end of the opening 334. Each air bushing 336a, 336b may be positioned within the opening 334 in a manner adapted to allow some movement between the air bushings 336a, 336b and the frame subassembly 370. This fitting relationship may be provided by inserting the air bushings 336a, 336b into the opening 334 with an interference fit or a press fit. Additionally, each air bushing 336a, 336b is shown as including a plurality of O-rings 372, which may be made of a corresponding elastomeric material and may provide some fit between the air bushings 336a, 336b and the opening 334 (and thereby the frame subassembly 370). Each of the air bushings 336a, 336b may be installed by manually inserting them into the openings 334, and may be manually removed, for example, for maintenance.

[0122] Each of the air bushings 336a, 336b has a hollow cylindrical shape. Each of the air bushings 336a, 336b includes an outer body 374 and an inner body 378 made of different materials. While the inner body is porous and permeable to air, the outer body 374 is impermeable to air except through the air receiving port openings 376. This allows air to be received into each of the air bushings 336a, 336b through the respective air receiving port openings 376. This air is then transported through the porous inner body 378. Because the outer body 374 is impermeable to air and prevents air received by the air receiving port openings 376 from leaking out through the outer body 374, the received air is forced to escape only through the porous inner body 378, thereby confining the porous inner body 374 and the air received therein. Moving part Air pressure is generated between the shaft of the air bushing 336a, 336b and the inner body 378. The porous inner body 378 contains many (thousands, millions, etc.) sub-micron pores that create a permeability to air within the material. When the air bushings 336a, 336b receive air through the air receiving port openings 376, the air bushings 336a, 336b are forced to move in a direction away from the shaft of the air bushing 336a, 336b. Moving part The shaft may be configured to provide a full 360 degrees of non-contact movement.

[0123] As shown in the cutout, the air supply openings 384 of the first side frame 310 extend through the body of the frame and are directly aligned with the respective receiving port openings 376. Pressure relief openings 386 also extend through the body of the frame and are aligned with the spaces between each of the four O-rings 372 on the bushings. The pressure relief openings 386 in the body of the first side frame 310 can facilitate installation of the air bushings 336a, 336b and prevent air pressure buildup between the outer bodies 374 of the air bushings 336a, 336b and the inner walls of the vertical openings 334 of the first side frame 310. Moving part Additional openings may be provided from within the vertical opening 334 of the first side frame 310 to recycle air introduced into the bushings 336a, 336b and returned to the system through the respective receiving port options 376 for the purpose of cooling at least one of the 200 magnet arrays 212.

[0124] Although the test fixture 10 and linear motor 100 are shown to include four air bushings 336 (two on each of the first and second side frames 310, 312), Moving part More or fewer air bushings may be included as needed to accommodate any crushing forces caused by magnetic attraction between 200 and coil stacks 410, 412. For example, some embodiments may require only two air bushings. Other embodiments may require six air bushings (three for each of vertical openings 334, 338). In another contemplated embodiment, one or more additional air bushings may be added to provide additional suspension support for the system. Moving part 200 , may be configured to surround a specimen output shaft 210 extending from the specimen output shaft 210 .

[0125] FIG. 9 illustrates a linear motor 100 of FIGS. 1 and 3, according to one embodiment. Moving part 200 is shown in perspective view. Moving part200 includes a magnet frame 214 with a magnet array 212 extending between a top end plate 220 and a bottom end plate 222 in the direction of the axis of movement 500. The top end plate 220 and the bottom end plate 222 are configured to connect, attach, or otherwise assemble the magnet frame 214 and magnet array 212 to a first side air bushing shaft 230 and a second side air bushing shaft 232. The first and second side air bushing shafts 230, 232 also extend in the axis of movement 500. The first and second side air bushing shafts 230, 232 are shown as cylindrical shafts. The first and second side air bushing shafts 230, 232 have tight dimensional tolerances relative to the inner dimensions of the air bushings 336 within the first and second openings.

[0126] The air bushing 336 is a part of the suspension system 300. Moving part 200 and frame subassembly 370. The air bushing 336 is configured to provide frictionless movement between the air bushing 336 and the inner surface of the air bushing 336. Moving part 200. When air is forced through the inner body 378 of the air bushing 336, Moving part The air bushing shafts 230, 232 of 200 are forced through the air to a midpoint between the inner surface of the inner body 378. In one embodiment, the air bushings 230, 232 may have a radius that is 3-5 microns smaller than the inner radius of the inner surface of the air bushing 336 to provide space between the air bushing shafts 230, 232 and the inner surface of the inner body 378 of the air bushing 336 when the air bushing 336 is receiving airflow and the system is operating. In one embodiment, the air bushing shafts 230, 232 have a radius that is 4 microns smaller (8 microns smaller diameter) than the inner surface of the air bushing 336. Other dimensions are contemplated to provide a frictionless and / or contactless movement system between the air bushing shafts 230, 232 and the air bushing 336.

[0127] The top and bottom end plates 220, 222 are shown as having a width that is wider than the width of the magnet frame 214. This wider width provides a surface for engaging the bump stops 390a, 390b. Additionally, the top and bottom end plates 220, 222 include connection openings 234 that receive bolts, screws, or other attachment mechanisms for connection to the magnet frame 214. Various other connection openings may be provided to receive other bolts, screws, etc. to attach the top and bottom end plates 220, 222 to the air bushing shafts 230, 232. The top and bottom end plates 220, 222 are shown connecting the first and second air bushing shafts 230, 232 to the magnet frame 214 such that a first space extends parallel to the axis of movement 500 between the first air bushing shaft 230 and the magnet frame 214, and similarly a second space extends parallel to the axis of movement between the second air bushing shaft 232 and the magnet frame 214. These spaces may be larger than the thickness of the air bushing 336 and the body of the first and second side frames 310, 312 surrounding the vertical openings 334, 338. Thus, these vertical spaces between the air bushing shafts 230, 323 and the magnet frame 214 provide a vertical clearance for the suspension system 300. Moving part While allowing for 200 vertical movements Moving part 200 remains connected to the suspension system 300.

[0128] FIG. 10 illustrates the air bushing assembly of FIG. 9 prior to assembly with first and second air bushing shafts 230, 232 and top and bottom end plates 220, 222, according to one embodiment. Moving part200 illustrates the magnet frame 214. The magnet frame 214 includes a body extending between an L-shaped side 236 and an L-shaped right side 238. The L-shaped left and right sides 236, 238 extend the vertical length of the magnet frame 214. The magnet frame 214 has a central opening configured to receive the magnet array 212. Each magnet of the magnet array 212 may be attached to the magnet frame 214 with epoxy around the edges of the magnet array 212 and around the edges of each individual magnet to secure the magnets to one another. The epoxy may be a temperature-resistant epoxy that does not degrade at the high temperatures to which the magnets may be exposed during operation. In other embodiments, the magnets may be attached to the magnet frame 214 via mechanical means, such as via slots in tiles integrated with protrusions or slots in the magnet frame 214. Another alternative or additional approach may include utilizing set screws along the edges of the magnets to tighten, compress, or otherwise clamp the magnets by the magnet frame 214.

[0129] An array of magnets 380a mounted on one of the side frames 310, 312 is also shown in this view, with the side frame removed to show the close dimensional relationship between the array of magnets 380a and the magnet frame 214. The gap between the array magnets 380a and the magnet frame 214 may be optimized to provide a desired damping force when the system is shut off. For example, gaps of 3 mm, 25 mm, 2 mm, and 15 mm are contemplated. Any gap that achieves the desired amount of damping through interaction with eddy currents is contemplated.

[0130] FIG. 11 illustrates a portion of the magnet array 212 of the magnet frame of FIG. 10 , according to one embodiment. A magnified view of several individual magnets 212a, 212b, 212c, 212d, 212e, 212f, and 212g is shown to illustrate the distortion and dimensions of each of the magnets in the magnet array 212. Each of the magnets 212a, 212b, 212c, 212d, 212e, 212f, and 212g in the magnet array 212 (both those shown in FIG. 11 and those extending below the view) may be a permanent neo-magnet, such as an NdFeB magnet. Each of the magnets 212a, 212b, 212c, 212d, 212e, 212f, and 212g in the magnet array 212 is shown distorted at a slight angle, such as a single angle. Thus, magnets 212a, 212b, 212c, 212d, 212e, 212f, and 212g may have a parallelogram shape such that the bottom and top edges of each flat tile magnet are not perpendicular to the side edges of the flat tile magnet. As shown, the upper left edge of each of magnets 212a, 212c, and 212e is higher than the upper right edge. Similarly, the upper right edge of each of magnets 212b, 212d, 212f, and 212g is higher than the upper left edge. In other words, the dimensions of the magnets are smaller as they approach the center of magnet array 212 than at the edges of magnet array 212. This distortion may be reversed so that the dimensions of the magnets are larger as they approach the center of magnet array 212 than at the edges of magnet array 212. The distortion may be any suitable amount, such as a single degree, two degrees, or three degrees, and may be optimized to reduce cogging forces during interaction with the magnetic field generated by the stator assembly 400.

[0131] In an exemplary embodiment, the width of each magnet may be 50-100 mm and the height may be 10-50 mm. The thickness of each magnet may be 10-22 mm. In one exemplary embodiment, the magnets may have a width of 70 mm, a height of 28 mm, and a thickness of 18 mm. These dimensions may be varied depending on the force output desired by the magnet array 212.

[0132] FIG. 12 shows a perspective view of the first coil subassembly 414 of the linear motor 100 of FIGS. 1 and 3 , according to one embodiment. Although not shown, the second coil subassembly 418 may share the same features and dimensions as the first coil subassembly 414. The coil subassembly 414 is shown to include a first laminated magnetic core 422 having six separate poles 418a, 418b, 418c, 418d, 418e, 418f (generally 418) around which six separate windings 420a, 420b, 420c, 420d, 420e, 420f (generally 420) are wound, respectively, to create the first coil stack 410. The laminated magnetic core 422 may include many laminations held together by stack press bars on each side. The laminated magnet core 422 may include, for example, 200 laminations (metal sheets) of M19 magnetic steel. The laminations may include fins 428, which can increase the surface area of ​​the laminated magnet core 422 to facilitate cooling. In an exemplary embodiment, the pole spacing between the six separate poles 418a, 418b, 418c, 418d, 418e, and 418f may be 20-60 mm. In one embodiment, the pole spacing may be 38 mm. In some embodiments, the pole spacing may be equal between each of the poles 418a, 418b, 418c, 418d, 418e, and 418f. In other embodiments, different pole spacing may be advantageous to optimize heat distribution, magnetic field output, etc. In an exemplary embodiment, the thickness of the poles 418a, 418b, 418c, 418d, 418e, and 418f may be 10-20 mm. In one embodiment, the pole thickness may be 15.8 mm. The six separate windings 420a, 420b, 420c, 420d, 420e, 420f may be made of, for example, 16 AWG round wire and may include 168 turns. The windings 420a, 420b, 420c, 420d, 420e, 420f may each include six layers with 28 turns per layer. A coil bobbin 440a, 440b, 440c, 440d, 440e, 440f (generally, coil bobbin 440) may further be included with each of the poles 418a, 418b, 418c, 418d, 418e, 418f.Coil bobbins 440a, 440b, 440c, 440d, 440e, 440f are described below and shown in FIG.

[0133] FIG. 13 shows a side view of a portion of the coil subassembly 414 of FIG. 12 , according to one embodiment. After being wound onto poles 418a, 418b, 418c, 418d, 418e, and 418f, gaps 430 may exist between the windings 420a, 420b, 420c, 420d, 420e, and 420f. The gaps 430 may allow cooling airflow to pass through them. Each of the gaps 430 may have a thickness of several millimeters. For example, a gap thickness of 4.5 mm is contemplated between each of the windings 420a, 420b, 420c, 420d, 420e, and 420f. The gap thickness may be, for example, 3 to 10 mm. In other embodiments, the gap thickness may be filled with a potting material, as described below and shown in FIG. 15 .

[0134] 14 shows a perspective view of one of the coil bobbins 440 having integrated cooling fins 448a, 448b, 448c, 448d, 448e, and 448f, according to one embodiment. The coil bobbin 440 includes a body 442 extending from a base 444. The body 442 includes a generally rectangular cross-section that surrounds and defines an opening 446 sized to surround and receive one of the poles 418. The coil bobbin 440 further includes a plurality of fins 448a, 448b, 448c, 448d, 448e, and 448f extending from the body 442. Winding gaps 450a, 450b may be located between the plurality of fins 448a, 448b, 448c, 448d, 448e, and 448f. The winding gaps allow the wire of the windings 420 to be wound between sections of the coil bobbin 440. The fins 448a, 448b, 448c, 448d, 448e, and 448f of the coil bobbin 440 may be tall enough to extend through the windings 420 and into the forced convection areas between the coils, thereby allowing the coil bobbin 440 to help increase the conduction of heat from the windings 420. The fins 448a, 448b, 448c, 448d, 448e, and 448f can further increase the surface area available for forced convection.

[0135] 15 shows a perspective view of the coil subassembly 414 of FIG. 12 with a heat pipe 475 and additional cooling fins 470 attached thereto, according to one embodiment. This embodiment may be applied in addition to or as an alternative to the coil bobbin 440. In this embodiment, potting material 460a, 460b, 460c, 460d, and 460e may be included within each of the gaps between the windings 420a, 420b, 420c, 420d, 420e, and 420f. Four heat pipes 475 are shown extending from the potting material within each of the gaps. For example, four heat pipes 475a extend from the left side between the upper gaps of the windings, four heat pipes 475b extend from the left side between the second gaps, four heat pipes 475c extend from the left side between the third gaps, four heat pipes 475d extend from the left side between the fourth gaps, and four heat pipes 475e extend from the left side between the fifth gaps. Similarly, four heat pipes 475f extend from the right side between the upper gaps of the windings, four heat pipes 475g extend from the right side between the second gaps, four heat pipes 475h extend from the right side between the third gaps, four heat pipes 475i extend from the right side between the fourth gaps, and four heat pipes 475j extend from the right side between the fifth gaps. In some embodiments, the heat pipes 475a and 475f extending from the left and right sides, respectively, may be the same component (i.e., a single heat pipe extending in both directions). The heat pipes may be configured to transfer heat from the windings 420 to multiple cooling fins 470 a, 470 b located on each side. As shown, each of the left and right sides includes eight cooling fins 470. The cooling fins 470 may provide increased surface area for cooling. In this embodiment, instead of or in addition to forcing air through the gaps between the windings 420, cooling air is configured to be blown across the cooling fins 470 and the fins 428 of the laminated magnet core 422.

[0136] 1 and 3, where e1, e2, and e3 are voltages driven by amplifiers to control three respective currents i1, i2, and i3, and therefore the force output of the motor. 11 , L 22 , L 33 is in series with the resistance R of each phase.

[0137] Using the Linear Motor 100 three-phase motor, Moving part The acceleration of can be defined as follows: m×”(t)=-k×(t)-bx'(t)+NBL1i1(t)+NBL2i2(t)+NBL3i3(t)-mg In the formula, m is Moving part is the mass of, and x”(t) is Moving part is the acceleration of the system, and k is the spring constant of the system ( Moving part is related to the spring constant of the connected test material, or Moving part is zero if not connected to the test material), b is the damping constant, and x(t) is Moving part and x'(t) is the position of Moving part is the speed of the motor, is an array of motor force / back EMF constants, each 120° apart for each phase, and i is the current in each of phases a, b, and c. The voltage on the first leg can be defined as: e1(t)=L 11 i ’ 1(t)+L 12 i ’ 2(t)+L 13 i ’ 3(t)+R1i1(t)+x'(t)NBL1 where e1[t] is the voltage of the first phase and L 11 is the inductance in the first phase induced by the inductor of the first phase, and L 12 is the inductance in the first phase induced by the inductor of the second phase, and L 13where i(t) is the inductance in the first phase induced by the inductor of the third phase, i(t), i(t), and i(t) are the changes in current in phases a, b, and c, and R is the resistance of each individual phase. Similarly, the voltages in the second and third legs can be defined as follows: e2(t)=L 21 i1 ’ (t)+L 22 i2 ’ (t)+L 23 i3 ’ (t)+R2i2(t)+x'(t)NBL2 e3(t)=L 31 i1 ’ (t)+L 32 i2 ’ (t)+L 33 i3 ’ (t)+R3i3(t)+x'(t)NBL3 Moving part As long as there is a shift in the voltage, even if the voltages on the three legs (e1(t), e2(t), e3(t)) are cut to zero, Moving part Since the motor is moving, the x'(t)NBL terms in each voltage equation do not go to zero. This indicates that an EMF is generated by these x'(t)NBL terms, which results in a force that resists the current change and therefore the motion according to the acceleration equation. Therefore, a three phase motor, and Moving part The movement of the magnets is in addition to the eddy current magnet system described herein above when the current in each phase is cut or shorted. Moving part The damping force is configured to generate a damping force that further slows the movement of the

[0138] Thus, an embodiment of the present invention comprises: Moving part without physical contact and without sliding and / or rolling friction between them, Moving part For example, the suspension system may include: Moving part One-dimensional measurement of the stator assembly without physical contact Moving partIn one embodiment or implementation, the air bushing may be configured to facilitate movement of the suspension system mechanically or structurally connected, attached, or Moving part In one dimension (back and forth along a single axis of movement) without touching Moving part A suspension system can provide, support, or otherwise facilitate a range of motion (stroke length) in this one dimension or along this one axis of movement. Moving part The air bushing may be configured to limit, or at least substantially limit, the movement of the air bushing (if the air bushing is compliant and allows for a very small degree of compliance in another dimension).

[0139] In exemplary embodiments, the absence of a mechanical or structural connection allows for a smooth transition between the suspension system and the vehicle during operation or movement. Moving part Prevents contact friction between the air bushings in the suspension system and Moving part The suspension system contemplated herein may be provided by an air gap located between the air bushing shaft and the air bushing. Moving part The suspension system contemplated herein creates a support system for maintaining precise motion of the vehicle during operation and movement. Moving part can be considered to be in indirect mechanical communication (e.g., via an air gap) with

[0140] Methods of operating a linear motor and / or a materials testing device or system are also contemplated. For example, contemplated methods include a multi-phase stator assembly and a multi-phase stator assembly adjacent to the multi-phase stator assembly. Moving part and a suspension system, the method including receiving power by a multi-phase stator assembly, and after receiving power by the multi-phase stator assembly: Moving part moving the movable member back and forth along a moving axis; Moving part to the multiphase stator assembly so that there is no sliding or rolling contact between the Moving part By controlling the movement of Moving part and supporting the three-phase linear motor with a suspension system. Moving part The method includes creating a magnetic field that moves the magnetic field along the axis of movement at a stroke length greater than 70 mm, 80 mm, 90 mm, or 100 mm. Moving part A contemplated method includes arranging the poles in the stator so that the phases alternate in an ABCABC relationship.

[0141] A further contemplated method involves placing a stator assembly, a flat magnet array disposed thereon, and a magnet assembly adjacent the stator assembly. Moving part A contemplated method includes receiving power from a stator assembly, exposing a planar magnet array to a magnetic field generated by the stator assembly, and providing a suspension system. Moving part generating a back and forth motion within the Moving part to the multiphase stator assembly so that there is no sliding or rolling contact between the Moving part By controlling the movement of Moving part with a suspension system. The method may further include skew- ing the planar magnets in the array of planar magnets at a skew angle between 0.5 degrees and 5 degrees.

[0142] Further contemplated methods include a stator assembly, a Moving part and providing a suspension system. The method includes receiving power by a stator assembly, and providing a suspension system after receiving power by the stator assembly. Moving part The robot can move back and forth along the axis of travel, and the suspension system can Moving part without physically touching Moving part and supporting the vehicle with a suspension system. Moving partwithout sliding or rolling contact between the suspension system and Moving part to the suspension system without a structural connection between the Moving part The method may further include providing at least one air bushing to the suspension system, the air bushing enabling movement of the Moving part to the suspension system without sliding or rolling contact between the Moving part The method of using air bushings may include using recycled air from the air bushings to cool components of the linear motor, such as the stator assembly and its magnets.

[0143] The contemplated method includes: a stator assembly; Moving part The method further includes receiving power by a stator assembly, and after receiving the power by the stator assembly, Moving part moving the movable member back and forth along a moving axis; Moving part to the stator assembly so that there is no sliding or rolling contact between the suspension system and the Moving part By controlling the movement of Moving part by supporting the linear motor with a suspension system, by cutting off power to the stator assembly, and by a magnetic damping system when power to the linear motor is cut off. Moving part If the damping method uses a multi-phase linear motor, such as a three-phase linear motor, the method may include simultaneously cutting power to each of the phases and using the generated overcurrent to Moving part The method may include damping the movement of the coils of the system. Moving part Use the move Moving part The method further includes generating a current, and therefore a force, that resists the movement of the electrode.

[0144] While embodiments of the present invention have been described herein for purposes of illustration, many modifications and changes will become apparent to those skilled in the art. It is, therefore, intended in the appended claims to cover all such modifications and changes that fall within the true spirit and scope of the invention.

[0145] The description of various embodiments of the present invention has been presented for purposes of illustration and is not intended to be exhaustive or limited to the disclosed embodiments. For example, the suspension system 300 in the embodiments described herein Moving part While the absence of any mechanical connection or attachment between 200 is a key inventive concept for some embodiments of the present invention described herein, other inventive embodiments may be able to incorporate other aspects of the inventive concepts described herein into a connected or attached suspension system, such as taught in U.S. Patent No. 6,405,599. For example, embodiments of the present invention may incorporate a polyphase or three-phase linear motor, planar magnet array, or the like, as described herein, in conjunction with an attached flexure component suspension system as taught in U.S. Patent No. 6,405,599. Moving part and / or damping systems may be utilized. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the described embodiments. The terminology used herein has been selected to best explain the principles of the embodiments, practical applications or technical improvements to technology found in the market, or to enable those skilled in the art to understand the embodiments disclosed herein.

Claims

1. A test apparatus comprising: a linear motor including a stator assembly and a moving portion, the moving portion being mechanically coupleable to a test piece configured to move relative to the stator assembly upon operation of the linear motor, the stator assembly including a first coil subassembly and a second coil subassembly, each of the first coil subassembly and the second coil subassembly including a magnetic core having a plurality of poles around which a winding is wound, the moving portion being disposed and extending between the first coil subassembly and the second coil subassembly; a suspension system configured to facilitate movement of the moving part relative to the stator assembly along an axis perpendicular to the movement of the moving part without physically touching the moving part during its movement, the suspension system including at least one vertically arranged air bushing configured to allow vertical movement of the moving part relative to the suspension system without sliding or rolling contact between the moving part and the suspension system; the linear motor and the suspension system are configured to provide frictionless suspension of the moving part and vertical movement of the moving part. Test equipment.

2. The testing device of claim 1 , wherein the moving portion includes a test specimen shaft configured to mechanically couple to the test specimen.

3. the at least one air bushing is disposed in a first opening of the suspension system, the suspension system including a frame body having the first opening extending along a first axis parallel to an axis perpendicular to the movement; the at least one air bushing is located within the first opening; The testing device of claim 1 , wherein the moving portion includes a first air bushing shaft extending into the first opening.

4. 4. The testing apparatus of claim 3, wherein the at least one air bushing includes a first air bushing located proximate a first end of the first opening and a second air bushing located proximate a second end of the first opening.

5. the frame body includes a second opening extending along a second axis parallel to the axis perpendicular to the movement; the moving portion includes a second air bushing shaft extending into the second opening; 5. The testing apparatus of claim 4, wherein the second opening includes a third air bushing located proximate a first end of the second opening and a fourth air bushing located proximate a second end of the second opening.

6. 4. The testing device of claim 3, wherein the at least one air bushing is mounted within the first opening of the frame body in a flexible manner such that some movement between the air bushing and the frame body is permitted.

7. The testing device of claim 3 , wherein the at least one air bushing is removably mounted within the first opening in the frame body with an interference fit.

8. 8. The testing apparatus of claim 7, wherein the at least one air bushing has a hollow cylindrical shape, and the first air bushing shaft is a cylindrical shaft having a radius that is 3 to 5 microns smaller than an inner radius of the at least one air bushing.

9. The moving part includes a magnet frame having a plurality of permanent magnets disposed thereon, the first air bushing shaft extends parallel to the magnet frame; a top end plate and a bottom end plate disposed on the top and bottom sides of the magnet frame connect the first and second air bushing shafts to the magnet frame such that a first space extends between the first air bushing shaft and the magnet frame parallel to an axis perpendicular to the movement, and a second space extends between the second air bushing shaft and the magnet frame parallel to the axis perpendicular to the movement; 6. The test apparatus of claim 5, further comprising a duct system configured to use airflow through at least one air bushing in cooling at least one of the first coil subassembly, the second coil subassembly, and the moving part coil.

10. The testing apparatus of claim 9 , wherein the travel portion includes a specimen shaft extending from at least one of the top end plate and the bottom end plate, and a fifth air bushing surrounds the specimen shaft.

11. A linear motor, a stator assembly configured to receive power, the stator assembly including a first coil subassembly and a second coil subassembly, each of the first coil subassembly and the second coil subassembly including a magnetic core having a plurality of poles around which a winding is wound; a moving part adjacent to the stator assembly and configured to move relative to the stator assembly when the stator assembly receives power, the moving part being disposed and extending between the first coil subassembly and the second coil subassembly; a suspension system configured to facilitate movement of the moving part relative to the stator assembly along an axis perpendicular to the movement of the moving part without physically touching the moving part during its movement, the suspension system including at least one vertically arranged air bushing configured to allow vertical movement of the moving part relative to the suspension system without sliding or rolling contact between the moving part and the suspension system; the linear motor and the suspension system are configured to provide frictionless suspension of the moving part and vertical movement of the moving part. Linear motor.

12. The linear motor of claim 11 , wherein the moving portion includes a test piece shaft configured to mechanically couple to a test piece.

13. the at least one air bushing is disposed in a first opening of the suspension system, the suspension system including a frame body having the first opening extending along a first axis parallel to an axis perpendicular to the movement; the at least one air bushing is located within the first opening; The linear motor of claim 12 , wherein the moving portion includes a first air bushing shaft extending into the first opening.

14. 14. The linear motor of claim 13, wherein the at least one air bushing includes a first air bushing located proximate a first end of the first opening and a second air bushing located proximate a second end of the first opening.

15. the frame body includes a second opening extending along a second axis parallel to the axis perpendicular to the movement; the moving portion includes a second air bushing shaft extending into the second opening; 15. The linear motor of claim 14, wherein the second opening includes a third air bushing located proximate a first end of the second opening and a fourth air bushing located proximate a second end of the second opening.

16. 14. The linear motor of claim 13, wherein the at least one air bushing is mounted within the first opening of the frame body in a flexible manner such that some movement between the air bushing and the frame body is permitted.

17. The linear motor of claim 13 , wherein the at least one air bushing is removably mounted within the first opening in the frame body with an interference fit.

18. 18. The linear motor of claim 17, wherein the at least one air bushing has a hollow cylindrical shape, and the first air bushing shaft is a cylindrical shaft having a radius that is 3 to 5 microns smaller than an inner radius of the at least one air bushing.

19. The moving part includes a magnet frame having a plurality of permanent magnets disposed thereon; the first air bushing shaft extends parallel to the magnet frame; a top end plate and a bottom end plate connect the first and second air bushing shafts to the magnet frame such that a first space extends between the first air bushing shaft and the magnet frame parallel to an axis perpendicular to the movement, and a second space extends between the second air bushing shaft and the magnet frame parallel to an axis perpendicular to the movement; 16. The linear motor of claim 15, further comprising a duct system configured to use airflow through at least one air bushing in cooling at least one of the first coil subassembly, the second coil subassembly, and a coil of the moving part.

20. 1. A method comprising: providing a stator assembly, a moving part adjacent to the stator assembly, and a suspension system, the stator assembly including a first coil subassembly and a second coil subassembly, each of the first coil subassembly and the second coil subassembly including a magnetic core having a plurality of poles around which a winding is wound, the moving part being disposed and extending between the first coil subassembly and the second coil subassembly, the suspension system including at least one vertically disposed air bushing configured to allow vertical movement of the moving part relative to the suspension system without sliding or rolling contact between the moving part and the suspension system; receiving electrical power by the stator assembly; moving the moving part back and forth along an axis perpendicular to the movement relative to the stator assembly after receiving power by the stator assembly; supporting the linear motor and the suspension system in a frictionless manner; supporting the moving part with the suspension system without physically touching the moving part during movement of the moving part and without sliding or rolling contact between the moving part and the suspension system.

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