Branching Linear Conveyance Stator Layout for Lower Motor Weight
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Solution Overview
Problem
Conventional linear conveyance systems face issues with increased motor weight and inverter size due to the use of the same coils on both sides of branch and non-branch portions, leading to inefficient utilization of inverters and excess weight.
Innovation Solution
A linear conveyance system with one-side stator modules on non-branch portions and both-side stator modules on branch portions, where the number and arrangement of coils are optimized to reduce weight and capacity, allowing for equal thrust generation and independent control of electromagnetic forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the same coils as coils disposed at a non-branch portion are disposed on both sides of a branch portion, then the linear conveyance system can achieve path branching capability, but the weight of the motor increases
Solution Approach 1:
The stator modules are segmented into two distinct types: one-side stator modules for non-branch portions and both-side stator modules for branch portions. This segmentation allows each type to be optimized for its specific function, with both-side stator modules having coils on both sides for branching capability and one-side stator modules having coils on one side for straightforward propulsion, thereby reducing overall motor weight while maintaining branching capability.
Solution Approach 2:
Different structural configurations are applied to different locations along the conveyance path. Both-side stator modules with dual-sided coils are placed only at branch portions where path diversion is needed, while one-side stator modules with single-sided coils are used at non-branch portions. This local differentiation ensures that the increased coil complexity is applied only where necessary, minimizing overall weight while preserving branching functionality.
2Adaptability or versatility
If the same inverters are used for the branch portion and the non-branch portion with coils disposed on both sides only in the branch portion, then path branching is enabled, but half of the coils of the branch portion just need to be energized so as to generate equal thrust, causing inverter underutilization and increased inverter size
Solution Approach 1:
The inverter system is segmented into two independent inverters: a first inverter dedicated to controlling coils in one-side stator modules at non-branch portions, and a second inverter dedicated to controlling coils in both-side stator modules at branch portions. This segmentation allows each inverter to be sized appropriately for its specific workload, eliminating the need for oversized inverters that would be required to handle peak demands of both-sided coil configurations.
Solution Approach 2:
Each inverter type is designed to handle the specific requirements of its associated stator module type. The first inverter is optimized for single-sided coil configurations at non-branch portions, while the second inverter is optimized for dual-sided coil configurations at branch portions. This specialized design allows both inverters to operate at optimal capacity utilization, with neither being oversized for its intended application.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system achieves reduced motor weight and inverter capacity, facilitating miniaturization and improved assembly efficiency while maintaining thrust performance.
Implementation Method 1
The mover is propelled by electromagnetic force produced by the plurality of coils
Data Source
AI summary
A linear conveyance system includes a plurality of stator modules forming a conveyance path, and a mover including a plurality of magnets disposed on both side surfaces. The plurality of stator modules includes a one-side stator module and a both-side stator module, the one-side stator module being disposed on one side of a non-branch portion of the conveyance path, the both-side stator module being disposed on both sides of a branch portion of the conveyance path. Each of the one-side stator module and the both-side stator module includes an iron core and a plurality of coils. The mover is propelled by electromagnetic force produced by the plurality of coils. A coil amount of the one-side stator module is equal to a coil amount of the both-side stator module.