Linear Motor Coil Assembly Heat Dissipation Design
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Solution Overview
Problem
Conventional coil assemblies for linear motors without a core face inadequate heat dissipation, particularly when higher currents are required, leading to overheating issues due to the limited heat dissipation efficiency of high polymer plastic resin encapsulated layers.
Innovation Solution
A coil assembly design featuring interlaced coils with specific bending sections and a base with a corresponding receiving slot shape, along with a resin encapsulated layer and a cooling channel, increases the contacting area for thermal conduction and includes an insulating layer to enhance heat dissipation through both conduction and convection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the coil is directly inserted in the indentation on the rotor installing platen, then the structure is simple, but the heat dissipation rate is insufficient when higher currents are required
Solution Approach 1:
The coil is transformed from a straight configuration to a bent configuration with bending sections that extend along the inner wall of the receiving slot. This dimensional change in the coil's spatial arrangement increases the contact area between the coil and the base, thereby enhancing heat dissipation while maintaining structural feasibility
Solution Approach 2:
The coil incorporates bending sections with curved configurations instead of straight lines. These curved bending sections increase the surface area of the coil that contacts the base, improving thermal conduction efficiency without significantly complicating the manufacturing process
2Force
If the current value on the coil winding is enhanced to generate higher thrust, then the thrust increases, but the heat dissipation efficiency becomes insufficient
Solution Approach 1:
By extending the coil along the inner wall of the receiving slot through bending sections, the heat dissipation pathway is extended in the vertical dimension. This allows higher currents to be sustained without overheating, as the increased contact area provides more efficient thermal conduction to the base
Solution Approach 2:
The base acts as an intermediary heat sink between the coil and the surrounding environment. The bending sections increase the coil-to-base contact area, making the base more effective at absorbing and dissipating the heat generated by high current operation
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
This design significantly enhances heat dissipation rates by increasing the thermal conduction between coils and the base, while the insulating layer maintains high insulating competence, effectively managing temperature gradients and promoting efficient heat removal.
Implementation Method 1
increases the contacting area between the coils and the inner wall of a receiving slot of a base to promote the heat dissipation rate
Implementation Method 2
a resin encapsulated layer covering portions of the coils that are exposed to the receiving slot of the base, permitting the resin encapsulated layer to seal the receiving slot of the base
Data Source
AI summary
A coil assembly for a linear motor includes a coil unit which has multiple adjacently arranged coils, a base, and a resin encapsulated layer. The coils have two corresponding vertical action sides, a first non-action side, and a second non-action side. The coils further form multiple interlaced first bending sections on the first non-action side. Plural conducting wires disposed on the second non-action side could connect to an external cable on an end section of the coil unit. The base has a receiving slot thereon. The cross-section of the receiving slot corresponds in shape to that of the first bending sections for insertion of the coils. The resin encapsulated layer covering the coils and sealing the receiving slot of the base increases the contacting area between the coils and the inner wall of the receiving slot of the base to enhance the heat dissipation rate.