Coreless Linear Motor Coil Assembly Segmentation
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Solution Overview
Problem
Existing coreless type linear motor coil assemblies face challenges in maximizing driving force while minimizing space and weight, with issues of insufficient rigidity, increased thickness, and difficulty in bending due to large radii differences and poor insulation, especially in overlapping concentrated winding layouts.
Innovation Solution
A coil assembly design featuring a plurality of bent subcoils arranged adjacent to each other on the non-acting side, with a resin layer and alternately stacked tri-phase unit coil modules, allowing for reduced thickness and increased radius of curvature, facilitating easier manufacturing and improved insulation, and enabling flexible connection methods for subcoils in series, parallel, or series-parallel configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If overlapping concentrated winding layout method is used to maximize driving force in minimal space, then driving force is improved, but the thickness of the axial non-action side increases substantially requiring more reserved space for wire connection
Solution Approach 1:
The unit coil is divided into multiple subcoils (first subcoil, second subcoil, third subcoil, fourth subcoil) that are arranged and connected in a specific configuration. This segmentation allows the wire to be routed more efficiently through the coil structure, reducing the required thickness of the axial non-action side while maintaining the overlapping concentrated winding layout's driving force capability.
Solution Approach 2:
The patent reconfigures the spatial arrangement of subcoils and wire routing in the axial non-action side, transitioning from a conventional thick-layer structure to a more compact multi-dimensional layout. The wire connects subcoils across different axial positions and radial layers, optimizing space utilization and reducing the overall thickness requirement.
2Force
If unit coil with larger number of windings is used to produce larger driving force, then driving force is improved, but the thickness or width of the unit coil increases making bending process more difficult
Solution Approach 1:
The unit coil is segmented into multiple thinner subcoils rather than using a single thick coil. This segmentation reduces the thickness of individual components that need to be bent, making the bending process easier while achieving the required total number of windings for sufficient driving force through the combination of multiple subcoils.
Solution Approach 2:
The patent introduces flexibility in the bending process by dividing the rigid thick coil into multiple flexible thinner subcoils. This allows each subcoil to be bent more easily to the required curvature, and the subcoils are then assembled together to form the complete unit coil structure.
3Force
If flat tri-phase unit coil modules are stacked and fixed to insulating element to form larger driving force, then driving force is improved, but the weight of the linear motor coil assembly increases substantially and joint strength is insufficient
Solution Approach 1:
The patent merges the insulating element function into the coil structure itself by using the resin layer that bonds subcoils together to also serve as the insulating element. This integration eliminates the need for separate insulating components, reducing overall weight while maintaining sufficient driving force through the combined subcoil structure.
Solution Approach 2:
The patent employs composite material construction where resin layers are used to bond subcoils together, creating a unified structure that provides both mechanical strength and electrical insulation. This composite approach replaces traditional separate insulating elements, reducing weight while maintaining structural integrity and driving force capability.
4Force
If unit coil is bent with larger thickness to achieve overlapping effect, then overlapping effect is improved, but the radius of curvature decreases resulting in poor insulation
Solution Approach 1:
The unit coil is divided into multiple thinner subcoils that can be bent with larger radii of curvature, maintaining good insulation. The overlapping effect is achieved not by bending a single thick coil sharply, but by stacking and connecting multiple thinner subcoils in an overlapping configuration, thus preserving both the overlapping effect and insulation quality.
Solution Approach 2:
The resin layer acts as an intermediary that bonds subcoils together while maintaining electrical insulation. This allows the subcoils to be arranged in an overlapping configuration with adequate spacing and larger bending radii, ensuring both the overlapping effect for driving force and sufficient insulation for reliability.
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 enhances the manufacturability and longevity of the subcoils, reduces the thickness and length of the axial non-action side, and provides a space-saving coreless type linear motor with adjustable height, while offering customizable driving force and speed characteristics by varying subcoil connections.
Implementation Method 1
The coil assembly is interacted with the magnetic flux produced by a tri-phase current and a driving force produced by a magnetic field of the magnetic rail
Data Source
AI summary
The present invention discloses a unit coil, a coil assembly and a coreless type linear motor. The unit coil includes bent subcoils arranged adjacent to one another and disposed on a non-acting side axially. The coil assembly includes tri-phase unit coil modules arranged in an operating direction, and the tri-phase unit coil module is composed of three identical unit coils alternately stacked and sealed by a resin layer, and the unit coil is formed by bending and stacking sub-coils. The bent sub-coils are stacked to a sufficient thickness or arranged to a sufficient width to achieve the desired driving force, and then a magnetic rail is provided to form a coreless type linear motor. In the aforementioned structure, the unit coil composed by an alternately overlapping layout method effectively reduces the required space of the coil assembly, and the sub-coils can be manufactured easily and will not be damaged easily.