Discontinuous Linear Motor with Curved-Line Correction
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Solution Overview
Problem
Conventional linear motor systems face challenges with low thrust, complex power feeding systems, and increased costs due to continuous coil arrangements, which limit the length and precision of transport paths, especially in curved sections, and require dedicated control devices for different path types.
Innovation Solution
A discontinuous linear motor system with individually spaced motors acting as armatures, each with coils of different phases, and a motor control device that includes a sensor and control unit for accurate position and speed control, using a curved-line correspondence corrector to enable shared components and simplified power supply, allowing for reduced coil usage and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If primary coils are continuously disposed over the entire length of movement path in a linear motor, then the motor can provide continuous thrust, but the number of coils increases leading to increased costs
Solution Approach 1:
The continuous movement path is divided into multiple discrete sections, each served by an individual motor unit. This segmentation allows the system to provide continuous thrust through coordinated operation of multiple units while using fewer total coils compared to a single continuous motor spanning the entire path.
Solution Approach 2:
The linear motor system operates in periodic cycles, with each motor unit activating sequentially as the mover passes through its operational range. This periodic activation pattern allows continuous motion to be achieved through discrete, intermittent coil energization rather than continuous operation of all coils.
2Power
If power is supplied to the movable coil side in a linear synchronous motor, then the motor can be driven, but wiring lines are required limiting the transport path length and complicating the power feeding system
Solution Approach 1:
Instead of supplying power to the movable side (secondary), the system inverts the approach by placing the power-consuming coils on the stationary ground side (primary). This inversion eliminates the need for complex wireless power transmission or sliding contacts to the mover, simplifying the power feeding system and enabling longer transport paths.
Solution Approach 2:
The power supply system is extracted from the movable side and relocated to the stationary side. By removing the power consumption requirement from the mover, the system eliminates wiring lines and power feeding complexity associated with moving components, allowing the mover to be a simple magnetic array without electrical connections.
3Measurement precision
If a dedicated control device is used for curved path sections in a linear motor system, then position and speed control can be performed, but the cost increases and components cannot be shared
Solution Approach 1:
The control device is designed with multi-functionality to handle both straight and curved path sections. By integrating curved path control capabilities into the same control system used for linear motion, the device can perform position and speed control for all path types without requiring separate dedicated controllers, thereby reducing overall system complexity and cost.
Solution Approach 2:
The control functions for straight path sections and curved path sections are merged into a single integrated control device. This combination allows the system to share control hardware, software resources, and processing capabilities across different path types, eliminating the need for separate control systems and reducing total device complexity.
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 solution reduces the number of coils needed, simplifies the power supply, and enables accurate position and speed control in both straight and curved paths by using shared components, thereby lowering costs and enhancing operational efficiency.
Implementation Method 1
a linear motor system that includes a linear motor
Implementation Method 2
a sensor, as a linear scale, arranged to detect a position of the mover
Data Source
AI summary
A linear motor system includes a discontinuous linear motor and motor control device. The discontinuous linear motor includes a mover and a plurality of individual motors spaced from each other along a movement path of the mover. Each of the individual motors functions as an armature on a primary side of one independent linear motor. A sensor, arranged to act as a linear scale, is disposed for each individual motor and detects a position of the mover. The motor control device includes a plurality of individual motor control units and a multiple unit controller to comprehensively control the individual motor control units. The individual motor control units control the individual motors disposed in curved path sections, and each of the individual motor control units includes a curved-line correspondence corrector to correct a detection value obtained from the sensor according to a relationship between a curved line of the path and a position of the sensor.