Electromagnetic Actuator With Linear Encoder And THK Rails
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Solution Overview
Problem
Existing heavy load moving technologies, such as hydraulic and pneumatic actuators, require frequent maintenance, are limited in lifting capacity, and suffer from dirt accumulation and replacement part needs, whereas electromagnetic actuators face challenges in handling heavy loads efficiently with electronic controls and minor lubrication needs.
Innovation Solution
An electromagnetic actuator assembly with multiple pistons and THK linear rails, driven by motor coil assemblies, featuring an extendable design up to sixteen feet, internal dowel pins for assembly stability, and an exposed linear encoder for positional feedback, allowing for precise movement and handling of heavy loads without mechanical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If hydraulic actuators are used to handle heavy loads, then lifting capacity is improved, but maintenance requirements increase and dirt accumulation occurs
Solution Approach 1:
The patent replaces the hydraulic mechanical system with an electromagnetic system. The electromagnetic actuator uses magnetic fields generated by coil assemblies to move the piston and handle loads, eliminating hydraulic fluid, seals, and mechanical linkages that require maintenance and are susceptible to dirt accumulation.
Solution Approach 2:
The patent eliminates hydraulic systems entirely in favor of electromagnetic actuation. By using electromagnetic forces instead of hydraulic pressure, the system avoids the maintenance issues associated with hydraulic fluid leakage, seal wear, and contamination while maintaining high lifting capacity.
2Ease of operation
If pneumatic actuators are used to handle loads, then operation simplicity is improved, but lifting capacity is limited
Solution Approach 1:
The patent changes the operating parameters of the electromagnetic system by using multiple coil assemblies that can be independently controlled. This allows the system to generate high forces through coordinated electromagnetic activation while maintaining simple electronic control, thus achieving both high lifting capacity and ease of operation.
3Measurement precision
If electromagnetic actuators are used for precise positioning, then measurement precision is improved, but device complexity increases due to electronic controls
Solution Approach 1:
The patent incorporates linear encoders that provide real-time positional feedback to the control system. This feedback mechanism enables precise positioning by continuously monitoring the piston position and adjusting the electromagnetic coil activation to achieve the desired position, thereby improving measurement precision while managing the complexity through intelligent control.
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 electromagnetic actuator assembly effectively moves heavy loads with high precision and reliability, reducing maintenance needs and extending lifting capacity, while maintaining cleanliness and minimizing electronic component wear.
Implementation Method 1
A pair of drive motor coil assemblies provides a force to the two pairs of THK linear rails
Implementation Method 2
Each of the pair of piston outboard plates and each of the pair of piston side plates has a cross-section that allows for deflection between the pair of drive motor coil assemblies
Data Source
AI summary
An electromagnetic actuator assembly for moving heavy loads and running on electromagnetic energy has at least one piston providing movement of heavy loads. Two pairs of THK linear rails controls the electromagnetic actuator assembly. A pair of drive motor coil assemblies provides a force to the two pairs of THK linear rails. A foundation houses an internal tube that contains a plurality of cables. A housing mount weldment connects the plurality of cables to a pair of electrical connections of the pair of drive motor coil assemblies, and allows the plurality of cables to extend when traveling back and forth inside the internal tube. The housing mount weldment has a plurality of openings for access to the plurality of cables. An exposed linear encoder runs along the at least one piston, comprising at least one scale providing positional feedback of the at least one piston.