Integrally Formed Stator Linear Motor for Compact High-Thrust Applications
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Solution Overview
Problem
Conventional linear motors face issues with large installation area, thrust ripple, varying motor thrust, and reduced accuracy due to low rigidity and air gap variations when multiple motors are arranged in parallel, leading to increased magnetic resistance and positional errors.
Innovation Solution
The design integrates two stators with salient poles between adjacent movers, featuring a U-shaped base and plate-like supporting members to maintain constant air gaps and increase stator rigidity, reducing installation area and thrust ripple while improving motor control and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If multiple linear motors are arranged in parallel to increase thrust, then the thrust force is improved, but the installation area increases
Solution Approach 1:
The patent merges two separate linear motors into a single integrated motor structure by sharing a common stator core and magnetic circuit. The stator core includes two stator cores extending in parallel, with yokes connecting them, allowing both motors to operate from a unified structure that reduces the overall installation area while maintaining the combined thrust force of multiple motors.
2Force
If multiple linear motors are arranged in parallel, then the thrust force is improved, but the rigidity decreases leading to varying motor thrust
Solution Approach 1:
The integrated motor structure combines two motor systems into a single rigid framework. The common stator core with interconnected yokes provides structural rigidity that prevents variations in motor thrust, ensuring stable operation while delivering the combined force of both motors.
Solution Approach 2:
The yokes are formed with curved surfaces that connect the two stator cores. These curved structural elements enhance the overall rigidity of the stator assembly by distributing mechanical stresses more effectively, preventing deformation that could lead to thrust variations.
3Ease of manufacture
If conventional stator structure is used, then the manufacturing is simple, but the air gap varies leading to reduced accuracy
Solution Approach 1:
The stator core is segmented into two separate stator cores with distinct winding sets, allowing independent manufacturing and assembly. Each stator core can be manufactured separately with controlled dimensions, and then assembled together using the curved yokes, ensuring consistent air gaps while maintaining manufacturing feasibility.
Solution Approach 2:
The design changes the geometric parameters of the stator structure by introducing curved yokes with specific radii of curvature. This parameter optimization ensures that the air gap between the stator and mover remains constant throughout the magnetic circuit, improving positioning accuracy while maintaining ease of manufacture through standardized curved components.
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 configuration allows for a compact installation area, reduced thrust ripple, consistent motor thrust, and enhanced feedback controllability, leading to improved machine tool precision and surface quality.
Implementation Method 1
Three-phase alternating current coils are wound around each of the mover blocks 53, 54, 55. When current is applied to the three-phase alternating current coils 56, 57, 58, the mover blocks 53, 54, 55 are excited in the positive direction or in the negative direction on the Y-axis
Implementation Method 2
a magnetic flux 62 is excited in the linear motor. Magnetic fluxes having passed through the respective mover blocks 53, 54, 55 and the stator 52a, 52b sides form a flux path as shown by reference numeral 62 in FIG. 7A
Implementation Method 3
magnetic attractive force is generated depending on the positions of the mover 51 and the stators 52a, 52b, generating thrust in the mover 51, resulting in a movement of the mover 51
Data Source
AI summary
A linear motor assembly includes two stators extending in parallel and having salient poles arranged at a predetermined interval on opposing surfaces and a mover having three types of mover blocks. The mover blocks are made up of three-phase alternating current coils configuring magnetic poles of three phases and permanent magnets arranged in alternating polarities on two surfaces of the mover blocks opposing each of the two stators. The mover blocks are movable between the two stators along a direction in which the stators extend. A plurality of linear motors are arranged in parallel with respect to a travel direction of the movers, and the stators provided between adjacent movers are integrally formed such that they have said salient poles on the two surfaces opposing these movers.