Integrated Magnetic Secondary for Linear Motor Commutation
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Solution Overview
Problem
Conventional linear drive motors face challenges in establishing and maintaining commutation, particularly with sinusoidally commutated motors, due to manufacturing variations and the need for Hall Effect sensors, which increase complexity and calibration time.
Innovation Solution
A thin sheet of magnetic permeable material with slots and recesses is used to form motor teeth, encoder teeth, and commutation teeth simultaneously, eliminating the need for Hall Effect devices and allowing for standardized commutation angles, thereby reducing setup and calibration times and increasing flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate encoder scales and Hall Effect sensors are used for motor commutation, then positioning information and commutation control can be obtained, but device complexity and calibration time increase
Solution Approach 1:
The patent combines encoder teeth and commutation teeth into a single integrated secondary structure formed from one sheet of magnetic material. This merging eliminates the need for separate Hall Effect sensors and encoder scales, reducing device complexity while maintaining reliable commutation control through the unified tooth pattern design.
Solution Approach 2:
The integrated secondary structure serves multiple functions simultaneously: it provides both encoder positioning information and commutation control signals through its synchronized tooth patterns. This multi-functionality eliminates the need for separate dedicated components for each function, reducing overall system complexity.
2Ease of manufacture
If separate encoder scales are attached after motor teeth are created, then manufacturing flexibility is maintained, but manufacturing precision and alignment accuracy deteriorate
Solution Approach 1:
The encoder teeth and motor teeth are merged into a single integrated structure formed simultaneously from one sheet of magnetic material. This eliminates the subsequent attachment process entirely, ensuring perfect alignment accuracy while maintaining manufacturing flexibility through the unified formation process.
Solution Approach 2:
The encoder teeth and commutation teeth are formed simultaneously with the motor teeth during the initial sheet formation process, rather than being added later. This preliminary action ensures precise alignment from the start and eliminates alignment errors that would occur with post-manufacturing attachment.
3Reliability
If conventional Hall Effect devices are used for commutation, then commutation control is achieved, but setup time and calibration time increase
Solution Approach 1:
The patent extracts and eliminates the Hall Effect devices from the system by using the integrated encoder and commutation teeth patterns directly for commutation control. This removal of unnecessary components reduces both setup time and calibration time while maintaining reliable commutation through the simplified tooth-based control mechanism.
4Ease of manufacture
If manufacturing variations are present in separate components, then manufacturing flexibility is maintained, but commutation angle offset standardization deteriorates
Solution Approach 1:
By merging all tooth patterns (motor teeth, encoder teeth, commutation teeth) into a single integrated secondary structure formed from one sheet, the patent eliminates cumulative manufacturing variations between separate components. This ensures standardized commutation angle offset while maintaining manufacturing flexibility through the unified formation process.
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 approach standardizes the electrical angle or commutation angle offset, reduces manufacturing variations, and enables flexible programming of motor commutation patterns without the need for phase searching, allowing for seamless interchanging of motor components and maintaining consistent commutation across multiple platen segments.
Implementation Method 1
a thin sheet of magnetic permeable material is formed with slots extending through the material to form teeth of the secondary
Data Source
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AI summary
A secondary for a motor, for instance a linear drive motor, has a sheet of highly magnetic permeable material with a plurality of slots extending through the sheet spaced along a length of the sheet. The slots define a plurality of teeth in the sheet and enable the sheet to be conformable to a mounting surface when forming the secondary of the motor. The top surface of the sheet has a plurality of pockets formed adjacent the plurality of slots. The pockets extend parallel to the width and are spaced along the length of the sheet. The pockets form a sensor operatively connected to a control of the motor. The sensor may be an encoder, and/or the sensor may be operatively connected to a control for controlling commutation of the motor, and/or setting positional limits and/or "home(s)" for the motor, providing absolute positional information and/or providing information about the sheet, for instance, the identity of one platen among many.