Integrated PCB Linear Motion System for Compact Automation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional linear motion systems are cumbersome and costly due to the need for multiple components, extensive cabling, and a third center plate in dual-axis systems, which increases bulk, weight, and manufacturing costs.
Innovation Solution
A linear motion system with integrated components such as a controller, drive, and encoder mounted on a printed circuit board (PCB), eliminating the need for additional cables by using traces for electrical communications and power distribution, and employing linear guideways like crossed roller or recirculating bearings for precise motion guidance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional linear motion systems use separate components with extensive cabling, then reliable electrical connections are achieved, but system weight and size increase significantly
Solution Approach 1:
The patent combines the controller, drive electronics, and encoder into a single integrated printed circuit board assembly that is mounted directly on the moving carriage. This eliminates the need for separate components and extensive cabling, reducing system weight while maintaining reliable electrical connections through direct trace connections on the PCB.
2Adaptability or versatility
If traditional linear motion systems use interface cables with multiple conductors, then complete electrical connectivity is achieved, but manufacturing complexity and assembly cost increase
Solution Approach 1:
The patent replaces the mechanical cabling system with multiple conductors with a printed circuit board that provides all electrical connections through etched traces. This substitution eliminates the need for complex cable routing and connector assembly, significantly simplifying manufacturing and assembly processes while maintaining complete electrical connectivity between the controller, drive, and motor coils.
3Strength
If dual-axis linear motion systems use a third center plate, then structural support is achieved, but bulk and weight increase
Solution Approach 1:
The patent eliminates the third center plate from dual-axis linear motion systems by integrating the control electronics directly onto the moving carriage. This extraction of unnecessary structural elements reduces system bulk and weight while maintaining adequate structural support through the optimized carriage design that carries only the essential integrated electronics.
4Adaptability or versatility
If traditional linear motion systems use separate controller, drive, and encoder components, then functional modularity is achieved, but device complexity increases
Solution Approach 1:
The patent merges the controller, drive electronics, and encoder into a single integrated printed circuit board assembly mounted on the moving carriage. This integration reduces the number of discrete components and interconnections, thereby decreasing device complexity while maintaining the functional capabilities of each component through their coordinated operation on the unified PCB platform.
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 integration reduces the size, weight, and cost of the system while enabling precise control and motion accuracy, making it more cost-effective and suitable for compact, high-precision applications like medical imaging and factory automation.
Implementation Method 1
The array of magnets may produce a static magnetic field, whereas the coils produce a time-varying magnetic field that depends on the current flowing through the coils. The magnetic field produced by the coils interacts with the static magnetic field to generate a force.
Implementation Method 2
employing linear guideways like crossed roller or recirculating bearings for precise motion guidance
Data Source
AI summary
A linear motion system utilizing one or more printed circuit boards embedded within a stage wherein the system components, including the controller, drive, and controller, may be mounted to a printed circuit board (PCB), and the electrical communications between the system components and the power to the system components are supplied through traces or etchings on the printed circuit board, thereby omitting the need for additional power and communication cables.