Ironless Linear Motor Coil Assembly Length Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing ironless linear motor coil assemblies have limitations in space utilization and volume power density, necessitating an improvement in these aspects.
Innovation Solution
A coil assembly design featuring a coil base elongated in the X-direction with top, intermediate, and bottom coil modules, each with interaction and non-interaction sides forming a loop to create an accommodating space, allowing for efficient packing and reduced length while maintaining power density, integrated within an ironless linear motor with a magnetic rail assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If overlapping concentrated winding type coil assembly is used, then driving force is improved in relatively small space, but space utilization rate and volume power density have room for improvement
Solution Approach 1:
The coil assembly is divided into multiple coil units, each comprising top, intermediate, and bottom coil modules. These modular segments can be independently designed and optimized, allowing for better space utilization while maintaining the required driving force through strategic arrangement of the segmented coil structures.
Solution Approach 2:
The patent transitions from traditional planar coil arrangements to a three-dimensional stacked configuration with top, intermediate, and bottom coil modules arranged vertically. This dimensional change enables more efficient use of space by utilizing the Z-axis direction, thereby improving both space utilization rate and volume power density while maintaining compact form factor.
2Force
If overlapping concentrated winding type coil assembly is used, then driving force is improved in relatively small space, but volume power density has room for improvement
Solution Approach 1:
The coil modules are arranged in a nested-like stacked configuration where top, intermediate, and bottom coil modules occupy different vertical levels. This nesting approach allows multiple functional elements to be packed into a compact volume, increasing the effective coil density and thereby improving volume power density while maintaining the required driving force output.
Solution Approach 2:
By arranging coil modules in the vertical dimension rather than only in-plane, the patent increases the effective use of available volume. This three-dimensional arrangement allows more coil turns and higher current density within the same footprint, directly improving volume power density while preserving the driving force characteristics.
3Force
If conventional coil assembly design is used, then driving force is achieved, but length is not optimized
Solution Approach 1:
The coil assembly is segmented into discrete coil units with defined interaction and non-interaction sides. This segmentation allows for compact arrangement where the length in the X-direction can be optimized by positioning interaction sides to face magnetic members and minimizing the extent of non-interaction sides, thereby reducing overall length while maintaining driving force through efficient magnetic interaction.
Solution Approach 2:
The patent optimizes length by transitioning from extended planar arrangements to compact three-dimensional stacking. By arranging coil modules vertically with interaction sides oriented toward magnetic members, the design reduces the X-direction length requirement while maintaining sufficient coil turns and magnetic interaction area through the vertical dimension, achieving compact linear motor design.
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 coil assembly achieves an 8% reduction in length while maintaining or exceeding power density compared to prior art, enhancing space utilization and simplifying assembly by allowing non-overlapping coil units and easier expansion.
Implementation Method 1
Each of the top, intermediate and bottom coil modules has a first interaction side, a second interaction side spaced apart from the first interaction side in the X-direction... The first interaction sides of the intermediate and bottom coil modules are juxtaposed with each other and situated within the accommodating space of the top coil module... The second interaction sides of the top and intermediate coil modules are juxtaposed with each other and situated within the accommodating space of the bottom coil module
Data Source
AI summary
A coil assembly includes coil units connected to a coil base. Each coil unit includes top, intermediate and bottom coil modules, each of which has spaced-apart first and second interaction sides, and two non-interaction sides connected to the first and second interaction sides to form an accommodating space. The first interaction sides of the intermediate and bottom coil modules are juxtaposed with each other in the accommodating space of the top coil module. The second interaction sides of the top and intermediate coil modules are juxtaposed with each other in the accommodating space of the bottom coil module. An ironless motor includes a magnetic rail assembly and the aforesaid coil assembly.