Linear Actuator Cooling via Radial Apertures
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Solution Overview
Problem
Existing manufacturing systems face challenges in achieving high-speed operations for complex assembly tasks, such as inserting paper separators into battery casings, due to limitations in motor current ratings and heat management, which restrict throughput rates and require frequent maintenance.
Innovation Solution
A linear actuator system with an axially-slidable core member and radial apertures for fluid communication, allowing for enhanced cooling and integration of pneumatic processing capabilities, enabling high-speed operations by increasing the maximum current rating and supporting complex sub-operations like vacuum holding and rapid pressure reversal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If motor current rating is increased to achieve higher thrust for high-speed operations, then productivity is improved, but thermal characteristics deteriorate causing overheating
Solution Approach 1:
The patent applies pneumatic cooling by directing a fluid (air) through the motor windings using radial apertures in the shaft and spaced windings. This fluid flow removes heat from the windings, enabling higher current ratings and sustained high-speed operations without overheating, thereby resolving the contradiction between productivity improvement and temperature control
Solution Approach 2:
The motor windings are spaced apart to create a porous-like structure that permits fluid flow through the winding tube. This spacing allows cooling fluid to penetrate and cool the windings effectively, enabling higher current ratings while managing thermal characteristics, thus resolving the contradiction between power output and temperature control
2Productivity
If complex assembly operations are performed at high throughput rates, then productivity is improved, but device complexity increases
Solution Approach 1:
The linear actuator system is designed to perform multiple functions including complex assembly operations, vacuum holding, and rapid pressure reversal through integrated pneumatic capabilities. The fluid flow system serves both cooling and pneumatic processing functions, reducing the need for separate systems and managing complexity while enabling high-speed multi-function operations
Solution Approach 2:
The patent merges the cooling function and pneumatic processing function into a single fluid flow system. The same fluid that cools the motor windings also provides vacuum holding and blow-off capabilities, consolidating multiple functions into one system and managing complexity while achieving high throughput rates
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 system achieves high throughput rates of up to 500 operations per minute, reduces maintenance needs, and allows for flexible configuration on existing manufacturing lines, enabling efficient and cost-effective high-speed assembly operations with minimal downtime.
Implementation Method 1
fluid that is directed to flow between the windings may sufficiently cool the windings and other components to increase the machine's maximum current rating
Implementation Method 2
A linear motor can convert electrical input energy to a linear force (i.e., thrust)
Implementation Method 3
applying a vacuum pressure to apertures in the mandrel to hold at least one object to be manipulated
Data Source
AI summary
Apparatus and associated systems or methods include a linear machine with an elongate, axially-slidable core member (i.e., shaft). In one embodiment, the shaft includes at least one radial aperture to provide fluid (e.g., air) communication from an interior volume of a winding tube that contains one or more stationary windings, to either end of the shaft through a lumen that extends axially through the length of the shaft. The stationary windings are spaced apart to permit fluid to flow through a plurality of radial apertures in the winding tube. In particular, fluid circulation across the windings may provide sufficient cooling to increase the machine's maximum current rating. The fluid circulation may also provide pneumatic processing capabilities (e.g., vacuum hold, blow-off). In one exemplary embodiment, the apparatus may be used to insert tube-and-square paper separators into battery casings at high rates.