Linear Actuator Magnet Assembly for Flux Linearity and Force

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Solution Overview

Problem

Non-commutated linear actuators face issues such as varying forces due to misalignment, poor protection from external forces, and reliability of electrical connections, leading to distortion and shifting of magnetic flux lines, which affect motor control, force application, frequency response, and repeatability.

Innovation Solution

A permanent magnet assembly with a magnetic core structure featuring protrusions that confine and guide magnetic fields, reducing distortion and shifting, and a flexible conductive band for improved electrical connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a conventional permanent magnet assembly without protrusions is used, then the structure is simple, but magnetic flux distortion and shifting occur during high-load conditions, resulting in poor motor control linearity and reduced available force

Engineering Contradiction:

Improvemagnetic core structureVSAvoidmotor control linearity

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The magnetic core structure incorporates protrusions at specific locations within the gap region to locally modify magnetic flux distribution. These protrusions create regions of concentrated flux that compensate for distortion and shifting, improving motor control linearity without requiring complete redesign of the entire magnetic core structure.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention adds a dimensional feature (protrusions extending into the gap region) to the magnetic core structure. This three-dimensional modification allows for better control of magnetic flux paths, reducing distortion and shifting effects that occur in conventional flat-core designs during high-load conditions.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Force

If the gap region between central core portion and outer hollow portion is reduced to increase magnetic flux density, then more force is available, but the risk of misalignment between stationary and movable components increases due to poor protection from external forces

Engineering Contradiction:

Improveavailable forceVSAvoidalignment stability

Core Design Contradiction:

ForceVSReliability

Solution Approach 1:

The protrusions on the magnetic core structure serve as protective elements that extend into the gap region, providing mechanical guidance and protection for the movable component. These protrusions act as cushions or guides that prevent misalignment caused by external forces, allowing the gap to be reduced without compromising reliability.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Reliability

If wires are used to connect to the coil assembly on the movable component, then electrical connection is achieved, but regular movement leads to quick wear on the wires, resulting in motor failure

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidwire lifespan

Core Design Contradiction:

ReliabilityVSDuration of action of moving object

Solution Approach 1:

The invention replaces the conventional wire-based electrical connection system with a flexible conductive band system. This substitution eliminates the mechanical wear issues associated with wires by using a more durable flexible band that can accommodate repeated movement cycles without degrading, significantly extending the operational lifespan of the movable component's electrical connections.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Enhances magnetic flux density, improves motor control linearity, increases available force, and ensures better repeatability and compliance, while reducing wear and enhancing shock resistance.

Implementation Method 1

the current flowing through the coil assembly interacts with the permanent magnetic field generated by the permanent magnet assembly so as to generate a force vector perpendicular to the direction of the current

Methodology Applied

Scientific EffectLorentz force: Lorentz Force

Implementation Method 2

a magnetic core structure having a high magnetic permeability (i.e., the internal dipoles of the material of the structure are easily oriented in response to an applied magnetic field), so as to confine and guide magnetic fields

Methodology Applied

Scientific EffectMagnetic permeability: Ferromagnetism

Data Source

PatentUS20260066719A1Improved linear actuator

Publication Date: 2026.03.05 TETHR LTD

AI summary

This disclosure relates to a permanent magnet assembly and non-commutated linear actuator. There is provided a permanent magnet assembly for a non-commutated linear actuator, the permanent magnet assembly comprising: a magnetic core structure, and a permanent magnet having a first pole and a second pole, wherein the magnetic core structure comprises a central core portion connected to the first pole of the permanent magnet, an outer hollow portion connected to the second pole of the permanent magnet, and a gap region positioned between the central core portion and the outer hollow portion, wherein the magnetic core structure is configured such that magnetic flux generated by the permanent magnet flows between the central core portion and the outer hollow portion via the gap region, and wherein the magnetic core structure comprises one or more protrusions extending into the gap region.