Integrated Linear Module With Encoder for Confined-Space Positioning
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Solution Overview
Problem
Existing linear modules are complex to operate, require external control devices, and are not suitable for confined spaces due to their design and control complexity, which limits their flexibility and compatibility with various installation environments.
Innovation Solution
A compact linear module design with a brushless motor, spindle, spindle nut, and guide rail system, incorporating a magnet and encoder device for determining angular and axial positions, allowing for internal control and reduced complexity, and featuring a flexible cover to protect components from contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If external control devices are used to control linear modules, then control functionality is achieved, but device complexity and installation space requirements increase
Solution Approach 1:
The control device is integrated directly into the linear module housing, merging the control system with the actuator unit. This eliminates the need for separate external control devices, reducing overall system complexity and installation space requirements while maintaining full control functionality.
Solution Approach 2:
The integrated control device serves multiple functions: it controls the brushless motor, processes encoder signals for position feedback, and provides communication interfaces. This multi-functionality consolidates what would traditionally require separate external devices into a single unified unit.
2Force
If traditional linear module designs are used, then driving force transmission is achieved, but adaptability to confined spaces and various installation environments is reduced
Solution Approach 1:
The linear module is designed as a compact, self-contained unit with all necessary components (motor, spindle, control device) integrated within a single housing. This segmentation into a modular unit allows flexible installation in confined spaces and various orientations while maintaining full driving force transmission capability.
Solution Approach 2:
The guide rail runs parallel to the spindle in a configuration that optimizes space utilization. The carriage moves along the guide rail in a manner that allows the module to be installed in different spatial configurations, increasing adaptability to various installation environments without compromising force transmission.
3Duration of action of stationary object
If brushless motors are used instead of brushed motors, then service life is improved, but manufacturing complexity increases
Solution Approach 1:
The brushless motor replaces the brushed motor design, eliminating mechanical brushes and commutators. This substitution uses electronic commutation controlled by the integrated control device, which reduces wear and extends service life while the integration of control functionality offsets the increased electronic control complexity.
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
Enables simple, cost-effective control and operation in confined spaces with reduced complexity, flexibility, and improved reliability, minimizing wear and power consumption while maintaining precise position determination without external control devices.
Implementation Method 1
a brushless motor with stator and rotor for driving the spindle
Implementation Method 2
at least one magnet on or in an end face of the rotor and/or the spindle, as well as an encoder device substantially axial to a rotation axis of the spindle for reading an angular position of the magnet
Implementation Method 3
a spindle nut for converting a rotational movement of the spindle into an axial movement of the spindle nut
Implementation Method 4
The carriage and the coupling unit can slide along the cover parallel to the spindle with little friction loss
Data Source
AI summary
A linear module (101) comprising a spindle (5) to be rotated about an axis of rotation (D) of the spindle (5), a spindle nut (51) for converting a rotary movement of the spindle (5) into an axial movement of the spindle nut (51), a coupling unit (6) to be moved axially along a guide rail (7), driven by the spindle nut (51), the guide rail (7) for guiding the coupling unit (6), which runs parallel to the spindle (5), a preferably brushless motor (8) having a stator (9) and a rotor (10) for driving the spindle (5), a control device (14) that is configured to control the motor (8) and comprises at least one circuit board (13), a housing (21) that at least partially encloses a housing interior (211) and a carriage (19) that is arranged at least partially outside the housing (21) and is able to be coupled with a movement of the coupling unit (6), such that the carriage (19) is able to be moved parallel to the guide rail (7) by the movement of the coupling unit (6), characterized in that the motor (8), the control device (14), the spindle (5), the spindle nut (51) and the guide rail (7) are arranged in the housing interior (211).