Iron-Core Linear Motor Forcer With Integrated Aerostatic Guidance
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Solution Overview
Problem
Conventional iron-core linear motors with standalone aerostatic bearings require careful mechanical design to achieve favorable system dynamics and high geometric accuracy due to preload forces being applied at different locations and motor acceleration forces acting away from the center-of-stiffness of each bearing element.
Innovation Solution
An integrated iron-core linear motor with aerostatic bearing guidance, where the bearing element, preloading element, and actuation element are combined into a single unit, featuring air supply channels and hypodermic tubings to create a preloaded load-bearing air film between the forcer and stator, aligning inertial, stiffness, and force centers, and allowing frictionless movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standalone aerostatic bearing elements are combined with iron-core linear motors in an assembly, then the bearing can provide support and guidance, but the preload force is applied at a different location than the bearing air film, requiring careful mechanical design to achieve favourable system dynamics and high geometric accuracy
Solution Approach 1:
The patent combines the aerostatic bearing elements and linear motor into a single integrated forcer unit. The bearing orifices are directly formed in the forcer body, and the motor coils are wound around the iron core within the same housing. This integration merges the bearing support function and motor actuation function into one unified structure, eliminating the need for separate bearing assemblies and complex mechanical coupling mechanisms.
Solution Approach 2:
The forcer structure serves multiple functions simultaneously: it acts as both the motor housing containing the coils and iron core, and as the bearing element with integrated air supply channels and orifices. The bottom surface of the forcer directly forms the bearing running surface, eliminating the need for separate bearing components and simplifying the overall system architecture.
2Ease of operation
If standalone aerostatic bearings are used with iron-core linear motors, then frictionless motion is achieved, but the mass and size of the system increase due to separate bearing assemblies
Solution Approach 1:
The aerostatic bearing function is merged into the motor forcer structure itself. The air supply channels are formed directly within the forcer body, and the orifices are integrated into the bearing surface. This eliminates the need for separate bearing assemblies, reducing both the mass and volume of the moving components while maintaining frictionless motion capability.
3Manufacturing precision
If separate aerostatic bearing assemblies are integrated with linear motors, then precision guidance is achieved, but the part count and assembly complexity increase
Solution Approach 1:
The patent integrates the aerostatic bearing guidance function directly into the motor forcer structure. The air supply channels and orifices are formed as integral features of the forcer body, and the bearing surface is the bottom surface of the forcer itself. This single-integration approach maintains precision guidance capability while reducing the total part count and eliminating complex assembly procedures.
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 part count, size, and mass, enhancing precision motion systems by self-regulating air film thickness and improving geometric accuracy and motion repeatability, while reducing assembly complexity and costs compared to standalone designs.
Implementation Method 1
a pressurized air being injected via the plurality of the air supply channels and through the orifices into a magnetic air gap formed between the bottom surface and the stator surface of the motor stator in creating a preloaded load-bearing air film
Implementation Method 2
magnetic attraction force between a forcer and stator of an open-faced iron-core linear motors can be used as a source of preload for aerostatic bearings
Data Source
AI summary
An iron-core linear motor forcer (100) with integrated aerostatic bearing guidance is disclosed. The motor forcer (100) comprises(i) an iron-core (10) enclosed within an enclosure (13) having an upper surface (11) and a bottom surface (12), wherein the iron-core (10) is mounted with a plurality of coil windings (16), and a plurality of air supply channels (50) are provided substantially in vertical from the upper surface (11) to the bottom surface (12) of the enclosure (13), and each of the air supply channels (50) is terminated at the bottom surface (12) with one or more orifices (32); and(ii) a linear motor stator (20) having a stator surface (22).The iron-core linear motor forcer (100) is frictionless moving on the motor stator (20).