Modular Linear Motor Layout for Airflow-Based Coil Cooling

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Solution Overview

Problem

Conventional linear motors face challenges in effectively dissipating heat generated during high-thrust and high-speed operations, which can lead to increased operating temperatures and reduced precision.

Innovation Solution

The linear motor design incorporates a structure that facilitates smooth airflow between armature modules by maintaining a larger distance between neighboring armature modules compared to the distance between salient poles within the same armature module, allowing for efficient heat dissipation through airflow or refrigerant conduits.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If power is supplied to increase propulsion force and operating speed, then thrust and speed are improved, but heat generation in the armature module increases

Engineering Contradiction:

Improvepropulsion forceVSAvoidheat generation

Core Design Contradiction:

PowerVSTemperature

Solution Approach 1:

The linear motor is divided into multiple armature modules arranged in series along the moving direction. Each module can be independently cooled through airflow passages, allowing distributed heat management rather than concentrating all heat generation in a single location.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Airflow passages are integrated into the structure between adjacent armature modules to enable convective cooling. The passages allow air to flow through and carry away heat generated in the coils, providing active thermal management during high-power operation.

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Productivity

If armature modules are placed closer together to increase power density, then compactness is improved, but heat dissipation capability deteriorates

Engineering Contradiction:

Improvepower densityVSAvoidheat dissipation

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

Instead of increasing spacing in the horizontal plane (which would reduce power density), the design creates vertical airflow passages between modules. This three-dimensional approach to cooling allows modules to be closely spaced while maintaining effective heat dissipation through the vertical dimension.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The airflow passages act as intermediary channels between adjacent armature modules. These passages facilitate heat transfer from the coils to the moving air without requiring large physical separations between modules, enabling both compactness and effective cooling.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Temperature

If distance between armature modules is increased to improve heat dissipation, then temperature control is improved, but motor length increases

Engineering Contradiction:

Improveoperating temperatureVSAvoidmotor length

Core Design Contradiction:

TemperatureVSLength of moving object

Solution Approach 1:

The design uses thin-walled structural components and integrated airflow channels that can be formed as thin films or shells between modules. This allows effective cooling passages to be created without adding significant length to the motor assembly.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The airflow passages are nested within the structural framework of the motor, utilizing the space between existing components rather than adding external cooling structures. This nested approach provides effective cooling while minimizing increases in overall motor length.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 design effectively dissipates heat generated in the coils of the armature modules, lowering operating temperatures and reducing the risk of thermal deformation and cogging, thereby improving precision and operational reliability.

Implementation Method 1

generating an electromagnetic force between the motor and the stator to produce a thrust in a predetermined direction

Methodology Applied

Scientific EffectElectromagnetic force: Lorentz Force

Implementation Method 2

dissipating the heat generated during high-thrust and high-speed operation of a linear motor

Methodology Applied

Scientific EffectHeat dissipation through airflow: Convection

Data Source

PatentUS20250030327A1Linear motor

Publication Date: 2025.01.23 KOVERY CO LTD

AI summary

A linear motor may comprise a first member including a plurality of amature modules; and a second member including a permanent magnet module that includes a plurality of permanent magnets, of which the poles are alternated in a first direction along which the plurality of amature modules are arranged, wherein each armature module includes a magnet core including a connection part, and two or more salient poles protruding from the connection part, and a coil carrying a current of the same phase and wound around the magnetic core; wherein the permanent magnet module is disposed between two salient poles of the amature module; and wherein a distance between two neighboring armature modules is larger than a distance between two neighboring salient poles within the same amateur module.