Linear Motor Coil Holder with Integral Resin Spacers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional linear motor coil assembly methods are time-consuming and prone to variations in coil pitch and overall length, requiring extensive manpower and complex wire connecting operations.
Innovation Solution
A linear motor design featuring a coil holder with integrally formed resin spacers and an insulating substrate with conductive patterns for simplified assembly and stable coil unit length, where coils are held in place by a housing and lead wires are wired through the substrate for reduced assembly steps and improved stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If coils and spacers are assembled alternately onto a coil arrangement shaft one by one, then the coil unit can be assembled, but the assembly process becomes time-consuming and labor-intensive as the number of coils increases
Solution Approach 1:
The coil assembly is segmented into modular units where multiple coils are pre-assembled in groups (one-by-one or two-by-two) using coil guides, then these modular units are laminated together. This segmentation allows parallel processing and reduces the overall assembly time compared to assembling all coils sequentially one-by-one.
Solution Approach 2:
Coils are preliminarily assembled into coil guides before final lamination. This preliminary action prepares sub-assemblies in advance, allowing the main assembly process to proceed more efficiently by simply laminating the pre-prepared coil guides together rather than assembling all coils from scratch in sequence.
2Ease of manufacture
If coils and spacers are arranged sequentially, then the coil unit can be assembled, but dimensional variations accumulate resulting in inconsistent coil pitch and overall length
Solution Approach 1:
A coil guide serves as an intermediary tool that precisely positions multiple coils relative to each other during assembly. The coil guide acts as a master reference that transfers accurate dimensional relationships to the coil assembly, preventing accumulation of dimensional variations that would occur with direct sequential placement.
Solution Approach 2:
The coil guide structure incorporates built-in positioning features and reference surfaces that automatically ensure correct coil placement without requiring additional measurement or adjustment operations. The assembly process becomes self-correcting as the coil guide's geometry enforces consistent coil pitch and alignment.
3Ease of manufacture
If wire connecting operations are performed for each coil, then all coils can be wired, but the process requires extensive manpower and time
Solution Approach 1:
Multiple coil wiring operations are merged into a single lamination step. By assembling coils in groups within coil guides and then laminating the guides together, the wiring process for multiple coils is combined into one operation performed on the entire laminated assembly rather than individual operations on each coil.
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 method simplifies the assembly of coil units, stabilizes coil pitch and length, and reduces the complexity of wiring operations, enabling more efficient and balanced coil placement and connection.
Implementation Method 1
a linear motor for obtaining a thrust for linear movement with use of a magnetic field and coil carrying current
Data Source
AI summary
Provided is a linear motor capable of simplifying assembling of a coil unit and stabilizing a coil pitch and the overall length of the coil unit.The linear motor has a rod 1 having magnets 3, a plurality of coils 4 arranged in the axial direction of the rod 1, a housing 2 covering the coils 4, and a coil holder 5 holding the coils 4 in the housing 2. The coil holder 5 includes a holder main body 5a elongating in the coil arrangement direction and a plurality of spacer portions 5b made of resin and each interposed between each adjacent two of the coils 4 to insulate the coils 4 from each other, the spacer portions 5b being formed integrally with the holder main body 5a.