Linear Motor Coil Pair Layout for Dense Low-Profile Windings
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Solution Overview
Problem
Existing linear motor stators face challenges in achieving a small thickness dimension with high copper density while minimizing the risk of incorrect wiring and short circuits, and require complex assembly and electrical connections that increase manufacturing costs and error potential.
Innovation Solution
The design incorporates single-conductor coil pairs with electrical connections made in the coil pair eye area, allowing for simplified manufacturing and reduced error potential, while ensuring a homogeneous magnetic field generation with minimal thickness and improved thermal management through a coil housing that includes receiving cavities and cooling channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If complex coil arrangements with multiple layers and offsets are used to achieve high copper density and small thickness, then the copper density increases and thickness decreases, but the wiring complexity increases and the risk of incorrect wiring and short circuits increases
Solution Approach 1:
The winding arrangement is segmented into multiple coil layers (first coil layer, second coil layer, etc.) with each layer containing coils of specific positions. This segmentation allows for systematic organization of conductors while maintaining high copper density through the layered structure.
Solution Approach 2:
Coils of different positions are nested across multiple layers, with each layer containing a subset of coils. The nested layer structure enables high copper density by stacking conductors vertically while the systematic connection scheme within each layer simplifies the overall wiring complexity.
2Quantity of substance
If complex coil arrangements with multiple layers and offsets are used to achieve high copper density and small thickness, then the copper density increases and thickness decreases, but the risk of short circuits increases due to complex routing of intersecting conductor sections
Solution Approach 1:
The conductor path is segmented into distinct sections within each coil layer, with clear separation between layers. This segmentation reduces the complexity of routing intersecting conductors and minimizes the risk of short circuits by organizing current paths in a systematic, non-interfering manner.
Solution Approach 2:
The winding arrangement utilizes multiple layers (vertical dimension) to achieve high copper density without increasing the horizontal footprint. By distributing coils across multiple layers and connecting them systematically, the patent achieves high conductor density while maintaining simple, reliable wiring paths that avoid complex three-dimensional intersections.
3Quantity of substance
If separate coil layers are arranged side by side to increase copper content, then the copper density increases, but the electrical connection effort between individual coils in their respective layers increases significantly
Solution Approach 1:
Coils from different positions are merged into continuous single-conductor coil pairs that span across coil positions. This merging eliminates the need for separate electrical connections between individual coils, as each single-conductor coil pair forms a continuous electrical path, significantly reducing connection effort while maintaining high copper density through the multi-layer arrangement.
Solution Approach 2:
The single-conductor coil pairs are pre-configured with their electrical connections established during the winding process itself, rather than requiring subsequent separate connection steps. This preliminary action of establishing continuous conductor paths before assembly simplifies manufacturing by eliminating complex post-assembly wiring operations.
4Length of moving object
If the thickness dimension along coil winding axes and coil pair winding axes is reduced, then the motor compactness improves, but the space for thermal management and cooling becomes limited
Solution Approach 1:
The patent utilizes the vertical dimension (stacking multiple coil layers) to achieve high copper density without increasing the horizontal thickness. This dimensional reorganization creates efficient thermal pathways through the layered structure, allowing heat to be conducted vertically through the stack while maintaining compact horizontal dimensions.
Solution Approach 2:
The winding arrangement optimizes local thermal management by positioning coils and conductors in specific layers with configurations that facilitate heat dissipation. The single-conductor coil pair structure and multi-layer arrangement create localized thermal pathways that efficiently conduct heat from high-density conductor regions to cooling surfaces, maintaining compact overall dimensions.
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 solution enables a linear motor stator with reduced thickness and enhanced reliability, allowing for efficient magnetic field generation and thermal management, while minimizing manufacturing errors and costs.
Implementation Method 1
The coil housing (12) has cooling channels (88) arranged in the coil section (20), into which the single-conductor coil pairs (70) project, so that sections of the single-conductor coil pairs (70) can be wetted by a cooling medium flowing through the cooling channels (88)
Implementation Method 2
The stator (10) has a winding arrangement (11) with single-conductor coil pairs (70), which can be supplied with electrical energy and with which, in conjunction with a magnet arrangement, a force can be exerted that acts on a linearly movable component in a direction parallel to the coil pair winding axes
Data Source
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AI summary
The present invention relates to an energizable winding arrangement (11) for generating a changing magnetic field (M) in the vicinity of the winding arrangement (11), comprising a plurality of coil pairs (70) arranged one behind the other along a subsequent axis (F) with a virtual coil pair winding axis (PW) oriented transversely to the subsequent axis (F), of which each coil pair (70) comprises a first coil (56) and a second coil (58) with each parallel to the coil pair winding axis (PW) respectively.has collinear coil winding axes (SW), wherein the first and second coils (56, 58) are arranged axially adjacent to each other with respect to the coil pair winding axis (PW) such that turns of the first and second coils (56, 58) are axially adjacent to each other and that eye regions (62, 64) of the first coil (56) and the second coil (58) are axially adjacent to each other forming a common coil pair eye region (72), wherein the coil pair winding axis (PW) penetrates the coil pair eye region (72).According to the invention, at least one coil pair (70) is designed as a single-conductor coil pair (70), in which the first and the second coil (56, 58) each have a connection section (56b, 58b) located radially outside the coil pair winding axis (PW) for connection to a phase of a power supply or to another coil (56, 58) and are electrically connected to each other in the coil pair eye area (72).