Linear Motor Core Ratio Layout for Higher Ferrite-Magnet Thrust
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Solution Overview
Problem
Existing linear motors using rare-earth-free permanent magnets face limitations in achieving desired thrust due to their relatively small magnetic force, necessitating structural design improvements.
Innovation Solution
The linear motor design incorporates a specific ratio of iron core dimensions to winding arrangement and a 5-pole 6-slot configuration, optimizing parameters c (0.1 to 0.35) and d (0.47 to 0.61) to enhance thrust, utilizing rare-earth-free permanent magnets like ferrite magnets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If rare-earth-free permanent magnets (e.g., ferrite magnets) are used instead of neodymium magnets, then cost is reduced and coercivity requirements are met, but magnetic force (residual magnetic flux density) decreases, making it difficult to achieve desired thrust
Solution Approach 1:
The patent optimizes the ratio of the dimension of the first iron core to the arrangement pitch of the windings (set to 0.1-0.35) and the ratio of armature dimension to linear motor dimension (set to 0.47-0.61). These parameter changes maximize the utilization of magnetic flux from the permanent magnets, thereby improving thrust output even when using rare-earth-free magnets with lower residual magnetic flux density.
Solution Approach 2:
The patent employs a 5-pole 6-slot configuration specifically in the direction of relative movement, creating an optimized magnetic circuit structure. This local structural optimization enhances the magnetic field distribution and flux linkage, compensating for the lower magnetic force of ferrite magnets and achieving improved thrust performance.
2Force
If the ratio of iron core dimension to winding pitch is increased to improve thrust, then magnetic force utilization improves, but device complexity and manufacturing precision requirements increase
Solution Approach 1:
The patent defines specific ratio ranges (0.1-0.35 for core dimension to winding pitch, 0.47-0.61 for armature dimension to motor dimension) that balance thrust performance with manufacturing feasibility. These ranges provide design flexibility while ensuring adequate thrust output, avoiding overly stringent precision requirements.
3Force
If the armature dimension to linear motor dimension ratio is optimized to improve thrust, then magnetic flux utilization improves, but the design flexibility and adaptability to different applications is reduced
Solution Approach 1:
The patent specifies a ratio range (0.47-0.61) for armature dimension to linear motor dimension rather than a fixed value. This range-based approach maintains optimal thrust performance while providing sufficient design flexibility to adapt to different application requirements, sizes, and configurations.
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 configuration structurally improves thrust, maintaining or exceeding the performance of motors using rare earth magnets, even with lower magnetic force magnets, while reducing material costs.
Implementation Method 1
The armature includes a plurality of windings that are arranged along a direction of the relative movement. Each of the windings is wound around a first iron core.
Implementation Method 2
The field magnet includes a plurality of permanent magnets that are disposed to face both sides of the armature in a direction perpendicular to the direction of the relative movement
Implementation Method 3
Each of the windings is wound around a first iron core
Implementation Method 4
utilizing the magnetic reluctance force in addition to magnetic force for enhanced performance
Data Source
AI summary
A linear motor includes an armature and a field magnet that are disposed to face each other and configured to be subjected to relative movement. The armature includes a plurality of windings that are arranged along a direction of the relative movement. Each of the windings is wound around a first iron core. The field magnet includes a plurality of permanent magnets that are disposed to face both sides of the armature in a direction perpendicular to the direction of the relative movement, and are arranged along the direction of the relative movement. A ratio of a dimension of the first iron core to an arrangement pitch of the windings in the direction of the relative movement is in a range from 0.1 to 0.35.