Linear Motor Cableless Control via Hall Sensors
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Solution Overview
Problem
Linear motors require controlling cables to manage the movement of the mover on a stator, restricting movement distance and pattern, and existing solutions lack precise control mechanisms.
Innovation Solution
A linear motor design that eliminates the need for controlling cables by using Hall switching boards and absolute position measurement boards with Hall sensors to control phase conversion and position measurement, combined with an encoder system for precise feedback control, allowing the mover to move freely on the stator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If controlling cables are used to manage the mover on the stator, then the linear motor can operate with basic control functionality, but the movement distance and movement pattern are restricted
Solution Approach 1:
The patent extracts the Hall sensors from the mover and places them on the stator, separating the sensing function from the moving component. This eliminates the need for cables connecting the mover to external control systems, thereby removing the restriction on movement distance and pattern while maintaining control functionality
Solution Approach 2:
The patent introduces a magnetic field as an intermediary between the mover and stator. Hall sensors on the stator detect the magnetic field generated by magnets on the mover, enabling contactless sensing and control without requiring physical cable connections, thus achieving unrestricted movement
2Adaptability or versatility
If Hall sensors are mounted on the mover to enable cableless operation, then movement flexibility is improved, but position measurement precision and phase conversion control may be compromised
Solution Approach 1:
The patent segments the sensing functions by using different types of Hall sensors for different purposes: switching Hall sensors for phase conversion control and linear Hall sensors for absolute position measurement. This segmentation allows each sensor type to be optimized for its specific function, maintaining high precision while enabling cableless operation
Solution Approach 2:
The patent implements feedback control by using Hall sensors to detect the position of the mover and providing this information to the control system. The control system uses this feedback to precisely control the phase conversion of coil modules, ensuring accurate positioning and movement control without cables
3Measurement precision
If multiple Hall sensors and encoder systems are integrated, then position measurement precision is enhanced, but the device complexity increases
Solution Approach 1:
The patent makes the stator serve multiple functions: it houses the coil modules for actuation, the switching Hall sensors for phase conversion control, and the linear Hall sensors for absolute position measurement. By integrating these different functions into a single component, the patent reduces overall system complexity while maintaining high measurement precision
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
Enables precise control of the linear motor without cables, enhancing movement flexibility and precision, and facilitating high-speed and constant-speed operations while reducing system size.
Implementation Method 1
a Hall switching board mounted on an inner surface of one of the two sidewalls and having first Hall sensors (switching Hall sensors) operated by a magnetic field corresponding to the thrust magnets
Implementation Method 2
multiple coil modules repeatedly disposed on the bottom in the longitudinal direction and configured to constitute a stator, a mover disposed on the two sidewalls in a width direction intersecting the longitudinal direction, the mover being movable in the longitudinal direction, thrust magnets mounted at a lower side of the mover and selectively corresponding to the multiple coil modules
Implementation Method 3
an encoder head may be provided on the outer surface of one of the two sidewalls, and an encoder scale facing the encoder head may be provided on the outer wall
Data Source
AI summary
A linear motor according to an exemplary embodiment of the present invention includes a frame having a bottom and two sidewalls and extending in a longitudinal direction, multiple coil modules repeatedly disposed on the bottom in the longitudinal direction and configured to constitute a stator, a mover disposed on the two sidewalls in a width direction intersecting the longitudinal direction, the mover being movable in the longitudinal direction, thrust magnets mounted at a lower side of the mover and selectively corresponding to the multiple coil modules, and a Hall switching board mounted on an inner surface of one of the two sidewalls and having first Hall sensors (switching Hall sensors) operated by a magnetic field corresponding to the thrust magnets so that a driver controls phase conversion of the multiple coil modules.