Linear Motor With Multilayer PCB Stator and Inverted Magnet Rotor
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Solution Overview
Problem
Existing linear motor designs, particularly those using printed-circuit board technology, are complex and costly due to challenging contacting and energizing of the rotor, especially in multi-layer configurations.
Innovation Solution
A linear motor with a primary part featuring multilayer printed circuit board technology for the motor winding and a secondary part equipped with permanent magnets, utilizing a double-stator design with laminated magnetic yokes for improved heat dissipation and a magnetic position detection system, including Hall sensors and encoder tracks, to enhance electromagnetic efficiency and reduce production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multi-layer printed circuit board technology is used for the motor winding in the primary part, then manufacturing precision and electromagnetic efficiency are improved, but device complexity and production cost increase due to challenging contacting and energizing of the rotor
Solution Approach 1:
The patent inverts the traditional linear motor configuration by placing permanent magnets on the stationary primary part (stator) instead of the moving secondary part (rotor). This inversion eliminates the need for complex contacting and energizing mechanisms on the rotor, as the moving part now only carries permanent magnets and requires no electrical connections. The multi-layer PCB technology is applied to the stationary primary part where complex wiring is manageable, resolving the contradiction between manufacturing precision and device complexity.
Solution Approach 2:
The patent extracts the electromagnetic excitation function from the moving secondary part and relocates it to the stationary primary part. By removing the motor winding from the rotor and placing it on the stator, the complex contacting and energizing requirements are extracted from the moving component and placed where they are manageable (stationary component), thereby reducing device complexity while maintaining manufacturing precision through multi-layer PCB technology.
2Ease of manufacture
If the secondary part is equipped with permanent magnets instead of coil windings, then ease of manufacture and device complexity are reduced, but the electromagnetic efficiency may be compromised
Solution Approach 1:
The patent applies the inversion principle by swapping the roles of magnets and windings between stator and rotor. The secondary part (rotor) is equipped with permanent magnets which are simple to manufacture and require no electrical connections, while the primary part (stator) contains the motor windings using multi-layer PCB technology. This configuration maintains electromagnetic efficiency because the interaction between stator windings and rotor magnets produces the necessary electromagnetic force, while greatly simplifying the manufacturing of the moving part.
3Temperature
If a double-stator design with laminated magnetic yokes is used, then heat dissipation and electromagnetic flow are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the magnetic circuit function and heat dissipation function into the laminated magnetic yoke structure of the double-stator design. The laminated construction provides both magnetic flux pathways and thermal conduction paths, while the dual-stator configuration creates symmetric heat dissipation zones. This integration approach improves heat dissipation and electromagnetic flow without adding separate complex systems, thereby mitigating the increase in device complexity.
Solution Approach 2:
The laminated magnetic yoke in the double-stator design serves multiple functions simultaneously: it provides magnetic flux conduction, structural support, and heat dissipation. By making the magnetic yoke multi-functional, the patent improves thermal management and electromagnetic performance without requiring additional dedicated components, thus limiting the increase in device complexity and manufacturing cost.
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 results in a cost-effective and efficient linear motor with reduced production costs, improved heat dissipation, and enhanced electromagnetic flow, achieved through the use of multilayer printed circuit board technology and a magnetic position detection system.
Implementation Method 1
the force driving the secondary part being proportional to the product of the armature current and excitation flux generated by the permanent magnets of the secondary part
Implementation Method 2
each primary part has a preferably laminated, i. H. designed as a laminated core magnetic yoke
Implementation Method 3
The position detection system has a corresponding sensor and an expediently encoded encoder track, for example encoded in the so-called Gray code
Data Source
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AI summary
The invention relates to a linear motor (1) having a stator, which is fitted with a motor winding, as the primary part(2), and having a moving secondary part (3), wherein the primary part (2) has at least one printed circuit board (4) with coil turns (8), which are designed as conductor tracks, of the motor winding.