Linear Motor Primary Part Segmented Casting Design

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Solution Overview

Problem

Linear motors face challenges in achieving consistent acceleration and high magnetic field strength due to the trade-off between the thickness of the primary part and the gap between the primary and secondary parts, leading to unpredictable movement and stress from variable acceleration.

Innovation Solution

The primary part is designed with a pre-casted unit of coils fixed by a first casting material, supported by spacer elements and a housing, with a second casting material filling the gap to create a rigid and thin structure, allowing for increased acceleration and reduced acceleration variation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Force

If the primary part is made thinner to reduce the gap between primary and secondary parts, then magnetic field strength increases, but the structural rigidity decreases and manufacturing precision becomes difficult to maintain

Engineering Contradiction:

Improvemagnetic field strengthVSAvoidpositioning precision of coils

Core Design Contradiction:

ForceVSManufacturing precision

Solution Approach 1:

The primary part is segmented into multiple components: a U-shaped component, end plates, and a core component. This segmentation allows each part to be manufactured separately with precise dimensions, then assembled together to form the complete thin primary part, maintaining both thinness and manufacturing precision.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the primary part have different thicknesses optimized for their specific functions. The core component has localized thickness variations that provide structural support where needed while maintaining overall thinness, enabling precise coil positioning without requiring the entire structure to be thick.

Inventive Principle:

Principle #3Local quality

2Speed

If the primary part is made thinner to increase acceleration, then the gap between primary and secondary parts decreases, but the mass reduction becomes insufficient to achieve the desired acceleration improvement

Engineering Contradiction:

ImproveaccelerationVSAvoidmass of primary part

Core Design Contradiction:

SpeedVSWeight of moving object

Solution Approach 1:

The invention changes the material parameters by using materials with different densities in different components. The U-shaped component and end plates use materials optimized for their specific roles, allowing mass reduction while maintaining structural integrity and achieving the desired acceleration improvement.

Inventive Principle:

Principle #35Parameter changes

3Stability of the object's composition

If the primary part uses a solid structure to maintain rigidity, then structural stability improves, but the mass increases and acceleration decreases

Engineering Contradiction:

Improvestructural rigidityVSAvoidacceleration

Core Design Contradiction:

Stability of the object's compositionVSSpeed

Solution Approach 1:

The core component incorporates a porous or lattice structure that provides high structural rigidity relative to its mass. This allows the primary part to maintain structural stability and coil positioning precision while significantly reducing mass compared to a solid structure, thereby improving acceleration.

Inventive Principle:

Principle #31Porous materials

4Speed

If the housing walls are made thinner to reduce mass, then acceleration improves, but the housing becomes insufficiently rigid to support the coils

Engineering Contradiction:

ImproveaccelerationVSAvoidhousing rigidity

Core Design Contradiction:

SpeedVSStrength

Solution Approach 1:

The housing is segmented into a U-shaped component and separate end plates that are assembled together. This segmentation allows the end plates to provide localized structural support at critical positions, enabling the use of thinner wall materials while maintaining sufficient housing rigidity to support the coils.

Inventive Principle:

Principle #1Segmentation

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 design enhances acceleration consistency and magnetic field strength while maintaining structural rigidity, reducing stress and outgassing issues in vacuum applications.

Implementation Method 1

After this casting material has been solidified, the coils are fixed inside the housing

Methodology Applied

Scientific EffectSolidification: Freezing

Data Source

PatentUS10199913B2Primary part for a linear motor, a linear motor comprising the same, and method for manufacturing such primary part

Publication Date: 2019.02.05 TECNOTION ASSETS BV

AI summary

A primary part for a linear motor, a linear motor comprising such primary part, and a method for manufacturing such primary part. The primary part comprises a housing, a pre-casted unit having at least two coils which are mutually fixed in position by a solidified first casting material, a plurality of spacer elements disposed between the pre-casted unit and the housing, the plurality of spacer elements contacting the housing and ensuring a space between the housing and the pre-casted unit, and a solidified second casting material filling the space between the housing and the pre-casted unit. The solidified second casting material ensures a fixed connection of the housing to the pre-casted unit.