Linear Motor Using Standard Profile Guide Rails
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Solution Overview
Problem
The high manufacturing costs of existing linear motors due to their complex and technically demanding construction make them economically unfavorable for widespread adoption.
Innovation Solution
The use of commercially available profile guide rails and carriages, with additional rail parts for larger permanent magnets and interchangeable processing devices, allows for a cost-effective construction that enables movement along a straight line and potentially in a plane, with support options including fixed or movable bearings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex construction with custom linear guides and steel plates is used, then the linear motor achieves proper functionality, but the manufacturing costs increase significantly
Solution Approach 1:
The invention uses a profile guide rail that serves multiple functions: it provides structural support, guides the carriage movement, and serves as the mounting base for permanent magnets. This multi-functional design eliminates the need for separate custom linear guides and base plates, reducing manufacturing complexity and costs while maintaining proper motor functionality
Solution Approach 2:
The invention employs commercially available standardized profile guide rails and carriages instead of custom-manufactured components. These off-the-shelf components are more economical to produce and purchase, allowing the linear motor to achieve functionality at lower manufacturing costs
2Power
If permanent magnets larger than the rail width are used, then the motor power increases, but the standard profile guide rail cannot accommodate them
Solution Approach 1:
The support structure for permanent magnets is divided into two segments: the standard profile guide rail and an additional rail part attached to its underside. This segmentation allows the system to use both standardized components and custom extensions, accommodating larger permanent magnets while maintaining compatibility with commercial guide rails
Solution Approach 2:
Instead of expanding the rail width horizontally, the invention attaches an additional rail part to the underside of the standard profile guide rail. This vertical dimension approach allows larger permanent magnets to be mounted without compromising the horizontal stability and standardized interface of the main rail structure
3Device complexity
If fixed bearings are used at the ends of the profile guide rail, then the structure is simple, but the carriage cannot move in multiple directions
Solution Approach 1:
The invention allows dynamic configuration of bearings at the rail ends - they can be fixed for simple linear motion or replaced with movable bearings to enable planar movement. This dynamic adaptability lets the same profile guide rail structure serve different application requirements without redesigning the entire system
Solution Approach 2:
The profile guide rail system is designed to accommodate multiple bearing configurations and carriage arrangements, making it universally applicable for both simple linear motion and complex planar movement applications. This multi-functionality allows a single standardized component to replace multiple specialized designs
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 significantly reduces manufacturing costs while maintaining functionality, allowing for versatile device placement and operation in various orientations, enhancing the economic viability of linear motors.
Implementation Method 1
a linear motor (10) which works in a linear direction (28)
Implementation Method 2
Permanent magnets are attached to the steel plate
Implementation Method 3
A carriage containing the motor windings can be moved along the two linear guides
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
An electric linear motor has a primary part comprising electromagnets (44, 46), a secondary part comprising permanent magnets (34), a base carrier on which the permanent magnets are fastened, and at least one carriage (30), on which the electromagnets (44) are fastened and which can be displaced along linear guides provided on the base carrier. Together with the linear guides thereof, the base carrier is a conventional, standardized profile guide rail (12). Each carriage (30) is composed of at least one conventional, standardized glider (24, 26), which is adjusted to the profile guide rail (12) and can be displaced along this rail (12), and of a carrying frame supporting the electromagnets (44, 46), wherein the frame can be fastened to the at least one glider (24, 26).