Linear Motor Coil Carrier Using Reluctance Force for Weight Compensation
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Solution Overview
Problem
Linear motors in automation technology face challenges with uncontrolled movement and high-speed impacts due to gravitational forces, requiring complex control and additional components for weight compensation, which increase structural complexity and costs.
Innovation Solution
Incorporating a magnetic component part with high magnetic permeability in the coil carrier to generate a reluctance force that compensates for weight forces without external actuators, allowing the armature to maintain position with low friction when coils are deenergized, thereby reducing structural space and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If additional components (springs, counterweights, diverting rollers, or additional actuators) are used to compensate for weight force acting on the armature, then the armature can be supported against gravitational force, but the structural space requirement, complexity and costs of the device increase
Solution Approach 1:
The patent combines the weight compensation function with the existing coil carrier structure by integrating a magnetic component part into the coil carrier. This merging eliminates the need for separate external compensation components (springs, counterweights, or additional actuators), thereby reducing structural complexity while maintaining the force compensation capability
Solution Approach 2:
The magnetic component part in the coil carrier serves multiple functions: it provides weight force compensation through reluctance force generation and simultaneously acts as part of the motor's magnetic circuit structure. This multi-functionality reduces the overall component count and simplifies the device structure
2Force
If additional components (springs, counterweights, diverting rollers, or additional actuators) are used to compensate for weight force acting on the armature, then the armature can be supported against gravitational force, but the structural space requirement increases
Solution Approach 1:
The patent integrates the weight compensation mechanism within the existing coil carrier footprint by adding a magnetic component part. This approach eliminates the need for additional external components that would occupy extra space, thereby maintaining a compact structure while achieving force compensation
3Loss of energy
If the armature is allowed to move freely under gravitational force with low friction, then the linear motor achieves efficient operation, but the armature is pulled to its lowest position and may cause high-speed impact against stops
Solution Approach 1:
The patent generates an upward reluctance force through the magnetic component part that counteracts the downward gravitational force on the armature. This counterbalancing force prevents the armature from being pulled to its lowest position and eliminates the risk of high-speed impact against stops, while maintaining low friction operation
Solution Approach 2:
The magnetic component part automatically generates the necessary reluctance force to balance the armature weight without requiring external control systems or additional actuators. This self-service mechanism ensures reliable position control while maintaining the low-friction advantage of the linear motor
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 solution enables improved operating behavior of linear motors by eliminating the need for external weight force compensation, minimizing friction, and reducing cogging forces, resulting in more efficient and cost-effective designs for industrial automation applications.
Implementation Method 1
the magnetic permeability of the magnetic component part is greater, at least by a factor of 10 or at least by a factor of 50, than the magnetic permeability of the coil carrier in the first longitudinal portion of the coil carrier, wherein, at least for some of the possible positions of the armature on the movement path, there is only a partial overlap in the longitudinal direction between the magnetic component part or at least one of the magnetic component parts and a longitudinal portion, which bears the magnets, of the armature or of the stator, resulting in a reluctance force which, when the coils are electrically deenergized, pulls the armature toward a specified rest position on the movement path and/or at least partially compensates a force on the armature
Implementation Method 2
by electrical energization of at least some of the coils, a magnetic force can be imparted to the armature, whereby the armature is movable in a longitudinal direction relative to the stator within a movement path
Data Source
AI summary
A linear motor having a stator and an armature, wherein the stator includes multiple coils and a coil carrier and the armature includes multiple permanent magnets, or the armature includes multiple coils and a coil carrier and the stator includes multiple permanent magnets. The armature is positively guided linearly relative to the stator. The coils, when energized, in part a magnetic force to the armature to move the armature in a longitudinal direction relative to the stator within a movement path. The coil carrier holds the coils within a first longitudinal portion of the coil carrier. In a second longitudinal portion of the coil carrier, the coil carrier is formed at least in part from a magnetic component part or is rigidly connected to the magnetic component part. The magnetic permeability of the magnetic component part is greater, at least by a factor of 10, than the magnetic permeability of the coil carrier in the first longitudinal portion. At least for some of the possible positions of the armature on the movement path, there is only a partial overlap in the longitudinal direction between the magnetic component part and a longitudinal portion, which bears the permanent magnets, of the armature or of the stator, resulting in a reluctance force which, when the coils are electrically deenergized, pulls the armature toward a specified rest position on the movement path and/or at least partially compensates a force on the armature, which counteracts the reluctance force.