Linear Motor Sensor Substrate Segmentation for Long Stroke Handling
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Solution Overview
Problem
Existing linear motors face challenges in handling and operation due to the need to disassemble and reassemble sensor heads when connecting multiple stator units, which complicates the detection of slider positions over a long stroke range and requires complex sensor placement.
Innovation Solution
The linear motor design incorporates sensor substrates integrated within the stator units, allowing for position detection signals from upstream and downstream sensors to be combined, enabling continuous position tracking across a longer stroke range without sensor protrusion, thus simplifying handling and connection processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the origin sensor is disposed at the position where the origin sensor meets the end of the stator in the direction along the moving path, then the position of the slider can be detected in a relatively long stroke range, but the sensor head protrudes from the end of the stator unit requiring complex handling and disassembly operations
Solution Approach 1:
The sensor head is separated from the stator unit into an independent component. The sensor head can be detached and reattached without disassembling the stator unit itself, allowing the origin sensor to be positioned at the end of the stator for long-range detection while maintaining simple handling operations.
Solution Approach 2:
The sensor head is extracted as a separate component from the stator unit assembly. This extraction allows the sensor head to be independently positioned at the stator end for origin detection while the stator unit remains intact and easy to handle during connection and disconnection operations.
2Measurement precision
If the sensor head is offset relative to the stator unit to enable origin sensor placement at the stator end, then continuous position tracking across long stroke ranges is achieved, but the linear motor requires protection for the protruding sensor head and becomes difficult to handle
Solution Approach 1:
The sensor head is segmented as a separate component that can be independently positioned and protected. This segmentation eliminates the need for complex protection structures on the main stator unit, as the sensor head itself can be designed with integrated protection while maintaining simple overall handling.
Solution Approach 2:
The sensor head is extracted as an independent component with its own protection mechanism. This allows the protection structure to be minimized and integrated into the sensor head assembly rather than requiring additional protection structures on the stator unit, reducing overall device complexity.
3Length of moving object
If multiple stator units are connected to form a linear motor with long stroke range, then position detection over extended ranges is enabled, but the operation becomes complicated requiring disassembly of stator units to attach sensor heads
Solution Approach 1:
The sensor head is segmented as a separate component that can be independently attached to each stator unit without disassembling the stator units themselves. This segmentation simplifies the assembly process for multiple stator units, as the sensor heads can be independently positioned and secured without complex disassembly and reassembly operations.
Solution Approach 2:
The sensor head is extracted as a separate component from the stator unit assembly process. This extraction allows sensor heads to be independently attached to each stator unit in a simple, standardized operation, eliminating the need for complex disassembly and reassembly when connecting multiple stator units to form a long-stroke 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 design enhances handling efficiency and maintains accurate slider position detection over a longer range, reducing operational complexity and facilitating easier connection and disconnection of stator units.
Implementation Method 1
stators are arranged along the moving path so that the stators face the mover and move the slider along the moving path while generating attractive force between the stators
Implementation Method 2
a position detection sensor that detects the linear scale to output a wave signal
Implementation Method 3
an origin sensor that outputs a signal for specifying an origin position of the wave signal
Data Source
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AI summary
In the present invention, handling of a linear motor is made easy while maintaining a slider position detection function in a relatively long stroke range. This linear motor is equipped with sensor substrates that are attached to main motor bodies in the X-direction along a conveyance path in such a manner that the sensor substrates are accommodated within the dimensions of the main motor bodies. Each sensor substrate is equipped with a sensor for outputting an A-phase position detection signal upon detecting a slider, a sensor for outputting a B-phase position detection signal, and a position detection signal summer unit. Each position detection signal summer unit adds up, for A-phase and for B-phase, position detection signals that are output from the position detections means of the adjoining substrates provided on either side of the relevant substrate.