Linear Motor Single Coil Winding Air Gap Reduction

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Solution Overview

Problem

Existing linear motors with coil windings of opposite polarities are complex and costly to manufacture, while maintaining functionality.

Innovation Solution

A linear motor design featuring a single electrical coil with multiple layers wound in the same direction, positioned within an air gap between magnets, eliminating the need for internal wire connections and reducing the air gap width, thus increasing the motor's force output and simplifying manufacturing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If coil windings are wound in opposite directions to achieve different polarities, then the motor can generate force, but the manufacturing complexity and cost increase

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidcoil winding complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent combines multiple coil windings into a single continuous winding that passes through the magnetic assembly multiple times. This single winding replaces what would traditionally require multiple separate windings with opposite polarities, eliminating the need for complex internal wire connections and simplifying the manufacturing process while maintaining the necessary polarity variations through the winding path geometry

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Instead of creating opposite polarities by winding coils in opposite directions (traditional approach), the patent inverts the approach by winding all coils in the same direction and achieving polarity differentiation through the spatial arrangement and path of the single continuous winding through the magnetic assembly

Inventive Principle:

Principle #13The other way round (Inversion)

2Force

If the air gap between magnets and coil carrier is reduced to increase force output, then the motor generates more force, but the manufacturing precision requirements increase

Engineering Contradiction:

Improvemotor force outputVSAvoidair gap tolerance

Core Design Contradiction:

ForceVSManufacturing precision

Solution Approach 1:

The patent segments the coil carrier into multiple independent coil windings that are positioned around the magnetic assembly. This segmentation allows each coil to be independently adjusted and positioned, enabling precise control of the air gap at multiple locations and reducing the overall manufacturing precision requirements compared to a single large air gap

Inventive Principle:

Principle #1Segmentation

3Reliability

If multiple separate coils are used instead of a single continuous winding, then the motor can achieve uniform polarity, but the internal wire connections and manufacturing complexity increase

Engineering Contradiction:

Improvepolarity uniformityVSAvoidcoil structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges multiple coil windings into a single continuous winding that passes through the magnetic assembly in a systematic pattern. This unified structure eliminates internal wire connections between separate coils, reduces manufacturing complexity, and ensures polarity uniformity through the consistent geometry of the single winding path

Inventive Principle:

Principle #5Merging (Combining)

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 design reduces manufacturing costs, increases force output by minimizing the air gap, and ensures uniform polarity when supplied with electricity, enhancing the motor's efficiency and ease of production.

Implementation Method 1

The coil carrier moves along an axial direction of the motor when the coil carrier is driven by forces resulting from an interaction of the magnets and the single electrical coil after it is supplied with electricity

Methodology Applied

Scientific EffectElectromagnetic interaction: Lorentz Force

Data Source

PatentUS8742632B1Linear motor with two magnets and a coil carrier having multiple winding areas with each area having a section of a coil wound with one continuous wire, or separate coils respectively wound around each area with all coils wound in the same direction

Publication Date: 2014.06.03 MOTICONT

AI summary

A linear motor includes an assembly of two magnets separated by a non-magnetic spacer wherein the assembly is coaxially affixed inside of a housing, which results in an air gap therebetween. The magnets are positioned to have a same direction of magnetization. A first embodiment of the motor includes a coil carrier having a single electrical coil of two sections wound in the same direction and positioned into the corresponding two winding areas of the carrier. The coil carrier is movably positioned into the air gap and further to surround the assembly, thereby moving along an axial direction of the motor. A second embodiment includes two coils that wound in a same direction with the respective separated wires and positioned into the respective two winding areas of the coil carrier.