Linear Motor Single Coil Axial Winding Reduces Complexity

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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 a housing and magnet assembly, where the coil carrier moves axially driven by magnetic interaction, simplifying the structure and reducing manufacturing costs by eliminating the need for internal wire connections and maintaining uniform polarity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

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

Engineering Contradiction:

Improvemotor functionalityVSAvoidcoil winding complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges multiple coil windings with opposite polarities into a single continuous winding that passes through the magnetic field multiple times. Instead of winding separate coils in opposite directions, a single coil carrier carries one continuous wire that is wound in the same direction but creates alternating polarities by passing through different magnetic field regions, thereby reducing manufacturing complexity while maintaining functionality

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent segments the coil winding into multiple sections along the axial direction, where each section interacts with a corresponding magnet assembly. The single continuous coil is divided into effective winding sections that are distributed along the axial direction, allowing each section to generate force in the same direction while simplifying the overall winding structure

Inventive Principle:

Principle #1Segmentation

2Reliability

If coil windings are wound in opposite directions, then proper magnetic interaction is achieved, but internal wire connections are required increasing manufacturing difficulty

Engineering Contradiction:

Improvemagnetic interactionVSAvoidwire connection complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent combines multiple coil sections into a single continuous winding without requiring internal wire connections. The coil wire passes through the magnetic field multiple times in sequence, eliminating the need for splicing or connecting separate coils, thereby significantly simplifying manufacturing while maintaining proper magnetic interaction across all sections

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If multiple separate coils are used with opposite polarities, then the motor functions correctly, but the air gap width increases reducing force output

Engineering Contradiction:

Improvemotor functionalityVSAvoidmotor force output

Core Design Contradiction:

ReliabilityVSForce

Solution Approach 1:

The patent merges multiple coil sections into a single continuous winding that operates within a reduced air gap. By eliminating the need for separate coils and their associated spacing requirements, the air gap between the coil carrier and magnet assembly can be minimized, thereby increasing magnetic flux density and force output while maintaining proper motor functionality

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

This design reduces the air gap width, increasing the motor's force output, simplifies manufacturing, and ensures uniform polarity when supplied with electricity, enhancing operational efficiency and cost-effectiveness.

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

PatentUS8531062B1Linear motor with three 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: 2013.09.10 MOTICONT

AI summary

A linear motor includes an assembly of three magnets in series coaxially affixed inside of a housing, which results in an air gap therebetween, wherein the assembly includes a middle magnet whose direction of magnetization is opposite to that of the rest of the magnets. 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. The carrier is movably positioned into the air gap and further surrounds the assembly, thereby moving along an axial direction of the motor. A second embodiment includes two coils that are wound in a same direction with the respective separated wires and positioned into the respective two winding areas of the coil carrier.