Linear Motor Stator with PCB Holding Device
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Solution Overview
Problem
Existing linear motor systems face challenges with large installation space requirements, mechanical instabilities, and high magnetic leakage losses due to the use of air-core coils, leading to reduced thrust force and increased complexity and costs.
Innovation Solution
A stator device for linear motors featuring an electrically energizable magnetic field generator with a coil wound around a stator tooth, held by a non-conductive printed circuit board that serves both as a holding device and for electrical contacting, and a support profile element with power electronics, allowing for efficient electrical contacting and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If air-core coils are used in the linear motor, then the construction is simpler, but magnetic leakage losses increase and thrust force decreases
Solution Approach 1:
The patent employs composite material construction by combining iron cores with coil windings to form integrated core/winding units. The iron core provides high magnetic permeability to guide magnetic flux, while the coil provides electromagnetic excitation. This composite structure reduces magnetic leakage losses compared to air-core coils while maintaining construction simplicity.
2Ease of manufacture
If air-core coils are used, then manufacturing is easier, but inductivity is low leading to reduced thrust force
Solution Approach 1:
The iron core in the core/winding unit provides high magnetic permeability, concentrating magnetic flux and increasing inductivity. This allows the coil to generate stronger magnetic fields for the same current, thereby increasing thrust force while maintaining ease of manufacture through standardized core and coil components.
Solution Approach 2:
The patent replaces the purely air-based magnetic path with an iron core structure, substituting the low-permeability air path with a high-permeability ferromagnetic path. This substitution increases magnetic coupling and inductivity, resulting in higher thrust force generation capability.
3Power
If multiple coils are arranged within the U-shaped yoke, then magnetic field generation is improved, but installation space requirements increase
Solution Approach 1:
The stator is divided into multiple discrete core/winding units, each comprising an iron core with coils wound around it. These modular units can be independently manufactured and then assembled into the final stator structure. This segmentation allows for optimized space utilization and reduces the overall installation volume compared to traditional multi-coil arrangements within a single yoke structure.
Solution Approach 2:
The patent transitions from a two-dimensional coil arrangement within a planar yoke to a three-dimensional modular structure where core/winding units are stacked or arranged in multiple dimensions. This dimensional change allows for more efficient space utilization and reduced installation footprint while maintaining or enhancing magnetic field generation capability.
4Stability of the object's composition
If fastening elements are used to hold coils, then mechanical stability is improved, but device complexity increases
Solution Approach 1:
The iron core and coil winding are merged into an integrated core/winding unit, eliminating the need for separate fastening elements to secure coils to the yoke. The core itself serves as the structural support and magnetic conductor, while the coil is directly wound around or mounted to the core. This merging reduces mechanical complexity while maintaining stability through the inherent structural integrity of the integrated unit.
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 reduces eddy-current losses, enhances mechanical strength, and simplifies assembly while achieving higher thrust forces and more uniform movement with reduced structural volume and complexity.
Implementation Method 1
When the air-core coils are electrically energized, a magnetic field forms, which magnetic field interacts with the magnetic field of the permanent magnets of the yoke such that the carriage is subjected to a translatory movement
Implementation Method 2
a magnetic field forms, which magnetic field interacts with the magnetic field of the permanent magnets of the yoke such that the carriage is subjected to a translatory movement
Implementation Method 3
The first holding device is in the form of a printed circuit board for electrical contacting of the magnetic field generator
Data Source
AI summary
A stator device for a linear motor comprises an electrically energizable magnetic field generator for forming a magnetic field, and a first holding device for holding the magnetic field generator, wherein the magnetic field generator is fastened to the first holding device, wherein the first holding device is formed at least partially from an any of an electrically and magnetically non-conductive material, wherein the magnetic field generator comprises a coil and a stator tooth as a core around which the coil is wound, and wherein the first holding device is in the form of a printed circuit board for electrical contacting of the magnetic field generator.