Linear Motor Thread Guide Single Rail Design
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Solution Overview
Problem
Existing thread guides for winding devices, driven by linear motors, are unsuitable for high speeds and accelerations due to their heavy structure and the need for multiple wheels, which increases weight and manufacturing costs, and results in unwanted sliding and wear.
Innovation Solution
A thread guide with a structurally simple design featuring a runner mounted on a single rail with minimal wheels, utilizing a magnetic yoke and permanent magnets to optimize positioning and force transmission, reducing weight and manufacturing costs while preventing sliding and wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If multiple roller bodies are used to support the rotor, then the thread guide can be stably mounted, but the weight increases and high speeds/accelerations cannot be achieved
Solution Approach 1:
The invention extracts and eliminates unnecessary roller bodies from the support system. Instead of using multiple rollers along the entire length of the stator, only two roller bodies are provided at the longitudinal ends of the stator, significantly reducing the weight of the thread guide while maintaining stable mounting through the linear motor's magnetic forces.
Solution Approach 2:
The invention replaces the traditional mechanical support system with multiple rollers with a simplified system using only two rollers, relying on the linear motor's magnetic field to provide the necessary support and stability. This substitution reduces mechanical complexity and weight while enabling high speeds and accelerations.
2Stability of the object's composition
If the runner is mounted on multiple rails, then stable mounting is achieved, but the number of wheels increases and manufacturing costs rise
Solution Approach 1:
The invention extracts and eliminates unnecessary rails from the mounting system. Instead of using multiple rails along the stator length, only two rails are provided at the longitudinal ends, reducing the number of wheels required for stable mounting while lowering manufacturing costs and structural complexity.
Solution Approach 2:
The invention segments the rail support system into only two discrete locations at the longitudinal ends of the stator, rather than continuous or multiple distributed rails. This segmentation reduces the total number of wheels needed while maintaining stability through the magnetic forces of the linear motor.
3Stability of the object's composition
If the thread guide is heavy, then structural stability is improved, but high speeds and accelerations cannot be achieved
Solution Approach 1:
The invention replaces heavy mechanical support structures with a lightweight design that relies on the linear motor's magnetic field for stability. The runner is mounted on only two roller bodies at the ends, significantly reducing weight while the magnetic forces provide the necessary structural stability for high-speed operation.
Solution Approach 2:
The invention uses the linear motor's magnetic forces to counteract the effects of reduced mechanical support. The electromagnetic forces generated by the linear motor provide the necessary holding and stabilizing forces that would otherwise require heavy mechanical structures, enabling lightweight construction while maintaining stability at high speeds.
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 solution enables a lightweight thread guide that can achieve high speeds and accelerations with reduced manufacturing costs, maintaining stable positioning and minimizing wear, allowing for efficient and cost-effective operation.
Implementation Method 1
a stator, which is used to generate a traveling magnetic field is provided
Implementation Method 2
the thread guide being designed as the runner of an electric linear motor
Implementation Method 3
The stator has roller bodies with a horizontal axis over its entire length, on which the rotor is supported and can move back and forth along the stator by means of rolling friction in the longitudinal direction
Data Source
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AI summary
The invention relates to a thread guide (FAD) for a spool unit (SEI) for winding product to be wound (GUT) onto a spool (SPU) of the spool unit (SEI), wherein the thread guide (FAD) carries out a back and forth movement during winding, and wherein the thread guide (FAD) is configured as a rotor (LAU) of an electric linear motor (LIN), and wherein the rotor (LAU) is supported on at least one wheel (R1", R2") and disposed opposite a stator (STA), the stator (STA) being provided for generating a magnetic travelling field, and wherein the rotor (LAU) comprises at least one permanent magnet (PE1", PE2") such that the rotor (LAU) moves in the travelling field along the stator (STA), wherein according to the invention above the stator (STA) exactly one rail (SC") is disposed, on which the rotor (LAU) is supported by means of at least one wheel (R1", R2"). Advantageously, the rotor (LAU) also comprises at least one back iron (REU"), which follows a movement of the rotor (LAU), for forming a magnetic return path.