Linear Motor Mover Magnetic Structure Centering
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Solution Overview
Problem
Inconsistent mechanical and magnetic tolerances in the parts and subassemblies of linear motor movers result in inaccurate positioning and movement within the motor system, leading to reduced accuracy and inconsistent locations.
Innovation Solution
A multi-piece magnetic structure is coupled to the magnet subassembly, centered on the detected center of the magnetic field, to ensure consistent positioning and alignment, using adhesives like epoxy or glue to secure the magnetic structure, which includes a top plate and side plates with tabs and slots for precise alignment and centering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional single-piece magnetic structures are used in linear motor movers, then manufacturing is simpler, but positioning accuracy deteriorates due to cumulative tolerances in parts and subassemblies
Solution Approach 1:
The magnetic structure is divided into multiple separate magnetic structure pieces that are positioned relative to each other. Each piece can be manufactured and positioned independently, allowing for precise alignment without cumulative tolerances from a single monolithic structure. The pieces are secured to the magnet subassembly in a configured relationship that achieves the desired positioning accuracy.
Solution Approach 2:
The magnetic structure pieces are pre-positioned and pre-aligned before being permanently secured to the magnet subassembly. This preliminary positioning allows for precise adjustment and alignment to achieve the desired magnetic field centering, and then the pieces are fixed in place using adhesives or other securing mechanisms to maintain the precise positioning.
2Manufacturing precision
If multiple magnetic structure pieces are used to improve positioning accuracy, then manufacturing precision improves, but assembly complexity increases
Solution Approach 1:
The magnetic structure is segmented into multiple pieces that can be manufactured separately using standard manufacturing processes. Each piece is designed with features that facilitate independent positioning and alignment, and the segmented approach allows for modular assembly that simplifies the overall manufacturing process while maintaining high precision.
Solution Approach 2:
Adhesives or other securing mechanisms serve as intermediaries between the magnetic structure pieces and the magnet subassembly, allowing for precise positioning without requiring complex mechanical fastening systems. The adhesive layer accommodates minor tolerances while maintaining the precise relative positioning of the magnetic structure pieces.
3Manufacturing precision
If magnetic structure pieces are precisely aligned and secured, then positional accuracy improves, but manufacturing time increases
Solution Approach 1:
The magnetic structure pieces are pre-positioned and pre-aligned outside the main assembly process, allowing for precise adjustment without time pressure. The pre-assembled pieces are then quickly installed onto the magnet subassembly, separating the time-consuming precision alignment work from the final assembly operation and improving overall productivity.
Solution Approach 2:
The magnetic structure is divided into a smaller number of larger pieces rather than many small pieces, reducing the number of alignment operations required. Each segmented piece is designed to be positioned and secured in a single operation, minimizing the total assembly time while maintaining the precision benefits of having multiple separate components.
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 approach enhances the positional accuracy of the movers by reducing machine, assembly, and magnetic tolerances, allowing the movers to move to consistent locations, with the magnetic structure centered within +/- 0.25 mm of the detected center, improving the overall precision and reliability of the linear motor system.
Implementation Method 1
a magnetic structure disposed on at least one side of the magnet subassembly and creating with the magnetic subassembly a resultant magnetic field, the magnetic structure being centered on a detected center of the resultant magnetic field
Implementation Method 2
using adhesives like epoxy or glue to secure the magnetic structure
Data Source
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AI summary
A mover for a linear motor system includes a magnet subassembly. The mover includes a magnetic structure disposed on at least one side of the magnet subassembly and creating with the magnetic subassembly a resultant magnetic field. The magnetic structure being centered on the center of the resultant magnetic field. The mover includes a body structure mounted on or with reference to the magnetic structure to position a physical center of the body structure at approximately the center of the resultant magnetic field.