Modular Coil Housing for Ironless Linear Motor Cooling
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Solution Overview
Problem
Existing electric motor technologies face challenges in cost-effectively producing different power classes of ironless linear motors, which require larger coil currents and efficient cooling due to the absence of an iron core, necessitating innovative solutions for housing and cooling of individual coils.
Innovation Solution
A modular coil arrangement for ironless linear motors comprising individual coils enclosed in plastic housing modules, where each module is designed to enclose a specific number of coils corresponding to the motor's phases, allowing for cost-effective production and enhanced stability through insulating fillers and reinforcement elements, enabling efficient cooling and robust construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If ironless linear motors are used to achieve precise positioning without latching forces, then positioning precision is improved, but larger coil currents are required which worsens the cooling requirement
Solution Approach 1:
The coil arrangement is divided into multiple individual coils that are separately housed in individual housing modules. This segmentation allows for distributed cooling where each module can be independently cooled, managing the thermal load generated by larger coil currents while maintaining the ironless design for precision positioning
Solution Approach 2:
Housing modules serve as intermediary structures that enclose individual coils and provide cooling functionality. These modules act as mediators between the coil arrangement and the cooling system, allowing efficient heat dissipation from coils carrying larger currents while preserving the precision positioning capabilities of the ironless motor design
2Adaptability or versatility
If individual coils are manufactured separately and assembled into housing modules, then production flexibility for different power classes is improved, but assembly complexity increases
Solution Approach 1:
The overall motor system is segmented into standardized housing modules, each containing an individual coil. This modular segmentation enables flexible assembly where modules can be combined in different quantities to produce various power classes, while the standardized interface reduces the actual assembly complexity despite the increased configurability
3Temperature
If housing modules are used to enclose individual coils, then cooling efficiency is improved, but manufacturing cost increases
Solution Approach 1:
The cooling system is segmented into distributed cooling channels within each housing module rather than a single complex cooling system. This allows for simpler, more cost-effective manufacturing of individual modules while achieving efficient cooling through the cumulative effect of multiple modules, each with its own integrated cooling paths
Solution Approach 2:
The housing modules serve multiple functions simultaneously: they enclose the individual coils for structural support, provide integrated cooling channels for thermal management, and enable modular assembly for production flexibility. This multi-functionality reduces the need for separate components, lowering overall manufacturing cost while maintaining cooling efficiency
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 modular design enables the production of electric motors with varying power classes at reduced costs while ensuring effective cooling and stability, addressing the need for precise positioning and force generation without the need for iron cores.
Implementation Method 1
The housing modules are filled with an insulating filler material in order to ensure adequate spacing and electrical insulation between adjacent coils and housing modules
Implementation Method 2
Each housing module has integrated cooling channels for cooling the respective individual coils
Data Source
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AI summary
A coil assembly for an electric motor comprises: a number of individual coils (10), a number of housing modules (1), each of which is configured to enclose the same proportion of the number of individual coils (10), each of the housing modules (1) being manufactured separately from the coil assembly as a plastic part.