Modular Coil Modules for Tubular Linear Motor Stators
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge lies in constructing long stators for tubular electric linear motors that require a high linear motive force and long stroke, while ensuring a rugged and reliable design, particularly for applications where the stator needs to be cost-effective and easily maintainable.
Innovation Solution
A modular design where multiple identical coil modules are assembled to form a stator of any required length, with intermediate connectors ensuring the combined length is an integral multiple of the pole pitch of the magnets, allowing for easy replacement of defective modules and simplifying assembly and repair.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If a single long stator is manufactured as one piece, then the motor can provide long stroke and high linear motive force, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The stator is divided into multiple identical modular units, each containing a subset of the total coils. These modules can be manufactured separately using standardized processes and then assembled together to form the complete long stator, thereby reducing individual manufacturing complexity while achieving the required total length.
Solution Approach 2:
Each stator module is designed as a universal, identical unit that can be used in any position within the sequence. This standardization allows the same manufacturing process and tooling to be reused for producing multiple modules, reducing overall manufacturing complexity and cost while enabling flexible assembly to achieve various total lengths.
2Device complexity
If a single long stator is manufactured as one piece, then the motor structure remains simple, but the cost of manufacture increases
Solution Approach 1:
By segmenting the stator into identical modular units, the patent enables parallel manufacturing of multiple modules, which reduces tooling costs and allows for more efficient production processes. The modular approach maintains structural simplicity through standardization while significantly reducing per-unit manufacturing cost.
Solution Approach 2:
The modular design allows for easier recovery and reuse of components. If a defect is found in one module, only that specific module needs to be replaced rather than discarding the entire long stator, thereby reducing waste and effective manufacturing cost.
3Ease of repair
If the stator is made from multiple identical modules, then assembly and repair are simplified, but the device complexity increases due to intermediate connectors
Solution Approach 1:
The stator is segmented into modular units connected by intermediate connectors, which simplifies repair by allowing individual module replacement. The connectors are designed as standardized components that facilitate easy assembly and disassembly, making the overall system easier to maintain despite the increased modular complexity.
Solution Approach 2:
Intermediate connectors serve as standardized intermediary components between modules. These connectors are designed to be simple, reliable, and easy to manufacture, providing the necessary electrical and mechanical connections while minimizing the complexity they introduce to the overall system.
4Adaptability or versatility
If coil modules are connected by intermediate connectors, then the stator can be assembled from standardized parts, but the total length must be an integral multiple of pole pitch
Solution Approach 1:
The intermediate connectors are designed with standardized dimensions that are integral multiples of the pole pitch. This universal design allows any number of modules to be connected while automatically satisfying the length precision requirement, as each connector-module combination contributes a predetermined, precise length to the total stator length.
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 simplifies the manufacturing and assembly of long stators, enhances reliability, and facilitates repair by enabling the replacement of individual modules, thereby improving the longevity and efficiency of tubular electric linear motors.
Implementation Method 1
a cylindrical housing enclosing a series of ring-shaped coils for generating a variable magnetic field
Data Source
AI summary
A method for manufacturing a coil module for a stator for a tubular linear motor includes placing a plurality of bobbins and spacers on a winding mandrel and winding the plurality of bobbins with a single length of wire to form a set of coils. Three sets of such coils are interleaved on an encapsulation mandrel. A plurality of metal comb shaped elements, each including a longitudinal spine and a plurality of teeth are distributed about the circumference of the three interleaved sets of coils to form a coil module. The coil module and the mandrel are surrounded with an encapsulation mold. An encapsulating material is introduced into the encapsulation mold. The encapsulated coil module is removed from the encapsulating mold and the encapsulation mandrel after setting of the encapsulating material.