Modular Ironless Linear Motor Secondary Part
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Solution Overview
Problem
Ironless linear motors require larger coil currents to generate sufficient forces without an iron core, necessitating effective cooling and posing challenges in manufacturing secondary parts of varying lengths while maintaining mechanical stability and cost-effectiveness.
Innovation Solution
A set of components comprising identically dimensioned magnetic pole plates, mounts, and spacers allows for the formation of a secondary part with adjustable length, achieving high mechanical stability and flexibility by arranging these components along a longitudinal direction, with spacers and mounts configured to accommodate multiple magnetic pole plates and ensure offset transitions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the secondary part is manufactured as a single piece for each length, then the mechanical stability is high, but the manufacturing cost and complexity increase for multiple lengths
Solution Approach 1:
The secondary part is divided into multiple identical modules, each comprising a mount with magnetic pole plates and spacers. These modules can be assembled in different quantities to create secondary parts of various lengths while maintaining mechanical stability through standardized connections.
Solution Approach 2:
A universal mount design is created that can accommodate multiple magnetic pole plates (at least two first mounts and at least one second mount that is at least twice as long). This universal mount serves multiple functions across different secondary part lengths, reducing the need for custom-manufactured components for each length variant.
2Adaptability or versatility
If modular components are used to form the secondary part, then the adaptability to different lengths is improved, but the mechanical stability may be compromised
Solution Approach 1:
The secondary part is segmented into standardized modules that can be assembled in different quantities to achieve various lengths. Each module maintains structural integrity through the mount-spacer-magnetic pole plate configuration, ensuring that mechanical stability is preserved across different length configurations.
Solution Approach 2:
The mount design incorporates localized features with different dimensions (first mounts and second mounts with at least twice the length) to optimize the local structural properties. This allows the modular system to maintain high mechanical stability at connection points while achieving overall length adaptability through modular assembly.
3Force
If an iron core is used in the coils, then the force generation is efficient, but the positioning precision is reduced due to latching forces
Solution Approach 1:
The iron core is completely removed from the coil structure in the ironless linear motor design. The coils operate without ferromagnetic cores, eliminating the latching forces that would compromise positioning precision. The magnetic field is generated purely through electromagnetic induction in the air core configuration.
4Force
If larger coil currents are used to compensate for the absence of an iron core, then the force generation is sufficient, but the cooling requirements increase
Solution Approach 1:
The mount structure serves multiple functions: it provides mechanical support for the magnetic pole plates, acts as a structural framework for the secondary part, and functions as a heat dissipation pathway. The standardized mount design with its robust construction helps manage the thermal load from larger coil currents while maintaining force generation capability.
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 the formation of secondary parts with high mechanical stability and adjustable length, using a minimal set of components, thereby addressing the need for cost-effective and precise positioning in linear motors while ensuring efficient cooling and reduced weight.
Implementation Method 1
Linear motors are used, for example, when it comes to highly accurate and possibly also fast positioning of objects... at least one coil provided on the primary part is not assigned a core... in order to be able to generate sufficiently large forces on the primary part of the linear motor even without a core
Implementation Method 2
A set of components comprising identically dimensioned magnetic pole plates, mounts, and spacers allows for the formation of a secondary part with adjustable length, achieving high mechanical stability and flexibility
Data Source
Figure 1
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Figure 2B
AI summary
A component set for forming a secondary part (100) for a linear motor, having a length that is at least an integer multiple of twice a unit length, comprises: a plurality of identically dimensioned magnetic pole plates (131), each magnetic pole plate (131) having a unit length; a plurality of supports (141, 142), each of which is designed to receive at least two of the magnetic pole plates (131), wherein the supports comprise at least two identically dimensioned first supports (141) and at least one second support (142), and wherein the at least one second support (142) is dimensioned at least twice as long as each of the first supports (141) so that it can receive at least twice the number of magnetic pole plates (131);a plurality of spacers (151, 153, 154), each of which is designed to accommodate at least one of the supports (141, 142) on both sides, wherein a first spacer (151) has a length which differs by at least one unit length from the length of one of the first supports (141).