Modular Multi-Coil Linear Actuator Design
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Solution Overview
Problem
Traditional low cost linear actuators with a single coil provide limited stroke distance and force, while multiple coil designs are more expensive due to increased moving mass, complexity, and the need for reversing magnetic polarities.
Innovation Solution
A magnet housing and coil assembly design that allows for interchangeable configurations with any number of coils and magnets, using a uniform base part to reduce manufacturing and maintenance costs, and enabling programmable control of magnetic fields for varied applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If multiple coils are added to generate more force for longer stroke, then force and stroke value are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The actuator is divided into modular segments where coils are arranged in series along the stroke path. Each coil segment can independently generate force, and multiple segments work together to achieve longer total stroke while maintaining force output. This segmentation allows the system to scale force and stroke independently rather than requiring a single large complex coil assembly.
Solution Approach 2:
The patent implements dynamic coil activation where different coil segments are activated sequentially or simultaneously based on the required stroke position and force demands. This dynamic control allows the system to optimize force output for each position along the stroke, maintaining high force capability without requiring all coils to be active at once, thus reducing effective complexity.
2Force
If multiple coils are added to generate more force for longer stroke, then force and stroke value are improved, but manufacturing cost increases
Solution Approach 1:
The patent designs universal coil segments that can serve multiple functions: each segment can operate independently for short-stroke applications or be combined with other segments for long-stroke applications. The same basic coil module design can be used across different actuator configurations, allowing standardization of manufacturing processes and reducing tooling costs despite offering multiple force and stroke options.
Solution Approach 2:
The system achieves different force and stroke characteristics by changing the activation parameters (which coils are active, their sequence, and duty cycles) rather than requiring physically different coil assemblies. This allows a single manufactured set of coil segments to provide multiple performance levels, eliminating the need to manufacture and inventory multiple specialized coil types.
3Ease of manufacture
If a single coil is used in low cost actuators, then manufacturing cost is reduced, but stroke distance and force are limited
Solution Approach 1:
Instead of using one large expensive coil, the patent segments the magnetic circuit into multiple smaller coil sections arranged along the stroke path. Each segment contributes a portion of the total stroke, and their combined effect achieves the longer total stroke distance that would be impossible with a single coil of equivalent cost. This segmentation maintains cost-effectiveness while extending travel distance.
4Ease of manufacture
If a single coil is used in low cost actuators, then manufacturing cost is reduced, but force generation is limited
Solution Approach 1:
The patent merges the force output of multiple coil segments through the mechanical coupling of the plunger and guide assembly. While each individual coil segment generates modest force, their forces combine constructively when activated together or in sequence, producing total force output that exceeds what a single coil of equivalent manufacturing cost could achieve. The mechanical structure efficiently transmits and combines these forces.
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 design allows for cost-effective production and maintenance of linear actuators with adjustable stroke values and forces, reducing complexity and training needs while maintaining performance across different applications.
Implementation Method 1
a coil assembly that can be used in any number of coil configurations. For example, a coil assembly for a 6 coil actuator is the same as a coil assembly for a 3 coil actuator
Implementation Method 2
The linear guide assembly is configured to guide the piston in and out of the actuator housing according to a magnetic field whenever a current is driven through the coils of the coil assembly
Data Source
AI summary
Disclosed herein are methods and systems for low cost linear actuators that can deliver strokes and forces at different values. The embodiments presented herein have parts and components that may be usable for both multi-coil and single-coil actuator designs. According to one embodiment, a magnet housing may removably or permanently coupled to a coil assembly having any number of coils. According to a further embodiment, an actuator housing may be coupled to a magnet housing having any number of magnets or coils.