PCB Coil Linear Actuator for Fast Steering Mirrors
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Solution Overview
Problem
Conventional voice coil actuators have limitations in terms of weight, profile, reliability, and performance, particularly in fast steering mirror applications, where improved efficiency and reduced assembly time are desired.
Innovation Solution
A printed circuit board (PCB) coil linear actuator design featuring a coil assembly with multiple, low-profile, oval-shaped coil layers connected in series and a magnet assembly with alternating magnet units, providing a modular, thermally conductive, and vibration-tolerant solution with simplified electromechanical interfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a conventional voice coil actuator with a coil wrapped around a slotted bobbin is used, then the actuator can provide basic linear motion, but the weight is high and the profile is large
Solution Approach 1:
The coil assembly is segmented into multiple individual PCB coils that can be independently mounted on the circuit board, replacing the single complex wound coil structure. This segmentation reduces overall weight while maintaining the necessary electromagnetic functionality through parallel or series configurations.
Solution Approach 2:
The traditional mechanical coil winding process is replaced with PCB-based coil structures that are manufactured through standard PCB fabrication processes. This substitution eliminates the need for complex bobbin structures and manual winding, significantly reducing weight and simplifying the overall assembly.
2Productivity
If a conventional voice coil actuator with manual coil winding is used, then the actuator can be assembled, but the assembly time is long and manufacturing reliability is reduced
Solution Approach 1:
Manual coil winding operations are completely replaced by automated PCB fabrication processes including trace deposition, lamination, and drilling. This substitution eliminates human error and variability in coil winding, ensuring consistent electrical properties and significantly reducing assembly time.
Solution Approach 2:
The manufacturing process parameters are changed from manual winding variables (tension, speed, consistency) to controlled PCB fabrication parameters (trace width, copper thickness, lamination pressure). These parameter changes enable automated manufacturing with higher precision and repeatability, improving both productivity and reliability.
3Temperature
If a conventional voice coil actuator with poor thermal management is used, then the actuator can operate, but thermal conductivity to the mounting base is insufficient
Solution Approach 1:
The PCB mounting board serves multiple functions simultaneously: it provides electrical connections through the coil traces, mechanical support for the coil structure, and a thermal conduction path to the mounting base. This multi-functionality eliminates the need for separate thermal management components and improves overall thermal conductivity.
Solution Approach 2:
The PCB board acts as an intermediary thermal conduction medium between the coil windings and the mounting base. The copper traces and PCB substrate materials provide a continuous thermal pathway that efficiently conducts heat away from the coil assembly to the heat sink or mounting base, reducing energy loss through improved thermal management.
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 PCB coil actuator offers enhanced reliability, reduced assembly time, improved thermal conductivity, high shock and vibration tolerance, and exceptional high-frequency performance, achieving superior efficiency and reduced power consumption compared to conventional voice coil actuators.
Implementation Method 1
A printed circuit board (PCB) coil linear actuator includes a coil assembly for attaching to a base side of a device, such as a fast steering mirror (FSM), and a magnet assembly for attaching to a moveable side of the device
Data Source
AI summary
A printed circuit board (PCB) coil linear actuator is disclosed. The actuator includes a coil assembly and a magnet assembly. The coil assembly includes a plurality of PCB coils electrically connected in series. The PCB coils arranged in a row and adjacent PCB coils are separated by a gap. Each PCB coil includes a low aspect ratio, multi-layer coil member disposed on a board member. The actuator assembly includes a plurality of magnet units arranged in a row, wherein adjacent magnet units are separated by a gap. When the actuator is assembled, the PCB coils arranged in alternating sequence with the magnet units. The PCB coil linear actuator is intended to replace traditional slotted bobbin voice coil actuators (VCAs) and is particularly useful in fast steering mirror (FSM) applications. The PCB coil linear actuator provides many advantages over a VCA of an equivalent motor constant, including improved performance, lower weight and a lower profile.