Printed-Coil Linear Actuator With Integrated PCB Control
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Solution Overview
Problem
Current moving coil linear motors are expensive due to costly components like wound coils, separate linear encoders, and expensive controllers, limiting their adoption over pneumatic actuators, despite offering higher performance and longer lifetimes.
Innovation Solution
A low-cost moving coil linear actuator design featuring a printed coil assembly on a multi-layer printed circuit board within a laser-cut magnet housing, integrating encoders and controllers, and using 'industrial Origami' designed laser parts to reduce production costs and cycle time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If moving coil linear motors are used, then cycle rate and lifetime are improved, but manufacturing cost increases significantly
Solution Approach 1:
The patent combines multiple separate components (coils, encoders, controllers) into a single integrated printed circuit board assembly. The PCB serves as both the structural support and the functional platform, with coils printed directly on the board and encoder magnets mounted on the same substrate, eliminating the need for separate housings and assemblies for each component.
Solution Approach 2:
The patent replaces traditional mechanical winding of coils with printed circuit board technology. Instead of manually or mechanically winding wire around bobbins, the coil windings are created through PCB manufacturing processes (copper trace deposition), which are more automated and cost-effective. The mechanical assembly processes are replaced with standardized PCB fabrication and mounting procedures.
2Duration of action of stationary object
If moving coil linear motors are used, then lifetime is improved, but manufacturing cost increases significantly
Solution Approach 1:
The patent combines multiple separate components (coils, encoders, controllers) into a single integrated printed circuit board assembly. The PCB serves as both the structural support and the functional platform, with coils printed directly on the board and encoder magnets mounted on the same substrate, eliminating the need for separate housings and assemblies for each component.
Solution Approach 2:
The patent uses standard, off-the-shelf components (PCB, magnets, encoders) that can be readily replaced if needed, rather than custom-machined parts. The PCB itself is a disposable, low-cost substrate that can be manufactured in high volumes at low cost, replacing the need for expensive custom-machined coil forms and encoder housings.
3Productivity
If traditional moving coil linear motors are used, then performance is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple separate components (coils, encoders, controllers) into a single integrated printed circuit board assembly. The PCB serves as both the structural support and the functional platform, with coils printed directly on the board and encoder magnets mounted on the same substrate, eliminating the need for separate housings and assemblies for each component.
Solution Approach 2:
The printed circuit board serves multiple functions simultaneously: it provides structural support for the moving assembly, carries the coil windings for electromagnetic actuation, mounts the encoder magnets for position sensing, and serves as the controller substrate. This multi-functionality reduces the overall number of components and simplifies the device architecture.
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 actuator to be manufactured cost-competitively with pneumatic devices while offering higher performance, with twice the cycle rate and up to ten times longer lifespan compared to pneumatic actuators.
Implementation Method 1
moving coil linear motors typically have higher cycle rates (>2000 CPM) and enjoy a longer lifetime (e.g., 100 M cycles or more) than pneumatic systems
Implementation Method 2
The printed coil assembly includes a plurality of printed coils where ones of the printed coils are positioned between the first plurality of magnets and the second plurality of magnets during operation of the linear actuator
Data Source
AI summary
A linear actuator includes a magnet housing having first and second planar sides, a front plate and a rear plate, and a base plate covering a channel defined by the magnet housing. A first plurality of magnets is secured to the first planar side and a second plurality of magnets is secured to the second planar side. A linear guide is slidably secured to an inner surface of the base plate. A piston assembly has a piston element attached to the linear guide. The piston assembly includes a shaft and a printed circuit board attached to the piston element. The printed circuit board defines a controller and a printed coil assembly. A flex cable is electrically connected to the printed circuit board. The piston assembly is disposed to move linearly during operation of the linear actuator.