Segmented Linear Motor Core for High Propulsive Force
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Solution Overview
Problem
Conventional linear motors face issues with magnetic saturation limiting propulsive force and cogging fluctuations, which hinder high-accuracy positioning.
Innovation Solution
A linear motor design featuring core units with alternating magnetic poles and coils wound around them, forming magnetic circuits that sandwich the movable element, allowing for increased propulsive force and reduced cogging by canceling attractive forces and minimizing magnetic leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the core of the stator has a long magnetic circuit path, then the structure can accommodate the magnetic poles, but magnetic saturation occurs in the core limiting propulsive force
Solution Approach 1:
The stator core is divided into multiple core units, each with its own independent magnetic circuit path. This segmentation prevents magnetic saturation in any single core by distributing the magnetic flux across multiple shorter paths, thereby maintaining propulsive force without saturation limitations.
Solution Approach 2:
The patent introduces a dual-core configuration where magnetic circuits extend in multiple spatial dimensions. By arranging first and second cores with alternating polarities facing each other, the magnetic flux paths are optimized to reduce saturation while maintaining force generation.
2Force
If two stators are disposed above and below the movable element to counterbalance attractive forces, then the overall attractive force is reduced, but cogging or fluctuation in propulsive force occurs
Solution Approach 1:
The stator is segmented into multiple core units with alternating polarities arranged in a specific sequence. This segmentation allows the magnetic flux to be distributed evenly, reducing cogging and propulsive force fluctuations while maintaining counterbalanced attractive forces.
Solution Approach 2:
Different core units have different polarity arrangements (first core with N-S polarity, second core with S-N polarity) to create localized magnetic field variations that cancel out cogging effects while maintaining overall propulsive force stability.
3Force
If the magnetic circuit path is extended to accommodate more poles, then the motor can generate more force, but magnetic leakage increases causing noise
Solution Approach 1:
The magnetic circuit is divided into multiple independent core units, each containing its own magnetic flux path. This segmentation confines the magnetic flux within shorter, controlled paths, reducing magnetic leakage and associated noise while maintaining overall magnetic force generation.
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 enhances propulsive force, reduces cogging, and minimizes magnetic noise, enabling more precise positioning and stable operation.
Implementation Method 1
an interaction of a magnetic flux generated in the magnet and a magnetic flux generated in the core causes the movable element to move relative to the stator
Implementation Method 2
a magnetic flux that alternates up and down is generated in the space sandwiched between the upper magnetic pole teeth and the lower magnetic pole teeth
Implementation Method 3
the attractive force acting between the upper stator and the movable element can be counterbalanced by an attractive force acting between the lower stator and the movable element
Data Source
AI summary
Disclosed is a linear motor that can exert a high propulsive force and reduce cogging. A stator has a plurality of core units in a stroke direction. Each of the core units has a first core having a first magnetic pole and a second magnetic pole, which is different in polarity from the first magnetic pole, coils wound around the first core, a second core having a third magnetic pole and a fourth magnetic pole, which is different in polarity from the third magnetic pole, and coils wound around the second core. The third magnetic pole faces the first magnetic pole, and the fourth magnetic pole faces the second magnetic pole. A movable element is sandwiched between the first magnetic poles and the third magnetic poles, and between the second magnetic poles and the fourth magnetic poles.