Variable-Pitch Printed Coil Rollers for Lower-Cost Moving Coil Actuators
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Solution Overview
Problem
The widespread adoption of moving coil actuators is limited by their high cost compared to pneumatic cylinders and stepper-motor-based ball screw technologies, despite offering high force, long cycle life, and high repeatability.
Innovation Solution
A multi-layer, variable-pitch printed coil arrangement is used in electromagnetic actuators and brushless motors, featuring flexible dielectric materials with patterned conductive layers, allowing for concentric coil rollers with different pitches to be aligned axially, reducing material usage and manufacturing costs while maintaining high precision and force production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If traditional moving coil actuators use conventional coil structures, then high force and long cycle life are achieved, but manufacturing cost increases
Solution Approach 1:
The coil structure is divided into multiple discrete printed coil segments arranged in concentric rollers, each segment being independently manufacturable through printing processes. This segmentation allows for cost-effective production while maintaining the cumulative force output of multiple coil segments working together in the magnetic field.
Solution Approach 2:
Traditional mechanical wire-winding coil manufacturing is replaced with printed circuit board technology and conductive ink printing processes. This substitution enables automated, precise, and cost-effective coil fabrication with consistent electrical properties, eliminating labor-intensive manual winding operations.
2Loss of substance
If multi-layer concentric coil rollers with variable pitch are used, then material usage is reduced and cost decreases, but manufacturing precision requirements increase
Solution Approach 1:
Different radial layers of coil rollers employ different pitch values optimized for their specific position and function. Inner rollers may use tighter spacing while outer rollers use wider spacing, allowing each layer to use minimal material while maintaining electromagnetic performance. This local optimization reduces overall material consumption.
Solution Approach 2:
The coil pitch parameter is varied across different radial layers and angular positions to optimize material usage. By changing the pitch parameter locally rather than using a uniform pitch throughout, the design achieves material efficiency while the printed circuit manufacturing process maintains the required precision through automated deposition control.
3Force
If variable-pitch printed coils are used, then force production increases, but device complexity increases
Solution Approach 1:
Multiple coil segments with different pitch characteristics are merged into a unified multi-layer roller assembly that functions as a single electromagnetic component. The printed circuit board technology integrates the variable-pitch coils with the roller structure itself, eliminating the need for separate mounting hardware and simplifying the overall device architecture.
Solution Approach 2:
The printed coil structure serves multiple functions simultaneously: it provides the electromagnetic winding, defines the mechanical roller geometry, establishes the variable pitch pattern, and integrates the electrical connection paths. This multi-functionality reduces the number of separate components needed and simplifies manufacturing.
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 creation of low-mass, high-precision actuators and motors with increased force production at a lower cost, facilitating greater acceleration and reduced tolerances, thus overcoming the cost limitations of traditional moving coil actuators.
Implementation Method 1
Passing current through the coil generates transverse motion of the coil and an output shaft or shuttle to which the coil is coupled. The force of that output is proportional to the number of coils turns and the magnetic flux within the actuator as well as to the current.
Implementation Method 2
Passing current through the coil generates transverse motion of the coil... The force of that output is proportional to the number of coils turns and the magnetic flux within the actuator as well as to the current.
Data Source
AI summary
A printed coil assembly including a flexible dielectric material, a patterned top conductive layer formed on a top surface of the flexible dielectric material, and a patterned bottom conductive layer formed on a bottom surface of the flexible dielectric material. The patterned top conductive layer and the patterned bottom conductive layer form a plurality of printed coils arranged in a plurality of printed coil rollers concentrically arranged in a cylindrical shape. Each of the plurality of printed coils includes a top layer printed coil disposed within the patterned top conductive layer and a bottom layer printed coil disposed within the patterned bottom conductive layer. Coil pitches of the coils within each roller are chosen such that corresponding ones of the plurality of printed coils in adjacent rollers are axially aligned relative to a center of the cylindrical shape.