CN109217518B

CN109217518B - Linear motor and stator thereof

Info

Publication number: CN109217518B
Application number: CN201710547578.2A
Authority: CN
Inventors: 池峰
Original assignee: Shanghai Heli Intelligent Technology Co ltd
Current assignee: Guoli Zhizao Shanghai Technology Co ltd
Priority date: 2017-07-06
Filing date: 2017-07-06
Publication date: 2021-07-27
Anticipated expiration: 2037-07-06
Also published as: WO2019007201A1; CN109217518A

Abstract

The application discloses a linear motor and a stator module thereof. The stator module comprises a base body and a stator coil assembly fixed on the base body. The stator coil assembly comprises at least two layers of coil units which are mutually stacked and arranged, and the adjacent two layers of coil units comprise a plurality of armature winding units. Each armature winding unit is provided with three coil windings which are respectively a U phase, a V phase and a W phase of the armature winding unit, wherein the U phase and the W phase of the armature winding unit are adjacently arranged on the same layer, the V phase is arranged on the upper layer or the lower layer of the U phase and the W phase and is aligned with the centers of the U phase and the W phase, and in the adjacent two layers of coil units, if the V phase of one armature winding unit of the adjacent two armature winding units is arranged on the upper layer of the U phase and the W phase of the armature winding unit, the V phase of the armature winding unit of the other armature winding unit is arranged on the lower layer of the U phase and the W phase of the armature winding unit. The stator module of this application can not produce the tooth's socket power, and control accuracy is high.

Description

Linear motor and stator thereof

Technical Field

The present invention relates to linear motors, and in particular to stators for linear motors.

Background

With the development of manufacturing technology towards high yield and high precision, the research of precision motion control technology becomes more and more important, and accordingly, the demand of motion positioning control systems is also more and more large, so that the precision motion positioning control system is widely applied to industries such as automatic production lines, packaging and transportation, assembly automation, screen printing and the like, and higher speed and processing flexibility are provided. The traditional driving system adopts a rotary motor driving structure, and gear heads, shafts, keys, chain wheels, chains, belts and other parts commonly used for transmission of the traditional rotary motor in the transmission system are very complex and heavy. Linear motors employ a moving magnetic field to directly drive moving parts, reducing structural complexity and also reducing costs and speed gains due to reduced inertia, compliance, damping, friction and wear.

The linear motor is a core actuator component of the motion positioning control system, and under the action of support limitation and electromagnetic thrust, a motor rotor can drive a load to generate high-speed and high-thrust drive, a plurality of linear motors can be combined to construct two-dimensional or multidimensional motion, and a precise linear transmission device and a precise XY workbench can be designed and constructed by adopting the linear motors.

However, the stator of the current linear motor may generate Cogging force jamming influence, which may result in a decrease in the accuracy of the servo motion positioning control. At the same time, the length of the stator is difficult to set as desired.

Disclosure of Invention

The invention aims to provide a linear motor stator which is free from the influence of tooth groove force and high in servo motion positioning precision.

In order to achieve the above object, according to a first aspect of the present invention, there is provided a stator module of a linear motor, the stator module including a base and a stator coil assembly fixed to the base, the stator coil assembly including at least two layers of coil units arranged one on another, adjacent two layers of the coil units including a plurality of armature winding units, each of the armature winding units having three coil windings, the three coil windings being a U-phase, a V-phase and a W-phase of the armature winding unit, respectively, wherein the U-phase and the W-phase of the armature winding unit are adjacently arranged in the same layer, the V-phase is arranged in a layer above or below the U-phase and the W-phase and is aligned with centers of the U-phase and the W-phase, and if the V-phase of one of the adjacent two armature winding units is arranged in an upper layer of the U-phase and the W-phase of the armature winding unit, the V-phase of the armature winding unit of the other armature winding unit is lower than the U-phase and the W-phase of the armature winding unit.

In one embodiment, each coil winding is formed by stacking a plurality of layers of coils, wherein the connecting interfaces of the coils among the layers are vertically interconnected, so that the coils of the layers are connected in series.

In one embodiment, the coil is rectangular and the stator coil assembly is rectangular; alternatively, the coil is in the shape of a sector ring and the stator coil assembly is in the shape of a sector ring.

In one embodiment, the stator coil assembly is manufactured by a printed circuit board process.

In one embodiment, the coil windings are provided with connecting terminals, and adjacent coil windings are connected according to a UVW three-phase connection mode, a delta connection mode or a star connection mode.

In one embodiment, the armature winding units are periodically and repeatedly arranged along one direction.

In one embodiment, the coil winding is a coreless coil winding.

In one embodiment, the base includes a stator base, wherein the stator coil assembly is mounted to the stator base.

According to the second aspect of the present invention, there is also provided a stator of a linear motor, the stator being formed by sequentially splicing a plurality of stator modules as described above.

In one embodiment, the stator includes a stator coil assembly having an annular shape and a stator coil assembly having a rectangular parallelepiped shape, which are connected in series.

According to a third aspect of the present invention, there is also provided a linear motor, including a mover and a stator, the stator being the stator described above, and the linear motor including a plurality of movers, each of the movers being provided to be independently movable relative to the stator and provided with a permanent magnet array.

In one embodiment, the mover includes two upper and lower permanent magnet arrays, wherein the stator coil assembly is located between the two permanent magnet arrays.

Compared with the prior art, the invention has the following progressive effects:

1) the coil winding is not provided with an iron core component made of soft magnetic materials, so that Cogging force coupling influence cannot be generated, and high-precision servo motion positioning control can be provided;

2) the coil stacking layout method can compensate the winding gaps by wiring, realizes no cogging force fluctuation, keeps stable thrust ratio, and has very standard thrust linearity and good consistency.

3) The stator module of the invention realizes the standardized module application of the linear motor, can realize the free splicing and expansion among a plurality of coil stators, can meet the application requirements of clients on any length, and can simultaneously operate a plurality of rotors on the coil stators.

Drawings

Fig. 1 is a schematic structural diagram of a linear motor linear segment according to an embodiment of the present invention.

Fig. 2 is a schematic view of a linear motor according to an embodiment of the present invention, wherein the linear motor has a linear section and an arc section.

Fig. 3 is a schematic structural view of a stator coil according to an embodiment of the present invention.

Fig. 4 is a schematic structural view of a linear motor mover according to an embodiment of the present invention.

Fig. 5 is a magnet array distribution of a linear motor mover according to an embodiment of the present invention.

Fig. 6 is a magnet array distribution of a linear motor mover according to another embodiment of the present invention.

Fig. 7 is a schematic structural diagram of a linear motor module according to an embodiment of the present invention.

Fig. 8 is a schematic structural view of a linear motor module according to another embodiment of the present invention.

Fig. 9 is a schematic structural view of a transfer system of a linear motor using the linear motor module of the present invention.

Fig. 10 is an example thrust constant effect curve of the linear motor of the present invention.

Detailed Description

The preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings so that the objects, features and advantages of the invention can be more clearly understood. It should be understood that the embodiments shown in the drawings are not intended to limit the scope of the present invention, but are merely intended to illustrate the spirit of the technical solution of the present invention.

In the following description, for the purposes of illustrating various disclosed embodiments, certain specific details are set forth in order to provide a thorough understanding of the various disclosed embodiments. One skilled in the relevant art will recognize, however, that the embodiments may be practiced without one or more of the specific details. In other instances, well-known devices, structures and techniques associated with linear motors may not be shown or described in detail to avoid unnecessarily obscuring the description of the embodiments.

Throughout the specification and claims, the word "comprise" and variations thereof, such as "comprises" and "comprising," are to be understood as an open, inclusive meaning, i.e., as being interpreted to mean "including, but not limited to," unless the context requires otherwise.

Reference throughout this specification to "one embodiment" or "an embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, the appearances of the phrases "in one embodiment" or "in an embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.

As used in this specification and the appended claims, the singular forms "a", "an", and "the" include plural referents unless the context clearly dictates otherwise. It should be noted that the term "or" is generally employed in its sense including "and/or" unless the context clearly dictates otherwise.

In the following description, for the purposes of clearly illustrating the structure and operation of the present invention, directional terms will be used, but terms such as "front", "rear", "left", "right", "outer", "inner", "outer", "inward", "upper", "lower", etc. should be construed as words of convenience and should not be construed as limiting terms.

Further, the term "D1 direction" used in the following description mainly refers to a direction parallel to the horizontal direction; the term "D2 direction" refers primarily to a direction parallel to the horizontal direction and perpendicular to the D1 direction; the term "first direction" or "first axis" refers primarily to a direction or axis parallel to the horizontal direction; the term "second direction" or "second axis" refers primarily to a direction or axis parallel to the horizontal direction and perpendicular to the first direction; the term "third direction" or "third axis" refers primarily to a direction or coordinate perpendicular to the horizontal direction.

Fig. 1 shows a schematic structural diagram of a linear motor linear segment according to an embodiment of the present invention. As shown in fig. 1, the linear motor straight line segment includes two

movers

211, 212 and a stator 200. The stator 200 is formed by a printed circuit board fixed to the stator base 101, wherein 213 are positioning and mounting holes for screwing and fixing the stator 200. On the printed circuit board 200, the stator coil assembly is formed by alternately stacking rectangular coil windings.

The stator coil assembly includes a plurality of armature winding units, wherein the

coil windings

209a, 209b, 209c are U, V, W three-phase coils of one armature winding unit, respectively, and the

coil windings

210a, 210b, 210c are U, V, W three-phase coils of another armature winding unit, respectively. The coils of the

coil windings

209b, 210a and 210c are adjacently arranged on the same layer, and the

coils

209a, 209c and 210b are adjacently arranged on the same layer, namely, the coils corresponding to the V phase are arranged on the upper layer or the lower layer of the U phase and the W phase and are aligned with the centers of the U phase and the W phase. When the U-phase coil and the W-phase coil are adjacently arranged on the upper layer, the V-phase coil is arranged on the lower layer of the U-phase coil and the W-phase coil and is aligned with the geometric centers of the U-phase coil and the W-phase coil. U, V, W three-phase coils constitute basic armature winding units, which are repeatedly arranged along the transverse cycle, 1 group, 2 groups, 3 groups, … … basic units, and so on, and the number of groups of armature winding units is constructed according to the stroke requirement of the linear motor. Each stator coil winding is provided with a wiring terminal, and adjacent wiring terminals are connected in a UVW three-phase connection mode, a triangular connection mode or a star connection mode. Each of the

coil windings

209a, 209b, 209c, 210a, 210b, 210c is manufactured by a multilayer coil lamination process, and the connection interfaces of the coils between the layers are vertically interconnected, so that each layer of the coils are connected in series to form one winding.

The armature winding unit can be periodically extended and can be integrally manufactured, the coil winding can be manufactured according to modules with standard lengths, and the stator modules can be assembled and spliced aiming at long-stroke application. In addition, the stator coil assembly can be applied in a splicing mode of being stacked up and down, and larger thrust can be provided. In particular, the coil assembly may be adapted for manufacture by a printed circuit board process. Moreover, the air gap of each coil of the stator coil assembly is very small and uniform, so that the thrust ripple of the linear motor is very small, the influence of the cogging force is small, and the linear motor is particularly suitable for high-precision control application scenarios. Fig. 10 shows an example of a thrust constant effect curve of the linear motor of the present invention. The data in the figure shows that the fluctuation of the thrust constant in the technology is less than 5%, which is far lower than the thrust fluctuation of the conventional iron core linear motor, or even better than the conventional iron core-free linear motor.

As shown in fig. 1, the

permanent magnet arrays

211 and 212 of the rotor units are permanent magnet arrays of two rotors, each array is composed of a group of NS arrays or Halbach arrays arranged periodically, and the width of the permanent magnet array unit is W_mThe distance from the center of the N pole to the center of the adjacent S pole is recorded as tau, and the length of the permanent magnet array is recorded as W_mThe width of the array. The width of 2 tau from the N pole to the center of the N pole is taken as a basic unit, the basic units are distributed along the first axis X direction and are repeatedly arranged, 1 basic unit and 2 groups of basic units … … are arranged, and the like, and the number of groups of the rotor magnet array is constructed according to the thrust requirement of the linear motor. The main scaling relationship between the magnet array and the coil windings is as follows:

W_m＝n_m·τ

wherein, W_mThe width of the rotor permanent magnet array is p, the width of each coil on the center line of a pitch circle is p, the angle range corresponding to each coil based on the width of the pitch circle is alpha, and R is the radius of the pitch circle. τ is the pole pitch of the magnet, defined as the distance from the center of the S pole to the center of the N pole, N_cIs the number of coil windings, n_mThe number of pole pairs of the magnet.

When a plurality of movers run above the stator coils, corresponding coil windings of the permanent magnet coverage area of each mover are electrified and excited to generate horizontal thrust. The linear transmission control system judges the stator coil area covered by the next operation to be moved in advance through the actual position information of each mover measured by the position sensor, and the coils are electrified in advance in the area to be operated by the mover.

Fig. 2 shows a schematic structural diagram of a linear motor with straight and arc segments (180 °) joined according to an embodiment of the present invention. As shown in fig. 2, the linear motor stator 300 includes a stator base 301, arc-shaped stator coils 302, 303, and straight-line segment stator coils 307 and 308. The straight stator coils 307 and 308 are connected to the arc stator coils 302 and 303 with a constant radius (180 °) arc, respectively, and they are joined to form a seamless interface.

The stator 300 is formed by a printed circuit board fixed to a stator base 301, wherein the stator coils 302, 303 of the arc-shaped segments are fan-shaped and have a constant center radius R. Stator coils 302 and 303 are fixed to stator base 301 with screws. The

stator coil arrays

302, 303 are formed by alternately stacking and arranging the coil windings having fan-shaped rings, the center of each coil is arranged according to a pitch circle line 309 with a constant radius, the width of each coil at the pitch circle center line is p, the width is based on the angle of the pitch circle is alpha, and the conversion relation between the pitch circle center line, the magnet pole pitch tau and the radius R of the pitch circle line 309 is as follows:

p＝R·α

wherein p is the width of each coil on the pitch circle center line, alpha is the angle range corresponding to each coil based on the pitch circle width, and R is the pitch circle radius. τ is the pole pitch of the magnet, defined as the distance from the center of the S pole to the center of the N pole, N_cIs the number of coil windings, n_mThe number of pole pairs of the magnet.

The

coil windings

304a, 304b, 304c are U, V, W three-phase coils of one set of armature winding units, respectively, and the

coil windings

305a, 305b, 305c are U, V, W three-phase coils of another set of armature winding units, respectively. The

coils

304a, 304b and 304c are adjacently arranged in the same layer, and the

coils

305a, 305b and 305c are adjacently arranged in the same layer, namely, the coils corresponding to the V phase are arranged on the upper layer or the lower layer of the U phase and the W phase and are aligned with the centers of the U phase and the W phase. The U-phase coil and the W-phase coil are adjacently arranged on the same layer, and the V-phase coil is arranged on the upper layer or the lower layer of the U-phase coil and the W-phase coil and is aligned with the geometric centers of the U-phase coil and the W-phase coil. When the U-phase coil and the W-phase coil are adjacently arranged on the upper layer, the V-phase coil is arranged on the lower layer of the U-phase coil and the W-phase coil and is aligned with the geometric centers of the U-phase coil and the W-phase coil. The U, V, W three-phase coils form basic armature winding units, the stator coil assemblies are repeatedly arranged along the transverse cycle, 1 group, 2 groups, 3 groups, … … basic units, and the like, and the number of groups of the coil units is constructed according to the stroke requirement of the linear motor. Each of the

coil windings

304a, 304b, 304c, 305a, 305b, 305c is manufactured by laminating a plurality of layers of coils, and is connected according to a UVW three-phase connection mode, a triangle connection mode or a star connection mode.

The stator coil assembly of the linear motor with the constant radius arc (180 degrees) can be periodically extended and can be integrally manufactured. The stator coil assembly can also be assembled according to two groups of modules with standard 90-degree arc lengths, or a plurality of stator coil assemblies, and the stator module can be assembled and spliced aiming at long-stroke application. In addition, the stator coil assembly can be applied in a splicing mode of being stacked up and down, and larger thrust can be provided. In particular, the stator coil assembly may be adapted to be manufactured by a printed circuit board process. Moreover, the air gap of each coil of the stator coil assembly is very small and uniform, so that the thrust ripple of the linear motor is very small, the influence of the cogging force is small, and the linear motor is particularly suitable for high-precision control application scenarios. The fluctuation of the thrust constant of the linear motor provided by the invention is far lower than that of the conventional iron core linear motor, or even superior to that of the conventional iron core-free linear motor.

Fig. 3 shows a schematic structural diagram of a stator coil according to an embodiment of the present invention. As shown in fig. 3, the stator coil assembly is composed of a plurality of layers of coils, including 501, 502, 503, 504, …, 508, ….

Coil windings

511, 512 and 513 in the layers where 501 and 502 are located are U, V, W three-phase coils of the armature winding unit respectively. The U-phase coil and the W-phase coil are adjacently arranged on the same layer, and the V-phase coil is arranged on the upper layer or the lower layer of the U-phase coil and the W-phase coil and is aligned with the centers of the U-phase coil and the W-phase coil. When the U-phase coil and the W-phase coil are adjacently arranged on the upper layer, the V-phase coil is arranged on the lower layer of the U-phase coil and the W-phase coil and is aligned with the centers of the U-phase coil and the W-phase coil. U, V, W three-phase coil constitutes basic armature winding units, which are arranged repeatedly along the first axis direction X, 1 group, 2 groups, 3 groups, … … basic units, and so on, and the number of groups of armature winding units is constructed according to the stroke requirement of the linear motor. Similarly, the coil windings in the

layers

503 and 504 are constructed by the same method, and the armature winding units are arranged repeatedly in the first axis direction X in a periodic manner, 1 group, 2 groups, 3 groups, … …, basic units, and so on, and the number of groups of the armature winding units is constructed according to the stroke requirement of the linear motor. By analogy, the processes of 505, 506, 507, 508 and … repeated above are combined layer by layer in an overlapping way, and can be constructed by any number of layers.

The armature winding unit can be subjected to periodic extension and can be integrally manufactured. The winding coils can be manufactured in modules of standard length, assembled and spliced stator modules for long-stroke applications. In addition, the armature winding unit can be applied in a splicing mode of being stacked up and down, and larger thrust can be provided. In particular, the coil assembly may be adapted for manufacture by a printed circuit board process.

Fig. 4 is a schematic structural view of a linear motor mover according to an embodiment of the present invention. As shown in fig. 4, the linear motor mover includes a base 100, a first permanent magnet array 130a, a second permanent magnet array 130b, a first back iron 131a, a second back iron 131b, a first auxiliary support plate 132a, a second auxiliary support plate 132b, a back iron support plate 129, a guide rail guide roller 121, a slide 122, and an anti-collision block 111. The first subsidiary support plate 132a is installed at an upper side of the base 100. The second subsidiary support plate 132b is placed spaced apart from the first subsidiary support plate 132 a. The first back iron 131a is mounted on the first subsidiary support plate 132 a. The second back iron 131b is mounted to the second subsidiary support plate 132b and spaced apart from the first back iron 131 a. The back iron support plate 129 is disposed between the first back iron 131a and the second back iron 131b and forms a U-shaped structure together with the first back iron and the second back iron. The first permanent magnet array 130a of the linear motor is adhered to the first back iron 131 a. The second permanent magnet array 130b of the linear motor is bonded to the first back iron 131 b. The first permanent magnet array 130a and the second permanent magnet array 130b form a bilateral permanent magnet U-shaped mover in a face-to-face manner. A slider 122 is mounted to the underside of the base 100. A set of guide rollers 121 is mounted on the underside of the carriage 122.

Crash blocks 111 are installed at both ends of the base 100. The anti-collision block 111 is made of soft materials such as polyurethane, when a plurality of rotors run on the same closed motion track and accidental collision occurs, the anti-collision block firstly deforms to absorb impact energy, impact force is relieved, and safety of materials on the rotors or the rotors is protected.

The mover may also be provided with a detection element such as a straight section grating 125 or an arc section grating 126. The linear magnetic grating or grating 125 is mounted on the guide surface of the base 100 and can be measured by an encoder array mounted on the linear section. The arc-shaped section magnetic grid or optical grating 126 is installed on the lateral side of the base 100, has a curved arc shape consistent with the guide rail, and can be detected and measured by an encoder array installed on the arc-shaped section. The straight line segment ruler and the arc segment ruler do not interfere with the encoder in motion.

When the linear motor works, the permanent magnet array of the rotor generates driving force under the current excitation of the coil stator to push the whole rotor to move along the guide rail through the guide rail guide roller 121. The guide roller 121 may move along a linear guide or an arc guide. The detection element may detect a movement position of the mover.

Fig. 5 is a magnet array distribution of a linear motor mover according to an embodiment of the present invention. As shown in fig. 5, the first permanent magnet array 131a and the second permanent magnet array 131b are 2 sets of permanent magnet arrays facing each other, and include a first permanent magnet, a second permanent magnet, and a third permanent magnet, wherein the first and second permanent magnets are main magnets, and the third permanent magnet is an auxiliary magnet. The first

permanent magnets

413a, 413b, 417a, 417b, 421a, 421b have magnetization directions directed from the S pole to the N pole, i.e., in the positive direction of the Z axis along the third coordinate axis. The magnetization direction of the second

permanent magnets

415a, 415b, 419a, 419b, 423a, 423b is directed from the S pole to the N pole, i.e., in the negative Z-axis direction along the third coordinate axis.

The third

permanent magnets

412a, 412b, 414a, 414b, 416a, 416b, 418a, 418b, 420a, 420b, 422a, 422b, 424a, 424b are auxiliary magnets, and the magnetization direction thereof is along the first coordinate axis X direction.

The third

permanent magnets

412a, 414a have magnetization directions directed in the first coordinate axis in the direction of the first

permanent magnet

413a, 412a in the positive direction of the X-axis, and 414a in the negative direction of the X-axis.

The third

permanent magnet

414a, 416a has a magnetization direction pointing away from the second permanent magnet 415a along the first coordinate axis, and the magnetization direction of 416a points in the positive direction of the X-axis.

The third

permanent magnets

416a, 418a have magnetization directions directed in the direction of the first permanent magnet 417a along the first coordinate axis, and the magnetization direction of the third permanent magnet 418a is directed in the negative direction of the X axis.

The third

permanent magnets

418a, 420a have magnetization directions pointing away from the second permanent magnet 419a along the first coordinate axis, and the magnetization direction of 420a points in the positive direction of the X-axis.

The third

permanent magnets

418a, 420a have magnetization directions pointing away from the first permanent magnet 419a along the first coordinate axis, and the magnetization direction of 420a points in the positive direction of the X-axis.

The third

permanent magnets

420a, 422a have magnetization directions directed in the direction of the second permanent magnet 421a along the first coordinate axis, and the 422a magnetization direction is directed in the negative direction of the X axis.

Third

permanent magnet

422a, 424a has a magnetization direction pointing away from first permanent magnet 423a along the first coordinate axis, and 424a has a magnetization direction pointing in the positive direction of the X-axis.

The third

permanent magnets

412b, 414b have magnetization directions pointing away from the first permanent magnet 413b along the first coordinate axis, the magnetization direction of 412b pointing in the positive direction of the X-axis, and the magnetization direction of 414b pointing in the negative direction of the X-axis.

The third

permanent magnets

414b, 416b have magnetization directions directed in the direction of the second permanent magnet 415b along the first coordinate axis, and 416b have magnetization directions directed in the negative direction of the X-axis.

The third

permanent magnets

416b, 418b have magnetization directions directed away from the first permanent magnet 417b along the first coordinate axis, and the magnetization direction of the third permanent magnet 418b is directed in the positive direction of the X-axis.

The third

permanent magnets

418b, 420b have magnetization directions directed in the direction of the second permanent magnet 419b along the first coordinate axis, and the magnetization direction of 420b is directed in the negative direction of the X axis.

The third

permanent magnets

420b, 422b have magnetization directions directed away from the second permanent magnet 421b along the first coordinate axis, and the 422b magnetization direction is directed in the positive direction of the X-axis.

Third

permanent magnets

422b, 424b have magnetization directions pointing in the direction of first permanent magnet 423b along the first coordinate axis, and 424b have magnetization directions pointing in the negative direction of the X-axis.

The first, second and third permanent magnets are typically combined into a Halbach array unit by using prism-shaped magnet blocks, and they jointly form a permanent magnet array with a symmetrical layout of a rotor. Halbach array element width W_mThe distance from the N pole to the center of the adjacent S pole permanent magnet is recorded as tau, and the length of the permanent magnet array is recorded as W_mThe width of the array. The first, second and third permanent magnets construct a Halbach magnet group with a complete cycle, the Halbach magnet group is distributed along the X direction of the first shaft in a cycle repeated arrangement mode, 1 Halbach basic unit, 2 Halbach basic units … … are arranged, and by analogy, the number of groups of the rotor magnet array is constructed according to the thrust requirement of the linear motor.

The first back iron 403 and the second back iron 402 are made of a material with high magnetic permeability, such as steel, iron, and the like. The magnetic flux of the Halbach basic unit in the direction of the back iron is used for constructing a magnetic line of force loop, so that the magnetic leakage is reduced. The Halbach basic unit has the characteristic of single-side flux density, the flux density distribution of the coil-facing side of the Halbach basic unit is higher than that of a traditional NS array, and the flux density of the back iron-facing side is very weak, so that the thickness of the back iron can be thinner than that of the back iron of the traditional NS array. And the weight of the rotor unit can be reduced by using a low-density high-strength material as an auxiliary support. To reduce local magnetic leakage, the thickness of the back iron is kept at least 1 mm. In order to reduce the influence of the edge leakage flux, the width of the third

permanent magnets

412a, 412b, 424a, 424b along the third axis X is half the width of the

permanent magnets

414a, 414 b. The width of the first and second permanent magnets along the X direction is 0.5-0.9 times of tau. The first auxiliary support plate 401 and the second auxiliary support plate 404 are auxiliary support members made of a low-density high-rigidity material, and are used for enhancing the support rigidity of the back iron.

Fig. 6 is a magnet array distribution of a linear motor mover according to another embodiment of the present invention. As shown in fig. 6, the magnet array unit of the mover is composed of 2 sets of base units of the NS permanent magnet array facing each other and a yoke, and the first

permanent magnets

512a, 512b, 514a, 514b, 516a, 516b in the center of the base units have their magnetization directions directed from the S pole to the N pole, i.e., directed in the positive direction of the Z axis along the third coordinate axis; the magnetization direction of the second

permanent magnet

513a, 513b, 515a, 515b, 517a, 517b in the center of the basic unit is directed from the S pole to the N pole, i.e., in the negative direction of the Z axis along the third coordinate axis.

The first and second permanent magnets are typically combined into an NS base unit using prismatic magnet blocks, which together form a symmetrically arranged permanent magnet array of mover units. The width of the NS permanent magnet array unit is W_mAnd the distance from the N pole to the center of the adjacent S pole permanent magnet is recorded as tau. The first permanent magnet and the second permanent magnet construct NS magnet groups of a complete cycle, the NS magnet groups are distributed along the first axis direction X and are repeatedly arranged periodically, 1 NS basic unit, 2 groups of NS basic units … … are arranged, and the like, and the number of groups of the rotor magnet array is constructed according to the thrust requirement of the linear motor.

The back irons 601 and 602 are soft magnetic materials, such as cobalt iron alloy, iron nickel alloy, silicon steel, iron aluminum silicon alloy and the like, and the soft magnetic materials refer to IEC60404-1 standard, and form magnetic line loops by the magnetic flux of the NS basic unit in the direction of the back iron. The NS basic unit has bidirectional magnetic density characteristics, according to the requirement of electromagnetic thrust, the higher the magnetic density intensity distribution of the coil facing side is required to be, the better the magnetic density of the back iron facing side is required to be, the smaller the magnetic density is required to be, the better the back iron thickness is, therefore, the back iron thickness is enough to reduce the magnetic leakage, and the thickness is kept to be at least 5 mm. In addition, the width of the first and second permanent magnets along the X direction is 0.5-1 times of τ.

Fig. 7 is a schematic structural diagram of a linear motor module according to an embodiment of the present invention. As shown in fig. 7, the linear motor module includes a mover and a stator module. The mover module may employ a mover structure as shown in fig. 4 to 5. The stator module comprises a base body and a stator coil assembly fixed on the base body, wherein the stator coil assembly comprises at least two layers of coil units which are mutually overlapped and arranged. The coil unit may be made of a coreless coil through a printed circuit board process. The stator coil assembly is operatively disposed between the first permanent magnet array and the second permanent magnet array.

The adjacent two layers of coil units contain a plurality of armature winding units each having three

coil windings

401a, 401b, 401 c. The three

coil windings

401a, 401b, 401c are respectively U-phase, V-phase and W-phase of the armature winding unit, wherein the U-phase and W-phase of each armature winding unit are adjacently arranged in the same layer, and the V-phase is arranged on the upper layer or the lower layer of the U-phase and W-phase and aligned with the centers of the U-phase and W-phase. In the adjacent two layers of coil units, if the V phase of one armature winding unit in the two adjacent armature winding units is on the upper layer of the U phase and the W phase of the armature winding unit, the V phase of the armature winding unit of the other armature winding unit is on the lower layer of the U phase and the W phase of the armature winding unit.

U, V, W three-phase coils form basic armature winding units which are repeatedly arranged along the first axis direction X periodically, 1 group, 2 groups, 3 groups, … … groups, the basic units and so on, and the number of groups of the armature winding units is constructed according to the stroke requirement of the linear motor.

Fig. 8 is a schematic structural view of a linear motor module according to another embodiment of the present invention. As shown in fig. 8, the linear motor module includes a magnet mover and a stator coil unit. The mover is composed of 2 sets of basic units of the permanent magnet array facing each other and a magnetic yoke, the first permanent magnet 430a, 430b in the center of the basic unit has the magnetization direction pointing from the S pole to the N pole, i.e. pointing to the positive direction of the Z axis along the third coordinate axis; the magnetization direction of the second permanent magnets 431a, 431b at the center of the basic unit is directed from the S pole to the N pole, i.e., in the negative direction of the Z axis along the third coordinate axis.

The first and second permanent magnets are typically combined into an NS base unit using prismatic magnet blocks, which together form a symmetrically arranged permanent magnet array of mover units. Width of NS element is W_mThe half period length is denoted as τ. The first magnet and the second magnet construct NS magnet groups of a complete period, the NS magnet groups are distributed along the first axis direction X and are arranged repeatedly in a periodic mode, 1 NS basic unit, 2 groups of NS basic units … … are arranged, and the like, and the number of groups of the rotor magnet arrays is constructed according to the thrust requirement of the linear motor.

The NS basic unit has bidirectional magnetic density characteristics, according to the requirement of electromagnetic thrust, the magnetic density intensity distribution of the coil facing side of the NS basic unit needs to be higher and better, and the magnetic density of the back iron facing side needs to be smaller and better, so that the back iron thickness can have enough thickness to reduce magnetic leakage, and the thickness of the back iron can be kept at least 5 mm. In addition, the width of the first and second permanent magnets along the X direction is 0.5-1 times of tau.

Fig. 9 is a schematic structural view of a transfer system of a linear motor using the linear motor module of the present invention. As shown in fig. 9, the transmission system includes a plurality of movers 108, two-stage linear stator coil module stator modules 104 and two-stage constant radius arc motor stator modules 106, a magnetic grid or grating 110, a magnetic grid or grating encoder array 109, a guide rail unit 103, a fixed mount 102, and a stator base 101. The mover 108 is mounted on a stator module of the linear motor, and is moved in translation along the guide direction by the roller guide 103. Each mover 108 is independently movable relative to all other movers. The mover 108 includes a permanent magnet array and is mounted on the inner surface of the mover yoke. The linear and arcuate motor stator modules formed by

stator modules

104, 106 are attached to the stationary frame 102. The fixing bracket 102 is mounted on the stator base 101. The roller guide 103 is fixed on the stator base 101 by fastening screws. A magnetic grating or grating encoder array 109 is mounted on the fixed support 102. The signals of the encoder array 109 are used for position measurement of the mover. The

stator modules

104 and 106 are energized with exciting currents, so that the designated coils are activated and energized and excited, and excitation magnetic fields generated by the coils interact with permanent magnetic fields generated by the permanent magnetic arrays of the rotor unit 108 to form thrust, so that the rotor unit 108 moves in a translation manner along the guide rail. In an embodiment, the

stator modules

104, 106 and the movers 108 independently control the movement of each mover 108 along the roller guide 103 as a combined function of the motion control system.

While the preferred embodiments of the present invention have been described in detail above, it should be understood that aspects of the embodiments can be modified, if necessary, to employ aspects, features and concepts of the various patents, applications and publications to provide yet further embodiments.

These and other changes can be made to the embodiments in light of the above detailed description. In general, in the claims, the terms used should not be construed to be limited to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled.

Claims

1. A stator module for a linear motor, comprising a base and a stator coil assembly fixed to the base, the stator coil assembly comprising at least two layers of coil units arranged one on top of the other, two adjacent layers of the coil units comprising a plurality of armature winding units, each armature winding unit having three coil windings, the three coil windings being a U-phase, a V-phase and a W-phase of the armature winding unit, respectively, wherein the U-phase and the W-phase of the armature winding unit are adjacently arranged in the same layer, the V-phase is arranged on the upper layer or the lower layer of the U-phase and the W-phase, and aligned with the centers of the U-phase and the W-phase, and, in the adjacent two layers of the coil units, if the V-phase of one of the adjacent two armature winding units is on the upper layer of the U-phase and the W-phase of the armature winding unit, the V-phase of the other armature winding unit is on the lower layer of the U-phase and the W-phase of the armature winding unit, wherein the coil unit is made of a coreless coil by a printed circuit board process.

2. The stator module of claim 1, wherein each coil winding is constructed by stacking a plurality of layers of coils, wherein the connection interfaces of the coils between the layers are vertically interconnected such that the coils of each layer are connected in series.

3. The stator module according to claim 2, wherein the coil is rectangular and the stator coil assembly is rectangular; alternatively, the coil is in the shape of a sector ring and the stator coil assembly is in the shape of a sector ring.

4. A stator module according to claim 1, wherein the coil windings are provided with terminals, and adjacent coil windings are connected according to a UVW three-phase connection, a delta connection or a star connection.

5. The stator module according to claim 1, wherein a plurality of the armature winding units are periodically and repeatedly arranged along a direction.

6. The stator module of claim 1, wherein the base includes a stator base, wherein the stator coil assembly is mounted to the stator base.

7. A stator for a linear motor, characterized in that the stator is formed by sequentially splicing a plurality of stator modules according to any one of claims 1 to 6.

8. The stator according to claim 7, wherein the stator comprises a stator coil assembly having a ring shape and a stator coil assembly having a rectangular parallelepiped shape which are connected in series.

9. A linear motor comprising a mover and a stator, wherein the stator is the stator of claim 7, and the linear motor comprises a plurality of movers, each of the movers being arranged to be independently movable relative to the stator and being provided with an array of permanent magnets.

10. The linear motor of claim 9, wherein said mover comprises upper and lower permanent magnet arrays, wherein said stator coil assembly is located between said two permanent magnet arrays.