WO2019007201A1 - 线性马达及其定子 - Google Patents

线性马达及其定子 Download PDF

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Publication number
WO2019007201A1
WO2019007201A1 PCT/CN2018/091193 CN2018091193W WO2019007201A1 WO 2019007201 A1 WO2019007201 A1 WO 2019007201A1 CN 2018091193 W CN2018091193 W CN 2018091193W WO 2019007201 A1 WO2019007201 A1 WO 2019007201A1
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WO
WIPO (PCT)
Prior art keywords
phase
stator
coil
armature winding
linear motor
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Application number
PCT/CN2018/091193
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English (en)
French (fr)
Inventor
池峰
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上海合栗智能科技有限公司
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Publication of WO2019007201A1 publication Critical patent/WO2019007201A1/zh

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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K16/00—Machines with more than one rotor or stator
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H02K3/12—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H02K3/28—Layout of windings or of connections between windings
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/46—Fastening of windings on the stator or rotor structure
    • H02K3/47—Air-gap windings, i.e. iron-free windings
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K41/00—Propulsion systems in which a rigid body is moved along a path due to dynamo-electric interaction between the body and a magnetic field travelling along the path
    • H02K41/02—Linear motors; Sectional motors

Definitions

  • the present invention relates to a linear motor, and in particular to a stator of a linear motor.
  • the conventional drive system uses a rotary motor drive structure, and the components commonly used in conventional rotary motor transmissions such as gear heads, shafts, keys, sprocket teeth, chains, belts, etc. in the transmission system are very complicated and cumbersome.
  • Linear motors use a moving magnetic field to directly drive moving parts, reducing structural complexity, and reducing costs and speed increases due to reduced inertia, compliance, damping, friction, and wear.
  • the core actuator component of the motion positioning control system - linear motor under the support of the limit and electromagnetic thrust, the motor mover can drive the load to produce high-speed, high-thrust drive, multiple linear motors can be combined to build two-dimensional or Multi-dimensional motion, linear motor can be used to design precise linear transmission equipment, precision XY table, simple and compact structure, small mechanical size, fast response, high precision, and no wear due to no relative friction between the mover and stator. The service life is very long.
  • the stator of the linear motor generates Cogging influence of the cogging force, resulting in a decrease in the accuracy of the servo motion positioning control.
  • the length of the stator is also difficult to set as needed.
  • a stator module of a linear motor including a base body and a stator coil assembly fixed to the base body, the stator coil assembly including stacked rows of each other At least two layers of coil units of the cloth, the adjacent two layers of the coil unit comprise a plurality of armature winding units, each armature winding unit has three coil windings, and the three coil windings are respectively the armature winding unit U phase, V phase and W phase, wherein the U phase and the W phase of the armature winding unit are arranged adjacent to each other in the same layer, and the V phase is on the upper layer or the next layer of the U phase and the W phase, with the U phase and W The center of the phase is aligned, and in the adjacent two-layer coil unit, if the V-phase of one of the two adjacent armature winding units is in the U-phase and the W-phase of the armature winding unit In the upper layer
  • each of the coil windings is formed by a multilayer coil stack in which the connection interfaces of the inter-layer coils are vertically interconnected such that the layers of the coils are connected in series.
  • the coil is rectangular, and the stator coil assembly has a rectangular parallelepiped shape; or the coil is fan-shaped, and the stator coil assembly has a fan-ring shape.
  • the stator coil assembly is fabricated by a printed circuit board process.
  • the coil winding is provided with a connection terminal, and the adjacent coil windings are connected according to a UVW three-phase connection manner, a delta connection manner or a star connection manner.
  • a plurality of the armature winding units are repeatedly arranged along a direction.
  • the coil winding is a coreless coil winding.
  • the base body includes a stator base, and wherein the stator coil assembly is mounted to be mounted to the stator base.
  • a stator of a linear motor which is sequentially assembled from a plurality of stator modules as described above.
  • the stator includes a stator coil assembly in a ring shape and a stator coil assembly in a rectangular parallelepiped shape.
  • a linear motor including a mover and a stator, the stator adopting the stator described above, and the linear motor includes a plurality of movers, each of the movers It is arranged to be independently movable relative to the stator and provided with a permanent magnet array.
  • the mover includes two upper and lower permanent magnet arrays, wherein the stator coil assembly is located between the two permanent magnet arrays.
  • the coil lamination layout method of the present invention can make up the winding gap to make up the gap, realize the gearless force fluctuation, maintain a stable thrust ratio, and the linearity of the thrust is very standard and the consistency is good.
  • the stator module of the invention realizes the standardized module application of the linear motor, can realize the free splicing and expansion between the plurality of coil stators, can meet the application requirements of the customer for any length, and can run multiple movers simultaneously on the coil stator.
  • FIG. 1 is a schematic view showing the structure of a linear segment of a linear motor according to an embodiment of the present invention.
  • FIG. 2 is a structural schematic view of a straight line segment and an arc segment of a linear motor according to an embodiment of the invention.
  • FIG. 3 is a schematic structural view of a stator coil according to an embodiment of the present invention.
  • FIG. 4 is a schematic view showing the structure of a linear motor mover according to an embodiment of the present invention.
  • Figure 5 is a diagram of a magnet array distribution of a linear motor mover in accordance with an embodiment of the present invention.
  • Figure 6 is a diagram of a magnet array distribution of a linear motor mover in accordance with another embodiment of the present invention.
  • FIG. 7 is a schematic structural view of a linear motor module in accordance with an embodiment of the present invention.
  • Figure 8 is a block diagram showing the structure of a linear motor module in accordance with another embodiment of the present invention.
  • Figure 9 is a schematic view showing the structure of a transmission system of a linear motor composed of the linear motor module of the present invention.
  • Fig. 10 is a view showing an example of a thrust constant effect curve of the linear motor of the present invention.
  • references to "one embodiment” or “an embodiment” in the specification are intended to mean that the particular features, structures, or features described in connection with the embodiments are included in at least one embodiment. Thus, appearances of the “a” or “an” In addition, the particular features, structures, or characteristics may be combined in any manner in one or more embodiments.
  • D1 direction mainly refers to a direction parallel to the horizontal direction
  • D2 direction mainly refers to a direction parallel to the horizontal direction and perpendicular to the direction D1
  • first direction or The term “first axis” mainly refers to a direction or coordinate axis parallel to the horizontal direction
  • second direction or “second axis” mainly refers to a direction or axis parallel to the horizontal direction and perpendicular to the first direction.
  • third direction or “third axis” mainly refers to a direction or coordinate perpendicular to the horizontal direction.
  • the linear motor straight section includes two movers 211, 212 and a stator 200.
  • the stator 200 is constituted by a printed circuit board fixed to the stator base 101, wherein 213 is a positioning mounting hole for screwing and fixing the stator 200.
  • the stator coil assembly is constructed by alternately arranging rectangular coil windings.
  • the stator coil assembly includes a plurality of armature winding units, wherein the coil windings 209a, 209b, 209c are respectively U, V, W three-phase coils of one armature winding unit, and the coil windings 210a, 210b, 210c are respectively another armature winding Unit U, V, W three-phase coil.
  • the coil windings 209b, 210a, and 210c are arranged adjacent to each other in the same layer, and the coils 209a, 209c, and 210b are adjacently arranged in the same layer, that is, corresponding to the upper or lower layer of the U-phase and the W-phase of the V-phase coil, and The center of the U phase and the W phase are aligned.
  • each stator coil winding has a connection terminal, and the adjacent connection terminals are connected according to a UVW three-phase connection mode, a triangle or a star connection manner.
  • Each of the coil windings 209a, 209b, 209c, 210a, 210b, 210c is manufactured by laminating a multilayer coil, and the connection interfaces of the coils of the respective layers are vertically interconnected such that each layer of the coils is connected in series to form one winding.
  • the armature winding unit can be cyclically extended and can be manufactured in one piece.
  • the coil winding can be manufactured according to a standard length module, and the spliced stator module can be assembled for long stroke applications.
  • the stator coil assembly can also be stacked up and down to provide greater thrust.
  • the coil assembly described can be adapted for fabrication by a printed circuit board process.
  • the air gap of each coil of the stator coil assembly is very small and relatively uniform, and therefore, the thrust ripple of the linear motor is very small, and the influence of cogging force cogging is small, especially 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 this 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 traditional ironless linear motor.
  • the permanent magnet arrays 211 and 212 of the mover unit are permanent magnet arrays of two movers, each array consisting of a set of periodically arranged NS arrays or Halbach arrays, the permanent magnets
  • the width of the array unit is W m
  • the distance from the center of the N pole to the center of the adjacent S pole is denoted by ⁇
  • the length of the permanent magnet array is denoted as the width of the W m array.
  • the base of the N pole to the N pole has a width of 2 ⁇ as a basic unit, and the distribution is repeatedly arranged along the first axis X direction, one basic unit, two sets of basic units, and so on, according to the thrust demand of the linear motor.
  • the number of sets of the mover magnet array is constructed.
  • the main conversion relationship between the magnet array and the coil winding is as follows:
  • W m is the width of the permanent magnet array
  • p is the width of each coil in the center line of the pitch circle
  • ⁇ is the angular range corresponding to the pitch circle width of each coil
  • R is the pitch circle radius.
  • ⁇ is the magnet pole pitch, defined as the distance from the center of the S pole to the center of the N pole
  • n c is the number of coil windings
  • n m is the number of pole pairs of the magnet.
  • the linear transmission control system determines the actual position information of each mover measured by the position sensor, predetermines the stator coil area covered by the next operation to be moved, and pre-energizes the area coil to be operated by the mover.
  • the linear motor stator 300 includes a stator base 301, curved stator coils 302, 303, and linear segment stator coils 307 and 308.
  • the linear segment stator coils 307 and 308 are respectively connected to the arc-shaped stator coils 302 and 303 having a constant radius arc type (180°), and the two are connected to realize a seamless interface connection.
  • the stator 300 is constructed of a printed circuit board that is fixed to the stator base 301, wherein the stator coils 302, 303 of the arcuate segments are fan-shaped with a constant center radius R. Among them, the stator coils 302 and 303 are screwed to the stator base 301.
  • the stator coil arrays 302, 303 are composed of alternately stacked rows of fan-coil coil windings, the center of each coil being arranged according to a pitch circle line 309 of constant radius, each coil having a width p at the center line of the pitch circle, which is based on the pitch
  • the angle of the circle is ⁇ , and its conversion relationship with the pole pitch ⁇ of the magnet and the radius R of the pitch circle 309 is as follows:
  • ⁇ is the angular range corresponding to each coil based on the pitch circle width
  • R is the pitch circle radius.
  • ⁇ is the magnet pole pitch, defined as the distance from the center of the S pole to the center of the N pole
  • n c is the number of coil windings
  • n m is the number of pole pairs of the magnet.
  • the coil windings 304a, 304b, 304c are respectively U, V, W three-phase coils of one set of armature winding units, and 305a, 305b, 305c are respectively U, V, W three-phase coils of another set of armature winding units .
  • the coils 304a, 304b, and 304c are arranged adjacent to each other in the same layer, and the coils 305a, 305b, and 305c are adjacently arranged in the same layer, that is, corresponding to the upper or lower layer of the U-phase and the W-phase of the V-phase coil. Align with the center of the U and W phases.
  • the U-phase and W-phase coils are arranged adjacent to each other in the same layer, and the V-phase coil is arranged in the upper or lower layer of the U phase and the W phase, aligned with the geometric centers of the U phase and the W phase.
  • the V-phase coil is arranged in alignment with the geometric centers of the U-phase and the W-phase in the lower layer of the U-phase and the W-phase.
  • the U, V, W three-phase coils constitute a basic armature winding unit, and the stator coil assembly is repeatedly arranged along a lateral period, one group, two groups, three groups, ..., a basic unit, and so on.
  • the number of sets of coil units is constructed according to the stroke demand of the linear motor.
  • Each of the coil windings 304a, 304b, 304c, 305a, 305b, and 305c is manufactured by laminating a plurality of layers of coils, and is connected by a triangular or star connection according to a UVW three-phase connection method.
  • the stator stator coil assembly with a constant radius arc (180°) linear motor can be cyclically extended and can be manufactured in one piece.
  • the stator coil assembly can also be assembled according to two sets of standard 90° arc length modules, or can be assembled from multiple stator coil assemblies, which can be assembled for long stroke applications.
  • the stator coil assembly can also be stacked up and down to provide greater thrust.
  • the stator coil assembly can be adapted for fabrication by a printed circuit board process.
  • the air gap of each coil of the stator coil assembly is very small and relatively uniform, and therefore, the thrust ripple of the linear motor is very small, and the influence of cogging force cogging is small, especially suitable for high-precision control application scenarios. .
  • the fluctuation of the thrust constant of the linear motor proposed by the present invention is much lower than that of the conventional iron core linear motor, or even superior to the conventional ironless linear motor.
  • FIG. 3 shows a schematic structural view of a stator coil according to an embodiment of the present invention.
  • the stator coil assembly is composed of a plurality of layers of coils, including 501, 502, 503, 504, ..., 508, .
  • the coil windings 511, 512, and 513 in the layers where the 501 and 502 are located are respectively U, V, and W three-phase coils of the armature winding unit.
  • the U-phase and W-phase coils are arranged adjacent to each other in the same layer, and the V-phase coil is arranged in alignment with the centers of the U phase and the W phase in the upper layer or the lower layer of the U phase and the W phase.
  • the V-phase coil When the U-phase and W-phase coils are adjacently arranged in the upper layer, the V-phase coil is arranged in alignment with the centers of the U phase and the W phase in the lower layer of the U phase and the W phase.
  • the U, V, W three-phase coils constitute a basic armature winding unit, and the armature winding unit is repeatedly arranged along the first axis direction X period, one group, two groups, three groups, ..., the basic unit, Analogously, the number of sets of armature winding units is constructed according to the stroke demand of the linear motor.
  • the coil windings in the layers in which the 503th and 504th layers are located are constructed in the same manner, and the armature winding units are repeatedly arranged along the first axis direction X period, 1 group, 2 groups, 3 Group, ..., basic unit, and so on, the number of sets of armature winding units is constructed according to the stroke demand of the linear motor.
  • 505, 506, 507, 508, ... repeat the above process layer overlap combination, which can be any number of layer constructions.
  • the armature winding unit can be cyclically extended and can be manufactured in one piece.
  • the winding coils can be manufactured in accordance with standard length modules and can be assembled for long stroke applications.
  • the armature winding unit can also be stacked up and down to provide greater thrust.
  • the coil assembly described can be adapted for fabrication by a printed circuit board process.
  • 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, and a second The auxiliary support plate 132b, the back iron support plate 129, the guide rail guide roller 121, the carriage 122, and the collision block 111.
  • the first auxiliary support plate 132a is mounted on the upper side of the base 100.
  • the second auxiliary support plate 132b is spaced apart from the first auxiliary support plate 132a.
  • the first back iron 131a is mounted on the first auxiliary support plate 132a.
  • the second back iron 131b is mounted to the second auxiliary support plate 132b and spaced apart from the first back iron 131a.
  • 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 bonded to the first back iron 131a.
  • the second permanent magnet array 130b of the linear motor is bonded to the first back iron 131b.
  • the first permanent magnet array 130a and the second permanent magnet array 130b face each other to form a bilateral permanent magnet U-shaped mover.
  • the carriage 122 is mounted on the lower side of the base 100.
  • a set of guide rail rollers 121 are mounted on the lower side of the carriage 122.
  • the bumper block 111 is attached to both ends of the base 100.
  • the anti-collision block 111 adopts a soft material such as polyurethane. When a plurality of movers run on the same closed moving orbit, when the accidental collision occurs, the anti-collision block first deforms to absorb the impact energy, slow the impact force, and protect the mover. Or the safety of materials on the mover.
  • a detector element such as a linear segment magnetic grid or grating 125, or a curved segment magnetic grid or grating 126 may also be provided on the mover.
  • the linear segment magnetic grid or grating 125 is mounted on the guiding surface of the susceptor 100 and can be detected and measured by an encoder array mounted on a straight line segment.
  • the curved segment magnetic grid or grating 126 is mounted laterally of the base 100 and has a curved curved surface that conforms to the guide rail and can be detected and measured by an encoder array mounted on the curved segment.
  • the straight line segment and the curved segment ruler do not interfere with the encoder during motion.
  • the permanent magnet array of the mover generates a driving force under the current excitation of the coil stator, and pushes the entire mover along the guide rail to guide the roller 121 to move along the guide rail.
  • the guide rail guide rollers 121 can move along the linear guide rails as well as along the curved guide rails.
  • the detecting element can detect the moving position of the mover.
  • Figure 5 is a diagram of a magnet array distribution of a linear motor mover in accordance with an embodiment of the present invention.
  • the first permanent magnet array 131a and the second permanent magnet array 131b are two sets of face-to-face permanent magnet arrays, including a first permanent magnet, a second permanent magnet, and a third permanent magnet, wherein the first and the first The second permanent magnet is the main magnet, and the third permanent magnet is the auxiliary magnet.
  • the first permanent magnets 413a, 413b, 417a, 417b, 421a, and 421b have magnetization directions pointing from the S pole to the N pole, that is, toward the Z axis positive direction along the third coordinate axis.
  • the second permanent magnets 415a, 415b, 419a, 419b, 423a, 423b have a magnetization direction pointing from the S pole to the N pole, that is, toward the Z axis negative 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 whose magnetization directions are along the first coordinate axis X direction.
  • the third permanent magnets 412a, 414a have a magnetization direction directed in the direction of the first permanent magnet 413a along the first coordinate axis, a magnetization direction of the 412a pointing in the positive direction of the X-axis, and a magnetization direction of the 414a pointing in the negative direction of the X-axis.
  • the third permanent magnets 414a, 416a have a magnetization direction directed away from the second permanent magnet 415a along the first coordinate axis, and a 411a magnetization direction directed in the positive direction of the X-axis.
  • the third permanent magnets 416a, 418a have a magnetization direction directed to the direction of the first permanent magnet 417a along the first coordinate axis, and a magnetization direction of the 418a is directed to the negative direction of the X-axis.
  • the third permanent magnets 418a, 420a have a magnetization direction directed away from the second permanent magnet 419a along the first coordinate axis, and a magnetization direction of the 420a is directed to the positive direction of the X-axis.
  • the third permanent magnets 418a, 420a have magnetization directions directed away from the first permanent magnet 419a along the first coordinate axis, and 420a magnetization directions are directed to the positive direction of the X-axis.
  • the third permanent magnets 420a and 422a have a magnetization direction directed to the direction of the second permanent magnet 421a along the first coordinate axis, and a magnetization direction of the 422a is directed to the negative direction of the X-axis.
  • the third permanent magnets 422a, 424a have a magnetization direction directed away from the first permanent magnet 423a along the first coordinate axis, and a 241a magnetization direction directed in the positive direction of the X-axis.
  • the third permanent magnets 412b, 414b have a magnetization direction pointing away from the first permanent magnet 413b along the first coordinate axis, a magnetization direction of the 412b pointing in the positive direction of the X-axis, and a magnetization direction of the 414b pointing in the negative direction of the X-axis.
  • the third permanent magnets 414b, 416b have a magnetization direction directed to the direction of the second permanent magnet 415b along the first coordinate axis, and a magnetization direction of the 416b is directed to the negative direction of the X-axis.
  • the third permanent magnets 416b, 418b have a magnetization direction directed away from the first permanent magnet 417b along the first coordinate axis, and a 418b magnetization direction directed in the positive direction of the X-axis.
  • the third permanent magnets 418b and 420b have a magnetization direction directed to the direction of the second permanent magnet 419b along the first coordinate axis, and a magnetization direction of the 420b is directed to the negative direction of the X-axis.
  • the third permanent magnets 420b and 422b have a magnetization direction directed away from the second permanent magnet 421b along the first coordinate axis, and a magnetization direction of the 422b is directed to the positive direction of the X-axis.
  • the third permanent magnets 422b and 424b have a magnetization direction directed in the direction of the first permanent magnet 423b along the first coordinate axis, and a magnetization direction of the 424b in the negative direction of the X-axis.
  • the first, second, and third permanent magnets are typically combined into a Halbach array unit using prismatic magnet blocks that together form a symmetrically arranged permanent magnet array of movers.
  • the width of the Halbach array unit is W m
  • the distance from the N pole to the adjacent S pole permanent magnet center is denoted by ⁇
  • the length of the permanent magnet array is denoted as the W m array width.
  • the first, second, and third permanent magnets are constructed with a complete cycle of Halbach magnets, the distribution is repeated periodically along the first axis X direction, one Halbach basic unit, two sets of Halbach basic units, and so on.
  • the number of sets of the mover magnet array is constructed according to the thrust demand of the linear motor.
  • the first back iron 403 and the second back iron 402 are materials having high magnetic permeability materials such as steel and iron. It builds magnetic flux loops in the magnetic flux of the Halbach base unit in the direction of the back iron to reduce magnetic leakage.
  • the Halbach basic unit has a single-sided magnetic density characteristic, and the magnetic tightness distribution facing the coil side is higher than that of the conventional NS array, and the magnetic density facing the back iron side is weak, so the thickness of the back iron is Applications can be thinner than the back iron of a conventional NS magnetic array.
  • the use of low-density high-strength materials as an auxiliary support can reduce the weight of the mover unit. In order to reduce local magnetic leakage, the thickness of the back iron is maintained at least 1 mm.
  • the width of the third permanent magnets 412a, 412b, 424a, 424b in the direction of the third axis X is half the width of the permanent magnets 414a, 414b.
  • the width of the first and second permanent magnets along the X direction is 0.5 to 0.9 times ⁇ .
  • the first auxiliary support plate 401 and the second auxiliary support plate 404 are auxiliary support members of a low density and high rigidity material for reinforcing the support rigidity of the back iron.
  • FIG. 6 is a diagram of a magnet array distribution of a linear motor mover in accordance with another embodiment of the present invention.
  • the magnet array unit of the mover is composed of two basic units of a face-to-face NS permanent magnet array and a yoke, and the first permanent magnets 512a, 512b, 514a, 514b, 516a, 516b at the center of the base unit,
  • the magnetization direction is from the S pole to the N pole, that is, along the third coordinate axis, pointing to the positive direction of the Z axis;
  • the second permanent magnets 513a, 513b, 515a, 515b, 517a, 517b at the center of the basic unit have magnetization directions from the S pole Pointing to the N pole, that is, pointing to the negative direction of the Z axis along the third coordinate axis.
  • the second permanent magnets are typically combined into prismatic magnet blocks into NS base units which together form a symmetrically arranged permanent magnet array of mover units.
  • the width of the NS permanent magnet array unit is W m
  • the distance from the N pole to the adjacent S pole permanent magnet center is denoted as ⁇ .
  • the first and second permanent magnets construct a complete period of NS magnet group, and the distribution is repeatedly arranged along the first axis direction X period, one NS basic unit, two sets of NS basic units, and so on, according to linear
  • the thrust demand of the motor is used to construct the number of sets of the moving magnet array.
  • the back irons 601 and 602 are soft magnetic materials, such as cobalt-iron alloy, iron-nickel alloy, silicon steel, iron-aluminum-silicon alloy, etc., and the soft magnetic material refers to the IEC60404-1 standard, which constructs a magnetic line circuit for the magnetic flux of the NS basic unit in the back iron direction. .
  • the NS basic unit has a bidirectional magnetic-tight characteristic. According to the electromagnetic thrust, the magnetic density distribution to the coil side needs to be higher, and the magnetic density facing the back iron side is preferably as small as possible.
  • the thickness should be of sufficient thickness to reduce magnetic leakage and maintain a thickness of at least 5 mm. Further, the width of the first and second permanent magnets along the X direction is 0.5 to 1 times ⁇ .
  • the linear motor module includes a mover and stator module.
  • the mover module can adopt the mover structure as shown in Figure 4-5.
  • the stator module includes a base body and a stator coil assembly fixed to the base body, and the stator coil assembly includes at least two layers of coil units arranged in a stack.
  • the coil unit can be made from a coreless coil through a printed circuit board process.
  • the stator coil assembly is operatively disposed between the first array of permanent magnets and the second array of permanent magnets.
  • the adjacent two-layer coil unit includes a plurality of armature winding units, each armature winding unit having three coil windings 401a, 401b, 401c.
  • the three coil windings 401a, 401b, 401c are respectively the U phase, the V phase and the W phase of the armature winding unit, wherein the U phase and the W phase of each armature winding unit are adjacently arranged in the same layer, and the V phase is in the U
  • the upper or lower layer of the phase and W phase are aligned with the center of the U phase and the W phase.
  • the V phase of one of the adjacent two armature winding units is in the upper layer of the U phase and the W phase of the armature winding unit, the other armature winding
  • the V phase of the armature winding unit of the unit is in the lower layer of the U phase and the W phase of the armature winding unit.
  • the U, V, W three-phase coils constitute the basic armature winding unit and are repeatedly arranged along the first axis direction X period, one group, two groups, three groups, ..., the basic unit, and so on, according to the linear motor
  • the stroke demand is to build the number of sets of armature winding units.
  • FIG 8 is a block diagram showing the structure of a linear motor module in accordance with another embodiment of the present invention.
  • the linear motor module includes a magnet mover and a stator coil unit.
  • the mover is composed of two basic units of a face-to-face permanent magnet array and a yoke.
  • the first permanent magnets 430a, 430b at the center of the basic unit have a magnetization direction from the S pole to the N pole, that is, the Z along the third coordinate axis.
  • the positive direction of the axis; the second permanent magnets 431a, 431b at the center of the basic unit have a magnetization direction pointing from the S pole to the N pole, that is, in the negative direction of the Z axis along the third coordinate axis.
  • the second permanent magnets are typically combined into prismatic magnet blocks into NS base units which together form a symmetrically arranged permanent magnet array of mover units.
  • the width of the NS basic unit is W m , and the length of the half period is denoted by ⁇ .
  • the first and second magnets construct a complete cycle of the NS magnet group, the distribution is repeated along the first axis direction X cycle, one NS basic unit, two sets of NS basic units, and so on, according to the linear motor
  • the thrust requirement is to build the number of groups of moving magnet arrays.
  • the NS basic unit has a two-way magnetic-density characteristic.
  • the magnetic dense magnetic intensity distribution facing the coil side needs to be higher, and the magnetic density facing the back iron side is preferably as small as possible, so the back iron thickness is required.
  • the magnetic leakage should be reduced to a sufficient thickness to maintain a thickness of at least 5 mm.
  • the first and second types of permanent magnets have a width in the X direction of 0.5 to 1 times ⁇ .
  • Figure 9 is a schematic view showing the structure of a transmission system of a linear motor composed of the linear motor module of the present invention.
  • the transmission system includes a plurality of movers 108, two linear stator coil module stator modules 104 and two constant radius curved motor stator modules 106, a magnetic grid or grating 110, a magnetic grid or a grating encoder.
  • the mover 108 is mounted on the stator module of the linear motor and is translated in translation along the guide rail by the roller guide 103. Each mover 108 moves independently of each other with respect to all other movers.
  • the mover 108 includes an array of permanent magnets mounted to the inner side surface of the mover yoke.
  • the linear motor stator module and the curved motor stator module formed by the stator modules 104, 106 are connected to the fixed bracket 102.
  • the fixing bracket 102 is mounted on the stator base 101.
  • the roller guide 103 is fixed to the stator base 101 by a fastening screw.
  • a grid or grating encoder array 109 is mounted on the mounting bracket 102. The signal of the encoder array 109 is used for position measurement of the mover.
  • the stator modules 104, 106 pass the excitation current so that the designated coils are energized and excited, and the exciting magnetic fields generated by the coils interact in the permanent magnet magnetic field generated by the permanent magnet array of the mover unit 108 to form a thrust so that the mover unit 108 along the guide rails Translational movement.
  • the stator modules 104, 106 and the mover 108 independently control each mover 108 to move along the roller guide 103 as a combined function of the motion control system.

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Abstract

本申请公开了一种线性马达及其定子模块。定子模块包括基体和固定于基体上的定子线圈组件。定子线圈组件包含相互层叠排布的至少两层线圈单元，相邻的两层线圈单元包含多个电枢绕组单元。每个电枢绕组单元具有三个线圈绕组，三个线圈绕组分别为该电枢绕组单元的U相、V相和W相，其中电枢绕组单元的U相和W相相邻布置在同一层，V相在U相和W相的上一层或下一层，与U相和W相的中心对齐排布，以及相邻的两层线圈单元中，如果相邻的两个电枢绕组单元中的一个电枢绕组单元的V相在该电枢绕组单元的U相和W相的上层，则另一个电枢绕组单元的电枢绕组单元的V相在该电枢绕组单元的U相和W相的下层。本申请的定子模块不会产生齿槽力，控制精度高。

Description

线性马达及其定子
相关申请交叉引用
本专利申请要求于2017年07月06日提交的、申请号为2017105475782、发明名称为“线性马达及其定子”的中国专利申请的优先权，上述申请的全文以引用的方式并入本文中。
技术领域
本发明涉及线性马达，具体涉及线性马达的定子。
背景技术
随着制造技术向高产率、高精密化方向发展，精密运动控制技术的研究变得越来越重要，相应地，运动定位控制系统需求量也越来越大，广泛应用于自动化生产线、包装与运输、装配自动化、丝网印刷等行业，提供具有更高速度和加工柔性。传统驱动系统采用旋转马达驱动结构，传递系统中齿轮头、轴、键、链轮齿、链条、皮带等常用于传统旋转马达传动的部件非常的复杂笨重。线性马达应用了一种运动磁场来直接驱动运动部件，降低了结构复杂性，还降低了成本和因减小惯量、柔顺性、阻尼、摩擦和磨损而带来的速度增加等优点。
运动定位控制系统的核心执行器部件——线性马达，它在支撑的限制和电磁推力的作用下，电机动子能够带动负载产生高速、大推力的驱动，多个线性马达可以组合构建两维或多维运动，采用线性马达可以设计构造精密的线性传输设备、精密XY工作台，结构简单紧凑，机械尺寸小，响应速度快，精度高，而且由于动子和定子间无相对摩擦，因此不存在磨损，使用寿命很长。
然而，目前线性马达的定子会产生齿槽力Cogging影响，导致伺服运动定位控制的精度下降。同时，定子的长度也难以根据需要来设置。
发明内容
本发明的目的是提供一种无齿槽力影响，伺服运动定位精度高的线性马达定子。
为实现上述目的，根据本发明的第一方面，提供了一种线性马达的定子模块，所述定子模块包括基体和固定于所述基体上的定子线圈组件，所述定子线圈组件包含相互层叠排布的至少两层线圈单元，相邻的两层所述线圈单元包含多个电枢绕组单元，每个电枢绕组单元具有三个线圈绕组，所述三个线圈绕组分别为该电枢绕组单元的U相、V相和W相，其中电枢绕组单元的U相和W相相邻布置在同一层，V相在U相和W相的上一层或下一层，与U相和W相的中心对齐排布，以及相邻的两层线圈单元中，如果相邻的两个电枢绕组单元中的一个电枢绕组单元的V相在该电枢绕组单元的U相和W相的上层，则另一个电枢绕组单元的电枢绕组单元的V相在该电枢绕组单元的U相和W相的下层。
一实施例中，每个线圈绕组由多层线圈叠加工而成，其中各层间线圈的连接接口垂向互联，使得各层线圈串联。
一实施例中，所述线圈呈矩形，以及所述定子线圈组件呈长方体形；或者，所述线圈呈扇环形，以及所述定子线圈组件呈扇环体形。
一实施例中，所述定子线圈组件通过印制电路板工艺制造。
一实施例中，所述线圈绕组设有接线端子，相邻的线圈绕组根据UVW三相连接方式，三角形连接方式或星形连接方式进行连接。
一实施例中，多个所述电枢绕组单元沿着一方向周期重复排布。
一实施例中，所述线圈绕组为无铁芯线圈绕组。
一实施例中，所述基体包括定子基座，其中所述定子线圈组件安装于安装于所述定子基座上。
根据本发明的第二方面，还提供了一种线性马达的定子，所述定子由多个如上所述的定子模块依次拼接而成。
一实施例中，所述定子包括依次连接的呈环形体形的定子线圈组件和呈长方体形的定子线圈组件。
根据本发明的第三方面，还提供了一种线性马达，所述线性马达包括动子和定子，所述定子采用上述的定子，且所述线性马达包含多个动子，各所述动子设置成能够独立地相对于所述定子运动并设有永磁铁阵列。
一实施例中，所述动子包含上下两个永磁铁阵列，其中所述定子线圈组件位于所述两个永磁铁阵列之间。
本发明与现有技术相比所具有的进步效果如下：
1)、线圈绕组中没有软磁材料的铁芯组件，因而不会产生齿槽力Cogging影响，可以提供高精度伺服运动定位控制；
2)、本发明的线圈层叠布局方法可以将绕组间隙进行布线弥补，实现无齿槽力波动，保持稳定的推力比，推力的线性度非常标准，一致性好。
3)本发明的定子模块实现线性马达的标准化模块应用，可实现多个线圈定子之间的自由拼接和扩展，可以满足客户任意长度的应用需求，线圈定子上可以同时运行多个动子。
附图说明
图1是根据本发明的一实施例的线性马达直线段的结构示意图。
图2是根据本发明的一实施例的线性马达直线段和弧形段衔接的结构示意图。
图3是根据本发明的一实施例的定子线圈的结构示意图。
图4是根据本发明的一实施例的线性马达动子的结构示意图。
图5是根据本发明的一实施例的线性马达动子的磁铁阵列分布。
图6是根据本发明的另一实施例的线性马达动子的磁铁阵列分布。
图7是根据本发明的一实施例的线性马达模块的结构示意图。
图8是根据本发明的另一实施例的线性马达模块的结构示意图。
图9是采用本发明的线性马达模块组成的线性马达的传输系统的结构示意图。
图10是本发明的线性马达的推力常数效果曲线示例。
具体实施方式
以下将结合附图对本发明的较佳实施例进行详细说明，以便更清楚理解本发明的目的、特点和优点。应理解的是，附图所示的实施例并不是对本发明范围的限制，而只是为了说明本发明技术方案的实质精神。
在下文的描述中，出于说明各种公开的实施例的目的阐述了某些具体细节以提供对各种公开实施例的透彻理解。但是，相关领域技术人员将认识到可在无这些具体细节中的一个或多个细节的情况来实践实施例。在其它情形下，与线性马达相关联的熟知的装置、结构和技术可能并未详细地示出或描述从而避 免不必要地混淆实施例的描述。
除非语境有其它需要，在整个说明书和权利要求中，词语“包括”和其变型，诸如“包含”和“具有”应被理解为开放的、包含的含义，即应解释为“包括，但不限于”。
在整个说明书中对“一个实施例”或“一实施例”的提及表示结合实施例所描述的特定特点、结构或特征包括于至少一个实施例中。因此，在整个说明书的各个位置“在一个实施例中”或“在一实施例”中的出现无需全都指相同实施例。另外，特定特点、结构或特征可在一个或多个实施例中以任何方式组合。
如该说明书和所附权利要求中所用的单数形式“一”和“所述”包括复数指代物，除非文中清楚地另外规定。应当指出的是术语“或”通常以其包括“和/或”的含义使用，除非文中清楚地另外规定。
在以下描述中，为了清楚展示本发明的结构及工作方式，将借助诸多方向性词语进行描述，但是应当将“前”、“后”、“左”、“右”、“外”、“内”、“向外”、“向内”、“上”、“下”等词语理解为方便用语，而不应当理解为限定性词语。
此外，在以下描述中所使用的“D1方向”一词主要指与水平向平行的方向；“D2方向”一词主要指与水平向平行同时与D1方向垂直的方向；“第一方向”或“第一轴”一词主要指与水平向平行的方向或坐标轴；“第二方向”或“第二轴”一词主要指与水平向平行且同时与第一方向垂直的方向或坐标轴；“第三方向”或“第三轴”一词主要指与水平向垂直的方向或坐标。
图1示出根据本发明的一实施例的线性马达直线段的结构示意图。如图1所示，线性马达直线段包含两个动子211、212和定子200。定子200由一个固定于定子基座101上的印制电路板构成，其中，213为定位安装孔，用于螺钉连接和固定定子200。在印制电路板200上，定子线圈组件由矩形线圈绕组交替层叠排布构成。
定子线圈组件包括多个电枢绕组单元，其中线圈绕组209a、209b、209c分别为一个电枢绕组单元的U、V、W三相线圈，线圈绕组210a、210b、210c分别 为另一个电枢绕组单元的U、V、W三相线圈。线圈绕组209b、210a和210c线圈在同一层相邻排列，209a、209c、210b线圈在同一层相邻排列，即对应于V相线圈在U相和W相的上一层或下一层，与U相和W相的中心对齐排布。当所述的U相和W相线圈相邻排列在上面一层时，V相线圈在U相和W相的下面一层，与U相和W相两相的几何中心对齐排布。U、V、W三相线圈构成基本的电枢绕组单元，该电枢绕组单元沿着横向周期重复排布，1组、2组、3组，……，基本单元，以此类推，根据线性马达的行程需求进行构建电枢绕组单元的组数。其中，每个定子线圈绕组均有接线端子，相邻的接线端子根据UVW三相连接方式，三角形或星型连接方式进行连接。线圈绕组209a、209b、209c、210a、210b、210c的每一个绕组为多层线圈层叠加工制造而成，各层间线圈的连接接口垂向互联，使得每层线圈串联成一个绕组。
电枢绕组单元可以进行周期延展，可以一体成型制造，线圈绕组可以按照标准长度的模块制造，针对长行程应用可组装拼接定子模块。此外，所述的定子线圈组件还可以上下层叠的拼接应用，可以提供更大的推力。特别地，所述的线圈组件可适用于通过印制电路板工艺制造。而且，所述的定子线圈组件的每个线圈的气隙非常小，且比较均匀，因而，线性马达的推力纹波非常小，齿槽力cogging的影响较小，尤其适应于高精密控制应用场景。图10示出本发明的线性马达的推力常数效果曲线示例。图中数据显示结果表明该技术中的推力常数的波动小于5％，远远低于常规的铁芯直线电机的推力波动，甚或优于传统的无铁芯直线电机。
还如图1所示，动子单元的永磁阵列211和212为两个动子的永磁阵列，每个阵列由一组周期性排布的NS阵列或Halbach阵列构成，所述的永磁阵列单元的宽度为W m，其N极中心到相邻S极中心的距离记为τ，所述永磁阵列的长度记为W m阵列宽度。以N极到N极中心具有2τ宽度作为基本单元，分布沿着第一轴X方向周期重复排布，1个基本单元、2组基本单元……，以此类推，根据线性马达的推力需求进行构建动子磁铁阵列的组数。磁铁阵列与线圈绕组之间的主要换算关系如下：
W m＝n m·τ
Figure PCTCN2018091193-appb-000001
Figure PCTCN2018091193-appb-000002
其中，W m为动子永磁阵列宽度，p为每个线圈在节圆中心线的宽度，α为每个线圈基于节圆宽度对应的角度范围，R为节圆半径。τ为磁铁极距，定义为S极中心到N极中心的距离，n c为线圈绕组的个数，n m为磁铁的磁极对数。
当多个动子在定子线圈上方运行时，每个动子永磁铁覆盖区域的对应的线圈绕组通电励磁，产生水平推力。线性传输控制系统通过位置传感器测量得到的每个动子的实际位置信息，预先判断即将运动的下一运行覆盖的定子线圈区域，在动子即将运行的区域线圈预先通电。
图2示出根据本发明的一实施例的线性马达直线段和弧形段(180°)衔接的结构示意图。如图2所示，线性马达定子300包括定子基座301，弧形定子线圈302、303，直线段定子线圈307和308。直线段定子线圈307和308分别为与具有恒定半径弧型(180°)弧形定子线圈302和303相连，二者衔接实现无缝接口连接。
定子300由一个固定于定子基座301上的印制电路板构成，其中弧形段的定子线圈302、303为扇环形，具有恒定的中心半径R。其中，定子线圈302和303用螺钉固定于定子基座301上。定子线圈阵列302、303由具有扇环形线圈绕组交替层叠排布构成，每个线圈的中心按照恒定半径的节圆线309排布，每个线圈在节圆中心线的宽度为p，它基于节圆的角度为α，它与磁铁极距τ以及节圆线309半径R的换算关系如下式：
p＝R·α
Figure PCTCN2018091193-appb-000003
其中，p为每个线圈在节圆中心线的宽度，α为每个线圈基于节圆宽度对应的角度范围，R为节圆半径。τ为磁铁极距，定义为S极中心到N极中心的距离，n c为线圈绕组的个数，n m为磁铁的磁极对数。
其中，线圈绕组304a、304b、304c分别为一组电枢绕组单元的U、V、W三相线圈，305a、305b、305c分别为另外一组电枢绕组单元的U、V、W三相线圈。 所述的304a、304b、304c线圈在同一层相邻排列，305a、305b、305c线圈在同一层相邻排列，即对应于V相线圈在U相和W相的上一层或下一层，与U相和W相的中心对齐排布。所述的U相和W相线圈在同一层相邻排列，V相线圈在U相和W相的上一层或下一层，与U相和W相两相的几何中心对齐排布。当所述的U相和W相线圈相邻排列在上面一层时，V相线圈在U相和W相的下面一层，与U相和W相两相的几何中心对齐排布。所述的U、V、W三相线圈构成基本的电枢绕组单元，该定子线圈组件沿着横向周期重复排布，1组、2组、3组，……，基本单元，以此类推，根据线性马达的行程需求进行构建线圈单元的组数。其其中，所述的线圈绕组304a、304b、304c、305a、305b、305c的每一个绕组为多层线圈层叠加工制造而成，根据UVW三相连接方式，三角形或星型连接方式进行连接。
具有恒定半径弧型(180°)线性马达定子定子线圈组件可以进行周期延展，可以一体成型制造。定子线圈组件也可以按照两组标准90°弧形长度的模块组装而成，也可以由多个定子线圈组件组装而成，针对长行程应用可组装拼接定子模块。此外，所述的定子线圈组件还可以上下层叠的拼接应用，可以提供更大的推力。特别地，所述的定子线圈组件可适用于通过印制电路板工艺制造。而且，所述的定子线圈组件的每个线圈的气隙非常小，且比较均匀，因而，线性马达的推力纹波非常小，齿槽力cogging的影响较小，尤其适应于高精密控制应用场景。本发明提出的线性马达的推力常数的波动远低于常规的铁芯直线电机的推力波动，甚或优于传统的无铁芯直线电机。
图3示出根据本发明的一实施例的定子线圈的结构示意图。如图3所示，定子线圈组件由多层线圈组成，包括501、502、503、504，…，508，…。其中，第501和502所在的层中的线圈绕组511、512、513分别为电枢绕组单元的U、V、W三相线圈。U相和W相线圈在同一层相邻排列，V相线圈在U相和W相的上一层或下一层，与U相和W相的中心对齐排布。当所述的U相和W相线圈相邻排列在上面一层时，V相线圈在U相和W相的下面一层，与U相和W相的中心对齐排布。U、V、W三相线圈构成基本的电枢绕组单元，该电枢绕组单元沿着第一轴方向X周期重复排布，1组、2组、3组，……，基本单元，以 此类推，根据线性马达的行程需求进行构建电枢绕组单元的组数。类似的，第503、504所在的层中的线圈绕组按照同样的方法进行三相绕组的构建，且该电枢绕组单元沿着第一轴方向X周期重复排布，1组、2组、3组，……，基本单元，以此类推，根据线性马达的行程需求进行构建电枢绕组单元的组数。以此类推，第505、506，第507、508，…，重复以上的过程层层重叠组合，可以是任意数量的层数构建。
电枢绕组单元可以进行周期延展，可以一体成型制造。绕组线圈可以按照标准长度的模块制造，针对长行程应用可组装拼接定子模块。此外，所述的电枢绕组单元还可以上下层叠的拼接应用，可以提供更大的推力。特别地，所述的线圈组件可适用于通过印制电路板工艺制造。
图4是根据本发明的一实施例的线性马达动子的结构示意图。如图4所示，线性马达动子包括基座100、第一永磁阵列130a、第二永磁阵列130b、第一背铁131a、第二背铁131b、第一辅助支撑板132a、第二辅助支撑板132b、背铁支撑板129、导轨导向滚子121、滑座122以及防撞块111。第一辅助支撑板132a安装于基座100的上侧。第二辅助支撑板132b与第一辅助支撑板132a间隔开放置。第一背铁131a安装于第一辅助支撑板132a上。第二背铁131b安装于第二辅助支撑板132b并与第一背铁131a间隔开。背铁支撑板129置于第一背铁131a与第二背铁131b之间并与第一背铁和第二背铁共同形成U字形结构。线性马达的第一永磁阵列130a粘接于第一背铁131a上。线性马达的第二永磁阵列130b粘接于第一背铁131b上。第一永磁阵列130a和第二永磁阵列130b面面相对构成双边永磁U型动子。滑座122安装于基座100的下侧。一组导轨导向滚子121安装于滑座122下侧。
防撞块111安装于基座100的两端。防撞块111采用诸如聚氨酯这样的软性材料，当多个动子运行于同一个闭合的运动轨道上，发生意外碰撞时，防撞块首先变形吸收冲击的能量，减缓撞击力，保护动子或动子上物料的安全。
动子上还可设有诸如直线段磁栅或光栅125，或者弧形段磁栅或光栅126的检测元件。直线段磁栅或光栅125安装于基座100的导向面上，可由安装于直线段的编码器阵列进行检测测量。弧形段磁栅或光栅126安装于基座100的 侧向，具有与导轨一致的曲面弧形，可由安装于弧形段的编码器阵列进行检测测量。直线段和弧形段尺与编码器在运动中互不干涉。
工作时，动子的永磁阵列在线圈定子的电流励磁下产生驱动力，推动整个动子通过导轨导向滚子121沿着导轨运动。导轨导向滚子121可以沿着直线导轨运动也可以沿着弧形导轨运动。检测元件可以检测动子的运动位置。
图5是根据本发明的一实施例的线性马达动子的磁铁阵列分布。如图5所示，第一永磁阵列131a和第二永磁阵列131b为2组面对面的永磁阵列，其包含第一永磁铁、第二永磁铁和第三永磁铁，其中第一和第二永磁铁为主磁铁，第三永磁铁为辅助磁铁。第一永磁铁413a、413b、417a、417b、421a、421b，其磁化方向从S极指向N极，即沿着第三坐标轴指向Z轴正方向。第二永磁铁415a、415b、419a、419b、423a、423b，其磁化方向从S极指向N极，即沿着第三坐标轴指向Z轴负方向。
第三永磁铁412a、412b、414a、414b、416a、416b、418a、418b、420a、420b、422a、422b、424a、424b为辅助磁铁，其磁化方向沿着第一坐标轴X方向。
第三永磁铁412a、414a，其磁化方向沿着第一坐标轴指向第一永磁铁413a的方向，412a磁化方向指向X轴的正方向，414a磁化方向指向X轴的负方向。
第三永磁铁414a、416a，其磁化方向沿着第一坐标轴指向远离第二永磁铁415a的方向，416a磁化方向指向X轴的正方向。
第三永磁铁416a、418a，其磁化方向沿着第一坐标轴指向第一永磁铁417a的方向，418a磁化方向指向X轴的负方向。
第三永磁铁418a、420a，其磁化方向沿着第一坐标轴指向远离第二永磁铁419a的方向，420a磁化方向指向X轴的正方向。
第三永磁铁418a、420a，其磁化方向沿着第一坐标轴指向远离第一永磁铁419a的方向，420a磁化方向指向X轴的正方向。
第三永磁铁420a、422a，其磁化方向沿着第一坐标轴指向第二永磁铁421a的方向，422a磁化方向指向X轴的负方向。
第三永磁铁422a、424a，其磁化方向沿着第一坐标轴指向远离第一永磁铁 423a的方向，424a磁化方向指向X轴的正方向。
第三永磁铁412b、414b，其磁化方向沿着第一坐标轴指向远离第一永磁铁413b的方向，412b磁化方向指向X轴的正方向，414b磁化方向指向X轴的负方向。
第三永磁铁414b、416b，其磁化方向沿着第一坐标轴指向第二永磁铁415b的方向，416b磁化方向指向X轴的负方向。
第三永磁铁416b、418b，其磁化方向沿着第一坐标轴指向远离第一永磁铁417b的方向，418b磁化方向指向X轴的正方向。
第三永磁铁418b、420b，其磁化方向沿着第一坐标轴指向第二永磁铁419b的方向，420b磁化方向指向X轴的负方向。
第三永磁铁420b、422b，其磁化方向沿着第一坐标轴指向远离第二永磁铁421b的方向，422b磁化方向指向X轴的正方向。
第三永磁铁422b、424b，其磁化方向沿着第一坐标轴指向第一永磁铁423b的方向，424b磁化方向指向X轴的负方向。
第一，第二，第三永磁铁典型地采用棱柱型磁铁块组合成Halbach阵列单元，它们共同组成动子的对称布局的永磁阵列。Halbach阵列单元的宽度为W m，其N极到相邻S极永磁中心的距离记为τ，所述永磁阵列的长度记为W m阵列宽度。该第一、第二、第三永磁铁构建具有完整周期的Halbach磁铁组，分布沿着第一轴X方向周期重复排布，1个Halbach基本单元、2组Halbach基本单元……，以此类推，根据线性马达的推力需求进行构建动子磁铁阵列的组数。
第一背铁403、第二背铁402为具有高磁导率材料，如钢、铁等材料。它将Halbach基本单元在背铁方向的磁通构建磁力线回路，减小磁泄露。所述的Halbach基本单元具有单侧磁密特性，其面向线圈侧的磁密分布比传统的NS阵列的磁密强度要高，而面向背铁侧的磁密则很弱，因此背铁的厚度应用可以传统NS磁阵列的背铁更薄。应用低密度高强度材料作辅助支撑，可以减小动子单元重量。为了减小局部磁泄露，背铁的厚度至少保持1mm。此外，为了减小边端漏磁影响，第三永磁铁412a、412b、424a、424b沿着第三轴X方向的宽度为永磁铁414a、414b宽度的一半。第一、二永磁铁沿着X方向的宽度为τ的0.5～0.9 倍。第一辅助支撑板401和第二辅助支撑板404为低密度高刚性材料的辅助支撑部件，用以加强背铁的支撑刚性。
图6是根据本发明的另一实施例的线性马达动子的磁铁阵列分布。如图6所示，动子的磁铁阵列单元由2组面对面的NS永磁阵列的基本单元和磁轭组成，该基本单元中心的第一永磁铁512a、512b、514a、514b、516a、516b，其磁化方向从S极指向N极，即沿着第三坐标轴指向Z轴正方向；该基本单元中心的第二永磁铁513a、513b、515a、515b、517a、517b，其磁化方向从S极指向N极，即沿着第三坐标轴指向Z轴负方向。
第一，第二永磁铁典型地采用棱柱型磁铁块组合成NS基本单元，它们共同组成动子单元的对称布局的永磁阵列。NS永磁阵列单元的宽度为W m，其N极到相邻S极永磁中心的距离记为τ。该第一、第二永磁铁构建一个完整周期的NS磁铁组，分布沿着第一轴方向X周期重复排布，1个NS基本单元、2组NS基本单元……，以此类推，根据线性马达的推力需求进行构建动子磁铁阵列的组数。
背铁601、602为软磁材料，例如钴铁合金、铁镍合金、硅钢、铁铝硅合金等，软磁材料参考IEC60404-1标准，它将NS基本单元在背铁方向的磁通构建磁力线回路。所述的NS基本单元具有双向磁密特性，根据电磁推力需要，其面向线圈侧的磁密强度分布需要越高越好，而面向背铁侧的磁密则希望越小越好，因此背铁厚度应具有足够厚度，以减小磁泄露，其厚度至少保持5mm。此外，所述的第一、二永磁铁沿着X方向的宽度为τ的0.5～1倍。
图7是根据本发明的一实施例的线性马达模块的结构示意图。如图7所示，线性马达模块包括动子和定子模块。动子模块可采用如图4-5所示的动子结构。定子模块包括基体和固定于基体上的定子线圈组件，定子线圈组件包含相互层叠排布的至少两层线圈单元。线圈单元可由无铁芯线圈通过印制电路板工艺制成。定子线圈组件可操作地置于第一永磁铁阵列与第二永磁铁阵列之间。
相邻的两层线圈单元包含多个电枢绕组单元，每个电枢绕组单元具有三个线圈绕组401a、401b、401c。三个线圈绕组401a、401b、401c分别为该电枢绕组单元的U相、V相和W相，其中每个电枢绕组单元的U相和W相相邻布置在同一层，V相在U相和W相的上一层或下一层，与U相和W相的中心对齐排布。相邻 的两层线圈单元中，如果相邻的两个电枢绕组单元中的一个电枢绕组单元的V相在该电枢绕组单元的U相和W相的上层，则另一个电枢绕组单元的电枢绕组单元的V相在该电枢绕组单元的U相和W相的下层。
U、V、W三相线圈构成基本的电枢绕组单元沿着第一轴方向X周期重复排布，1组、2组、3组，……，基本单元，以此类推，根据线性马达的行程需求进行构建电枢绕组单元的组数。
图8是根据本发明的另一实施例的线性马达模块的结构示意图。如图8所示，线性马达模块包括磁铁动子和定子线圈单元。动子由2组面对面的永磁阵列的基本单元和磁轭组成，该基本单元中心的第一永磁铁430a、430b，其磁化方向从S极指向N极，即沿着第三坐标轴指向Z轴正方向；该基本单元中心的第二永磁铁431a、431b，其磁化方向从S极指向N极，即沿着第三坐标轴指向Z轴负方向。
第一，第二永磁铁典型地采用棱柱型磁铁块组合成NS基本单元，它们共同组成动子单元的对称布局的永磁阵列。NS基本单元的宽度为W m，其半周期长度记为τ。该第一、第二磁铁构建一个完整周期的NS磁铁组，分布沿着第一轴方向X周期重复排布，1个NS基本单元、2组NS基本单元……，以此类推，根据线性马达的推力需求进行构建动子磁铁阵列的组数。
NS基本单元具有双向磁密特性，根据电磁推力需要，其面向线圈侧的磁密磁密强度分布需要越高越好，而面向背铁侧的磁密则希望越小越好，因此背铁厚度应以具有足够厚度，减小磁泄露，其厚度至少保持5mm。此外，所述的第一、二类永磁铁沿着X方向的宽度为τ的0.5～1倍。
图9是采用本发明的线性马达模块组成的线性马达的传输系统的结构示意图。如图9所示，该传输系统包括多个动子108，两段直线定子线圈模块定子模块104和两段恒定半径的弧形马达定子模块106，磁栅或光栅110，磁栅或光栅编码器阵列109，导轨单元103，固定支架102以及定子基座101。其中，动子108安装于线性马达的定子模块之上，通过滚子导轨103沿着导轨方向平移运动。每个动子108相对于所有的其他动子是相互独立运动的。动子108包含永磁铁阵列，安装于动子磁轭内侧表面。定子模块104、106构成的直线马达定子模块和弧形马达定子模块与固定支架102相连。固定支架102安装于定子基座101 之上。滚子导轨103通过紧固螺钉固定在定子基座101之上。磁栅或光栅编码器阵列109安装于固定支架102上。编码器阵列109的信号用于动子的位置测量。定子模块104、106通入励磁电流，使得指定线圈激活通电并励磁，线圈产生的励磁磁场在动子单元108的永磁阵列产生的永磁磁场中相互作用形成推力使得动子单元108沿着导轨平移运动。在实施例中，定子模块104，106与动子108作为运动控制系统的组合功能独立控制每个动子108沿着滚子导轨103运动。
以上已详细描述了本发明的较佳实施例，但应理解到，若需要，能修改实施例的方面来采用各种专利、申请和出版物的方面、特征和构思来提供另外的实施例。
考虑到上文的详细描述，能对实施例做出这些和其它变化。一般而言，在权利要求中，所用的术语不应被认为限制在说明书和权利要求中公开的具体实施例，而是应被理解为包括所有可能的实施例连同这些权利要求所享有的全部等同范围。

Claims (12)

  1. 一种线性马达的定子模块，其特征在于，所述定子模块包括基体和固定于所述基体上的定子线圈组件，所述定子线圈组件包含相互层叠排布的至少两层线圈单元，相邻的两层所述线圈单元包含多个电枢绕组单元，每个电枢绕组单元具有三个线圈绕组，所述三个线圈绕组分别为该电枢绕组单元的U相、V相和W相，其中电枢绕组单元的U相和W相相邻布置在同一层，V相在U相和W相的上一层或下一层，与U相和W相的中心对齐排布，以及相邻的两层线圈单元中，如果相邻的两个电枢绕组单元中的一个电枢绕组单元的V相在该电枢绕组单元的U相和W相的上层，则另一个电枢绕组单元的电枢绕组单元的V相在该电枢绕组单元的U相和W相的下层。
  2. 如权利要求1所述的定子模块，其特征在于，每个线圈绕组由多层线圈叠加工而成，其中各层间线圈的连接接口垂向互联，使得各层线圈串联。
  3. 如权利要求2所述的定子模块，其特征在于，所述线圈呈矩形，以及所述定子线圈组件呈长方体形；或者，所述线圈呈扇环形，以及所述定子线圈组件呈扇环体形。
  4. 如权利要求1所述的定子模块，其特征在于，所述定子线圈组件通过印制电路板工艺制造。
  5. 如权利要求1所述的定子模块，其特征在于，所述线圈绕组设有接线端子，相邻的线圈绕组根据UVW三相连接方式，三角形连接方式或星形连接方式进行连接。
  6. 如权利要求1所述的定子模块，其特征在于，多个所述电枢绕组单元沿着一方向周期重复排布。
  7. 如权利要求1所述的定子模块，其特征在于，所述线圈绕组为无铁芯线圈绕组。
  8. 如权利要求1所述的定子模块，其特征在于，所述基体包括定子基座，其中所述定子线圈组件安装于安装于所述定子基座上。
  9. 一种线性马达的定子，其特征在于，所述定子由多个如权利要求1至8任一项所述的定子模块依次拼接而成。
  10. 如权利要求1所述的定子，其特征在于，所述定子包括依次连接的呈环形 体形的定子线圈组件和呈长方体形的定子线圈组件。
  11. 一种线性马达，所述线性马达包括动子和定子，其特征在于，所述定子采用权利要求9所述的定子，且所述线性马达包含多个动子，各所述动子设置成能够独立地相对于所述定子运动并设有永磁铁阵列。
  12. 如权利要求11所述的线性马达，其特征在于，所述动子包含上下两个永磁铁阵列，其中所述定子线圈组件位于所述两个永磁铁阵列之间。
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