LINEAR MOTORS

Dr. Mohamed K. El-Nemr

Basics of Linear Motors
 Analogous to Unrolled DC Motor

• Force (F) is generated

when the current (I) I

(along vector L) and the

flux density (B) interact
• F = LI x B
 Linear Motors in Action

 http://www.parkermotion.com/video/Braas_Trilogy_T3E_Video.MPG
Hannes Daepp
Analysis of Linear Motors [1],[5]
 Analysis is similar to that of rotary machines
 Linear dimension and displacements replace angular ones
 Forces replace torques
 Commutation cycle is distance between two consecutive pole pairs
instead of 360 degrees
Benefits of Linear Motors [2]
 High Maximum Speed
 Limited primarily by bus voltage, control electronics
 High Precision
 Accuracy, resolution, repeatability limited by feedback device, budget
 Zero backlash: No mechanical transmission components.
 Fast Response
 Response rate can be over 100 times that of a mechanical transmission  faster accelerations, settling
time (more throughput)
 Stiffness
 No mechanical linkage, stiffness depends mostly on gain & current
 Durable
 Modern linear motors have few/no contacting parts  no wear
Downsides of Linear Motors
 Cost
 Low production volume (relative to demand)
 High price of magnets
 Linear encoders (feedback) are much more expensive than rotary encoders, cost increases with length
 Higher Bandwidth Drives and Controls
 Lower force per package size
 Heating issues
 Forcer is usually attached to load  I2R losses are directly coupled to load
 No (minimal) Friction
 No automatic brake
Components of Linear Motors
 Forcer (Motor Coil)
 Windings (coils) provide current (I)
 Windings are encapsulated within core material
 Mounting Plate on top
 Usually contains sensors (hall effect
and thermal)
 Magnet Rail
 Iron Plate / Base Plate
 Rare Earth Magnets of alternating polarity provide flux (B)
 Single or double rail F=
lI x
B

Hannes Daepp
Types of Linear Motors [1],[2],[3]
 Iron Core
 Coils wound around teeth of laminations on forcer

 Ironless Core
 Dual back iron separated by spacer
 Coils held together with epoxy

 Slotless
 Coil and back iron held together with epoxy

Hannes Daepp
Linear Motor Types: Iron Core
Distinguishing Feature
 Copper windings around forcer laminations over a single magnet rail
Advantages:
 Highest force available per unit volume
 Efficient Cooling
 Lower cost
Disadvantages: Laminated forcer
 High attractive force between forcer & magnet track assembly and mounting
 Cogging: iron forcer affects thrust plate Hall effect
force as it passes over each and
magnet (aka velocity ripple) Coil wound Around thermal
Forcer lamination sensors

Rare earth magnets Iron Plate

Linear Motor Types: Ironless
Distinguishing Feature
 Forcer constructed of wound coils held together with epoxy and running between two rails (North
and South)
Front View
 Also known as “Aircore” or “U-channel” motors
Forcer
Advantages: Mounting
 No attractive forces in forcer Plate
Winding, held
 No Cogging by epoxy Rare
Earth
 Low weight forcer - No iron means higher accel/decel rates Magnet
Hall Effect and
H
s orseshoe
Disadvantages: Thermal
Shaped
Sensors in coil
 Low force per package size backiron
 Lower Stiffness; limited max load without improved structure
 Poor heat dissipation
 Higher cost (2x Magnets!)
Linear Motor Types: Slotless Side View

Distinguishing Feature
 Mix of ironless and iron core: coils with back iron contained within aluminum housing over a single magnet
rail
Advantages over ironless:
 Lower cost (1x magnets)
 Better heat dissipation Coil Back Mounting
 Structurally stronger forcer Front View Thermal assembly iron plate
 More force per package size sensor
Advantages over iron core:
 Lighter weight and lower inertia forcer
 Lower attractive forces
Rare Iron
 Less cogging Earth plate
Magnets
Linear Motor Types: Slotless Side View

Disadvantages
 Some attractive force and cogging
 Less efficient than iron core and ironless - more heat to do the same job
Coil Back Mounting
Thermal assembly iron plate
sensor

Front View
Rare Iron
Earth plate
Magnets
Linear Motor Type Comparison
Linear Brushless DC Motor Type

Feature Iron Core Ironless Slotless

Attraction Force Most None Moderate

Cost Medium High Lowest

Force Cogging Highest None Medium

Power Density Highest Medium Medium

Forcer Weight Heaviest Lightest Moderate

Components of a “Complete” Linear Motor System
[3]

1. Motor components
2. Base/Bearings
3. Servo controller/feedback elements
• Typical sensors include Hall Effect (for position) and thermal sensors
4. Cable management
Sample Pricing
 $3529
 Trilogy T1S Ironless linear motor
 110V, 1 pole motor
 Single bearing rail
 ~12’’ travel
 magnetic encoder
 Peak Velocity = 7 m/s
 Resolution = 5μm
Applications
 Small Linear Motors
 Packaging and Material Handling
 Automated Assembly
 Reciprocating compressors and
alternators
 Large Linear Induction Machines
(3 phase)
 Transportation
 Materials handling
 Extrusion presses
References
[1] S. Cetinkunt, Mechatronics, John Wiley & Sons, Inc., Hoboken 2007.
[2] J. Barrett, T. Harned, J. Monnich, Linear Motor Basics, Parker Hannifin Corporation,
http://www.parkermotion.com/whitepages/linearmotorarticle.pdf
[3] Trilogy Linear Motor & Linear Motor Positioners, Parker Hannifin Corporation, 2008,
http://www.parkermotion.com/pdfs/Trilogy_Catalog.pdf
[4] Rockwell Automation, http://www.rockwellautomation.com/anorad/
products/linearmotors/questions.html
[5] J. Marsh, Motor Parameters Application Note, Parker-Trilogy Linear Motors, 2003.
http://www.parkermotion.com/whitepages/
Linear_Motor_Parameter_Application_Note.pdf
[6] Greg Paula, Linear motors take center stage, The American Society of Mechanical Engineers, 1998.
References (continued)
 http://www.physclips.unsw.edu.au/jw/electricmotors.html
 http://www.speedace.info/solar_car_motor_and_drivetrain.htm
 http://www.allaboutcircuits.com/vol_2/chpt_13/1.html
 http://www.tpub.com/neets/book5/18d.htm single phase
induction motor
 http://www.stefanv.com/rcstuff/qf200212.html Brushless DC
motors
 https://www.geckodrive.com/upload/Step_motor_basics.pdf
 http://www.solarbotics.net/library/pdflib/pdf/motorbas.pdf

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