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allowing an aggressive acceleration of loads up to 1,500 lbs (6,672 N) This drive utilizes two preloaded polyurethane drive wheels to transfer a motor torque from the drive module to the drive rail [14]
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533 Linear Motor Drive
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In order to eliminate the lead screw, nut and bearing drive usage, the linear motor drive has been invented, and this has several advantages In a rotating motor, alternating current flows through the motor s stator coils (primary) The current generates an alternating magnetic field, interacting with the magnetic poles of the rotor (motor s secondary), which thus helps in turning the rotor Linear servo motors essentially work in the same way as rotary motors do, only that they are opened up and laid out flat (Figure 536)
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Primary (stator) Secondary (rotor)
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Fig 536: Rotary and linear motors [15]
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As shown in Figure 537, each motor is made of only two parts a coil assembly and a magnet assembly The coil assembly encapsulates copper windings within a core material which is either epoxy based or made of steel The copper windings conduct current, I The magnet assembly consists of rare earth magnets, mounted in an alternating polarity on a steel plate, which generates magnetic flux density, B When the current and the flux density interact, force, F are generated in the direction shown in the figure where F = I B The advantages of linear motors are quoted from Anarod, one of the leading market providers of linear motor drives, and are as follows: Unlimited travel Linear motors do not have limitations on travel displacements Since the stationary magnet assemblies can be easily joined to form any length of motor, the travel length can be made as long as necessary Since the same moving coil assembly could be used
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Flux density (B) Current ( I )
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Force ( F )
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Magnet attraction (Fa) Magnet assembly
Fig 537: The working principle of a linear motor
for any travel length, there is no trade-off in the performance as a function of travel Screw driven systems, on the other hand, have critical speed limitations and higher inertia with added length Speed limitations, high inertia, and low stiffness are major performance tradeoffs with larger travels with other drive techniques They are used in LRTs (Light Rail Transit) Velocity Linear servo motors can be used in both very low and very high velocity applications, all with a very high precision They can precisely operate at velocities ranging from less than 1 m/sec (000004"/sec) to more than 10 m/sec (400"/sec) Ball screws and lead screws have critical speed limitations Belt drives exhibit a lower stiffness Rack-andpinion drives typically have a backlash and a poor low velocity performance They thus provide very low feed rates in ultra-precision machines and very high feed rates in large mould and die machine tools Acceleration Linear motors have a high ratio of peak force to motor inertia (about 30:1) Therefore, almost all of the motor force can be used to accelerate the moving load and perform useful work In typical screw-driven systems, a large portion of the motor torque is lost in overcoming the rotary inertia of the motor, coupling and screw Smoothness of motion Brushless linear servo motors can provide an extremely smooth motion, since they have no contacting surfaces to cause a jitter In contrast, ball screws are not as smooth due to the vibrating nature of the balls entering and exiting the ball nut raceways, which is easily observed in sub-micron systems Belt and rack-and-pinion drives also have contacting mechanisms, which are susceptible to friction and backlash caused vibrations Accuracy and repeatability With linear motors, the only limit to total system accuracy and repeatability is the sensing device and the bearings of the positioning system In rotary driven systems, there are additional factors, which affect these performance variables, including backlash, hysteresis, lost motion and jitter Stiffness Linear servo motors have a very high stiffness, typically higher than a stage s bearings and structural members With ball screws and rack-and-pinion drives, the couplings,
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