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Fig 545: A two axis linear stepper
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motor gantry stage [17]
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Apart from applications in various machines, linear motors are also used for transportation systems such as rail vehicles (Figure 546) For example, the linear motor used in the Linear Metro system has a thin rectangular body and requires no reduction gear, which is necessary for rotary motor railcars The flat linear motor used simplifies care maintenance saving labour It utilizes small-
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diameter wheels, a short wheelbase and a steering mechanism with fully electric brakes for stopping This significantly reduces maintenance of brake blocks The flat linear system also reduces tunnel cross sections by lowering the car floor [18]
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Fig 546: A linear motor driven system [18]
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Some other applications of linear motors include fun-park installations, automated multi-storey car parks, hybrid drives for transportation systems and material handling and transportation The requirements that usually point to a linear motor are long life or a number of cycles, high speed, very precise positioning, no wear, low noise, clean-room or vacuum compatibility and low maintenance Important specifications to consider when designing a linear motor include rated continuous thrust force, peak force, maximum speed, maximum acceleration, nominal stator length, slider or carriage travel, slide or carriage width and slider or carriage length The rated continuous thrust force is the maximum rated current that can be supplied to the motor windings without overheating The peak force is the maximum force of the linear motor The nominal stator length is the length of the fixed magnet or coil The slider or carriage travel is the range of travel of the moving coil or magnet The slider or carriage width and length are the dimensions of the moving coil or magnet In addition, the following considerations should be taken into account: The earth s core has a very strong attraction between the stationary and the moving component of the motor, which must be considered when calculating bearing system loads When used for vertical axis applications, precautions must be taken to prevent damage to the system, or injury to operations in the event of loss of power In most vertical applications, counterbalancing and fail safe brakes should be used In the case of a power loss, the system loses all stiffness Further, if the system feedback loop is lost, a runaway condition can occur Therefore, stops and a failsafe brake should be used Example: Linear Motor Analysis A detailed linear motor analysis is explained next in a simplified way to estimate the total force which is the key factor in the selection of linear motor drive power (notes provided by McKeown,
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Corbett, and Wills-Moren of Cranfield University, for MSc, lectures at GINTIC, NTU, Singapore) [19] Example : Specification (a) Total travel = 250 mm as follows: Phase 1: Accelerate to 500 mm/sec within 40 mm Phase 2: Travel for 125 mm at 500 mm/sec Phase 3: Decelerate to rest within the remaining 85 mm Phase 4: Dwell for 08 sec (b) Machining Force = 130 N in phase 2 (c) Coefficient of Friction = 008 (d) Moving Mass = 23 kg (e) Magnetic attraction force = 2000 N Kinematic analysis Table 52 Kinematic analysis for a linear motor drive [19]
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Positioning Phase Variable X (displacement) V (Velocity) A (Acceleration) T (Time) Units Mm mm/sec mm/sec2 Sec
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40 0 500 3125 016
125 500 0 025
85 500 0 1471 034
0 0 0 08
Fig 547: A graph of velocity versus time
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Force Analysis In the preceding example, assume a machining force of 130 N in Phase 2, a coefficient of friction of 008, and a moving mass of 23 kg (20 kg slide and a customer load and a 3 kg assumed mass for the motor coil) Finally, assume a magnetic attraction of 2,000 N Using the force equations, the resulting forces in this example are shown in the following table: Table 53 Force analysis for a linear motor drive
1 2 3 4
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