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A linear motor is essentially a rotary motor that has been opened out into a flat plane, but it operates on the same principles. A permanent-magnet DC linear motor is similar to a permanent-magnet rotary motor, and an AC induction squirrel cage motor is similar to an induction linear motor. The same electromagnetic force that produces torque in a rotary motor also produces torque in a linear motor. Linear motors use the same controls and programmable position controllers as rotary motors.
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Figure 1-27 Operating principles of a linear servomotor.
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Before the invention of linear motors, the only way to produce linear motion was to use pneumatic or hydraulic cylinders, or to translate rotary motion to linear motion with ballscrews or belts and pulleys. A linear motor consists of two mechanical assemblies: coil and magnet, as shown in Figure 1-27. Current flowing in a winding in a magnetic flux field produces a force. The copper windings conduct current (I ), and the assembly generates magnetic flux density (B). When the current and flux density interact, a force (F ) is generated in the direction shown in Figure 1-27, where F = I B. Even a small motor will run efficiently, and large forces can be created if a large number of turns are wound in the coil and the magnets are powerful rare-earth magnets. The windings are phased 120 electrical degrees apart, and they must be continually switched or commutated to sustain motion. Only brushless linear motors for closed-loop servomotor applications are discussed here. Two types of these motors are available commercially steel-core (also called iron-core) and epoxy-core (also called ironless). Each of these linear servomotors has characteristics and features that are optimal in different applications The coils of steel-core motors are wound on silicon steel to maximize the generated force available with a single-sided magnet assembly or way. Figure 1-28 shows a steel-core brushless linear motor. The steel in these motors focuses the magnetic flux to produce very high force density. The magnet assembly consists of rare-earth bar magnets mounted on the upper surface of a steel base plate arranged to have alternating polarities (i.e., N, S, N, S)
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Figure 1-28 A linear iron-core linear servomotor consists of a magnetic way and a mating coil assembly.
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The steel in the cores is attracted to the permanent magnets in a direction that is perpendicular (normal) to the operating motor force. The magnetic flux density within the air gap of linear motors is typically several thousand gauss. A constant magnetic force is present whether or not the motor is energized. The normal force of the magnetic attraction can be up to ten times the continuous force rating of the motor. This flux rapidly diminishes to a few gauss as the measuring point is moved a few centimeters away from the magnets. Cogging is a form of magnetic detenting that occurs in both linear and rotary motors when the motor coil s steel laminations cross the alternating poles of the motor s magnets. Because it can occur in steel-core motors, manufacturers include features that minimize cogging. The high thrust forces attainable with steel-core linear motors permit them to accelerate and move heavy masses while maintaining stiffness during machining or process operations. The features of epoxy-core or ironless-core motors differ from those of the steel-core motors. For example, their coil assemblies are wound and encapsulated within epoxy to form a thin plate that is inserted in the air gap between the two permanent-magnet strips fastened inside the magnet assembly, as shown in Figure 1-29. Because the coil assemblies do not contain steel cores, epoxy-core motors are lighter than steel-core motors and less subject to cogging. The strip magnets are separated to form the air gap into which the coil assembly is inserted. This design maximizes the generated thrust force and also provides a flux return path for the magnetic circuit. Con-
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