Çift taraflı hava çekirdekli lineer motor tasarımı ve gerçeklenmesiçift taraflı hava çekirdekli lineer motor tasarımı ve gerçeklenmesi

The history of linear motor technology can be traced back to the 1840s. The first model made by Charles Wheatstone was inefficient and impractical. The first feasible linear motor was created by a German engineer called Alfred Zehden in 1905 to drive trains and lifts. A more fundamental model was later developed by Herman Kemper in 1935. The best example of usage of linear motors today are in Maglev trains in Japan. Less than a decade ago, linear motors were only able to move 5 meters per second with straightness, load capacity and stiffness. This is a positive sign that linear motor technology is growing rapidly and is the focus of a great amount of research and development. Linear motors are widely used in the industry as they have a simple structure and their cost to produce is becoming much lower. However, linear motors have low power factor and low efficiency. Modern linear motor applications demand greater performance. The key demands of a linear motor are high acceleration, long life, low maintanence, few moving parts and precise positioning. Some of the applications include, DNA sequencing, health operations, rocket positioning etc. Therefore, precision of linear motors is becoming significantly more important. From ideas above, the study involves to produce a brand new linear motor. It has 22 pole pairs and 6 coils, designed in a FEM tool (ANSYS-Maxwell 2015®) and has since been into production. This purpose of the thesis is to demonstrate and explain the design of a high precision double-sided coreless linear motor. Materials simiar to the existing ones are chosen from ANSYS-Maxwell library. The materials are consisting of copper, NdFe35 and Steel_1010. Like Samarium Cobalt, NdFeB (Nd2Fe14B) is termed as rare earth magnet. These magnets have high coercive force and can be magnetized widthwise like a ferrite magnet. Copper windings are typically chosen over aluminum windings, even though aluminum is cheaper, copper is a better conductive material. As the application is having high precision that is applicable to many industrial areas that are listed above, it is a lot easier to design and produce the linear motor as a generic motor. The total motor weighs approximately 10.5 kg. This will be the perfect motor that can be mobile and be implemented anywhere needed. First, the electromagnetic design of the motor is performed. After the FE analysis is done using ANSYS-Maxwell software, the force value is verified by a hand calculation. The results between the two calculations are slightly different due to moving field that needs to be taken into account. Secondly, mechanical data set is examined for the motor design. Then, the CAD drawing of the motor is given followed by analytical verification of the design and electromagnetic analysis. The production and the tests of the electric motor that is designed is explained and finally the conclusion and future investigations are discussed. The drive circuit is a PWM circuit designed in ANSYS Maxwell Circuit Editor. The features that effect motor design are input voltage, output force and rated speed. To maintain the best electric design for the required force, choosing the proper materials and optimizing the coils are essential. An electrical machine is an electromechanical device that converts energy. When one investigates, when the input is electrical energy and the output is mechanical energy it works as an electrical motor. However, if the input is mechanical energy and the output is electrical energy electrical machine works as an electrical generator. Electrical machines can be divided into two different types which are listed as Alternative Current (AC) and Direct Current (DC) electrical machines. In an AC machine, alternative current flows into the coil and creates a rotating magnetic field in the airgap. In DC machines magnetic field is created straightly. Permanent magnet brushless DC motors are named DC but thinking of their working principle they can be considered in AC machine types. The designed linear motor can be thought like a BLDC machine. For the linear motor a special design is produced and laboratory tests are made. According to this special design, three coils would face four magnets. The design of the motor is made by computer aided software. After designing the linear motor, electromagnetic FEM analyses are made. The coils are optimized after making several analyses by using the finite element software. When the verification of the design is obtained, production is made as well as motor assembly. There are three hall sensors exist on the original motor. The hall sensors that are currently exist on the motor are ignored for the FEM design. An approximation is made for the FEM design for these hall sensors. In the thesis, hall sensors will not be discussed under the chapter of electromagnetic simulation.