Design, optimization and realization of a linear permanent magnet actuator with PCB windings

The permanent magnet synchronous linear motor is widely used in direct drive systems that require a high precision and a rapid dynamic response. However, the performances can be improved by printing the windings on PCB. This master thesis proposes to fully profit from the potential of this technology by optimizing the shape of the windings, with the objective of maximizing the force and minimizing the distortion. The magnetic and electrical characteristics of the motor have been modelled by means of analytical models, which have been validated by finite element models. The use of analytical models is justified as it allows a reduction of time during the optimizations. An experimental prototype has been designed in order to compare the performances of the developed motor with an existing motor on the market. Some measures have shown that the motor constant can be increased by a factor of two. The results of the optimizations have revealed that increasing more the width of the permanent magnets could lead to a further increase of 50 percents.