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Research on Low-Speed and Large-Thrust Linear

Motor Used in Electromagnetic Transporting


ZHENG Wei SUN Zhao-long CUI Feng-rui
School of Electrical Engineering School of Electrical Engineering School of Electrical Engineering
Naval University of Engineering Naval University of Engineering Naval University of Engineering
Wuhan, China Wuhan, China Wuhan, China
zzww0438@yeah.net bruceszl@126.com fengrui_cui@foxmail.com

QIAN Han-ning ZHOU Wei-chang


School of Electrical Engineering School of Electrical Engineering
Naval University of Engineering Naval University of Engineering
2021 13th International Symposium on Linear Drives for Industry Applications (LDIA) | 978-1-7281-7210-1/21/$31.00 ©2021 IEEE | DOI: 10.1109/LDIA49489.2021.9505728

Wuhan, China Wuhan, China


charlie_qian@foxmail.com 1758414657@qq.com

Abstract—In order to meet the rapid transportation of transmission of chains and ropes is eliminated. The structure
modern ton-level flammable and explosive materials such as oil, is simple, and its control accuracy and driving speed are
there is an increasing demand for the development of greatly improved [3]. At present, domestic research on this
electromagnetic transportation systems. For the type of linear motor is still in its infancy. Many developed
electromagnetic transportation systems, the linear motor is its countries such as the United States, Germany, France, Britain,
core component, which not only requires high thrust density, and Japan have conducted more related theoretical and
but also maintains a stable speed during operation, and requires experimental studies. As linear motors have become a
in-depth consideration of electromagnetic compatibility and research hotspot again, it is very necessary to carry out
reliability. In order to ensure the normal operation of the research on new linear motors.
transportation system, according to the actual operating
environment and needs, the optimal selection of the motor type The large-thrust linear induction motor (LIM) has a wide
is an important factor in determining the performance of the range of applications. The Beijing Capital Airport Line and
system. In this paper two linear induction motors based on the Guangzhou Metro Line 4 [4], Line 5, and Line 6 all use large-
working conditions that meet the requirements of rapid thrust LIM as the main drive part. In the field of
material transportation are designed by using the magnetic electromagnetic launch, the high-thrust LIM is used as the
circuit method, namely a bilateral long primary linear induction main device of the launching mechanism. References [5-12]
motor and a bilateral permanent magnet linear synchronous carried out the research of high-speed and high-thrust LIM for
motor. Using the finite element method to compare and analyze electromagnetic ejection applications, so that the motor can
the electromagnetic thrust, power factor, efficiency and other
adapt to high-speed working conditions mainly through
performances of the two types of motors in detail. As a result,
structural design and optimization to weaken the edge effect
both motors can better meet the design requirements of the
electromagnetic transportation system and have good
of linear induction motors. However, the linear induction
application prospects. The optimal selection can be made motor itself has the disadvantages of low efficiency and low
according to the adaptability of the actual application power factor, which also limits its development.
environment, which provides technical support for the optimal With the decrease in the cost of permanent magnets,
design of the electromagnetic transportation system. permanent magnet linear synchronous motors (PMLSM) with
Keywords—electromagnetic transporting, low-speed and large thrust have also been promoted. At the same time,
large-thrust linear motor, finite element method, electromagnetic
permanent magnet linear motors have many characteristics
performance
such as high thrust density, fast response, high efficiency and
I. INTRODUCTION power factor, and more controllable to make it more favored
in the linear motor market, and many famous international
Compared with rotating motors, linear motors have the companies have also begun to produce large-thrust permanent
following advantages: No intermediate conversion magnet linear synchronous motors [13]. In the field of vertical
mechanism is required, which greatly simplifies the structure. lifting, PMLSM is used as a driving source, and it can be
Speed is not limited. The environmental requirements are widely used in high-rise building elevators and mine hoists by
relatively low [1]. Under the same conditions, the output force taking advantage of its simple structure, good dynamic
per unit volume is large [2], which can also save space. Its loss characteristics, high energy index, and high thrust density. The
is relatively small, because it does not require conversion vertical lifting system it drives has significant advantages such
equipment and has good heat dissipation performance. Due to as good safety, high efficiency, large lifting capacity,
the superior performance of linear motors, its application adaptation to harsh environments, and the simultaneous
range is becoming wider and wider. Nowadays, linear operation of multiple cars (cages) [14]. References [15-16]
reciprocating motions with speeds below 1m/s and thrusts proposed a bilateral magnetic flux switching type high thrust
above 5kN are widely used, such as the feed of heavy-duty PMLSM, considering the edge effect on the inductance and
machine tools, reciprocating plunger pumps, train car reluctance thrust components, the thrust characteristics were
marshalling, elevators, cargo lifting, and electromagnetic studied, and a method to reduce the thrust fluctuation was
transportation. For example, in a three-dimensional garage, a proposed. References [17-18] studied the matching of the
linear motor is used to directly drive the car board, and the number of slot poles of the fractional slot winding of PMLSM,

978-1-7281-7210-1/21/$31.00 ©2021 IEEE

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and proposed a permanent magnet linear synchronous motor
with an inverted U-shaped mover structure. Its structure can
further improve the thrust performance of the motor and
Y
reduce the motor's thrust fluctuations. Reference [19]
proposes a Transverse Flux Machine (TFM), which breaks the X

limitation that the number of pole pairs distributed in the


armature winding of the traditional motor must be equal to the Z

number of pole pairs of the excitation permanent magnet, and Fig. 1.Linear lnduction motor
integrates the advantages of the high thrust density of the motor with short primary structure is difficult to carry out
transverse flux machine and the load for linear motion directly electromagnetic shielding design, which may cause problems
driven by the linear motor, which is very suitable for the such as oil explosion. However, long primary bilateral linear
application in the field of low-speed linear direct drive. motor, because of its fixed primary, is easy to develop
At present, the high-thrust linear motors for electromagnetic shielding design, so the motor types designed
electromagnetic transporting has been extensively studied at below all adopt long primary double-sided type.
home and abroad, but its research background is mainly B. Preliminary Design of Linear Induction Motor
concentrated in the environment of high-speed and high- LIM uses a long primary bilateral structure, as shown in
thrust, the research for motors with speeds below 1m/s and Fig. 1. The long primary double-sided winding composed of
thrusts above 5kN is still in its infancy, and there are few the armature winding and the iron core is designed as a stator.
studies on the transportation of flammable and explosive fuels. The windings are connected in parallel and pass three-phase
Therefore, the research on low-speed and high-thrust linear symmetrical alternating current. Considering the lower speed
motors for the transportation of flammable and explosive
of movement, a mover composed of copper plates and back
materials is very necessary.
iron is designed between the double-sided stators.
In this paper, the selection design and performance
According to the rated working conditions of the motor
comparison analysis of two different types of linear motors are
and the motor design method of the magnetic circuit method,
carried out. The use of a long primary structure makes it easier
the motor is initially designed. The motor has a bilateral
to design the shielding layer of the primary. For a linear motor
structure, and the effective magnetic circuit of the motor is
with a fixed primary, it can effectively solve the
designed as a bilateral symmetrical magnetic circuit in the
electromagnetic compatibility problem, so that the safety of
design. The bilateral primary and secondary form two
transporting flammable and explosive objects is guaranteed.
magnetic circuits. Therefore, in the design process of the
First, according to the transportation conditions and actual
motor, the thrust force of F=2.5kN can be generated on the
market demand, two different types of linear motors, low-
unilateral basis, and the influence of the normal force can be
speed high-thrust LIM and low-speed high-thrust PMLSM,
eliminated by adopting this structure. For general unilateral
are designed respectively. The design parameters were used to
linear induction motors, the main dimensions of the motor
establish finite element models respectively, and the motor
meet the following relationships:
characteristics such as the air gap flux density, back EMF,
electromagnetic thrust, efficiency and power factor of the two √2(1-ξL )F
L1 W= (1)
motors were analyzed. Finally, the performance of LIM and Kdp1 Bδ1 Aη cos φ
PMLSM was compared, and the advantages and In the equation, L1 is the secondary length; W is the width
disadvantages of the two motors under their application of the motor; (1-ξL ) is the voltage drop coefficient, which may
environment were obtained, which laid the foundation for the be 0.86; Kdp1 is the winding coefficient, which may be 0.933;
future development of this type of motor. Bδ1 is the magnetic load, which may be 0.35; A is the unilateral
II. LINEAR MOTOR DESIGN electric load, which may be 53000A/m. It can be assumed that
the motor thrust F=2.7kN. Taking the product of efficiency
A. Motor Input Conditions and power factor η cos φ as 0.28, we can get:
The actual demand designed in this paper is to require the L1 W=0.684m2 (2)
linear motor to transport 25 tons of flammable and explosive Set the motor width W=0.3m, then the single stator length
goods for 50 meters within 4 minutes. The rated operating L1=2.28m; prefetch the motor pole pair number p=10, then the
conditions of the motor are shown in Table 1. Since the motor pole pitch t=0.114m; prefetch the motor slip s=0.2, then
designed motor is used for the transportation of flammable and the motor frequency f=2.3Hz. Prefetch the number of slots per
explosive materials such as tons of oil, the traditional linear pole per phase q=2, then the slot pitch b=19mm; prefetch
TABLE I. THE MOTOR RATED WORKING CONDITION motor slot width and slot pitch ratio is 1:2, then the slot width
Parameter Number value b0=9.5mm.
Select the pitch = τ = 95mm and the corresponding
Quality of goods (including motor mover)
25000
M/kg
Operation hours t/min 4 current effective value I when the motor is at the maximum
Stroke S/m 50
thrust is:
Motor power P/kW 2.1
Motor rated thrust F/kN 5
= (3)
Motor rated operating speed v /m/s 0.42 η φ
Therefore, the number of series turns per phase of the
winding N is:
= = 3240
×
(4)

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Select the motor as double winding, the number of First, according to (1), the motor width and single-segment
conductors per slot N1: electronic length of the permanent magnet linear synchronous
motor are calculated, where +1 , ξ - = 0.9 , /0 = 0.8 T ,
=2× = 162
!"
(5) A=20000A/m, the preset iron core stacking coefficient:
Take the slot full rate S=0.5, the current density 4lam = 0.95 , the product of efficiency and power factor
J=3.5A/mm2, then the slot depth: η cos φ is 0.81, W=0.28m, the other preset values are the same

ℎ% = = 60mm
&
as those of the linear induction motor, then the single-stage
'()*
(6) stator length is calculated to be L1=1m; the number of preset
After calculation, the design parameters of the linear motor pole pairs: p=6, then the motor frequency: f=2.52Hz.
induction motor shown in Table 2 can be obtained. Magnetic flux per pole of PMLSM ϕδ :

ϕδ = /δ :
;4lam = 0.00169 Wb
C. Preliminary Design of Permanent Magnet Linear
!
Synchronous Motor (7)
π
The permanent magnet linear synchronous motor adopts It is proposed to use N38 grade permanent magnet,
the bilateral moving magnet type (the part where the remanence: Br =1.23 T, coercivity: Hc =910 kA/m.
permanent magnet is installed is the mover) structure. The PMLSM permanent magnet thickness ℎmp :
specific structure is shown in Fig. 2.
*
AB × ℎmp = /δ
μ

?ℎmp@ δ
The main body of the motor structure is the double-sided
ℎmp = 47 mm
(8)
stator of the motor with double-layer windings, and a moving
magnet type mover is placed on both sides of the stator. The PMLSM permanent magnet cross-sectional area Am :
mover (built-in type) uses DW310 silicon steel sheet as the
connection bracket and the magnetic circuit. Inside the silicon DE = = 0.009 m
ϕδ
FG
(9)
PMLSM permanent magnet width Hmp :
steel sheet are permanent magnets with alternating N and S

poles. The structure of the mover is shown in Fig. 3.
TABLE Ⅱ. LIM DESIGN PARAMETERS Hmp

= = 32 mm
I
(10)
Parameter Number value
Due to the bilateral structure, according to the principle of
Single stator length L 1 /mm 2280
symmetry of the magnetic circuit, the width of the permanent
Stator height H 1 /mm 90
Stator stack thickness W/mm 300 magnet bmp :

Hmp = 2Hmp = 64 mm
Number of single stator slots Q 1 120 ′
Number of pole pairs p 10 (11)
Tooth pitch t 1 /mm 19 After calculation, the design parameters of the permanent
Tooth width b t /mm 9.5 magnet linear synchronous motor shown in Table 3 can be
Slot width b 0 /mm 9.5 obtained.
Slot depth h 0 /mm 60
Number of conductors per slot Z 1 162 TABLE Ⅲ. PMLSM DESIGN PARAMETERS
Mover length L 2 /mm 2280 Parameter Number value
Thickness of unilateral copper plate of
3 Single stator length L 1 /mm 1000
mover H 2 /mm
Stator height H 1 /mm 50.5
Back iron thickness of mover H3 /mm 20
Stator stack thickness W/mm 280
Unilateral air gap length δ/mm 2
Number of single stator slots Q 1 72
Number of pole pairs p 6
Tooth pitch t 1 /mm 14
Tooth width b t /mm 6
Slot width b 0 /mm 8
Fig. 2. Permanent magnet linear synchronous motor Slot depth h 0 /mm 41
Number of conductors per slot Z 1 60
Mover length L 2 /mm 2280
Permanent magnet length b mp /mm 64
Permanent magnet height h mp /mm 32
Magnetic isolation Bridge thickness
3
l 1 /mm
Unilateral air gap length δ/mm 10

III. MOTOR FINITE ELEMENT MODEL AND PERFORMANCE


ANALYSIS
A. Finite Element Model of Linear Induction Motor
According to the structural characteristics of the linear
Fig. 3. PMLSM mover
According to the motor design input requirements, the size induction motor, combined with the electromagnetic design
of the permanent magnet linear motor is calculated. Since the parameters of the motor, the winding shape is simplified while
permanent magnet linear synchronous motor is designed, it the cross-sectional area of the winding wire and the coil
will be different from some preset values in the linear resistance are unchanged, and the finite element analysis
induction motor design process. The size of the permanent model of the motor is established. The air gap between the
magnet is calculated, and the specific process is as follows: unilateral mover and the motor stator is 2mm, and the length
of the motor stack thickness direction is 300mm.

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Regarding the choice of linear motor materials, DW310 is
used for the iron core silicon steel sheet of the motor stator and
secondary, the stator armature winding is copper rectangular
wire, and the mover uses copper plates and back iron in the
model. In order to simplify the analysis process, the change of
the magnetic field in the direction of the stator stack thickness
Fig. 6. LIM magnetic line of force
is ignored, and the distribution of the motor magnetic field is
equivalent to a two-dimensional field to solve the calculation.
The finite element model is shown in Fig. 4:
B. The Finite Element Model of Permanent Magnet Linear
Synchronous Motor
According to the structural characteristics of the
permanent magnet linear synchronous motor, combined with
the electromagnetic design parameters of the motor, a finite
element analysis model of the electromagnetic field is
Fig. 7. LIM magnetic field
established. The air gap between the unilateral mover and the
motor stator is 10mm, and the length of the motor in the stack
thickness direction is 280mm.
The iron core silicon steel sheet of the motor stator and
secondary is DW310, the stator armature winding is copper
rectangular wire, and the permanent magnet of the mover is
made of rare earth permanent magnet neodymium iron boron
(NdFeB), the grade is N38. The finite element model is shown
in Fig. 5.

Fig. 8. LIM back EMF

Fig. 4. Linear induction motor

Fig. 5. Permanent magnet linear synchronous motor

C. Analysis of Electromagnetic Performance of Linear


Induction Motor
In the linear induction motor designed in this paper, the
three-phase winding is fed with a three-phase alternating Fig. 9. LIM air gap flux density
current with an effective value of 6.2A and a frequency of
2.3Hz. The load performance is analyzed: From the motor
magnetic field distribution, the designed linear induction
motor has a uniform magnetic field line distribution and
magnetic leakage. Under the rated operating conditions, the
iron core saturation is low and the operating conditions are
good, as shown in Fig. 6-7.
Under load, the amplitude of the back EMF of the three-
phase winding is 256V, and the three opposite electric
potentials are symmetrically distributed and have a high sine
degree, as shown in Fig. 8. Fig. 10. LIM air gap flux density by FFT
The load air gap magnetic density has a high sine degree, 5

the fundamental wave amplitude accounts for 47%, and the


4.9
other harmonics account for a relatively low proportion. The
air gap magnetic density amplitude is 0.3T, the thrust is stable, 4.8
and the thrust fluctuation is 3.7%. The average value is
4.92kN, as shown in Fig. 9-11. 4.7

4.6

4.5
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
Times(s)
Fig. 11. LIM air gap thrust curve

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D. Analysis of Electromagnetic Performance of Permanent
Magnet Linear Synchronous Motor

Air gap flux density(T)


For a permanent magnet linear synchronous motor, it is
necessary to analyze the no-load performance and load
performance of the motor. First, its no-load performance is
analyzed. When the motor winding is not supplied with
current and its mover moves at the synchronous speed, the no-
load motor performance can be obtained, as shown in Fig. 12-
14.

Fig. 15. PMLSM air gap flux density


0.035

0.03

0.025

0.02

0.015

0.01

0.005

0
Fig. 12. PMLSM positioning force 0 50 100 150 200 250 300 350 400 450 500

Fig. 16. PMLSM air gap flux density by FFT

Fig. 13. PMLSM magnetic line of force under no load

Fig. 17. PMLSM magnetic field


5.3

5.2

5.1

Fig. 14. PMLSM back EMF 5


Combining the analysis of the magnetic field lines
obtained by the above simulation with the magnetic density 4.9
distribution, it can be seen that without considering the end
4.8
distortion, the magnetic field lines of the motor start from a 0 50 100 150 200 250 300 350 400
permanent magnet, flow through the stator core teeth, are Times(ms)
Fig. 18. PMLSM air gap thrust curve
disconnected in the center of the core yoke, are connected with
the adjacent magnetic circuit and returned to the permanent The load air gap magnetic density is high in sine, its
magnet to form two parallel magnetic circuits. To prove the amplitude is 0.8T, the fundamental wave amplitude accounts
rationality of the design of the mover structure, it can be seen for 43%, the thrust is stable, the thrust fluctuation is 4.8%, and
from the simulation results that the no-load positioning force the average thrust is 5.25kN.
of the permanent magnet linear synchronous motor designed IV. COMPARATIVE ANALYSIS OF MOTOR PERFORMANCE
in this paper is up to 43.5735N, which is very small compared
to the load thrust. The amplitude of the no-load back EMF is According to the finite element calculation results and the
264V, and the three-phase opposite electric potentials are characteristics of the two motors, their performance is
symmetrically distributed and have a high sine degree. analyzed, as shown in Table 4:
The permanent magnet linear synchronous motor designed It can be seen from the comparison results under the same
in this paper uses a three-phase sinusoidal constant frequency design input conditions, the permanent magnet linear motor
current as the excitation source. The effective value of the has a higher thrust density, a smaller current required, and a
current is 2.08A and the rated frequency is 2.52Hz. Through relatively high-power factor and efficiency. However, because
finite element simulation, the simulation results shown in Fig. its mover structure is a permanent magnet, there is risk of
15-18 are obtained. demagnetization, so the reliability is lower than that of
induction motors. Linear induction motors have lower back
EMF, smaller thrust fluctuations, and more stable operation,
which is more conducive to the smooth control of the motor.

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