Design Methodology of a Dual-Halbach Array Linear Actuator with Thermal-Electromagnetic Coupling

Area of Science:

• Engineering
• Electromagnetism
• Thermal Management

Background:

• Linear actuators are crucial components in various applications.
• Optimizing actuator performance requires considering coupled physical phenomena.
• Thermal constraints significantly impact actuator design and continuous operation.

Purpose of the Study:

• To propose a design methodology for linear actuators.
• To maximize force density and minimize force ripple.
• To ensure thermal constraints are met for continuous operation.

Main Methods:

• Development of a step-by-step design process.
• Utilizing quasi-static parametric finite element models for electromagnetic and thermal analysis.
• Coupling thermal and electromagnetic models with geometrical and temperature constraints.

Main Results:

• Successful design of a linear cylindrical actuator with a dual quasi-Halbach array.
• Achieved axial force of 120 N and a stroke of 80 mm.
• Demonstrated significant design differences when thermal-electromagnetic coupling is considered versus an electromagnetic-only model.

Conclusions:

• The proposed methodology effectively designs linear actuators under coupled thermal-electromagnetic conditions.
• Thermal analysis is critical for accurate actuator design, impacting active volume and loading.
• The methodology is adaptable for designing various linear electromagnetic devices.