Force and Torque Model of Magnetically Levitated System with 2D Halbach Array and Printed Circuit Board Coils

Area of Science:

• Engineering
• Materials Science
• Robotics

Background:

• Precision machining requires adaptable worktables with variable stroke sizes.
• Existing magnetic levitation systems face limitations in scalability and manufacturing integration.

Purpose of the Study:

• To propose a novel, infinitely expandable magnetically levitated planar motor (MLPM) for precision machining applications.
• To enhance scalability and manufacturing feasibility through an innovative MLPM design.

Main Methods:

• Utilized independent, smaller coil units structured in a spiral pattern on a 16-layer PCB.
• Implemented magnetic field modeling for stator coils and a 2D Halbach array.
• Employed a table lookup method for end effects and solved for current vectors to evaluate magnetic force and torque decoupling.

Main Results:

• Achieved a 50.31% improvement in magnetic force calculation accuracy compared to traditional methods.
• Demonstrated a 70.65% improvement in torque calculation accuracy.
• Verified model accuracy through prototype development and testing.

Conclusions:

• The proposed MLPM offers a scalable solution for precision machining worktables.
• The innovative design and enhanced accuracy present significant potential for robotics and advanced manufacturing.