Abstract
Double-sided DC-Vernier reluctance linear machine (DS-DC-VRLM) is very suitable for long stroke industrial processing applications, taking advantages of magnet-free design, eliminated magnetic pull and high dynamic response. However, its low trust force density due to poor excitation ability of DC windings, has been a long-existing bottleneck. Aiming to boost the output thrust force of the DS-DC-VRLM, a novel high-order harmonic non-overlapped toroidal winding design is proposed. The key is that the proposed armature winding makes full use of working harmonics modulated from both fundamental order and third-order harmonics generated by DC excitations, contributing to enhanced winding factor. Based on the finite element analysis (FEA), with the proposed winding design approach, DS-DC-VRLM could achieve 2.26 times higher thrust force than those with conventional concentrated winding under the same copper loss. In this paper, new winding arrangement of DS-DC-VRLM and its operation principle are introduced, along with some design considerations of it, such as slot/pole combinations, DC/AC current distributions and extra end teeth dimensions are discussed for performance improvement. Finally, the performances of this proposed machine are evaluated by prototype experiments to verify the correctness of FEA simulation results.
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