Operation Analysis of an Integrated Linear Flux Modulating Motor for a Direct-driven Belt Conveyor

The following article covers the novel design of a linear flux modulating motor for direct-driven belt conveyors and gives an insight into considerations for manufacturing and system efficiency. In common approaches, belt conveyors are driven by attaching a geared electric machine to one of the drums, using the traction force between the drum and the belt to introduce linear motion. Since the contact area between the belt and the drum is small compared to the total belt surface, the achievable force in contact with the drum is limited. In order to increase the traction force between drum and belt, the tension inside the belt must be increased. The downside of this is higher mechanical stress and more complex belt designs to withstand the additional force. To overcome the mentioned aspects of common belt conveyors and to pave the way for new material flow models, a novel highly integrated direct-driven belt conveyor is presented. Efficient 3D FEM simulation results are provided, utilizing the symmetric properties of the motor to reduce simulation time considerably. In addition, an optimized design is presented resulting in a decreased force ripple and higher average force. Furthermore, an efficiency map for the desired operation range is given. [653]