Analysis and Design of Ironless Toroidal Winding of Tubular Linear Voice Coil Motor for Minimum Copper Loss

Due to the ironless structure of the toroidal winding in the tubular linear voice coil motor (TLVCM), the winding thickness is one of the critical parameters that have an impact on air-gap flux density, and hence affects the copper loss at rated thrust. This paper investigates and determines the thickness of the ironless toroidal winding of the TLVCM for the purpose of a minimum copper loss. Magnetic equivalent circuit (MEC) method is used to analyze the air-gap flux density with respect to winding thickness, and the corresponding copper loss at the rated thrust is assessed by considering the slot fill factor. The optimal solution is obtained according to the U-shaped curve of the copper loss. Moreover, the finite-element analysis is combined to validate the results of MEC method, and a good agreement is reached. Two prototypes of TLVCMs having similar slot fill factor are made, one of which is with the optimal winding thickness. The expected current at the rated thrust is obtained by a test platform of static thrust, so as to obtain the corresponding copper loss for each prototype. The experimental results show that the TLVCM with optimal winding thickness features a lower copper loss. Hence, the attempt to minimize the copper loss by designing the thickness of the ironless winding is highly effective.