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Compared to conventional ironless and iron core linear motors, tubular motors are gradually getting traction for applications in different industries. The condition is especially true in case of medicinal and packaging industries, where linear tubular motor tools became preferred as ideal replacement options for pneumatics with similar form factor but were there for better reliability and efficiency.
What is a tubular motor?
Tubular liner motors are certain types of electric motor available with forcer that consist of solenoids that get wrapped around cylinder while enclosing movable rod containing permanent magnets that are strong cylinder shaped and are aligned in opposing and alternating ways.
Tubular motor use can mostly be seen in application that require linear actuators while delivering performance that can’t be matched through other types of linear actuators like lead screw linear actuators and pneumatic cylinders. Either forcer or the rod can be moving part, and this would be dependent on the application.
Being servomechanism part, tubular linear motors can simply get simultaneous high force combination, high precision and higher speeds that remain to be quite ahead of abilities of other actuators.
Just similar to various other counterparts, tubular linear motors are available with two parts: mainly permanent magnets and stator for housing windings. However, for tubular linear motor design, the magnets generally aren’t laid on flat track: rather these require magnets that are disc shaped and are embedded inside a tube (which is often referred to thrust rod). And stator which has also been referred similar to a forcer) that surrounds thrust rod.
Their primary motorized uses can be seen in roller blinds and roller shutter tube motor as well. These are also extensively used for roof shutters, retractable screens, retractable awnings, and various other roll up applications.
Why these are used over flat linear motors?
Compared to flat linear motors there are several key benefits that you get with tubular motor designs. Firstly, all magnetic flux present through permanent magnets are harnessed for generating higher amount of force. And, also according to the principle of Lorentz force, the total generated force through stator coils and thrust rod magnets remains perpendicular for both current and the magnetic field - in the travel direction. With such two attributes tubular linear motors provide much higher efficiency.
High efficiency means that less amount of heat has been generated, so less contraction and expansion of components are present because of thermal effects, and also less amount of heat has been transferred towards external load. Further end outcome of lesser heat generation and higher efficiency is better accuracy in positioning.
Tubular design force production is drive current linear function, as air gap present between thrust road and stator remains non-critical. This would mean that in case there is difference between air gap over stroke length, the force production for motor wouldn’t change.
One more benefit that you get with roller shutter tube motor designs over the flat linear ones is compact footprint. Also tubular linear motors are able to operate either through stator (forcer) while thrusting and moving tube stationery or through thrust tube moving when stator remains to be stationary. The ability of having trust tube moving would be among the different attributes making tubular linear motors as an ideal option for replacing pneumatic cylinders, which often operates with retracting and extending rod for pressing and pushing operations.
Similarly like the flat counterparts, tubular liner motors make use of iron in stator that surrounds soils and these are constructed through ironless stators. Less force is generated with ironless types, but these don’t experience cogging, so these get smooth motion even at lower speeds.
Tubular designs available with iron stator provide the benefit of ease of use compared to the flat-iron core counterparts as the cylindrical design can efficiently balance repulsive and attractive forces between thrust rod and stator, so here the assembly isn’t quite difficult, for tubular iron core designs as it has been for flat iron core designs. However, similarly to their flat counterparts, iron core tubular linear motors experience a lot of cogging.
Benefits of tubular motor in brief
· These are available with a manual operating system: For the case of power failure, this can manually be opened upon removing the rain shed shutter.
· You get a mechanical limit switch system
· Limit position can simply be set up
· Installation time and cost can be saved
· You get higher quality, unique design, and excellent performance, making it super mute, reliable and safe, and the use can be convenient and flexible.
General tubular motor design
These motors are designed for essentially getting a well fit inside rotating axle while appearing tubular. Typically, these are comprised of plastic or metal tube in addition to flange or drive wheel at a single end. At the simplest tubular rotating motor level comprising of an AC electrical motor driving series of planetary gear trains that get mounted in tubular motor tube.
Common limit stop for tubular motor tools are mechanical limits remembered and set through the use of pulse that count on encoder wheels present within tubular motor. For typical application this would require installer for setting limits after manually running tubular motors for extreme limits and also presenting motor button, or on the motor remote control. New tubular motors can include sophisticated electronics providing such limit setting entered in electronics without the need to get access for tubular motor. Such new models can also start including intermediate’ stop positions for offering further flexibility.
With this you allow the use of set and forget’ with a position leaving roller shutter getting retracted at half, for example.
Typical tubular motor application
Typically tubular motor tool application gets fitted well within an axle. This gets fitted within such that the tubular motor tube doesn’t rotate in respect for the axle that would fitter within. The tubular motor flange or drive wheel would typically involve attachment to axle, and it is fixed such that the wheel drive doesn’t rotate in respect with tubular motor for roller shutter. Such when tubular tool motor gets powered the drive wheel doesn’t rotate, but tubular tube does, further resulting in rotation of the axle.
Tubular motors largely get powered through alternating current electrical domestic system. You can also find some versions that operate from direct current power systems of low voltage power such as solar panels and batteries.
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