Design of Small Permanent-Magnet Linear Motors and Drivers for Automation Applications with S-Curve Motion Trajectory Control and Solutions for End Effects and Cogging Force

This paper designs and fabricates a small-type permanent-magnet linear motor and driver for automation applications. It covers structural design, magnetic circuit analysis, control strategies, and hardware development. Magnetic circuit analysis software JMAG is used for flux density distribution, back electromotive force (back-EMF), and electromagnetic force analysis. To address the lack of a complete closed magnetic circuit path at the ends of the linear motor, which causes magnetic field asymmetry, a phenomenon known as end effects, auxiliary core structures are proposed to compensate for the magnetic field at the ends. It successfully utilizes auxiliary cores to achieve the phase voltages of each phase, which are balanced at a phase voltage error of 0.02 V. To address the cogging force caused by variations in the magnetic reluctance of the core, this paper analyzes the relationship between electromagnetic force and mover position, conducting harmonic content analysis to obtain parameters. These parameters are applied to the designed cogging force control compensation strategy. It successfully achieves q-axis current compensation of around 1.05 A based on the mover’s position, ensuring that no jerking caused by cogging force occurs during closed-loop electromagnetic force control. The S-curve motion trajectory control is proposed to replace the traditional trapezoidal acceleration and deceleration, resulting in smoother position control of the linear motor. Simulations using JMAG-RT models in MATLAB/Simulink verified these control strategies. After verification, practical test results showed a maximum position error of approximately 5.0 μm. Practical tests show that the designed small-type permanent-magnet linear motor and its driver provide efficient, stable, and high-precision solutions for automation applications.