Introducing a Revolutionary
Principal Research Engineer
Moving Magnet Linear Motor
In 1998 EnduraTEC
Systems Corporation and
Bose Corporation joined
forces to bring to market
a new technology for the
fatigue testing and materi-
als characterization
industry. The result of this
alliance is EnduraTEC's
line of ELF and stent-graft
testers using Bose's elec-
tromagnetic actuator
technology, available
exclusively through
EnduraTEC. The patented
technology developed by
Bose uses a revolutionary
moving magnet motor
design capable of testing
the next generation of
materials at forces and
velocities heretofore
unattainable.
Why Bose?
Bose Corporation, a world leader in con-
sumer electronics products, has been
committed to research and innovation in
many aspects of electromagnetics since
its founding over 35 years ago. During
that time Bose has developed technical
strengths in electromagnetics, materials
science, and motion control in order to
produce high performance linear actua-
tors using moving coil motor designs
(e.g. audio transducers). However, after
nearly 15 years of R&D, Bose has intro-
duced a very different type of linear actu-
ator known as a moving magnet motor.
Why pursue a moving magnet motor?
There are several advantages in having
the magnet of a linear motor move rela-
tive to a stationary coil set. First, the sta-
tionary drive coils are intimately mounted
to a structure that can be more effectively
heat sunk. This facilitates the removal of
the resistive losses in the coils -- allowing
for much higher forces. Second, since
the coils are stationary their mass does
not affect the maximum velocity of the
motor. As a result a larger coil may be
used which enables a highly efficient
motor design. Third, the coils are station-
ary, so there are no "flying" leads; the
result is improved longevity of the motor.
Fourth, by design the moving magnet
does not make contact with any of the
stationary elements of motor, hence,
there is no frictional wear. These advan-
tages led Bose to pursue and develop
moving magnet technology.
How does a moving magnet motor work?
A simple view of the Bose moving mag-
net motor is illustrated in Figure 1. The
magnetic portion of the moving magnet
motor is comprised of three basic ele-
ments: the magnet, the coils, and the
core. In figure 1, the magnet moves left
By Ric Carreras
Bose Corporation
and right while the coils and core remain
stationary. The structure has depth w,
into the paper.
Magnetically, the magnet is "charged" or
magnetized with two polarities as illustrat-
ed. The function of the coil and core
assembly (also known as a stator) is to
carry and modulate the flux across the
gap where the magnet resides. The two
sections of core are connected to com-
plete the magnetic path, but for sake of
simplicity the core back iron has been
removed from the illustration. The coils
are wound and connected so that magnet-
ic flux generated by the current in each
coil adds constructively in the gap of the
motor.
The flux generated by the coils interacts
with the flux generated by the magnet
causing the magnet to react with a force
either left or right depending on the
polarity of the coil flux. A simpler way to
describe this is to view the core and coil
combination as an electromagnet produc-
ing a north and south pole as a function
of current. When the current is applied,
the appropriate poles of the magnet are
either attracted or repelled producing the
force. The stronger the current is the
stronger the resulting force is. The struc-
ture implemented will produce a force
that is directly proportional to the current
in the coils. Maximum force is only limit-
ed by the thermal performance of the
overall system design.
To meet the requirements of the testing
market Bose implemented the moving
magnet motor using state of the art
Neodymium Iron Boron (NdFeB) magnets.
These magnets have an energy product of
36 MGOe (mega Gauss Oersteads), ten
times more energetic than typical ferrite
magnets. The use of NdFeB magnets
allows the moving portion of the motor to
be very light producing a motor with high
acceleration (typically > 150G’s).
 How is the magnet suspended in the gap? less steel alloy that has exceptional fatigue
performance proven effective at more
To keep the performance of the motor
than 1010 cycles.
optimal, the gap between the magnet and
By design the stresses in the flexure are
core must be very small compared to the
kept below the fatigue limit of the alloy.
thickness of the magnet. Key to function-
This translates into infinite flexure life.
ality of the moving magnet motor is the
Because the flexures are thin, the suspen-
mechanical suspension. This suspension
sion is very compliant in the direction of
performs a number of important functions.
motion. However, the flexure must be
First, the suspension allows the magnet
stiff in the lateral direction to keep the
to move along the desired axial path with
magnet from making contact with the core
minimal use of the motor force. Second,
face. This requirement is met by designing
the suspension keeps the magnet from
the web of the flexure to be tall like an I-
crashing against the face of the core.
beam. This flexure geometry produces a
Contact with the core would produce
ratio of lateral stiffness to axial stiffness
Figure 1: Moving undesirable friction and nonlinear behav-
greater than 1000 to 1.
Magnet Motor ior of the motor. Third, the suspension is
For the testing market Bose has devel-
expected to last indefinitely over the nor-
oped an actuator with a suspension that
mal operating range and life of the motor.
has essentially no friction and will last bil-
Fourth, friction is expected to be kept to a
lions of cycles. Along with this durability,
minimum. Fifth, the suspension must have
the moving magnet motor design gives
low moving mass to avoid detracting from
the customer an actuator with accurate
the high acceleration capability of the
and repeatable motional characteristics.
motor.
To meet these requirements, Bose creat-
Conclusion
ed a low-mass flexure suspension with no
friction, infinite life, high lateral stiffness, EnduraTEC offers the Bose flexure-based
and low axial stiffness. Figure 2 shows a moving magnet actuator in its testing
simplified view of the flexural suspension equipment. The maintenance-free motor
of the moving magnet motor. The sus- is designed for materials testing that
pension is fabricated with a special stain- requires:

• High force, up to 5000 Newtons;

• High accelerations, greater than 150Gs;
• High bandwidth, greater than 200 Hertz;
• Near-infinite life, testing beyond a bil-
lion cycles;
• Precise position or load control and
accurate waveform control;
• Clean, quiet operation.

The patented advantages of stationary

coils and a moving magnet combined with
a frictionless flexural suspension deliver to
customers a performance envelop unavail-
able with any of voice coils, ball screws,
pneumatics, or hydraulics. For informa-
tion on how the moving magnet actuator
compares to conventional movers, or to
see if EnduraTEC's line of equipment
might be right for your application, please
Figure 2: Isometric View of the Patented Flexural call EnduraTEC or consult its other white
Suspension, Coils, and Core papers.

5610 Rowland Road, Minnetonka, Minnesota 55343 USA

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