Design, optimization and prototyping of a flexible linear actuator based on PCB windings

Details

Supervisors

Dehez, Bruno

Faculty

Ecole polytechnique de Louvain

Degree label

Master [120] : ingénieur civil électromécanicien, à finalité spécialisée: mécatronique
Master [120] : ingénieur civil électromécanicien, à finalité spécialisée: mécatronique

Abstract

enThis work investigates the design, optimization, and experimental validation of a flexible linear electromagnetic actuator based on flexible PCB windings. The proposed architecture combines a poly-articulated permanent-magnet structure with a flexible PCB mover, enabling linear actuation while preserving bending capability. Analytical electromagnetic, thermal, and mechanical models were developed and integrated into a bi-objective optimization framework aimed at maximizing the generated force per unit length while minimizing the bending radius. The optimization also highlights the potential of unbonded multilayer PCB windings to significantly improve force performance while maintaining flexibility. A single-layer prototype was manufactured and experimentally characterized. The measured phase resistance was 1.82 Ω, compared with a predicted 1.77 Ω, and the experimentally estimated force constant reached a mean value of 3.08 N/A, approximately 16% below the theoretical value. Thermal tests confirmed a maximum three-phase RMS current of approximately 3 A. The prototype successfully demonstrates the feasibility of the proposed actuator concept, while identifying friction during bending as the main limitation of the current design.