A Linear Brushless Direct Current Motor Design for Sliding Door of Commercial Vehicle

Abstract

The number of van-type commercial vehicles used for public transportation is rapidly increasing. Automatic opening and closing sliding door systems consist of a rack and pinion gear, DC motor, and bearing system, which increase the door's weight and are seen as a major cause of failures due to the rising number of mechanical components in the van-type commercial vehicles. In the market, the demand for lighter, quieter, and electronically controlled systems for commercial vehicles aimed at passenger transportation is growing. Therefore, linear motor-driven door opening systems stand out due to their volume, force-to-weight ratios, and silent operation. In this study, a sliding door system compliant with ECE R10 and ECE R107 regulations is designed. A linear brushless direct current (LBLDC) motor is designed to meet these requirements. The linear motor design stages are established in accordance with industrial requirements. The variables used in motor design optimization are winding, slot, tooth dimensions, and slot/pole combinations. The necessary translational force for motor design is determined through mechanical calculations by creating a finite element model (FEM) of the vehicle's door and defining the motion functions. A 12-slot/10-pole linear electric motor design is assessed based on efficiency, weight, torque production, and ease of manufacturing. The manufacturing and optimization process is presented in detail, including experimental studies. As a result of the studies, a lighter system with high control capability is achieved. The development process of the automation solution is particularly highlighted in the automotive sector, where electrical equipment is increasingly used.