Thrust ripple suppression and thrust density enhancement in halbach array permanent magnet synchronous linear motors via primary structure optimization

To address thrust ripple in permanent magnet synchronous linear motors (PMSLMs) and improve permanent magnet utilization efficiency, this paper proposes structural enhancements to the primary component. First, an analytical model of end force was established, and a dimension optimization scheme for the end-slot width was introduced. Subsequently, motor performance was compared between the original design and two Halbach-array secondary configurations. Finite element analysis (FEA) is employed to evaluate key parameters, including air-gap magnetic field harmonics, no-load back-EMF, and electromagnetic thrust. Simulation results validate the effectiveness of the proposed improvements, demonstrating a reduction in thrust ripple to approximately 4%, making the design suitable for high-precision machining applications.