Design and Analysis of PCB Winding Permanent Magnet Linear Motor

High-precision positioning systems increasingly demand linear actuators that balance high thrust density with compact form factors and ease of manufacturing. However, traditional iron-core linear motors suffer from significant cogging forces, while existing coreless designs are often limited by complex and costly wire-winding processes. This paper proposes a novel coreless linear motor topology designed to address these manufacturing challenges. The proposed system utilizes a modular Printed Circuit Board (PCB) stator architecture combined with a flux-concentrating Halbach permanent magnet array. By employing a modular stacking strategy, the design allows for scalable thrust generation without the fabrication complexity of monolithic high-layer-count boards. The electromagnetic performance of the motor was analyzed and validated through dynamic Finite Element Analysis (FEA) under motion conditions. Simulation results demonstrate that the proposed topology achieves highly linear force characteristics with almost zero cogging torque. Furthermore, the design realizes a significant reduction in volumetric profile compared to conventional wire-wound actuators, proving that the modular PCB approach is a viable solution for scalable, high-precision, and low-profile motion systems.