Optimization and Experimental Verification of a Moving-coil Cylindrical Halbach Linear Actuator for Enhanced Dynamic Performance

Balancing high dynamic response and high thrust density remains a prominent challenge for advanced permanent magnet linear motors (PMLMs), which has aroused persistent research interest. In contrast to conventional parametric iteration approaches relying merely on finite element analysis (FEA), this work develops an analytical‑guided parametric design framework for cylindrical Halbach moving-coil linear actuators (MCHLAs) to improve thrust performance. An analytical field model is constructed by solving the Laplace equation via separation of variables and Fourier series, which quantitatively establishes the parametric-thrust correlation and overcomes the drawback that pure FEA fails to reveal implicit parameter coupling mechanisms. Using the derived analytical model, the influences of pole-arc-to-pole-pitch ratio and radial dimensions on electromagnetic output are elaborated, and three-dimensional FEA is subsequently applied to acquire the geometric configuration. Prototype experiments validate the effectiveness of the design obtained from the analytical‑guided parametric design framework, the peak radial and axial air-gap flux densities of the MCHLA reach 1.2 T and 1.05 T, alongside an average thrust of 359.1 N. Dynamic tests confirm superior transient performance: the mover accelerates from rest to 0.98 m/s within 10 ms under no load, and an initial 27.41 mm impact vibration is rapidly eliminated within 400 ms with stable thrust and back-EMF waveforms. The proposed design strategy can facilitate the development of PMLMs for magnetic levitation and active vibration control applications.