Robotic device and method for manufacturing, using and controlling the same

Abstract

Various embodiments relate to apparatuses and methods for moving magnetic movable devices. Particular embodiments provide systems and corresponding methods for magnetically moving a plurality of movable robots relative to one or more work surfaces of a respective one or more work bodies, and systems and corresponding methods for moving the robots between one or more work bodies via a transfer device. The robots can carry one or more objects between different locations, manipulate the carried objects, and / or interact with their surroundings for specific functions, including but not limited to assembly, packaging, inspection, 3D printing, testing, laboratory automation, etc. Mechanical links can be mounted on planar motion units such as the robots.

Description

[0001] Related Applications

[0002] This application is a divisional application of the application patent application with the application date of March 27, 2018, the application number of 201880033976.5, and the invention name of "Robot device and method for manufacturing, using and controlling the same".

[0003] This application claims priority to U.S. Provisional Patent Application No. 62 / 476,871 filed March 27, 2017, U.S. Provisional Patent Application No. 62 / 485,402 filed April 14, 2017, U.S. Provisional Patent Application No. 62 / 490,270 filed April 26, 2017, U.S. Provisional Patent Application No. 62 / 513,975 filed June 1, 2017, U.S. Provisional Patent Application No. 62 / 590,323 filed November 23, 2017, and U.S. Provisional Patent Application No. 62 / 626,082 filed February 4, 2018, the contents of which are incorporated herein by reference. TECHNICAL FIELD

[0004] As discussed herein, various embodiments relate to magnetically movable displacement devices or robot devices. Particular embodiments provide systems and corresponding methods for magnetically moving a plurality of movable robots relative to one or more work surfaces of a respective one or more work bodies, and systems and corresponding methods for moving robots between one or more work bodies via a transfer device. The robots can carry one or more objects between different locations, manipulate the carried objects, and / or interact with their surrounding environment for particular functions, including but not limited to assembly, packaging, inspection, 3D printing, testing, laboratory automation, etc. A mechanical linkage can be mounted on a planar motion unit, such as the robot. The mechanical linkage can include a rotary joint comprising a pair of left and right helical gears that are pre-tensioned to each other by a magnet. The linkage system can be mounted on the planar motion unit, where the linkage elements are composed of plastic. BACKGROUND

[0005] The following is intended to help the reader by providing context for the specification and is in no way meant to admit prior art.

[0006] Mobile stages (XY stages and rotary stages) are widely used in various manufacturing, inspection, and assembly processes. A common solution currently in use is to stack two linear stages (i.e., an X stage and a Y stage) together via connecting bearings to achieve XY movement. A more desirable solution can include a single mobile stage that is capable of moving in two or more different linear directions relative to a work surface, which can eliminate the need for additional bearings. It can also be desirable for such a mobile stage to be capable of moving in a direction perpendicular to the work surface. Attempts have been made to design such displacement devices using the interaction between electric current flowing through a conductive element and a permanently magnetic body. Examples of efforts in this regard include the following: U.S. Patent No. 6,003,230; U.S. Patent No. 6,097,114; U.S. Patent No. 6,208,045; U.S. Patent No. 6,441,514; U.S. Patent No. 6,847,134; U.S. Patent No. 6,987,335; U.S. Patent No. 7,436,135; U.S. Patent No. 7,948,122; U.S. Patent No. 2008 / 0203828; W. J. Kim and D. L. Trumper, High-precision magnetic levitation stage for photolithography, Precision Eng. 22 2 (1998), pp. 66-77; D. L. Trumper et al., "Magnet arrays for synchronous machines", IEEE Industry Applications Society Annual Meeting, vol. 1, pp. 9-18, 1993; and J. W. Jansen, C. M. M. van Lierop, E. A. Lomonova, A. J. A. Van denput, "Magnetically Levitated Planar Actuator with Moving Magnets", IEEE Tran. Ind. App., Vol 44, No 4, 2008.

[0007] More recent techniques for implementing displacement devices with mobile stages are described in:

[0008] • PCT Application No. PCT / CA2012 / 050751 (Publication No. WO / 2013 / 059934) entitled "DISPLACEMENT DEVICES AND METHODS FOR FABRICATION, USE AND CONTROL OF SAME"; and

[0009] • PCT Application No. PCT / CA2014 / 050739 (Publication No. WO / 2015 / 017933) entitled "DISPLACEMENT DEVICES AND METHODS AND APPARATUS FOR DETECTING AND ESTIMATING MOTION ASSOCIATED WITH SAME"; and

[0010] • PCT Application No. PCT / CA2015 / 050549 (Publication No. WO / 2015 / 188281) entitled "DISPLACEMENT DEVICES, MOVEABLE STAGES FOR DISPLACEMENT DEVICES AND METHODS FOR FABRICATION, USE AND CONTROL OF SAME"; and

[0011] • PCT Application No. PCT / CA2015 / 050523 (Publication No. WO / 2015 / 184553) entitled "METHODS AND SYSTEMS FOR CONTROLLABLY MOVING MULTIPLE MOVEABLE STAGES IN A DISPLACEMENT DEVICE"; and

[0012] • PCT Application No. PCT / CA2015 / 050157 (Publication No. WO / 2015 / 179962) entitled "DISPLACEMENT DEVICES AND METHODS FOR FABRICATION, USE AND CONTROL OF SAME".

[0013] Some other devices can enable in-plane movement (e.g., in one or both of the X and Y directions on the XY plane), but have limited range of movement in other directions (e.g., the Z direction when the Z axis is orthogonal to the X and Y axes or the rotational directions Rx, Ry, Rz about the X, Y, and Z axes). For example, movable stages using permanent magnetic bodies have a certain range of movement in the Z (i.e., perpendicular to the work surface) direction, which is typically limited to a few millimeters because the interaction between the current in the work body and the permanent magnetic body in the movable stage decays exponentially as the movable stage moves away from the work body in the Z direction, so the power efficiency can become very low when the gap between the movable stage and the work body in the Z direction becomes large. Thus, one area where there can be room for improvement compared to existing displacement devices is to extend the range of movement of the movable stage in one or more directions substantially perpendicular to the work surface (i.e., in one or more out-of-plane linear directions) and in one or more rotational directions (e.g., Rx, Ry, and Rz).

[0014] Further, other devices can be limited to movement in one plane on one work surface. Another area where there can be room for improvement compared to existing displacement devices is to provide robotic devices with multiple work surfaces on multiple horizontal planes so that the 3D space can be fully utilized and the footprint can be reduced. Another area for improvement can be to integrate the magnetically movable robots with one or more low-cost mechanical conveyance devices (e.g., a conveyor belt or a conveyor system) because magnetic systems can be much more expensive than traditional mechanical conveyance devices. It should be appreciated that there can be multiple applications where it can be advantageous to be able to move the magnetically movable robots between work surfaces on multiple horizontal planes and / or between the work surfaces and the mechanical conveyance devices (e.g., for efficiency or any other reason).

[0015] Other devices are capable of long-range linear movement on planar work areas even without any mechanical contact, and workpieces can be passively dropped on these devices for further transportation from one location to another. However, these devices cannot actively hold workpieces or actively manipulate workpieces relative to the movable stage. Thus, it can be desirable to have a gripper or end effector mounted on the movable stage that can be actively controlled to hold and / or manipulate one or more components with controllable force or displacement. Another area where there can be room for improvement compared to existing displacement devices is to have powered driving capability (additional degrees of freedom of motion beyond the 6 degrees of freedom of rigid body motion) or power generation / transmission capability without any cables attached to the movers.

[0016] It will be appreciated that there are a variety of applications in which it can be desirable (e.g., for efficiency or any other reason) to be able to move the extent of a workpiece in two or more planar directions, and / or to manipulate the workpiece with actuators, tools, or other devices on the movers.

[0017] Some of these movable stages can be equipped with mechanical devices for allowing or enhancing motion on or within the movers. Moreover, for biologically clean applications, linkages such as rotary joints can be employed in an effort to reduce contamination, as each component can be required to be flushed due to potential contaminants or pathogens. However, such high-speed automated mechanisms quickly accumulate a large number of moving cycles, and can often suffer from failure of cables, seals, or mechanical bearings that connect the moving members to a fixed base. Even a rotary joint with a seal at the interface of the moving and solid members will have minute features, such as linear features with small but finite width and depth, that can harbor pathogens. Thus, there is a need for a new and improved automated system that moves relative to the ground without a physical connection to the ground. There is also a need for simple injection-molded plastic components to minimize cost.

[0018] The foregoing examples of the related art and limitations related thereto are intended to be illustrative and not exclusive. Other limitations of the related art will become apparent to those of skill in the art upon a reading of the specification and a study of the drawings. SUMMARY

[0019] In one embodiment, a magnetic mobile apparatus includes at least one mover comprising a plurality of magnetic bodies, the plurality of magnetic bodies comprising at least first and second magnetic bodies, each of the plurality of magnetic bodies comprising at least one magnetic array comprising a plurality of magnetized elements configured to subject the at least one mover to one or more forces when at least one of the plurality of magnetized elements interacts with one or more magnetic fields such that the at least first and second magnetic bodies move relative to one another.

[0020] According to another embodiment, a method of controlling movement of a mobile apparatus, the mobile apparatus comprising a plurality of magnetic bodies, each magnetic body comprising a plurality of magnets, includes causing a first one of the plurality of magnetic bodies to move relative to a second one of the plurality of magnetic bodies in response to modulating at least one magnetic field within a range of the first magnetic body.

[0021] According to another embodiment, a linkage apparatus includes a first at least one gear associated with a first magnetic field, and a second at least one gear, wherein the first and second at least one gears are configured to be detachably coupled to one another in response to a magnetic interaction between the first and second magnetic fields.

[0022] According to another embodiment, a method of detachably coupling a first at least one gear to a second at least one gear includes causing a first at least one gear associated with a first magnetic field to be detachably coupled to a second at least one gear in response to a magnetic interaction between the first magnetic field and the second at least one gear.

[0023] According to another embodiment, an apparatus for moving at least one magnetically movable device includes a plurality of work bodies, each work body including a work surface on which the at least one magnetically movable device is configured to move, wherein each work surface is associated with at least one work magnetic field, and at least one transfer device including a transfer surface on which the at least one magnetically movable device is configured to move. The magnetically movable device is movable between the transfer surface and the work surfaces of the work bodies in response to modulating the at least one work magnetic field.

[0024] According to another embodiment, a method of moving at least one magnetically movable device includes causing the at least one magnetically movable device to move from a first work surface of a first work body to a transfer surface of a transfer device located in proximity to the first work body in response to modulating at least one work magnetic field associated with the first work surface of the first work body; positioning the transfer device in proximity to a second work body having a second work surface associated with a second at least one work magnetic field after moving the at least one magnetically movable device onto the transfer surface; and modulating the second at least one magnetic field to cause the at least one magnetically movable device to move from the transfer surface to the second work surface after positioning the transfer device in proximity to the second work body.

[0025] According to another embodiment, an apparatus for controlling movement of at least one magnetically movable device includes a work body having a work surface on which the at least one magnetically movable device is movable, at least one magnetic field modulator, at least one sensor configured to detect a current position of the at least one magnetically movable device relative to the work surface and generate at least one position feedback signal indicative of the current position of the magnetically movable device relative to the work surface, and at least one controller. The controller is configured to receive the at least one position feedback signal from the at least one sensor, calculate at least one magnetic field command based on the at least one position feedback signal and a desired position of the magnetically movable device, and send at least one movement signal to the at least one magnetic field modulator to cause the at least one magnetic field modulator to modulate one or more magnetic fields to move the magnetically movable device from the current position to the desired position.

[0026] According to another embodiment, a method for controlling at least one magnetically movable device to a desired position relative to a working surface includes determining the actual position of at least one magnetically movable device relative to the working surface, calculating the difference between the desired position and the actual position, and using the difference to modulate at least one magnetic field associated with the working surface to move the magnetically movable device toward the desired position.

[0027] Other aspects and features will become apparent to those skilled in the art from the following description of illustrative embodiments taken in conjunction with the accompanying drawings. Attached Figure Description

[0028] Figure 1A This is a partial cross-sectional top view of a device according to one embodiment.

[0029] Figure 1B yes Figure 1A A cross-sectional side view of the device shown.

[0030] Figure 2 This is a schematic side view of the device shown in Figure 1.

[0031] Figure 3A This is a top cross-sectional view of the mover according to one embodiment.

[0032] Figure 3B It includes Figure 3A A schematic side view of the device showing the moving part.

[0033] Figure 4A This is a top cross-sectional view of the mover according to one embodiment.

[0034] Figure 4B yes Figure 4A A schematic partial side view of the moving part shown.

[0035] Figure 5A This is a top cross-sectional view of the mover according to one embodiment.

[0036] Figure 5B It has Figure 5A A schematic side view of the device showing the moving part.

[0037] Figure 5C This is a top view of the mover according to one embodiment.

[0038] Figure 5D This is an isometric top view of the device according to one embodiment.

[0039] Figure 5E It is based on Figure 5D A top view of the magnetic array in the illustrated embodiment.

[0040] Figure 5F It is based onFigure 5D Schematic cross-sectional top view of a conductive element of a working body of the illustrated embodiment.

[0041] Figure 6A Top view of a mover according to one embodiment.

[0042] Figure 6B Is Figure 6A Side view of the mover illustrated.

[0043] Figure 7A Top view of a mover according to one embodiment.

[0044] Figure 7B Top view of a mover according to one embodiment.

[0045] Figure 7C Side view of a device according to one embodiment.

[0046] Figure 8A Side view of a device according to one embodiment.

[0047] Figure 8B Is Figure 8A Side view of a hinge of the illustrated embodiment.

[0048] Figure 8C Is Figure 8A Cross-sectional top view of a mover of the illustrated embodiment.

[0049] Figure 8D Side view of a device according to one embodiment.

[0050] Figure 8E Side view of a device according to one embodiment.

[0051] Figure 8F Side view of a device according to one embodiment.

[0052] Figure 8G Top view of a device according to one embodiment.

[0053] Figure 8H Isometric top view of a mover according to one embodiment.

[0054] Figure 8I Is Figure 8H Isometric top view of a mover illustrated.

[0055] Figure 9A Isometric top view of a mover according to one embodiment.

[0056] Figure 9B Is Figure 9A Isometric top view of a mover illustrated.

[0057] Figure 9C is a portion of a mechanical linkage according to Figure 9A is a portion of a mechanical linkage according to

[0058] Figure 9D is a portion of a mechanical linkage according to Figure 9C is a portion of a mechanical linkage according to

[0059] Figure 9E is a portion of a mechanical linkage according to Figure 9C is a portion of a mechanical linkage according to

[0060] Figure 9F is a portion of a mechanical linkage according to Figure 9C is a portion of a mechanical linkage according to

[0061] Figure 9G is a portion of a mechanical linkage according to Figure 9A is a portion of a mechanical linkage according to

[0062] Figure 9H is a portion of a mechanical linkage according to Figure 9G is a portion of a mechanical linkage according to

[0063] Figure 9I is a portion of a mechanical linkage according to Figure 9A is a portion of a mechanical linkage according to

[0064] Figure 9J is a portion of a mechanical linkage according to Figure 9I is a portion of a mechanical linkage according to

[0065] Figure 9K is a portion of a mechanical linkage according to Figure 9I is a portion of a mechanical linkage according to

[0066] Figure 10A is a portion of a mechanical linkage according to is a portion of a mechanical linkage according to

[0067] is a portion of a mechanical linkage according to Figure 10B is a portion of a mechanical linkage according to Figure 10A is a portion of a mechanical linkage according to

[0068] Figure 10C is a portion of a mechanical linkage according to Figure 10A is a portion of a mechanical linkage according to

[0069] Figure 10D is a portion of a mechanical linkage according to Figure 10A is a portion of a mechanical linkage according to

[0070] Figure 10E is a portion of a mechanical linkage according to Figure 10A is a portion of a mechanical linkage according to is a portion of a mechanical linkage according to

[0071] Figure 10F It is based on Figure 10A A side view of a portion of the mechanical link in the illustrated embodiment.

[0072] Figure 10G It is based on Figure 10A An isometric view of a portion of the mechanical link in the illustrated embodiment.

[0073] Figure 11A This is an isometric view of the mover according to one embodiment.

[0074] Figure 11B It is based on Figure 11A An isometric view of a portion of the mechanical link in the illustrated embodiment.

[0075] Figure 12A This is an isometric view of the mover according to one embodiment.

[0076] Figure 12B yes Figure 12A An isometric view of the moving part shown.

[0077] Figure 12C It includes Figure 12A The side view of the device shown.

[0078] Figure 13A This is a top sectional view of the mover according to one embodiment.

[0079] Figure 13B It includes Figure 13A A schematic sectional view of the side of the device showing the moving part.

[0080] Figure 13C It is based on Figure 13B The magnetic body and working body of the device shown are schematic cross-sectional views from the side.

[0081] Figure 13D It is based on Figure 13C A side sectional view of the magnetic body of the mover shown.

[0082] Figure 14A This is a top cross-sectional view of a device according to one embodiment.

[0083] Figure 14B yes Figure 14A Side sectional view of the device shown.

[0084] Figure 15 This is a side view of a device according to one embodiment.

[0085] Figure 16A This is a side view of a device according to one embodiment.

[0086] Figure 16B is a partial top view cross-sectional view of the device shown. Figure 16A

[0087] Figure 16C is a side view of the device shown. Figure 16A

[0088] Figure 16D is a partial top view cross-sectional view of the device shown. Figure 16A

[0089] Figure 17A is a side view of the device according to one embodiment.

[0090] Figure 17B is a partial side view of the device shown. Figure 17A

[0091] Figure 17C is a side view of the device shown. Figure 17A

[0092] Figure 18 is a top view of the device according to one embodiment.

[0093] Figure 19 is a top view of the device according to one embodiment.

[0094] Figure 20A is an isometric top view of the device according to one embodiment.

[0095] Figure 20B is a partial side view of the device shown. Figure 20A

[0096] Figure 21A is an isometric top view of the device according to one embodiment.

[0097] Figure 21B is a side view of the device shown. Figure 21A

[0098] Figure 21C is a side view of the device shown. Figure 21A

[0099] Figure 22A is a schematic side view of a plurality of working subjects according to one embodiment.

[0100] Figure 22B is a schematic side view of a plurality of working subjects according to Figure 22A

[0101] Figure 23A is an isometric top view of the device according to one embodiment.

[0102] Figure 23B is​​​​​​​​​Figure 23A isometric top view of the device shown.

[0103] Figure 24A is a partial isometric top view of a device according to one embodiment.

[0104] Figure 24B is Figure 24A is a partial isometric top view of the device shown.

[0105] Figure 25A is a partial isometric top view of a device according to one embodiment.

[0106] Figure 25B is Figure 25A is a partial isometric top view of the device shown.

[0107] Figure 25C is Figure 25A is a partial isometric cross-sectional view of the device shown.

[0108] Figure 25D is Figure 25A is a partial isometric top view of the device shown.

[0109] Figure 25E is Figure 25A is a partial isometric top view of the device shown.

[0110] Figure 25F is Figure 25A is a partial top view cross-sectional view of the device shown.

[0111] Figure 26A is a partial isometric top view of a device according to one embodiment.

[0112] Figure 26B is Figure 26A is a partial isometric top view of the device shown.

[0113] Figure 27A is a partial isometric top view of a device according to one embodiment.

[0114] Figure 27B is Figure 27A is a partial isometric top view of the device shown.

[0115] Figure 28A is a partial isometric top view of a device according to one embodiment.

[0116] Figure 28B is Figure 28A is a partial isometric top view of the device shown.

[0117] Figure 29 is a partial isometric top view of a device according to one embodiment.

[0118] Figure 30 is a partial isometric top view of a device according to one embodiment.

[0119] Figure 31A is a partial isometric top view of a device according to one embodiment.

[0120] Figure 31B is a partial isometric top view of a device according to one embodiment. Figure 31A is a partial isometric top view of a device according to one embodiment.

[0121] Figure 31C is a partial isometric top view of a device according to one embodiment. Figure 31A is a partial isometric top view of a device according to one embodiment.

[0122] Figure 32 is an isometric top view of a device according to one embodiment.

[0123] Figure 33A is an isometric top view of a device according to one embodiment.

[0124] Figure 33B is a cross-sectional isometric side view of a device according to one embodiment. Figure 33A is a cross-sectional isometric side view of a device according to one embodiment.

[0125] Figure 34 is a cross-sectional top view of a device according to one embodiment.

[0126] Figure 35A is an isometric top view of a device according to one embodiment.

[0127] Figure 35B is an isometric top view of a device according to one embodiment. Figure 35B is an isometric top view of a device according to one embodiment.

[0128] Figure 36A is a partial isometric top view of a device according to one embodiment.

[0129] Figure 36B is a partial side view of a device according to one embodiment. Figure 36A is a partial side view of a device according to one embodiment.

[0130] Figure 36C is a partial side view of a device according to one embodiment. Figure 36A is a partial side view of a device according to one embodiment.

[0131] Figure 37 is a partial isometric top view of a device according to one embodiment.

[0132] Figure 38A is a 2D trajectory of a motile according to one embodiment in time domain.

[0133] Figure 38B is a 2D trajectory of a motile according to Figure 38A is a 2D trajectory of a motile according to one embodiment on a work surface of a 2D trajectory.

[0134] Figure 39 This is a top view of a device according to one embodiment.

[0135] Figure 40A This is a schematic diagram of a work unit control module according to one embodiment.

[0136] Figure 40B yes Figure 40A A schematic diagram of a portion of the working unit control module shown.

[0137] Figure 41A This is a top view of a working unit according to one embodiment.

[0138] Figure 41B This is a top view of the work area according to one embodiment.

[0139] Figure 42 This is a schematic diagram of a workflow according to one embodiment.

[0140] Figure 43 This is a top view of the work area according to one embodiment.

[0141] Figure 44A This is a graphical view of the speed adjustment factor according to one embodiment.

[0142] Figure 44B This is a schematic diagram of the X-direction trajectory generation process according to one embodiment.

[0143] Figure 45A This is a side view of a device according to one embodiment.

[0144] Figure 45B yes Figure 45A A partial top view of the device shown.

[0145] Figure 46A This is a cross-sectional side view of a device according to one embodiment.

[0146] Figure 46B yes Figure 46A A close-up partial side view of the device shown.

[0147] Figure 47 This is a force-assisted assembly process according to one embodiment.

[0148] Figure 48 This is a top view of a device according to one embodiment.

[0149] Figure 49A This is a top cross-sectional view of a device according to one embodiment.

[0150] Figure 49B yes Figure 49A A cross-sectional side view of the device shown.

[0151] Figure 50A is a cross-sectional schematic top view of a mover according to one embodiment.

[0152] Figure 50B is Figure 51A is a schematic side view of a magnetic gear on the mover shown.

[0153] Figure 51A is a cross-sectional schematic top view of a mover according to one embodiment.

[0154] Figure 51B is Figure 51A is a schematic side view of a magnetic gear on the mover shown.

[0155] Figure 52 is an isometric top view of an apparatus according to one embodiment.

[0156] In the drawings, embodiments of the application are shown by way of example, it should be clear that the description and drawings are for illustrative purposes only and are not intended to limit the application. DETAILED DESCRIPTION

[0157] SUMMARY

[0158] Throughout the following description, specific details are set forth in order to provide a more thorough understanding of the application. However, well known elements can not have been shown or described in detail to avoid unnecessarily obscuring the disclosure. Accordingly, the description and drawings are to be regarded as illustrative in nature and not as restrictive.

[0159] According to some aspects of the application, a magnetic mobile apparatus (herein also referred to as "movable robotic system" or simply "system") can comprise one or more working bodies and one or more movable robotic devices (herein also referred to as "robots").

[0160] In this document, and with reference to various embodiments, the work body can comprise or can be referred to as a stator. Each movable robot can be configured to carry one or more objects, such as workpieces or parts (“workpieces” and “parts” are used interchangeably in this document, and are general terms, non-limiting examples of which can include parts, samples, or assemblies). In some applications, multiple movable robots can carry one part holder, which can hold one or more parts. Generally, the work body and the one or more movable robots can interact with each other via one or more magnetic fields, which can be configured to exert one or more forces and / or torques to the movable robots to controllably move the movable robots. In various embodiments, the work body can comprise one or more electrically conductive elements, which can be distributed in one or more planar layers within the work body. In various embodiments, the one or more electrically conductive elements can comprise, for example, a plurality of ferrous teeth or a plurality of electrically conductive elements.

[0161] Generally, the work body comprises a work surface (which can be flat, curved, cylindrical, spherical, or any other planar or curved shape) on which the one or more movable robots can move. Each movable robot can move along the work surface by physical contact (e.g., through a contact medium such as sliding and / or rolling bearings), or by interacting between the movable robot and the one or more magnetic bodies to maintain a controllable gap between the movable robot and the work body in a direction perpendicular to the work surface without any physical contact. This controllable gap can be maintained while controlling the movement of the movable robot in one or more directions / degrees of freedom (also referred to herein as “DOF”) (i.e., operating in an “active levitation mode”), or by a passive levitation means (passive levitation mode) by maintaining a gap between the movable robot and the work body.

[0162] Each movable robot comprises one or more movable bodies (also referred to herein as “movers,” “movable mobiles,” “movable stations,” and / or “mobiles”). In various embodiments, one movable robot can comprise one mover. In various embodiments, one movable robot can comprise two movers. In various embodiments, one movable robot can comprise three or more movers. In various embodiments, the one or more movable robots can be substantially similar or nearly identical; however, it is necessary in all cases, and the system can comprise movable robots of various sizes and / or configurations in accordance with various embodiments as described below.

[0163] Each mover can include one or more magnetic bodies (also referred to herein interchangeably as "magnetic assemblies"). Each magnetic body includes one or more magnetic arrays, which can be rigidly connected together. Each magnetic array includes one or more magnetized elements (e.g., magnets). Each magnetized element has a magnetization direction.

[0164] In various embodiments, the magnets on the mover can interact with the current flowing in the electrically conductive elements in the work body across a distance that is much smaller than the dimensions of the mover. In other words, the mover can operate in the vicinity of the electrically conductive elements of the work body. Typically, the magnets on the mover can interact with the current flowing in the electrically conductive elements of the work body through a working gap that is much smaller than the width or length of the mover (i.e., the dimensions of the mover in a direction parallel to the working surface of the work body).

[0165] In various embodiments, one or more magnetic field modulators (also referred to herein interchangeably as "magnetic field generators" or "amplifiers" or "current generators") can be configured to modulate one or more magnetic fields in the work body. In one embodiment, for example, the magnetic field modulators can include one or more amplifiers connected to drive a plurality of currents in a plurality of electrically conductive elements in one or more work bodies. One or more controllers can be connected to deliver control signals (also referred to herein as "current reference commands") to the one or more amplifiers. The control signals can be used to control the currents driven by the one or more amplifiers into one or more of the plurality of electrically conductive elements such that the currents follow the current reference commands. The controllably driven currents into at least one of the plurality of electrically conductive elements generate one or more magnetic fields that induce corresponding magnetic forces on one or more magnetic array assemblies of the mover, thereby controllably moving the mover relative to the work body in at least 2 in-plane directions / DOFs (e.g., within a working area of a working surface of the work body), including but not limited to controllable motion in 3 in-plane directions / DOFs and 6 directions / DOFs.

[0166] In various embodiments, the magnetic forces related to the interaction between the magnetic fields generated by the currents in the at least one electrically conductive element and the magnetic fields related to the magnetic arrays of the mover can always attract the mover to the work body when the controller controls the currents driven by the one or more amplifiers. In various embodiments, the magnetic forces related to the interaction between the magnetic fields generated by the currents in the at least some electrically conductive elements and the magnetic fields related to the magnetic arrays can always force the mover to be a certain gap away from the work body to balance the gravitational force when the controller controls the currents driven by the one or more amplifiers. In various embodiments, the gap between the mover and the work body can be maintained by, for example, an air bearing, a compressed fluid bearing, or a sliding bearing or a rolling bearing.

[0167] In various embodiments, one mover can include multiple magnetic bodies and mechanical links. In various embodiments, the mechanical links can include a single component or an assembly of multiple components, such as bearings, connectors, hinges, etc. As used herein, “mechanical links” can describe any mechanical linkage system, assembly, device, or body that (removably or non-removably) connects, links, or couples two or more magnetic bodies.

[0168] In various embodiments, the mechanical links can constrain relative movement between two or more of the multiple magnetic bodies of the mover in a first set of one or more directions / degrees of freedom, and can allow relative movement between two or more of the multiple magnetic bodies in a second set of one or more directions / degrees of freedom. In various embodiments, the meaning of “constraining relative movement between two or more magnetic bodies in a first set of one or more degrees of freedom” in relation to the mechanical links can be interpreted as:

[0169] (1) when the mechanical links are removed from the mover, the two or more magnetic bodies can be moved relative to each other in the first set of one or more directions / DOFs by driving appropriate currents into the suitably selected electrically conductive elements;

[0170] (2) when the mechanical links are implemented, the two or more magnetic bodies cannot be moved relative to each other in the first set of one or more directions / DOFs.

[0171] In various embodiments, the mechanical links are “floating” relative to the working bodies; that is, the mechanical links are not fixed to the working bodies, but move with the mover.

[0172] In various embodiments, controllably moving a mover including first and second magnetic bodies in one direction of a first set of constrained directions / DOFs includes (1) calculating a coordinated position / rotation feedback for the mover in the one direction based on position / rotation feedback of the first magnetic body and the second magnetic body in the one direction; (2) using the coordinated position / rotation feedback and a suitable control algorithm to calculate a coordinated force / torque command in the one direction to be applied to each of the first magnetic body and the second magnetic body; (3) using the coordinated force / torque and algorithm (e.g., commutation algorithm) to calculate current reference commands and sending these current reference commands to amplifiers that drive currents into some electrically conductive elements of the working bodies. Although relative motion between the first magnetic body and the second magnetic body in the first set of directions / DOFs is constrained, the mover as a whole is still capable of controllable motion in one or more directions / DOFs of the first set of directions / DOFs.

[0173] In various embodiments, the mover can also include a brake (which can also be referred to herein interchangeably as a “brake assembly,” a “locking assembly,” a “braking mechanism,” or a “locking mechanism”). When the brake is deactivated, the mechanical linkage can constrain relative motion between the two or more magnetic bodies of the mover in a first set of one or more directions / degrees of freedom and allow relative motion between the two or more magnetic bodies in a second set of one or more directions / degrees of freedom. When the brake is activated, the mechanical linkage can constrain relative motion between the two or more magnetic bodies in the first set of extended directions / DOFs. In one embodiment, the first set of extended directions / DOFs can include the first set of directions / DOFs plus at least one direction / DOF from the second set of directions / DOFs.

[0174] In various embodiments, a movable robot can include two or more independently controllable movers and a mechanical linkage. The mechanical linkage is configured to link together at least a first mover and a second mover of the two or more movers in a non-limiting manner (the DOFs of controllable movement of each mover remain unchanged whether or not the mechanical linkage is installed). The mechanical linkage can translate the motion of the two or more movers into a desired movement of a workpiece holder (or carrier or end effector) mounted on the movable robot. In one embodiment, the position and orientation of the workpiece holder can be determined entirely from the position and orientation of the two or more movers.

[0175] In various embodiments, a movable robot can include two or more independently controllable movers and a mechanical linkage and a braking (or locking) mechanism. When the braking mechanism is not activated, the mechanical linkage links together the two or more movers in a non-limiting manner (the DOFs of controllable movement of each mover remain unchanged whether or not the mechanical linkage is installed). When the braking mechanism is activated, at least one DOF of relative motion between two movers of the two or more movers is constrained by the mechanical linkage. In various embodiments, the mechanical linkage can translate the motion of the two or more movers into a desired motion of a workpiece holder (or carrier or end effector) mounted on the robot, and the position and orientation of the workpiece holder can be determined entirely from the position and orientation of the two (or more) movers.

[0176] In various embodiments, the movers can operate in a levitation mode, i.e., levitate in a passive manner or in an active manner near or above a work surface of a work subject without contacting the work subject and move relative to the work surface extending in X and Y directions, for example, which are not parallel to each other and both parallel to the work surface. It should be appreciated that although the movement of the movers according to various embodiments herein is described with reference to a typical X, Y, Z Cartesian coordinate system, this is for illustrative purposes only and such movement can be described with respect to any other coordinate system. For the purposes of this disclosure, the work surface of the work subject is substantially parallel to the X-Y plane, with the Z direction being substantially perpendicular to the work surface, unless otherwise noted.

[0177] The separation gap between the work surface and the mover bottom surface can be much smaller than the dimensions of the mover in the X and Y directions. Although the movers in many embodiments are capable of 6-DOF controllable movement, this is not necessary in all cases. In certain applications, levitation features (i.e., where the movable robot is capable of fully detaching itself from the work subject without contacting the work subject) can not be needed and heavy load carrying capacity is more important, and as will be appreciated by those skilled in the art throughout the specification, the mover can be located on the work surface of the work subject by appropriate mechanical support (e.g., one or more bearings, including but not limited to planar slide bearings and ball transfer units, for example, one or more bearings) and is capable of three in-plane DOF controllable motion, i.e., translation in the X and Y directions (“X” and “Y”) and rotation about an axis of rotation parallel to the Z direction (“Rz”), where the X and Y directions are substantially parallel to the work surface but not parallel to each other, and the Z direction is substantially perpendicular to the work surface. For greater clarity, as used herein, “rotation about the X / Y / Z direction” or “rotation about the X / Y / Z axis” should be understood by those skilled in the art to mean rotation about an axis of rotation parallel to the X / Y / Z axis, or in other words, movement along the Rx / Ry / Rz direction, respectively.

[0178] The mover can be considered to be working in a seated mode when it is seated on a work surface by one or more sliding and / or rolling bearings. The mover can be considered to be working in a three degree of freedom controlled seated mode when it is seated on a work surface by one or more sliding and / or rolling bearings and the mover is capable of 3-DOF controllable motion (e.g., in the X, Y, and Rz directions). In various embodiments, the mover is capable of 3-DOF controllable motion (e.g., in the X, Y, and Rz directions) when it is capable of such motion while working in a levitated mode without contact with the work body. In the levitated mode, the mover can translate in the Z direction (i.e., substantially normal to the work surface) and can rotate about rotational axes in the X and Y directions (respectively, “Rx” and “Ry”). This rotational movement and associated DOF can be open-loop controlled without feedback using suitable passive levitation techniques known to those skilled in the art. The mover can be considered to be working in a three degree of freedom controlled levitated mode when it is capable of 3-DOF controllable motion without contact with the work body.

[0179] In various embodiments, the work surface of a work body according to any embodiment herein can decouple the mover with a magnetic body therein from the work body. The magnetic field generated by the electrically conductive element in the work body thus propagates through the work surface, and thus the magnetic body of the mover is subject to forces through the work surface. In various embodiments, the work surface can be flat, planar, or curved.

[0180] Generally, the work area of a work body, such as a work body, is a two-dimensional (“2D”) area provided by the work surface of the work body, and with suitable feedback control algorithms and suitable position feedback sensors, the mover can be controllably moved by at least two in-plane DOF motion within the work area of the work body.

[0181] In various embodiments, the mover can be transferred between a first work body and a second work body, or to and from a single work body, via a transfer device. The first work body can be located at a first Z position or first Z plane, the second work body can be located at a second Z position or second Z plane, and the two work bodies can overlap in the Z direction. In various embodiments, the mover can be transferred from a work body to a transfer device, such as a movable transfer table or conveyor, or vice versa.

[0182] See generally Figure 1A and 1B A magnetic mobility device 150 is shown according to one embodiment. Figure 1A and 1BPartial cutaway top and side views of non-limiting embodiments of a magnetic mobility device 150 are depicted. The magnetic mobility device 150 includes a work body 130, one or more movable robots 111 including at least one mover 110, one or more controllers 160, one or more amplifiers 170 for driving current through a selected set of electrically conductive elements in the work body 130, and one or more sensors 180 for providing position feedback signals indicative of the position of the one or more movable robots. The at least one mover 110 is controllably movable relative to the work body 130 in at least two in-plane directions / DOFs (e.g., X and Y) in a work area 136 on a work surface. In various embodiments, the work area 136 can include substantially all or a portion of the work surface of the work body. In other embodiments, the work area can include only a portion of the work surface. For the purposes of this specification, unless otherwise noted, it is always said that the work area is coplanar with the work surface (e.g., the X-Y plane). The work area 136 of the work body 130 is generally a planar work area. Thus, although the word “planar” is occasionally omitted when referring to the work area 136 herein, it should be understood that the work area 136 can be a planar or a 2D surface with curvature. For example, Figure 1A and 1B The non-limiting embodiment of a magnetic mobility device 150 shown includes a work area 136 that, in the embodiment shown, is the entire work surface of the work body 130.

[0183] In various embodiments, the at least one mover 110 is capable of 6-DOF controllable motion (e.g., in the X, Y, Z, Rx, Ry, and Rz directions); in various embodiments, the at least one mover 110 is capable of three in-plane DOF controllable motion (X, Y, Rz) in a passive levitation mode or a sit- and- go mode. In various embodiments, the mover 110 is capable of 1-DOF controllable motion, while motion in the other five DOFs is mechanically constrained and / or guided, e.g., by mechanical linkages 119, as will be described in greater detail below.

[0184] Although only one movable robot 111 including one mover 110 is shown in Figure 1A and 1B the skilled artisan will appreciate that two or more movable robots can work simultaneously on the work surface of one or more work bodies (e.g., the work body 130) and that each movable robot 111 can include one or more movers 110, as will become apparent in the following description. A mover, such as the mover 110, includes one or more magnetic arrays 112, each of which includes a plurality of magnetized elements, e.g., magnets 114.

[0185] To describe the mobile robot and mover disclosed herein, it may be useful to define a pair of coordinate systems: (1) relative to the working body, for example, Figure 1A and 1B The working body coordinate system (130) and the coordinate system relative to the moving part (e.g.) Figure 1A and 1B The description refers to at least one mover 110 and a mover coordinate system that moves with the mover 110 relative to the working body 130 and the working body coordinate system. These coordinate systems can be described using conventional Cartesian coordinates (X, Y, Z), but it should be understood that other coordinate systems may be used. For convenience and brevity, the X, Y, and Z directions in the working body coordinate system and the X, Y, and Z directions in the mover coordinate system are shown in this specification and related figures and described as consistent with each other; that is, the working body-X direction (“Xs”), the working body-Y direction (“Ys”), and the working body-Z direction (“Zs”) can be shown as consistent with the mover-X direction (“Xm”), the mover-Y direction (“Ym”), and the mover-Z direction (“Zm”), respectively. Therefore, the description and related figures may use directions (e.g., X, Y, and / or Z) to refer to directions in either or both of the working body and mover coordinate systems. However, it will be understood from the context of this description that, in various embodiments and / or environments, one or more movers (e.g., at least one mover 110) may be moved relative to a working body (e.g., working body 130) such that the directions of the working body and the movers no longer coincide. In this case, this disclosure may adopt the convention of using the terms working body-X, working body-Y, and working body-Z to refer to the directions and / or coordinates in the working body coordinate system, and the terms mover-X, mover-Y, and mover-Z to refer to the directions and / or coordinates in the mover coordinate system. In this specification and the associated drawings, the symbols Xm, Ym, and Zm may be used to refer to the mover-X, mover-Y, and mover-Z directions, respectively; the symbols Xs, Ys, and Zs may be used to refer to the working body-X, working body-Y, and working body-Z directions, respectively; and the symbols X, Y, and Z may be used to refer to any one or both of the mover-X, mover-Y, and mover-Z and / or the working body-X, working body-Y, and working body-Z directions, respectively. In various embodiments, during normal operation, the mover-Z and working body-Z directions may be substantially in the same direction (e.g., within ±30° in various embodiments; within ±10° in various embodiments; or within ±2° in various embodiments).

[0186] Although in various embodiments the work body's work surface can be substantially flat and planar, those skilled in the art will appreciate that this is not required and that the work body's work surface (i.e., the work surface facing the one or more movers) can be a curved surface, including but not limited to a cylindrical surface or a spherical surface, with appropriate modification of the work body's control algorithms and conductive element layout disclosed herein or elsewhere.

[0187] In various embodiments, the work body-X and work body-Y directions are non-parallel. In particular embodiments, the work body-X and work body-Y directions are generally orthogonal. In various embodiments, the mover-X and mover-Y directions are non-parallel. In particular embodiments, the mover-X and mover-Y directions are generally orthogonal. In various embodiments, the work body-X and work body-Y directions are parallel to the work surface, and the work body-Z is in the normal direction of the work surface.

[0188] In various embodiments, the one or more controllers 160, the one or more amplifiers 170, and the one or more sensors 180 can be in electrical communication with each other and configured to controllably move the at least one mover 110 in the work area 136 relative to the work body 130. For example, the one or more controllers 160 can be configured to receive signals from the one or more sensors 180 indicative of the position of the one or more movers 110, generate control signals (also referred to herein as current reference commands) based on the position using suitable algorithms, and provide such control signals to the one or more amplifiers 170. In response to receiving the control signals from the one or more controllers 160, the one or more amplifiers 170 can be configured to drive current in the conductive elements (e.g., conductive element traces 132 and 134) in the work body 130 to effect movement of the at least one mover 110 relative to the work body. In various embodiments, the combination of the one or more amplifiers 170 and the work body conductive elements 132 and 134 can constitute a magnetic field modulator. In other embodiments, the magnetic field modulator can include one or both of an amplifier (e.g., amplifier 170) and a conductive element (e.g., 132 and 134), or can include other means of modulating one or more magnetic fields, for example.

[0189] In various embodiments, the work body 130 can include one or more modular work body tiles, such as work body tile 137. Each work body tile 137 can include a work body conductive element assembly 131, which can include a plurality of work body conductive elements such as work body conductive elements 132 and 134. The work body conductive elements are generally distributed in one or more (flat or curved) layers, with the normal direction in the Z direction. Although in various embodiments the work body conductive elements are generally planar, those skilled in the art will appreciate that this is not required and that the work body conductive elements can be a curved surface, including but not limited to a cylindrical surface or a spherical surface, with appropriate modification of the work body's control algorithms and conductive element layout disclosed herein or elsewhere. Figure 1AIn particular embodiments, workpiece conductive elements 132 and 134 are linearly elongated, are distributed in layers at different Z-positions, and overlap each other in the workpiece Z-direction, although this is not required, and other suitable shapes / arrangements of workpiece conductive elements disclosed herein or elsewhere can also be used, including but not limited to circular, hexagonal, or racetrack-shaped workpiece conductive elements, which can be used in workpiece 130 by mounting a corresponding suitable magnetic array 112 on mover 110.

[0190] In various embodiments, one or more controllers 160 are configured to move at least one mover 110 to a desired position (x r , y r ) within work area 136, where x r is a desired position of the at least one mover 110 in the workpiece-X direction and y r is a desired position of the mover in the workpiece-Y direction. Unless context dictates otherwise, throughout this disclosure, when referring to a position of a mover, a positioning of a mover, movement of a movable stage, etc., generally within a work area, such position, positioning, movement, etc. should be understood to refer to a position, positioning, movement, etc. of a reference point on the mover. Such a reference point can be, but is not limited to, a point at the center of one magnetic array assembly of the movable stage. Such a reference point can be other locations on the mover. Generally, desired position (x r , y r ) can be a function of time t, and can represent a position to which the mover should ideally be positioned at each time t. In various embodiments, desired position (x r , y r ) can be a function of another principal axis (desired) position, which can vary over time. Although reference is made here to workpiece-X and workpiece-Y directions for x r , y r , one skilled in the art will appreciate that desired positions can be specified in one or more directions. In particular embodiments, desired position can be specified in 6 degrees of freedom: x r , y r , z r , Rx r , Ry r , Rz r , where z r is a desired position of the mover in the workpiece-Z direction, Rx r is a desired rotational position of the mover about the workpiece-X direction, Ry r is a desired rotational position of the mover about the workpiece-Y direction, and Rz r is a desired rotational position of the mover about the workpiece-Z direction.

[0191] Generally, the expected position (x r , y r ) of a mover over a time span t forms a two-dimensional (2D) configuration trajectory in the work subject work area, and desirably the mover is expected to follow the 2D trajectory by appropriate control means (as described in more detail below with reference to Figure 38A and 38B ). To meet the needs of automation tasks, such 2D trajectories can have configurable shapes and lengths defined by software, rather than hardware constraints like guide rails. Due to the at least controllable motion of each mover in X and Y directions, for example, one or more movers can be controllably moved in the work subject work area to follow one or more respective 2D trajectories.

[0192] Figure 1B A side view of a non-limiting embodiment of Figure 1A is shown. As shown in Figure 1B , the work subject block 137 can optionally include one or more of the following elements:

[0193] • a work subject electrically conductive element assembly 131 including a plurality of electrically conductive elements, e.g., work subject electrically conductive elements 132 and 134, which can be selectively driven with appropriate currents to interact with magnetic elements of the mover 110 to propel and / or or levitate the mover 110.

[0194] • a work subject sensor assembly 181 including one or more sensors, e.g., one or more sensors 180 that can be used to compute a position of the mover 110 relative to one or more directions or work surfaces.

[0195] • a work subject controller assembly 161 including one or more controllers, e.g., one or more controllers 160 that can receive signals from the work subject sensor assembly 181, receive information indicative of application requirements, and / or determine desired currents to drive through a specified set of electrically conductive elements inside the work subject 130 based on appropriate algorithms. In various embodiments, the one or more controllers 160 can include a plurality of work subject controller assemblies 161.

[0196] • a magnetic field modulator, e.g., a work subject amplifier assembly 171 including one or more amplifiers, e.g., one or more amplifiers 170 that can receive current reference command signals from the work subject controller assembly 161 to drive currents through electrically conductive elements inside the work subject electrically conductive element assembly 131.

[0197] Figure 1BThe Z-directional stacking arrangement in FIG. 1 should be interpreted as illustrative and not limiting, and the Z-position of each component can be adjusted based on application requirements. In various embodiments, a workpiece block such as workpiece block 137 can include one or more suitable cooling devices, including but not limited to fluid (e.g., water or air) cooling devices, fan-aided air cooling devices, and / or passive cooling devices relying on convection. In various embodiments, one or more cooling devices can be attached to workpiece conductive element assembly 131. In various embodiments, cooling fluid channels can be installed between workpiece conductive element assembly 131 and workpiece amplifier assembly 171 to carry heat away from a workpiece block such as workpiece block 137. In other various embodiments, one or more cooling devices can be attached to amplifier assembly 171, or can be sandwiched between workpiece conductive element assembly 131 and amplifier assembly 171. Those skilled in the art will appreciate that suitable mounting devices (not shown) can be included in magnetic mobility apparatus 150, including but not limited to mechanical mounting plates to which one or more workpiece blocks such as workpiece block 137 can be attached.

[0198] Referring to Figure 1A To control the position of one or more movers 110 relative to workpiece 130 in magnetic mobility apparatus 150, mover position feedback data 163 can be required, which can include, for example, measured characteristics of one or more movers 110 such as position, velocity, acceleration, and / or orientation of one or more movers 110 relative to workpiece 130 or some other reference. Feedback data 163 can be obtained from suitable sensors, measurement systems, measurement methods, etc., such as one or more sensors 180. Any suitable sensors, measurement systems, measurement methods, etc. can be used to determine feedback data 163. Non-limiting examples of suitable sensors that can be used to provide some or all of feedback data 163 include: laser displacement interferometers, two-dimensional optical encoders, laser triangulation sensors, capacitive displacement sensors, eddy current displacement sensors, reflective surfaces suitable for interferometric measurement, accelerometers, Hall effect sensors, etc.

[0199] In various embodiments such as Figure 1BIn a particular embodiment of the shown example, sensor assembly 181 may include multiple sensing elements, such as one or more sensors 180, which may be organized in a matrix (not shown) along a plane generally parallel to the working surface (the outer surface having Z as its normal direction and closer to one or more movers 110). Each sensing element may interact with a patterned target mounted on one or more movers 110 according to physical principles (including but not limited to magnetic, electromagnetic, eddy current, capacitance, resistance, optical, etc.), such that the output of each sensing element is sensitive to the position of the mover in one or more (linear or rotational) directions. The outputs of the sensing elements may be used directly or indirectly by one or more controllers 160 to determine the position of the mover based on a suitable algorithm. Different position sensing techniques may be combined to provide an overall position sensing system. Various suitable feedback sensor systems and methods are described elsewhere, such as Patent Cooperation Treaty applications PCT / CA2012 / 050751 and PCT / CA2014 / 050739.

[0200] One or more amplifiers 170 may be centralized in one location, or distributed and integrated into a main operating block (e.g., main operating block 137) as main operating amplifier components, such as main operating amplifier component 171. One or more controllers 160 may be centralized in one location, or distributed and integrated into a main operating block as main operating controller components (e.g., main operating controller component 161). In various embodiments, the magnetic mobile device 150 may include a centralized system controller 160 and multiple main operating controller components 161. One or more sensors 180 may be centralized in one location, or distributed and integrated into a main operating block as main operating sensor components (e.g., main operating sensor component 181).

[0201] Figure 1A and 1B One or more movers 110 in the embodiment each include two magnetic bodies, which in the illustrated embodiment include magnetic bodies 116I and 116II, each magnetic body including a magnetic array 112. Figure 1A (Seen relative to the magnetic body 116). The magnetic array 112 includes a plurality of magnetizing elements 114 (shown as 114A, 114B, 114C and 114D respectively), and each magnetizing element has a magnetization direction. Although Figure 1A The magnetizing element 114 in the design is linearly elongated, but those skilled in the art will understand that any suitable magnetic array arrangement that can be described elsewhere, including but not limited to, checkerboard magnetic arrays, two-dimensional Halbach arrays, or various one-dimensional Halbach arrays, may be used. Some non-limiting examples of designs for mover magnetic arrays and their corresponding working body conductive elements are shown in U.S. Patent 9,202,719,B2.

[0202] In various embodiments, the working distance between the bottom surface of the magnetic array 112 (normal in the Z direction) and the working body 130 (where the normal is in the Z direction) can be limited compared to the lateral dimensions (along the X and Y directions) and / or the lateral working stroke of one or more movers 110. As used herein, for example, the “stroke” or “working stroke” of any object, such as one or more movers 110, represents the range of movement of that object. For example, a mover might have a working stroke of 300 mm, meaning it can travel a maximum of 300 mm.

[0203] A mover with a relatively movable magnetic body

[0204] In such Figure 1A and 1B In various embodiments of the illustrated examples, one or more movers, such as one or more movers 110, may include one or more magnetic bodies, each of which may interact with one or more magnetic fields (e.g., a magnetic field generated by a current driven by conductive elements 132 and 134 of the operating body 130 according to a suitable current command signal generated by one or more controllers 160 according to a suitable control algorithm) to produce a desired relative motion between these magnetic bodies. In various embodiments, such relative motion between the magnetic bodies can produce a desired actuation effect. Figure 1A As shown, one or more movers, such as one or more movers 110, may include a first magnetic array assembly 116I (also referred to herein as the "first magnetic body") and a second magnetic array assembly 116II (also referred to herein as the "second magnetic body"). In the illustrated embodiment, the magnetic body is a rigid body comprising one or more magnetic arrays. In various embodiments, the magnetic body may be any suitable body comprising one or more magnets.

[0205] like Figure 1AAs shown, a mechanical linkage 119 can be installed between the magnetic array assembly 116I and the magnetic array assembly 116II. The mechanical linkage 119 can be configured to constrain relative motion between the magnetic array assemblies 116I and 116II in a first set of one or more directions or degrees of freedom, and can also be configured to allow relative motion between the magnetic array assemblies 116I and 116II in a second set of one or more directions or degrees of freedom. In various embodiments, the first set of constrained directions / degrees of freedom can include one or more linear directions, one or more rotational directions, or a combination of both. The magnetic array assembly 116I can be configured to controllably move relative to the magnetic array assembly 116II in the allowed second set of directions / degrees of freedom in response to current driven in selected working body conductive element traces. Due to the mechanical linkage 119 constraining movement in the first set of directions / degrees of freedom, the one or more movers 110 can not only move in the at least two planar DOFs, but the magnetic array assembly 116I can also move relative to the magnetic array assembly 116II in the allowed second set of directions / DOFs. As will be described in detail below, in various embodiments, such relative motion between the magnetic array assemblies 116I and 116II can be manually or automatically controlled to facilitate motion and / or control of an actuator or end effector (including but not limited to a tool such as, for example, a gripper with opposing jaws or a vacuum pump).

[0206] Generally, an axis or direction in which such controllable relative motion is achieved between magnetic array assemblies of a mover with respect thereto can be interchangeably referred to as an on-mover axis or an active axis. A mover can include multiple magnetic array assemblies, and thus can include one or more active axes. In various embodiments, an active axis existing due to a magnetically mobile device having a mechanical linkage that mechanically links one or more magnetic bodies can provide controllable relative motion and / or controllable actuation force or torque between the one or more magnetic bodies.

[0207] Figure 2 A schematic side view of a non-limiting embodiment is shown as Figure 1A and 1B A schematic side view of a non-limiting embodiment is shown as Figure 2As shown, the magnetic mobile device (150) includes a mover (110) and a working body (130), the mover (110) includes two or more magnetic bodies (116), the working body (130) includes a plurality of electrically conductive elements (not shown); each magnetic body (116) includes one or more magnetic arrays (not shown) rigidly connected together as a mobile body (not shown), each magnetic array includes one or more magnetized elements (not shown) each having a magnetization; the two or more magnetic bodies include a first magnetic body (116I) and a second magnetic body (116II); the first and second magnetic bodies are connected together by a mechanical linkage (119) that constrains relative motion between the first and second magnetic bodies in a first set of one or more directions / degrees of freedom and allows relative motion in a second set of one or more directions / degrees of freedom. As Figure 1A and 1B As shown, one or more controllers 160 and one or more amplifiers 170 can be connected to selectively and / or controllably drive current in the plurality of electrically conductive elements to induce magnetic interaction between the driven current and each magnetic body, whereby relative motion between the magnetic bodies and the working body can be effected. The mover can be controllably moved by the one or more controllers 160 in at least 2 DOF within the working region 136, including in the illustrated embodiment, independently controllable motion in the X direction and independently controllable motion in the Y direction. In various embodiments, the mover can be configured to be controllably moved in any number of alternative directions / degrees of freedom.

[0208] Generally, the mechanical linkage 119 is mounted on the mover 110 and moves with the mover 110. In other words, the mechanical linkage 119 is “floating” relative to the working body 130 (and its associated electrically conductive elements). In various embodiments, the mechanical linkage 119 can be a slider and a rail: both are mounted on the mover, and both move relative to the working body 130. In various embodiments, the mechanical linkage 119 can include one or more elastically deformable components, such as spring elements, for purposes including but not limited to reducing potential energy changes during relative position changes or to maintain relative positions within certain ranges when power is off. In various embodiments, the slider can be rigidly attached to the first magnetic body, and the rail can be rigidly attached to the second magnetic body, or vice versa, such that the first and second magnetic bodies are configured to be coupled together with a linear rolling or sliding bearing to constrain their relative motion in 5 degrees of freedom and allow relative motion in only a single degree of freedom. For greater clarity, as used herein, “attached” is understood by those skilled in the art to mean, in various embodiments, “rigidly attached”, “non-rigidly attached”, “coupled”, “detachably coupled”, “connected”, “linked”, or any similar.

[0209] As shown in Figure 2 , the end effector 117 can be connected between the first magnetic body 116I and the second magnetic body 116II and can be configured to carry the workpiece 118. In various embodiments, the mechanical linkage 119 can include the end effector 117. In various embodiments, the mechanical linkage 119 can include any suitable bearing, including but not limited to a plain bearing, a rotatable or rolling element bearing, a flexure bearing, a mechanical linkage, etc. In various embodiments, both the slider and the guide rail can include one or more respective retaining surfaces that can be configured to mechanically link the first and second magnetic bodies together when positioned against each other. As shown in Figure 2 , the allowed relative motion between the first magnetic body 116I and the second magnetic body 116II when mechanically linked by the mechanical linkage 119 is represented by the active axis 120. In various embodiments, the mover 110 is capable of 6-DOF controllable motion relative to the work body 130 without any mechanical contact with the work body 130. The 6-DOF controllable motion of the mover can include three translational directions of the mover in the X, Y, and Z directions, and three rotational directions about the X, Y, and Z directions or axes.

[0210] In one embodiment, only one of the magnetic bodies 116I and 116II is capable of 6-DOF controllable motion; in other embodiments, neither of the magnetic bodies 116I and 116II is capable of 6-DOF controllable motion. In various embodiments, the mover including the magnetic bodies 116I and 116II is capable of 6-DOF controllable motion, plus one or more additional directions / DOFs of controllable relative motion between the magnetic bodies 116I and 116II.

[0211] Due to the mechanical linkage 119 constraining the relative motion between the magnetic bodies 116I and 116II in a first set of one or more directions / degrees of freedom, the magnetic bodies 116I and 116II can generally not be controlled independently of each other in said directions / DOFs. However, in one or more of the first set of directions / DOFs, the magnetic bodies 116I and 116II can be configured to controllably move together in a coordinated manner through calculated coordinated position feedback and coordinated forces.

[0212] Referring to Figure 3A and 3B , another exemplary embodiment of a magnetic mobility device is disclosed. Figure 3A and 3BTop and side views of a magnetic mobile device 250 according to a specific embodiment of the present invention are shown respectively: the mover 210 includes a first magnetic body 216I and a second magnetic body 16II, wherein the first magnetic body 216I includes magnetic arrays 212A, 212B, 212C and 212D. Each magnetic array in the first magnetic body 216I includes a plurality of magnetizing elements, which in this embodiment include magnets. Figure 3A In this diagram, four magnets are shown in each magnetic array; however, other numbers of magnets can be used. The second magnetic body 216II may include one or more magnetic arrays ( Figure 3A A magnetic array (shown in FIG. 3) includes one or more magnets (one in the case of FIG. 3). A mechanical link 219 is mounted between a first magnetic body 216I and a second magnetic body 216II. In the illustrated embodiment, the mechanical link 219 constrains relative movement between the magnetic bodies 216I and 216II in a first set of five degrees of freedom (Ym, Zm, RXm representing rotation about Xm, RZm representing rotation about Zm, and RYm representing rotation about Ym) and allows relative movement in a second set of one degree of freedom (Xm direction). In various embodiments, the mechanical link 219 may include linear sliding bearings, rolling bearings, and / or bending bearings to allow relative movement between the magnetic bodies 216I and 216II. For example, the mechanical link 219 in FIG. 3 may include a linear guide mounted on the magnetic body 216I and a slider mounted on another magnetic array assembly 216II. In one embodiment, the linear guide and the slider may each include one or more respective retaining surfaces configured to abut against each other to mechanically link the first and second magnetic bodies 216I and 216II; in other embodiments, the mechanical link 219 may include alternative or additional linking mechanisms or bodies positioned beside or between the slider and the guide to achieve the mechanical link, such as one or more rotatable bearings. In various embodiments, the mechanical link 219 may also include a flexural bearing made of leaf springs and resilient hinges, such that the magnetic bodies 216I and 216II can move relative to each other in the Xm direction without friction, while their relative motion in other degrees of freedom is constrained by the working body of the flexural bearing.

[0213] In the illustrated embodiment, the appropriate driving current (e.g., in the conductive element of the working body 230) Figure 3B (As shown) can interact with the first magnetic body 216I to generate eight independent forces on the magnetic body 216I: Y and Z forces on the magnetic body of the magnetic array 12A, X and Z forces on the magnet of the magnetic array 12B, Y and Z forces on the magnet of the magnetic array 12C, and X and Z forces on the magnet of the magnetic array 12D.

[0214] The combination of the eight independent forces enables the motion of the first magnetic body 216I to be controlled in up to 6 directions / DOF (or up to 3 in-plane directions / DOF when operating in the sitting mode) when operating in the levitation mode. Additionally, the second magnetic body 216II can be independently driven in the Xm direction by the current in the working body 130. For example, the current driving method can be:

[0215] • A selected set of Y-conducting elements (i.e., conducting elements elongated in the Y direction) underneath the magnetic body 216II can generate a force in the Xm direction on the magnetic body 216II while producing negligible coupling forces on the magnetic arrays 12A and 12C by appropriately selecting the magnetization direction and magnetization direction of each magnetic element size;

[0216] • If the selected set of Y-conducting elements is far enough from the magnetic arrays 12D and 12B (e.g., if the selected set of Y-conducting elements is at a distance from the magnetic arrays 12D and 12B that is half the spatial wavelength of the magnetization spatial period of the magnetic arrays 12D and 12B), the current flowing through the selected set of Y-conducting elements can also produce negligible force coupling on the magnetic arrays 12D and 12B;

[0217] • Each of the magnetic arrays 12D and 12B can be associated with their own corresponding active conducting elements. By selecting one of the active conducting elements that is far enough from the magnetic body 216II (e.g., half or a third of the spatial period of the magnetization pattern of the magnetic arrays 12B and 12D), the interaction force between the magnetic body 216II and the current driven through the active conducting elements corresponding to the magnetic arrays 12B and 12D can also be negligible.

[0218] As a result, Xm direction forces can be generated independently of the actuation forces applied on the magnetic body 216I, and correspondingly, the Xm movement of the magnetic body 216II can be controlled independently of the controllable motion of the magnetic body 216I in 6 directions / DOF. In various embodiments, sensing elements in the working body 130 (including but not limited to magnetic field sensors) can be used to provide position information (also referred to herein as “feedback”) for the magnetic bodies 216I and 216II. In further embodiments, suitable control algorithms can be implemented that use the relative position information 220( Figure 3A X7) shown in FIG. 6 to controllably generate signals for certain application requirements, such as for controlling a gripper. In Figure 3A and 3B In the particular embodiments shown in FIGS. 1-5, only the first magnetic body 216I is capable of controllable motion in 6 directions / DOF when operating in the levitation mode. The mover 210 can also operate in the sitting mode, in which case only the magnetic body 216I can move in only three in-plane directions / DOF.

[0219] Figure 4A and 4B Another non-limiting example of a magnetically movable device including a mover 310 is shown; Figure 4B The mover 310 and its path are shown. Figure 4A A cross-sectional view of the Y-shaped, elongated active conductive element trace 334 of line BB. Although for simplicity... Figure 4A Or, 4B shows an elongated conductive element trace (X-trace) in the X direction; however, those skilled in the art should understand that the X-trace can also be distributed within the working body 330 as a working body. According to the illustrated embodiment, the mover 310 includes a first magnetic body 316I and a second magnetic body 316II. A mechanical link 319 is mounted between the first magnetic body 316I and the second magnetic body 316II to constrain relative movement between the magnetic bodies 316I and 316II in the first set of five degrees of freedom (Ym, Zm, RXm, RZm, RYm), while allowing relative movement between the magnetic bodies 316I and 316II in the Xm direction. In various embodiments, the mechanical link 319 may be a planar mechanical link (including, but not limited to, two linear guides orthogonally stacked together, one oriented in the Xm direction and the other in the Ym direction), which may be configured to constrain relative movement between magnetic bodies 316I and 316II in a first set of 4 degrees of freedom (Ym, RXm, RYm, RZm), while allowing relative movement between magnetic bodies 316I and 316II in a second set of 2 degrees of freedom (Xm and Zm).

[0220] In the illustrated embodiment, the first magnetic body 316I includes magnetic arrays 312A, 312B, 312C, and 312D, each magnetic array comprising multiple magnets (e.g., but not necessarily four linear, elongated magnets). The detailed magnetization directions of each magnet in magnetic arrays 12D and 12B are as follows... Figure 4B As shown. It should be understood by those skilled in the art that the magnetization directions of the magnetized segments in magnetic arrays 12A and 12C can exhibit a pattern similar to the magnetization directions in magnetic arrays 12B and 12D with appropriate arrangement. The second magnetic body 316II includes four magnets linearly elongated in the Ym direction, and each magnet has a magnetization direction orthogonal to the Ym direction, as shown. Figure 4B As shown. The magnetization direction of the magnetizing element in the magnetic body 316II can present a single spatial periodic pattern: clockwise, the magnetization direction rotates 90 degrees around the Ym axis from one element to the next.

[0221] As known to those skilled in the art, the first magnetic body 316I can interact with the current flowing in the working body 330 to produce controllable motion of the magnetic body 316I in up to 6 degrees of freedom. For example, the magnetic array 312D can interact with the current in its corresponding active electrically conductive element 334D to produce two independently controllable forces in the Xm and Zm directions, the magnetic array 312B can interact with the current in its corresponding active electrically conductive element 334B to produce two independently controllable forces in the Xm and Zm directions, and the magnetic array 312A can interact with the current in its corresponding X-oriented active electrically conductive element 332A (not shown in Figure 4B ) to produce controllable forces in the Ym and Zm directions, and the magnetic array 312C can interact with the current in its corresponding X-oriented active electrically conductive element 332C (not shown in Figure 4B ) to produce controllable forces in the Ym and Zm directions. Those skilled in the art will appreciate that the corresponding active electrically conductive element of each magnetic array can change as the magnetic array is displaced. Similarly to Figure 3A and 3B , the motion of the magnetic body 316I in Figure 4A and 4B can be controlled in 6-DOF when operating in a hover mode, or in three in-plane DOF when operating in a sit-stand mode.

[0222] The second magnetic body 316II can interact with appropriately commanded currents flowing in its corresponding active electrically conductive element traces 334II to produce two independently controllable forces in the Zm and Xm directions; these two controllable forces can be used to independently control the relative motion between the first magnetic body 316I and the second magnetic body 316II in the Xm and / or Zm directions. The relative motion between the magnetic bodies 316I and 316II can be controlled by selectively driving currents into the electrically conductive elements in the working body 330 and can be controlled independently of the controllable motion of the first magnetic body magnetic body 316I. The controllable relative motion between the magnetic bodies 316I and 316II is referred to as an active axis along which controllable relative motion can be controlled independent of the motion of the mover 310 in the 6 degrees of freedom of the mover 310. Those skilled in the art will appreciate that any suitable magnetic array layout and dimensions and / or any suitable electrically conductive element geometry and its corresponding current commutation method known to those skilled in the art can be applied here to construct the magnetic bodies 316I and 316II. In Figure 4A and 4B , only the motion of the first magnetic body 316I can be controlled in 6-DOF when operating in a hover mode, or in three in-plane DOF when operating in a sit-stand mode.

[0223] Figure 5A and Figure 5B A magnetic mobile device according to another embodiment of the application is shown. Figure 5A A top view of a mover 410 comprising a first magnetic body 416I and a second magnetic body 416II is shown. Figure 5B is a cross-sectional view along B-B as shown in Figure 5A The first magnetic body 416I comprises a first magnetic array 412C and a second magnetic array 412D rigidly connected together; the second magnetic body 416II comprises a third magnetic array 412A and a fourth magnetic array 412B rigidly connected together. A non-limiting example of these magnetic arrays is a magnetic array comprising a plurality of linearly elongated magnetized elements (segments), such as for example magnets, wherein each magnetized element has a magnetization direction orthogonal to its elongation direction. Figure 5B The magnetization direction of the magnetized elements in magnetic arrays 412D and 412B is shown. The magnetization direction of the magnetized elements in 412A and 412C can be substantially similar to the magnetization direction in 412B and 412D, with appropriate spatial arrangement and modification. In the shown embodiment, a mechanical link 419 is mounted between the first magnetic array assembly 416I and the second magnetic array assembly 416II. As Figure 5A shown, the mechanical link 419 comprises two linear guides and two sliders: a guide 419IR mounted on the magnetic body 416I, with its respective slider 419IIS mounted on (in other words, rigidly attached to) the magnetic body 416II; a guide 419IIR mounted on (in other words, rigidly attached to) the magnetic body 416II, with its respective slider 419IS mounted on the magnetic body 416I. In various embodiments, the mechanical link 419 can comprise any number of respective sets of guides and sliders, and can also comprise additional elements, such as rotating bearings. In Figure 5A and 5B In the shown embodiment, the mechanical link comprises a slider and a guide; the slider can be considered as the link body.

[0224] It should be noted that in the shown embodiment, all these components of the mechanical link 419 are floating, i.e. can move with respect to the working body 430. With appropriate adjustment and alignment, these two parallel guides (collectively referred to as the mechanical link 419) can constrain the relative motion between the magnetic bodies 416I and 416II in a first set of 5 degrees of freedom (Ym, Zm, RXm, RYm and RZm), and allow relative motion between them in a second set of 1 degree of freedom (Xm). The allowed direction of relative motion (allowed degree of freedom) is marked as 420, X7 in Figure 5A In summary, Figure 5A and 5BThe entire mover 410 in FIG. 4 can be said to have up to 7 degrees of freedom: the conventional 6 degrees of freedom of the mover 410 plus the relative motion X7 (along the active axis) between the magnetic bodies 416I and 416II. Here, the motion of the mover 410 can be understood as the motion of the first magnetic body 416I. As previously described and / or described elsewhere, Figure 5A and 5B Each of the magnetic arrays in FIG. 4 can interact with appropriately driven currents flowing in the respective active conductive element traces in the working body 430, such that each magnetic array experiences up to two independent forces that urge the mover 410 to move. For example, magnetic array 12A experiences a Ym-direction force Fya and a Zm-direction force Fza; magnetic array 12B experiences an Xm-direction force Fxb and a Zm-direction force Fzb; magnetic array 12C experiences a Ym-direction force Fyc and a Zm-direction force Fzc; and magnetic array 12D experiences an Xm-direction force Fxd and a Zm-direction force Fzd. Since up to 8 independently controllable forces can be applied on the magnetic arrays of the mover 410, there is a sufficient number of forces available to fully control the motion of the mover 410 in 6 DOF (degrees of freedom) plus the relative motion along the active axis 420 (X7).

[0225] In various embodiments, forces Fxd and Fxb can be used to control Xm-direction displacement of the magnetic body 416I (“XmI”) and Xm-direction displacement of the magnetic body 416II (“XmII”), respectively, which amounts to independent control of the Xm-direction displacement (XmI+XmII) / 2 and the active axis displacement X7 (XmII-XmI) of the mover’s center of gravity. Similarly, forces Fya and Fyc can be used to control Ym-direction displacement and rotational displacement about Z, and forces Fza, Fzb, Fzc, Fzd can be used to control Zm-direction displacement and rotational displacement about Xm and Ym. As a result, the mover 410 can be controllably moved in seven directions / DOF. In the directions related to the first set of DOF, the relative motion between the magnetic bodies 416I and 416II is constrained by the mechanical linkage 419, so the movement of the mover 410 must be controlled in a coordinated manner in these directions.

[0226] For example, relative motion between 416I and 416II can be constrained in the Ym direction, so Ym direction movement of the mover 410 should be controlled in a coordinated manner, for example by: (1) computing a Ym direction coordinated feedback (e.g., the average of the Ym direction position of magnetic array 12A and the Ym direction position of magnetic array 12C); (2) using the Ym direction coordinated feedback and a feedback control algorithm to compute Ym direction coordinated forces to be applied on each of the first and second magnetic bodies 416I and 416II; (3) using the coordinated force / torque and commutation algorithm to compute current commands and send these commands to amplifiers that drive currents into selected conductive elements of the working body. In this way, although the Ym direction relative motion between the magnetic bodies 416I and 416II is constrained, the mover 410 as a whole is still able to perform controllable motion in the Ym direction.

[0227] In another example, relative motion between 416I and 416II can be constrained in the Ym direction, so rotational motion of the slider 419IIR (or any other portion of the mechanical linkage 419) in the Zm direction about the axis of rotation should be controlled in a coordinated manner, for example by: (1) computing a coordinated rotational feedback about Zm from the difference in Ym positions of magnetic arrays 412C and 412A divided by the Xm direction distance of magnetic arrays 412C and 412A; (2) using the coordinated feedback and an appropriate feedback control algorithm to compute one or more coordinated forces in the Ym direction to be applied oppositely on magnetic arrays 412A and 412C; (3) using the coordinated force / torque and commutation algorithm to compute current commands and send these commands to amplifiers that drive currents into selected conductive elements of the working body.

[0228] For Figure 5A and 5B In particular embodiments, the movement of each of the magnetic bodies 416I and 416II can be controlled by up to four independently controllable forces that can be generated by controllable currents in the conductive elements of the working body 430. In various embodiments, each of the first and second magnetic bodies 416I and 416II in the mover can be subject to up to six independent controllable forces, and the relative motion between the magnetic bodies 416I and 416II can be controlled by driving appropriate commutation currents through selected conductive elements in the working body 430. In Figure 5A 5B ​In a specific embodiment, although neither the magnetic bodies 416I nor 416II can perform 6-DOF controllable motion, the mover 410 (i.e., the combination of the magnetic bodies 416I and 416II with the mechanical link 419) is configured to move controllably in six directions / DOF, and the magnetic bodies 416I and 416II are configured to be controllably movable relative to each other in one direction / DOF (along the active axis X7) when operating in suspension mode. Furthermore, the mover 410 is capable of controllable motion in three in-plane directions / DOF, and the magnetic bodies 416I and 416II are capable of controllable relative motion in one direction / DOF (along the active axis X7) in a seated position.

[0229] exist Figure 5A In the illustrated embodiment, the first and third magnetic arrays (412C and 412A) overlap in the Y direction; the second and fourth magnetic arrays (412D and 412B) overlap in the X direction. This configuration, where the first and second magnetic bodies overlap in the first elongation direction (X direction) and the second elongation direction (Y direction), allows for a very compact mover, significantly reducing the machine's footprint. Simultaneously, the attached mechanical links allow for relative movement between the first and second magnetic bodies.

[0230] Figure 5C This is yet another non-limiting example of an alternative embodiment of the mechanical link 519, the remaining details of which (e.g., magnetic body and magnetic array) are substantially similar to those in the reference. Figure 5A and 5B Those described. In Figure 5C In this embodiment, the mechanical link 519 comprises only one guide rail and one slider, which saves cost and weight and simplifies their installation / alignment. The slider and guide rail operate in a manner similar to those described above. In the illustrated embodiment, the slider 519I is mounted (in other words, rigidly attached) to the magnetic body 516I, and the guide rail 519II is fixed (in other words, rigidly attached) to the magnetic body 516II. In the illustrated embodiment, both the slider 519I and the guide rail 519II are floating and movable relative to the working body, for example... Figure 5B The working body 430. Although guide rail 519II is oriented in the X direction in the illustrated embodiment, in other embodiments, the guide rail may be oriented in the Y direction or in another direction perpendicular to the Z direction, for example, but not limited to, reducing the bending moment on guide rail 519II. It should be noted that when guide rail 519II and slider 519I are coupled together, their relative motion is constrained relative to five directions / degrees of freedom, and they may move relative to each other relative to one direction / degree of freedom.

[0231] Reference Figure 5D ,5E and 5F, another embodiment of a magnetically mobile device is disclosed. The mover 520 includes a first magnetic body 526I and a second magnetic body 526II. The mechanical linkage 529 includes a first bearing element 529I attached to the first magnetic body 526I and a second bearing element 529II attached to the second magnetic body 526II. In the illustrated embodiment, the first bearing element 529I is a slider and the second bearing element 529II is a linear rail. In various embodiments, the first and second bearing elements can include any other type of mechanical bearing mechanism, such as a rotational or flexural bearing. In the illustrated embodiment, the mechanical linkage 429 is connected between the magnetic bodies 526I and 526II such that the mechanical linkage 529 constrains relative motion between the magnetic bodies 526I and 526II in 5 degrees of freedom (Y, Z, Rx, Ry, and Rz) and allows relative motion between the magnetic bodies 526I and 526II in one degree of freedom (the X direction).

[0232] Referring to Figure 5E , an exemplary detailed layout of the magnetic arrays within the magnetic bodies 526I and 526II is disclosed. In the illustrated embodiment, the first magnetic body 526I includes a first magnetic array 512B and a second magnetic array 512A. The magnetic array 512A includes a plurality of magnetized segments 14 (e.g., magnets) linearly elongated in the Y direction, each segment having a magnetization direction perpendicular to the Y direction. In one non-limiting embodiment, the magnetized elements 14 can have magnetization directions as shown for the magnetic array 412B in Figure 5B , with a suitable arrangement. Similarly, the magnetic array 512B includes a plurality of magnetized segments linearly elongated in the X direction, each segment having a magnetization direction perpendicular to the X direction. In the illustrated embodiment, each magnetic array includes eight magnetized elements. In various embodiments, any suitable number of magnetized elements can be used, such as 4 or 12. The second magnetic body 526II includes a third magnetic array 512C and a fourth magnetic array 512D. The 512C and 512D are substantially similar to the magnetic arrays 512B and 512A, respectively. Figure 5E

[0233] Referring to Figure 5F , an internal view of the working body 540 is shown, according to an exemplary embodiment, in which the working body 540 includes independently driven conductive element traces 532 and 534 oriented in the working body X direction and the working body Y direction, respectively. For clarity, Figure 5F the working body conductive elements are shown in Figure 5E , the magnetic arrays of the mover 520 are shown; it should be understood by those skilled in the art that, in operation, Figure 5E the magnetic arrays of the mover 520 in Figure 5F ​The conductive element traces 532 and 534 in FIG. 5A overlap. In addition, only active conductive element traces (i.e., conductive elements driven with non-zero current) are shown in FIG. 5A; in various embodiments, the working bodies can include other conductive elements 532 elongated in the X direction and other conductive elements 534 elongated in the Y direction according to any suitable layout, in order to allow for greater working area as the mover 520 travels in the XY working body plane. In addition, the active conductive elements of each magnetic array can also be changed accordingly depending on the position of the mover 520 as it moves. Figure 5F

[0234] In operation, suitable currents are driven into the appropriate conductive elements according to suitable control algorithms as known to those skilled in the art, the magnetic array 512A interacts with the currents in its corresponding Y-oriented working body conductive element (534A in FIG. 5A) such that two independently controllable forces FAx and FAz are exerted on the magnetic array 512A in the X (lateral) and Z (vertical) directions, respectively. Similarly, suitable currents are driven into the appropriate conductive elements according to suitable control algorithms as known to those skilled in the art, the magnetic array 512B interacts with the currents in its corresponding X-oriented working body conductive element (532B in FIG. 5A) such that two independently controllable forces FBy and FBz are exerted on the magnetic array 512B in the Y (lateral) and Z (vertical) directions, respectively. Suitable currents are driven into the appropriate conductive elements according to control algorithms as known to those skilled in the art, the magnetic array 512C interacts with the currents in its corresponding X-oriented working body conductive element (532C in FIG. 5A) such that two independently controllable forces FCy and FCz are exerted on the magnetic array 512C in the Y (lateral) and Z (vertical) directions, respectively. Suitable currents are driven into the appropriate conductive elements according to control algorithms as known to those skilled in the art, the magnetic array 512D interacts with the currents in its corresponding Y-oriented working body conductive element (534D in FIG. 5A) such that two independently controllable forces FDx and FDz are exerted on the magnetic array 512D in the X (lateral) and Z (vertical) directions, respectively. Figure 5F Figure 5F Figure 5F Figure 5F

[0235] ​​​​​In various embodiments, the eight independently controllable forces (FAx, FAz, FBy, FBz, FCy, FCz, FDx, FDz) generated can be used to control the motion of the mover 520 in 6 directions / DOFs, as well as control the relative motion between the magnetic bodies 526I and 526II in the X direction, by suitable feedback measurement and control algorithms. The FBy + FCy forces can be used to control the Y direction motion of the mover 520, and the FBy - FCy forces can be used to control the rotational motion Rz of the mover 520 about the Z axis. The forces FAz, FBz, FCz, FDz can be used to control the motion in the Z direction, as well as the rotation about the X axis and the rotation about the Y axis. The force FAx can be used to control the motion of the magnetic body 526I in the X direction, and the force FDx can be used to control the motion of the magnetic body 526II in the Y direction.

[0236] In the illustrated embodiment, when a pair of "clamping" forces are applied to the magnetic bodies 526I and 526II, for example, Fc in the positive X direction on the magnetic body 526I, and an equal magnitude force Fc in the negative X direction on the magnetic body 526II, thus, since the two Y-shaped elongated magnetic arrays 512A and 512D are aligned in the X direction, the clamping force pair is collinear, thus, there can be no net torque on the mover 520. In particular, the second and fourth magnetic arrays (512A and 512D) overlap in the X direction by a width that is the same as the Y direction dimension of the magnetic arrays 512A and 512D. In various embodiments, the Y direction overlap width can be greater than 85% of the Y direction dimension of 512A and 512D, which can minimize induced torques about the Z axis. In contrast, with reference to Figure 5A , the clamping force on magnetic array 412D cannot be collinear with the clamping force on magnetic array 412B in the X direction; as a result, when a clamping force is required between magnetic arrays 412B and 412D, a net rotational torque about the Z axis can be generated by magnetic arrays 412B and 412D. To balance this net rotational torque and maintain position control of the mover 410 in the Rz direction, equal and opposite torques can need to be generated on magnetic arrays 412A and 412C, which can result in higher energy consumption than Figures 5D-5F the disclosed embodiments.

[0237] It should be noted that while the motion of the mover 520 can be controlled in 6 directions / DOFs, and the relative motion between the magnetic bodies 526I and 526II can be controlled, in various embodiments, it can not be desirable to control the motion in 6 directions. In certain applications, it can be advantageous to control the motion of the mover 520 in three directions / DOFs (e.g., X, Y, and Rz) in addition to the relative motion between the magnetic bodies 526I and 526II. In such embodiments, it can be desirable to support the mover 520 with additional rolling or sliding bearing elements supported by a surface of the workpiece having a normal direction along the Z direction.

[0238] Referring to Figure 6A and 6B According to another embodiment, relative motion between the first and second magnetic bodies 616I and 616II along the active axis X7 can be generated or controlled. For example, such relative linear motion can be useful in many automation applications. Figure 6B and Figure 6A A top view and a side view showing a non-limiting example of an embodiment configured to convert linear relative motion between the magnetic bodies 616I and 616II along the active axis X7 into rotational motion of at least one rotatable body 617 about a rotation axis parallel to the Zm axis. In various embodiments, the rotatable body 617 can comprise a gear assembly, a hinge assembly, or any other suitable rotatable assembly. In various embodiments, the mechanical linkage 619 comprises the at least one rotatable body 617. In other embodiments, the at least one rotatable body 617 can operate independently of the mechanical linkage 619.

[0239] As shown in Figure 6B , the magnetic bodies 616I and 616II are guided with the mechanical linkage 619 to enable independently controllable relative motion along the active axis X7 using a suitable bearing solution 619. In the shown embodiment, the at least one rotatable body 617 comprises a rack 617-I fixed on the first magnetic body 16I and a pinion 617-II operable to rotate about an axis 621. In the shown embodiment, the axis 621 is the Zm axis fixed on the magnetic body 616II. In various embodiments, the axis 621 can be disposed at other locations on the mover. In the shown embodiment, linear relative motion between the magnetic bodies 616II and 616I along the active axis X7 will be converted by the rack and pinion mechanism into rotational motion of the pinion 617-II about the axis 621 (fixed with the magnetic body 616II). In the shown embodiment, an end effector 617-E is coaxially mounted on the pinion 617-II and is configured to rotate about the axis 621 and can be used for any suitable purpose, for example for the purpose of extending the range of motion. In various embodiments, any other suitable tool, mechanism, assembly, component, or body can be attached to the pinion 617-II in order to achieve any other purpose. Although Figure 6A A non-limiting example of an arrangement of the end effector 617-E and the magnetic bodies 617II and 616II is shown, which is located at different locations in the Xm-Ym plane, but other arrangements are possible. It will be apparent to those skilled in the art that the rotational motion about the axis 621 resulting from linear motion along the active axis X7 can be significantly larger than any rigid body rotational motion of the mover 610.

[0240] More generally, the rotatable body 617 can be considered as a conversion mechanism operable to convert linear motion to rotational motion. In various embodiments, any other suitable conversion mechanism can be installed between the first and second magnetic bodies 616I and 616II. Such conversion mechanism can convert one or more types of relative motion between the magnetic bodies 616I and 616II to one or more different types of extension motion of any other suitable tool, mechanism, assembly, component or body. The range of extension motion of such attached tool, mechanism, assembly, component or body can be significantly larger than the range of motion of the magnetic bodies 616I and 616II in the direction of said extension motion. For Figure 7A and 6B For the specific embodiments in Figure 7A

[0241] Figure 7A Another non-limiting embodiment of relative motion of magnetic bodies along the active axis X7 between two magnetic bodies 716I and 16II utilizing a mover 710 is shown: the mover 710 comprises a first magnetic body 716I and a second magnetic body 716II, and a mechanical linkage 719 installed between the first magnetic body 716I and the second magnetic body 716II to constrain a first set of one or more DOF (Ym, Zm, RXm, RYm, RZm) relative motion and allow a second set of one or more DOF (Xm) relative motion. Although details of the corresponding working body (such as the working body for the mover 710) and the magnetic bodies are not shown in Figure 7A Figure 7A , a person skilled in the art will understand that these details can be designed in a suitable manner, similar to what has been described previously in this document or in the prior art. In Figure 7B , the two ends of a tool 717 comprising relative jaws are attached to the magnetic bodies 716I and 716II respectively, such that Xm-directional relative linear motion can be converted to opening, clamping and closing operations of the relative jaws. In one embodiment, the tool 717 can comprise a pincer-like end effector. In other embodiments, any suitable tool having one or more relative jaws can be used. In various embodiments, an elastically deformable component 721B can optionally be used to hold the tool 717 in an open (or optionally closed) position under certain circumstances such as, for example, power failure. The elastically deformable component 721B can be any suitable component, for example a spring, a flexure component or other elastically deformable component. ​

[0242] Figure 7B Another non-limiting embodiment is shown that utilizes relative linear motion (along the active axis X7) between two magnetic bodies 816I and 816II of the mover 810. In the shown embodiment, Figure 7A most of the details are substantially similar to the embodiment in Figure 7B except that Figure 7B the tool 817 in is a gripper that includes two (rigid or elastically deformable) fingers (in other words, tines), each of which includes one of a set of opposable jaws. The first finger 817I is mounted on the first magnetic body 816I and the second finger 817II is mounted on the second magnetic body 816II. According to the shown embodiment, relative motion between the magnetic bodies 816I and 816II along the active axis X7 in the Xm direction can result in motion between the first and second fingers 817I and 817II, which can be translated into one or more of opening, gripping, releasing, closing, or other such operations of the gripper 817. In various embodiments, the gripper 817 can be operated in a gap control mode (i.e., the opening gap between 817I and 817II can be controlled by appropriate feedback to follow a reference command based on application requirements), in a force control mode (i.e., the gripping force can be maintained by following a reference command based on application requirements), in a hybrid mode (by switching between force control mode and gap control mode from time to time), or in any other suitable mode of operation. When one or more of the fingers (or tines) 817 are made of an elastically or elastically deformable material, controlling the relative motion between the first and second magnetic bodies can help control the gripping force exerted on a workpiece (not shown) that is gripped by the fingers 817I and 817II. In various embodiments, varying the relative position between the first and second magnetic bodies can proportionally vary the gripping force exerted on the gripped workpiece. It should be noted that, Figure 7A the linkage assembly in can include elastically deformable components in a manner similar to 721B mounted in the embodiment of Figure 7C to obtain the gripping force between the two fingers 817I and 817II.

[0243] Figure 7C Another non-limiting embodiment is shown that utilizes relative motion between two magnetic bodies 916I and 916II of the mover 910. Figure 7CThe system in FIG. 9 includes a mover 910 and a work body 930. In various embodiments, the work body can include one work body. The mover 910 includes a first magnetic body 16I and a second magnetic body 16II. The magnetic bodies contain suitable magnetized elements, such as magnets, which can interact with suitable electrical currents driven into suitable electrically conductive elements in the work body 930 such that the mover 910 can be controllably moved in at least 2 degrees of freedom (e.g., X and Y directions), while the first magnetic body 16I and the second magnetic body 16II can be controllably moved relative to each other in at least one degree of freedom (including but not limited to linear movement between the first magnetic body 916I and the second magnetic body 916II in the X direction). Examples of suitable magnetic bodies and suitable work body electrically conductive element layouts and suitable electrical currents to be driven into the work body electrically conductive elements have been previously discussed and can be applied to the illustrated embodiment.

[0244] In various embodiments, the mover 910 can be controllably moved relative to its rigid body in up to 6 degrees of freedom in addition to at least one degree of freedom of relative motion between the magnetic bodies 916I and 916II. In various embodiments, a mechanical linkage (not shown) can be configured to be mounted between the magnetic bodies 916I and 916II, the magnetic bodies 916I and 916II being configured to guide their relative motion in the X direction.

[0245] Referring to FIG. 9, Figure 7C an actuator assembly 917 is mounted on the first magnetic body 916I. In the illustrated embodiment, the actuator assembly includes an elastically deformable chamber 917C, such as a vacuum cup, and a first actuator 917AI. A first activator 917AII is mounted on the second magnetic body 916II and can be used to actuate the first actuator 917AI upon relative motion between the first and second magnetic bodies 916II and 916I. In various embodiments, the elastically deformable chamber can be similar to a “thumb pump”; by actuating the first actuator 917AI, a vacuum can be created within the elastically deformable chamber when the elastically deformable chamber is pushed against a work surface (such as a work surface 926 of the work body 930). Controllable linear relative motion between the magnetic bodies 916I and 916II can be used to activate the vacuum. For example, the entire mover 910 in FIG. 9 can be operated to push against the work surface 926; when the magnetic body 916II is commanded to move relative to the magnetic body 916I in the X direction, the magnetic body 916I can controllably remain stationary such that the first activator 917AII (including but not limited to a surface) is in contact with the first actuator 917AI for actuating the first actuator 917AI. Figure 8A

[0246] ​In various embodiments, the actuator assembly 917 can include a second actuator 917BI mounted on the first magnetic body 916I and a corresponding second activator 917BII on the second magnetic body 916II. For example, the second actuator 917AI can be operable to release a vacuum established in the elastically deformable chamber 917C; that is, when the second activator 917BII pushes against the second actuator 917BI in response to a controllable relative motion between the magnetic bodies 916I and 916II in the Z direction, the elastically deformable chamber 917C can be released from the working surface and exposed to the atmosphere. In various embodiments, such a device for vacuum generation can be used in an emergency landing environment: for example, when the mover 910 is operated in the vertical direction (e.g., when gravity is in the Y direction), an actuatable vacuum system on the mover 910 can help hold the mover 910 on the working body 930 to withstand a power failure situation; when power is restored, the mover 910 can be released from the working surface 926 by releasing the vacuum generated within the elastically deformable chamber. In another example embodiment, the elastically deformable chamber can open upward in the Z direction instead of opening downward toward the working body in the -Z direction. In such an embodiment, when the component, tool, or other body falls on the upward-facing elastically deformable chamber, any vacuum generated in response to linear motion in the X direction can be used to hold the component, tool, or other body. A second actuator such as the second actuator 917BI can be configured to release any vacuum generated within the elastically deformable chamber in this embodiment, thereby also releasing the component or other body.

[0247] Referring to Figure 8B A magnetic mobile device 1050 is shown in accordance with another embodiment. The magnetic mobile device 1050 includes a mover 1010 and a working body 1030. The working body 1030 includes a plurality of suitable electrically conductive elements that can conduct electrical current to generate a magnetic field that can then interact with a magnetic array on the mover 1010 to generate actuation forces and / or torques to controllably move the mover 1010 in at least two degrees of freedom (e.g., in the X and Y directions). Such controllable motion can be achieved in a manner similar to that already described above. In various embodiments, the mover 1010 can be levitated in the vicinity of the working body 1030 without any mechanical contact. In various embodiments, the mover 1010 is capable of controllable movement in at least 6 degrees of freedom.

[0248] In the illustrated embodiment, the mover 1010 includes a first magnetic body 1016I and a second magnetic body 1016II, each of which includes one or more magnetic arrays that can interact with electrical current flowing in the conductive element traces of the working body 1030 to produce forces and / or torques to be applied to the magnetic arrays. A mechanical linkage 1019 connects the first and second magnetic bodies 1016I and 1016II together to constrain relative motion between the first and second magnetic bodies 1016I and 1016II in a first set of one or more directions / DOFs (in the current embodiment, the Ym, RXmand RYmdirections) and to allow relative motion between the first and second magnetic bodies 1016I and 1016II in a second set of one or more directions / DOFs (in the illustrated embodiment, the Xm, Zmand RYmdirections). The mechanical linkage 1019 according to the current embodiment includes a plurality of hinges (1092A through 1092F) and a plurality of connectors (1091A through 1091C) that extend substantially along the Zsdirection. In general, a hinge connecting two connectors allows relative motion between the connectors in only a single degree of rotational freedom about the hinge axis; that is, if a first connector is fixed as stationary, another connector that is connected to the first connector by a hinge can move in only a single degree of freedom.

[0249] In general, unless otherwise noted, any hinge contemplated herein can be implemented in any number of ways known in the art, such as a single piece flexure bearing or a compound flexure bearing, such as shown in U.S. Patent No. 9, 1 1 1, 1 1 1, issued July 19, 2016, or by a rolling element / slip bearing or a revolute joint or any other type of hinge known in the art. ​ In various embodiments, a cylindrical joint can be used in place of the hinges shown in U.S. Patent No. 9, 1 1 1, 1 1 1, issued July 19, 2016. Figure 8B In various embodiments, a cylindrical joint can be used in place of the hinges shown in U.S. Patent No. 9, 1 1 1, 1 1 1, issued July 19, 2016.

[0250] Referring to Figure 8A , the linkage body 1017 (e.g., a component carrier) is connected to the three connectors (1091A through 1091C) via hinges 1092A, 1092C, and 1092E. In such an arrangement, by translating relative motion between the magnetic bodies 1016I and 1016II in the Xm direction into motion of the linkage body 1017 in the Z direction, the linkage body 1017 can achieve a significantly higher range of motion in the Z direction compared to the controllable range of motion of either magnetic body 1016I or 1016II.

[0251] In the illustrated embodiment, mechanical linkage 1019 comprises a combination of a "four-bar linkage" (magnetic body 1016I, connector 1091A, connector 1091B, and linkage body 1017) and a "single-link" (magnetic body 1016II, connector 1091C, linkage body 1017); in this arrangement, the four-bar linkage is connected to first magnetic body 1016I; one end of the single-link is attached to second magnetic body 1016II through a hinge such as a revolute joint, and at a second end is attached to linkage body 1017 through a hinge such as a revolute joint. In this example embodiment, mechanical linkage 1019 itself comprises a conversion mechanism that converts relative motion between magnetic bodies 1016I and 1016II in the Xm direction into Z-direction motion of linkage body 1017. In various embodiments, the Z-motion stroke of 1017 can be significantly greater than the Z-motion stroke of magnetic bodies 1016I and 1016II. It should be noted that when the first and second magnetic bodies (1016I and 1016II) are driven with the same displacement in the Xm direction, linkage body 1017 will also be driven with the same displacement in the Xm direction. To drive the linkage body in the Xm direction, each of the first and second magnetic bodies can be driven using a force in the Xm direction.

[0252] Each of magnetic bodies 1016I and 1016II can comprise a plurality of magnetic arrays. In various embodiments, each of magnetic bodies 1016I and 1016II can comprise a plurality of magnetic arrays arranged substantially as shown in FIG. 10A. Figure 8CThe four magnetic arrays 1012A, 1012B, 1012C, and 1012D of the illustrated pattern; as a result, each magnetic body 1016I and 1016II can have 8 directions / DOF of controllable movement, i.e., the working body 1030 is capable of generating up to 8 independent forces on each magnetic body 1016I and 1016II. By using suitable position feedback methods, each magnetic body 1016I and 1016II itself can be capable of 6-DOF controllable motion in levitation mode, and three in-plane controllable motions in sitting mode. However, due to the constraints imposed by the mechanical linkages 1019, in various embodiments, some controllable motions of 1016I and some controllable motions of 1016II can not be achieved independently, and the entire mover 1010 can not be capable of controllable motion in 12 independent directions / DOF. When the mechanical linkages 1019 constrain the relative motion between the magnetic bodies 1016I and 1016II in three directions / DOF (e.g., Ym, Rzm, and Rxm directions), the Ym / Rzm / Rxm motions of the magnetic body 16I cannot be controlled independently of the Ym / Rzm / Rxm motions of the magnetic body 1016II. In other words, the control of the Ym / Rzm / Rxm motions of both magnetic bodies 1016I and 1016II needs to be coordinated. For example, to control the Ym motion of the linkage body, a position feedback describing the position of the linkage body in the Ym direction (i.e., the “Ym-direction coordinated position feedback” of the linkage body) can be calculated based on the Ym positions of the magnetic body 1016I and the magnetic body 1016II (e.g., by calculating the average of the Ym position of 1016I and the Ym position of 1016II). In various embodiments, the Ym-direction coordinated feedback can be a weighted sum of the Ym positions of the first and second magnetic bodies, and the weighting factors can be determined by the geometric lengths of the linkage rods in the mechanical linkages. Based on this Ym-direction coordinated position feedback signal, a suitable algorithm can be used by the controller described with reference to Figure 1A and 1B to calculate the required coordinated force to be applied to the magnetic bodies 1016I and 1016II in the Ym direction, and then generate suitable current command signals to the amplifiers (e.g., the amplifiers described with reference to Figure 1A and 1B to drive the corresponding currents into selected conductive elements in the working body 1030 accordingly. One way to apply the force on each magnetic body can be to drive each of the first and second magnetic bodies with half of the coordinated force calculated in the Ym direction, so that both the first and second magnetic bodies are subjected to some of the required coordinated force in the Ym direction.

[0253] Control of motion in the Rzm and Rxm and Rym directions can be implemented in a similar manner with appropriate modifications. To control the rotational motion of the link body about the Xm direction independent of translational motion in the Xm, Ym, and Zm directions, the coordinated feedback (rotational motion of the link body about the Xm axis) can be computed by averaging the rotational positions of the first and second magnetic bodies about the Xm axis, or more generally, by a weighted sum of the rotational positions of the first and second magnetic bodies about the Xm axis. Based on the computed coordinated feedback, a coordinated torque about the Xm direction can be computed using a suitable feedback control algorithm. The computed coordinated torque can be simultaneously applied to the first and second magnetic bodies about the Xm direction by current commands appropriately computed and sent to the magnetic field modulators.

[0254] To control the rotational motion of the link body about the Xm direction independent of translational motion in the Xm, Ym, and Zm directions and rotational motion about the Zm direction, the coordinated feedback (rotational motion of the link body about the Xm axis) can be computed by averaging the rotational positions of the first and second magnetic bodies about the Xm axis, or more generally, by a weighted sum of the rotational positions of the first and second magnetic bodies about the Xm axis. Based on the computed coordinated feedback, a coordinated torque about the Xm direction can be computed using a suitable feedback control algorithm. The computed coordinated torque can be simultaneously applied to the first and second magnetic bodies about the Xm direction by current commands appropriately computed and sent to the magnetic field modulators.

[0255] To control the rotational motion of the link body about the Xm direction independent of translational motion in the Xm, Ym, and Zm directions and rotational motion about the Zm direction, the coordinated feedback (rotational motion of the link body about the Xm axis) can be computed by averaging the rotational positions of the first and second magnetic bodies about the Xm axis, or more generally, by a weighted sum of the rotational positions of the first and second magnetic bodies about the Xm axis. Based on the computed coordinated feedback, a coordinated torque about the Xm direction can be computed using a suitable feedback control algorithm. The computed coordinated torque can be simultaneously applied to the first and second magnetic bodies about the Xm direction by current commands appropriately computed and sent to the magnetic field modulators.

[0256] In various embodiments, the mechanical linkage 1019 can allow the relative motion between the magnetic bodies 1016I and 1016II to be controlled in 3 of the second set of directions / DOF (Zm, Xm, Rym); thus, Zm / Xm / Rym motion of the magnetic body 1016I can be controlled independently of Zm / Xm / Rym motion of the magnetic body 1016II, and Zm / Xm / Rym motion of 1016II can be controlled independently of Zm / Xm / Rym motion of the magnetic body 1016I. As a result, relative motion between the magnetic bodies 1016I and 1016II (in the Xm, Zm, and Rym directions) can be independently controlled.

[0257] Figure 8D A non-limiting embodiment of a magnetic mobility device 1150 is shown that is capable of extended motion in the Z direction, using a similar configuration to that shown in Figures 8A-8C The magnetic mobility device 1150 includes a linkage body 1117 (e.g., a workpiece holder) that is configured to carry a workpiece 1193 in the illustrated embodiment. The robotic device 1111 can position the workpiece 1193 between a pair of opposing surface members 1194A and 1194B, and is configured to move up and down in the Z direction (e.g., a stamping tool) to perform a high force stamping operation, and then take the workpiece 1193 away. In the illustrated embodiment, there is space in the XY plane of the work body 1130 to accommodate the bottom member 1194A (e.g., which can include a support column). In various embodiments, the size of the space can be set such that the force generated by the stamping process cannot be transmitted to the work body 1130, since repeated high strength forces can damage or otherwise impede the operation of conductive elements within the work body 1130. The robotic device 1111 can be configured to use its ability to move in 6 directions / DOF to carry the workpiece 1193 in the X and Y directions, and to lower or raise the workpiece 1193 in the Z direction by controllably moving the linkage body 1117 that holds the workpiece 1193 in the Xm direction in response to relative motion between the magnetic bodies 1116I and 1116II.

[0258] Figure 8E Another non-limiting embodiment of a magnetic mobility device 1250 is shown that includes a linkage body 1217 and utilizes a robotic device 1211 that is capable of extended Z motion. In the illustrated embodiment, a holding body 1295 can optionally be mounted on the linkage body 1217. In general, the holding body 1295 can be any body or structure that is configured to hold one or more objects; in the illustrated embodiment, the holding body 1295 includes a vial holder that is configured to hold one or more vials. In other embodiments, the holding body 1295 can be configured to hold any other type of object.

[0259] In the illustrated embodiment, robotic device 1211 is configured to position one or more vials having one or more stationary liquid fill lines in the X and Y directions by moving in at least 2 directions / DOF during the filling process of the vials. In various embodiments, the vials can be gradually lowered by robotic device 1211 as the liquid is filled to maintain an almost constant distance between the fill line bottom opening and the liquid top surface within the vials by moving link body 1217 in the Z direction in response to controlling the relative motion between magnetic bodies 1216I and 1216II in the Xm direction. In this embodiment, the fill lines can remain stationary throughout the process. With the long stroke 3D (X, Y and Z) positioning capability of robotic device 1211, the liquid can be filled into the vials one at a time or, alternatively, the vials can be filled simultaneously when link body 1217 is held stationary.

[0260] Figure 8F Another non-limiting embodiment of a magnetic mobile apparatus 1350 is shown that includes a link body 1317 that is capable of extending motion in the Z direction. Robotic device 1311 includes a mover 1310 that includes two magnetic bodies 1316I and 1316II that are capable of interacting with a current flowing through an electrically conductive element within working body 1330, as previously described, to control the motion of mover 1310 in 6 directions / DOF and to control the relative motion between magnetic bodies 1316I and 1316II in one or more directions. Mechanical link 1319, which includes link body 1317, connectors 1391A, 1391B, 1391C, 1391D and the hinges (e.g., hinge or cylindrical joints) that connect them together, constrains the relative motion between magnetic bodies 1316I and 1316II in a first set of 4 directions / DOF (Ym, RXm, RYm, RZm) and allows the relative motion between magnetic bodies 1316I and 1316II in a second set of 2 directions / DOF (Xm, Zm). Figure 8F and 8E The difference between the illustrated embodiments is that, in Figure 8FThere is an additional fourth connector 1391D in the illustrated embodiment that further constrains the relative motion between the magnetic bodies 1316I and 1316II in the RYm direction. The link body 1317 can be configured to carry a component 1393 that can be positioned under a tool configured to work on the component, such as for example a 3D printing head (or nozzle) 1394A, which can remain stationary or operate with an additional actuator (not shown). For example, the robotic device 1311 can be configured to position the component in up to 3 linear directions / DOF (X, Y, Z) using a relatively long stroke for 3D printing operations. Such a long stroke in the Z direction can be significantly larger than the gap distance in the Z direction between the working surface of the work body 1330 and the bottom surface of the magnetic bodies 16I and 16II, where the Z direction can be the normal to the working face. Such a long stroke in the Z direction can be several centimeters or more. In this way, 3D printing operations can be implemented in a possibly clean manner without any lubricant, which is typically necessary in conventional bearings. Furthermore, all the required movements can be able to be provided by such a robotic device without any mechanical friction or contact, which is highly desirable in 3D bioprinting for producing living organs in a sterile environment. In various embodiments, multiple tools such as printing heads 1394B can be implemented, and the robotic device 1311 can be configured to carry the component 1393 in different printing heads for different purposes (e.g., printing using different materials). Typically in bioprinting, different cells are needed to produce a functional organ; with multiple parallel working printing heads, each head can be configured to hold one or more specialized materials. Multiple heads can also be used for pipe printing processes, which can improve productivity.

[0261] In various embodiments, the elastically deformable components 1321A and 1321B can optionally be installed to link one or more connectors to the link body 1317 in order to balance the gravitational force induced potential energy change during the movement of the link body 1317 in the Z direction. For example, the elastically deformable components 1321A and 1321B can be springs. When the carrying plate moves in the -Z direction and the gravitational force is in the -Z direction, the gravitational induced potential energy will decrease, and the potential energy stored in one or both of the elastically deformable components 1321A and 1321B can increase, and thus can reduce the overall system potential energy change, which helps to reduce the X direction lateral force required to be applied on the magnetic bodies 1316I and 1316II, which can help to reduce the power consumption. Other purposes for installing elastically deformable components can be to maintain certain relative positions between the components of the magnetic mobile device 1350 during power off. Non-limiting examples of suitable elastically deformable components include, for example, linear springs and rotational springs.

[0262] Figure 8GA non-limiting embodiment of a robotic device 1411 capable of extending motion in the Z direction is shown. The robotic device 1411 (including the mover 1410) can be designed substantially similar to the robotic device 1011 of Figures 8A to 8F The robotic device described is substantially similar. The robotic device 1411 can carry a holding body such as a vial holder 1495, which can be configured to carry one or more vials 1493. During a vial filling process, it can be important to precisely control the fill amount, for example for economic and / or medical reasons. As such, the illustrated embodiment includes a weighing station 1494A including a carrying fork 1494B configured such that any components loaded onto the carrying fork 1494B can be precisely weighed. The robotic device 1411 can use relative motion between the magnetic bodies 1416I and 1416II as described with respect to previous embodiments and corresponding resultant vertical motion of the vial holder 1495 to carry one or more vials 1493 by the following process: a) lifting the vial in the Z direction and moving in the +Y direction toward the carrying fork 1494B without contacting the carrying fork 1494B; b) lowering the vial holder 1495 to lower the vial 1493 (and the vial holder 1495) onto the carrying fork 1494B in order to further disengage the vial for a weighing operation; c) again lifting the vial 1493 in the +Z direction, moving the vial 1493 away from the carrying fork 1494B, and then moving in the -Y direction, away from the carrying fork 1494B, for subsequent operation processes (e.g., refilling the vial again if it is not sufficiently filled, or for a capping operation).

[0263] Figure 8H and Figure 8I A non-limiting exemplary embodiment of a magnetic mobile apparatus is shown. The illustrated embodiment includes a robotic device 1511 that is substantially similar to the robotic device 1011 of Figure 8A However, in the illustrated embodiment, Figure 8H The hinges of the robotic device 1511 in / 8I include cylindrical joints instead of hinge joints. Although Figure 8H and Figure 8I The magnetic mobile apparatus in / 8I and / 8II can further include one or more work bodies and any components described with respect to any previous embodiments disclosed herein, for example with respect to Figure 8H and 8I The magnetic mobile apparatus in / 8I and / 8II can further include one or more work bodies and any components described with respect to any previous embodiments disclosed herein, for example with respect to Figure 8AAny of the components described. The robotic device 1511 includes a mover 1510. The mover 1510 includes two magnetic bodies: a first magnetic body 1516I and a second magnetic body 1516II. Each of the magnetic bodies 1516I and 1516II includes one or more magnetic arrays that can interact with electric current flowing in conductive element traces of the working body to produce force and / or torque. A mechanical linkage 1519 connects the magnetic bodies 1516I and 1516II together to constrain relative motion therebetween in a first set of one or more directions / DOFs (Ym, RXm, RZm) to allow relative motion therebetween in a second set of one or more DOFs (Xm, Zm, RYm).

[0264] In the illustrated embodiment, the mechanical linkage 1519 includes a plurality of cylindrical joints (1592A-1592F) and a plurality of connectors (1591A-1591C) that extend substantially in the Ym direction. In various embodiments, the connectors can be connecting plates or other rigid or substantially rigid bodies that are operable to connect the magnetic bodies 1516I and 1516II to the linkage body 1517. Generally, a cylindrical joint connecting two rigid bodies allows relative motion between them in only a single rotational degree of freedom about the joint axis. In the illustrated embodiment, the linkage body 1517 (which may, for example, include a component carrier) is connected by cylindrical joints to three connectors (1591A-1591C) that, by translating relative motion in the Xm direction between the magnetic bodies 1516I and 1516II into motion in the Z direction of the linkage body 1517, can enable extensional motion in the Z direction that is substantially greater than the range of motion in the Z direction that one or both of 1516I and 1516II can achieve. The linkage 1519 includes a “four-bar linkage” (magnetic body 1516I, connectors 1591A and 1591B, and linkage body 1517) and a single link (connector 1591C); the four-bar linkage mechanism is connected to the first magnetic body 1516I; one end of the single link is attached to the second magnetic body 1516II by a rotational joint, and at a second end is attached to the linkage body 1517 by a rotational joint.

[0265] Figure 8H The linkage body 1517 is shown operating at a low Z position, for example by driving the magnetic bodies 1516I and 1516II away from each other in the Xm direction. Figure 8I The linkage body 1517 is shown operating at a high Z position, for example by driving the magnetic bodies 1516I and 1516II toward each other in the Xm direction. Each of the magnetic bodies 1516I and 1516II can include a plurality of magnetic arrays. In particular embodiments, each of the magnetic bodies 1516I and 1516II can include 4 magnetic arrays, for example Figure 8Cmagnetic arrays 1012A, 1012B, 1012C, 1012D shown in Figure 8H and Figure 8I not shown in Figures 8A-8C ) can generate up to 8 independent forces on each magnetic body 1516I and 1516II. Using suitable position feedback methods, the magnetic body 1516I can be controllably moved in up to 6 directions / DOF, and the relative motion between the magnetic bodies 1516I and 1516II (in Xm, Zmand RYmdirections) can also be independently controlled. In various embodiments, suitable position feedback methods can include the control methods described with reference to Figure 8H and Figure 8I , which can be similarly applied to the embodiments shown in

[0266] In various embodiments, robotic devices such as robotic device 1511 can optionally include one or more braking (or locking) devices, as shown as 1598A, 1598B, 1598C in Figure 8H and 8I Each brake 1598 can be associated with a particular cylindrical joint, and can be activated in one of a variety of different ways, for example by receiving a wireless signal and / or by using a battery and actuator mounted on the mover to activate wirelessly, or can be activated in a cooperative manner or in an automatic / self-activated manner, as described in further detail below with reference to Figure 18 and 19 In various embodiments, such brakes can help reduce system power consumption when the gravitational force is in the -Z direction: for example, in Figure 8HThe lateral X-direction actuation force from the work subject (not shown) can be needed to carry the load on the linkage body 1517 without any braking; this lateral force can not be necessary when one or more such brakes are activated, thus power consumption can be reduced. When one or more such brakes are deactivated, the corresponding cylindrical joint can allow rotational relative motion between two connected parts, for example; when the brake is activated, the corresponding cylindrical joint can constrain all relative motion between two connected parts, and the two parts can move together as rigid bodies. When the brakes (1598A, 1598B, 1598C) are deactivated, the mechanical linkage 1519 can constrain relative motion between the magnetic bodies 1516I and 1516II in the first set of 3 directions / DOFs (Ym, RXm, RZm), and can allow relative motion between the magnetic bodies 1516I and 1516II in the second set of 3 directions / DOFs (Xm, Zm, RYm). When the brakes (98A, 98B, 98C) are activated, the mechanical linkage 1519 can constrain relative motion between the magnetic bodies 1516I and 1516II in the expanded first set of 6 directions / DOFs (Ym, RXm, RZm, Xm, Zm, RYm). The first set of expanded relative motions includes the first set of relative motions plus at least one of the second set of relative motions. In this particular case, the first set of expanded relative motions includes the first set of relative motions plus three of the second set of relative motions. Although Figure 8H and 8I A four-bar linkage mechanism is shown in, but those skilled in the art will appreciate that other embodiments can include any other suitable linkage mechanism configured to convert relative motion between the magnetic bodies 1516I and 1516II in the Xm direction into relative motion of the linkage body 1517 in the Z direction.

[0267] Magnetic coupling linkage system

[0268] Referring to Figures 9A to 9K, embodiments of a magnetic mobile device having a mechanical linkage comprising two independently mobile members connected by a rotary joint based linkage system whereby relative motion of the members actuates the linkage system are disclosed. Generally, the embodiments shown below disclose an automation system that has no physical connection to the ground with respect to its movement and comprises at least one pair of independently mobile members connected by a rotary joint based linkage system whereby relative motion of the members actuates the linkage system and the rotary joint is formed by magnetically preloaded members such that all surfaces and interfaces between the moving components can be completely flushed to remove contaminants or pathogens. In various embodiments, the rotary joint can be formed by a pair of left hand (LH) and right hand (RH) helical gear contacts, whereby a LH-RH pair of magnets with NS orientation connected to each gear respectively mate with a RH-LH pair of magnets with SN orientation connected to each gear respectively, such that the rotary joint based on helical gears is completely preloaded by magnetic field lines flowing through the contacting gear teeth. As one helical gear pair rolls over the other, previously contacted surfaces can be exposed for cleaning to remove contaminants and pathogens. In various embodiments, such helical gear pairs can be generally useful in automating various processes where tools operating on components need to be moved or components or assemblies need to be moved to different stations to be operated on. Accordingly, the rotary joint can be formed by magnetically preloaded members such that all surfaces and interfaces between the moving components can be completely flushed to remove contaminants or pathogens. The rotary joint can be formed by a pair of left hand (LH) and right hand (RH) helical gear contacts, whereby a LH-RH pair of magnets with NS orientation connected to each gear respectively mate with a RH-LH pair of magnets with SN orientation connected to each gear respectively. The rotary joint based on helical gears can be completely preloaded by magnetic field lines flowing through the contacting gear teeth. As one helical gear pair rolls over the other, previously contacted surfaces can be exposed for cleaning to remove contaminants and pathogens.

[0269] Reference Figure 9AExemplary embodiments show a working body 1601 with an array of electrically conductive elements, such as wires or coils (not shown), through which electrical current can be made to flow, thereby electromagnetically levitating and moving magnetic bodies 1620 and 1630 above a surface 1602 of the working body 1601. The magnetic body 1620 includes a base 1621 to which a first connector 1640 is attached. In various embodiments, the mechanical link 1640 can include a link and joint (LAJ) module. The magnetic body 1630 has a base 1631 to which two additional connectors 1640 are attached. In various embodiments, more or fewer connectors can be attached to one or both of the magnetic body 1620 and the magnetic body 1630. A link body 1625 connects one end of each connector. In various embodiments, the link body 1625 can be a coupler plate. The magnetic bodies 1620 and 1630 can be controlled to move anywhere directly above the surface 1602, and as long as their relative distance in the plane of the connectors 1640 remains fixed, the position of the link body 1625 relative to the puck will be uniquely defined. Although the magnetic bodies 1620 and 1630 can be levitated above the working surface of the working body 1601 in a non-contacting manner, in various embodiments the magnetic bodies 1620 and 1630 can be in contact with the working body through sliding and / or rolling element bearings.

[0270] Referring to Figure 9A and 9B If the magnetic body 1620 is moved toward the magnetic body 1630, the link body 1625 will move vertically upward while remaining parallel to the base 1631 of the magnetic body 1630. If the magnetic body 1620 is moved away from the magnetic body 1630, the link body 1625 will move vertically downward while remaining parallel to the base 1631 of the magnetic body 1630. If the connectors 1640 have different link lengths, the angle of inclination of the link body 1625 relative to the base 1631 will not be parallel, which can be desirable in certain situations. In the illustrated embodiment, the relative motion between the connectors 1640 and the magnetic bodies together constitute a six-bar linkage.

[0271] Referring to Figure 9C and 9DAn exemplary connector 1640 is shown in more detail. The connector 1640 includes a connection module 1650, one on each end of which is a link module. As can be seen, a helical gear forms the interface between the connection module and the link module. A left-hand helical gear (LHHG) 1652L mates with a right-hand helical gear (RHHG) 1662R, whose axes of rotation are parallel, creating a thrust force when torque is transferred from one to the other. If the LHHG (1652L) is coaxial and rigid with the RHHG (1662R) and attached to the connection module base 51, and the RHHG (1662R) is coaxial and rigid with the LHHG (1662L) and attached to the link 1661, as shown in Figure 9C when torque is transferred between them; where the torque will come from moving one of the connection modules 1650 relative to the other connection module 1650 while keeping the base 1651 parallel. While helical gears are contemplated herein, those skilled in the art will appreciate that any type of gear can be used in other various embodiments.

[0272] Figure 9D A cross-section through the connector 1640 is shown, where the magnets 1653 can be seen connecting the helical gear sets together. Referring to Figure 9E and 9F the connection module 1650 is shown in more detail and in cross-sectional detail, respectively. The rotary joint in the connection module 1640 is formed by a left-hand (LH) 1652L and right-hand (RH) 1662R helical gear pair in contact, and a RH 1652R and LH 1662R helical gear pair in contact, whereby the LH-RH pair is held in the housing 1651 and the mating RH-LH pair in the end 1664 of the link 1661, with SN oriented magnets connecting each LH-RH and RH-LH gear, respectively, such that the rotary joint based on the helical gears is fully preloaded by the magnetic field lines 1654 flowing through the contacting gear teeth. As one helical gear pair rolls over the other, the previously contacting surfaces are exposed for washing to remove contaminants and pathogens. While two magnets 1653 are used in FIG. 9, one of the magnets 1653 can be replaced with a ferromagnetic component having a similar shape 1653 in other various embodiments.

[0273] In various embodiments, the gears can be ferromagnetic and the tubular structure can not be ferromagnetic, such that the magnetic flux will only flow through the magnets and gears. In one embodiment, a rare earth magnet having a diameter of about 3 / 8” and a length of about 1.5” and a steel gear having 15 teeth and a pitch diameter of about 21.2 mm will create an attractive force of about 50 N between the connection module 1650 and the link end 1651.

[0274] Referring back Figure 9A and 9B When the magnetic body 1620 moves away from the magnetic body 1630, due to the fact that the links 1640 are all of the same length, the link body 1625 must remain in the middle, so the links 1640 must move down. Due to the magnetic circuit, the mating helical gears are preloaded together and in rolling contact, so the coupler 1625 must also remain horizontal, so the mating helical gears roll on each other and due to the rolling constraint of the gear teeth on the axes of the gears on the links 1640 all remain coplanar. Moreover, because the gear teeth are helical and the LH and RH gears are mated together, the rolling contacts will remain planar, so the planar stability of the links does not require separate thrust bearings.

[0275] According to another embodiment, the plastic helical gears can be attached to a circular ferromagnetic metal disc of diameter equal to the pitch diameter of the gears, where the circular ferromagnetic metal disc is in rolling contact, the plastic helical gears are plastic, do not require lubrication, and will last a long time, and their engagement ensures that the axes of the circular metal discs remain coplanar as the links move. In this way, a smoother motion can be achieved, but at the cost of some preloading force. In both embodiments, because there is rolling contact when the links move, the surfaces are exposed and can then be flushed at a flushing station without having to separate the links, so flushing can be automated. Moreover, because the preload is magnetic, the links can be easily assembled (or disassembled) mechanically, so that in a fully automated system, repairs can be made mechanically, or disassembled for more thorough automated cleaning, for example by immersion or for example high pressure washing.

[0276] In various embodiments, lightweight elements can be used. For example, a typical configuration using gears of pitch diameter of about 21.2 mm and links of length of about 200 mm can weigh about 1 kg:

[0277]

[0278] Generally, in various embodiments, a six bar linkage mechanism for moving a linkage body up and down and left and right can include two movers, one mover having two connectors attached thereto, the other mover having one connector attached thereto, and a linkage body connected to the ends of the connectors not connected to the movers. The connectors can include a connection module on each end, where the connection module can have a tubular structure with a ferromagnetic LH helical gear and a ferromagnetic RH helical gear at each end of the tubular structure, and a magnet in a bore of the tubular structure connecting the LH helical gear and the RH helical gear, and a linkage between the connection modules, the linkage having a tubular structure at each end with a ferromagnetic LH helical gear and a ferromagnetic RH helical gear at each end of the tubular structure and a magnet in a bore of the tubular structure connecting the ferromagnetic LH helical gear and the ferromagnetic RH helical gear, where the N pole of the magnet is connected to the same hand gear as the magnet in the connection module, where one of the connection modules is connected to each end of the linkage, where the LH ferromagnetic helical gear mates with the RH ferromagnetic helical gear, and where the magnets complete a magnetic circuit through a mesh of gear teeth to preload the gear teeth together.

[0279] According to other various embodiments, a six bar linkage mechanism for moving a coupler linkage up and down and left and right can include two movers, one mover having two connectors attached thereto, the other mover having one connector attached thereto, and a coupler linkage connected to the ends of the connectors not connected to the movers. The connectors can include a connection module on each end, the connection module having a tubular structure with a LH helical gear and a RH helical gear at each end of the tubular structure, the LF and RH helical gears each attached to a ferromagnetic cylindrical member attached to the tubular structure and a magnet in a bore of the tubular structure connecting the ferromagnetic cylindrical members, the ferromagnetic cylindrical members having a diameter similar to the pitch diameter of the helical gears, and a linkage between the connection modules, the linkage having a tubular structure at each end with a LH helical gear and a RH helical gear at each end of the tubular structure, the LF and RH helical gears each attached to a ferromagnetic cylindrical member attached to the tubular structure and a magnetic body in a bore of the tubular structure connecting the ferromagnetic cylindrical members, the ferromagnetic cylindrical members having a diameter similar to the pitch diameter of the helical gears, where one of the connection modules is connected to each end of the linkage, where the LH helical gear mates with the RH helical gear, and the ferromagnetic cylindrical members are in contact, where the magnets complete a magnetic circuit through the ferromagnetic cylindrical members.

[0280] Rotatable linkage system

[0281] Reference Figure 10A, discloses a magnetic mobile device 1710 that has no physical connection to the ground with respect to its movement. The magnetic mobile device 1710 comprises at least one pair of independent planar mobile (MOP) units connected by a planar linkage system based on revolute joints, whereby relative motion of the MOP units towards or away from each other actuates the coupler elements of the planar linkage system to move up or down, and the revolute joints and linkages are formed of modular injection molded plastic elements and simple beam members, and each revolute joint at the coupler has a juxtaposed gear (a non-limiting example is a spur gear), so that the gears mesh, thereby causing the coupler to remain parallel to the plane of movement of the MOP units; additionally optionally mounted on the MOP units is a base revolute joint (turntable) whose axis of motion is perpendicular to the plane of movement of the MOP units, and two planar linkage systems are mounted on the turntable such that rotation of one MOP unit about the other causes the coupler linkages of the linkage systems to rotate about the base unit axis of rotation. In various embodiments, the joints are made of plastic material; but this is not essential. Other suitable materials with low coefficient of friction can also be used as the linkage material in one or more components. These embodiments can be generally useful in automating various processes where it is necessary to move a tool operating on a part, or to move a part or component to a different station to be operated on.

[0282] Referring to Figure 10A , 10B and 10C, the work body (not shown) can comprise an array of electrically conductive elements, where current is controlled to electromagnetically levitate and move the magnetic bodies 1720 and 1730 above the surface of the work body in accordance with any of the embodiments described previously. The ability of the system to move the magnetic bodies above the surface of the work body is the subject of patents such as PCT / CA2012 / 050751, PCT / CA2014 / 050739, PCT / CA2015 / 050549, PCT / CA2015 / 050523, PCT / PCT CA2015 / 050157, which are incorporated herein by reference. In the illustrated embodiment, the magnetic bodies 1720 and 1730 have top surfaces 1721 and 1731, respectively, to which hinges 1722 are attached. Connectors 1740a and 1740b are each connected to a hinge 1722 on each magnetic body 1720 and 1730. The connector 1740b can be identical to 1740a, but used to mount as a mirror image of 1740a. A linkage body 1725 is connected to one end of each connector 1740a and 1740b. In various embodiments, the connectors 1740a and 1740b can be, for example, Link and Joint (LAJ) modules, and the hinges 1722 can be, for example, revolute joint brackets. In various embodiments, the linkage body 1725 can comprise a coupling plate.

[0283] The magnetic bodies 1720 and 1730 can be controlled to move to any position above the surface of the work body, and as long as their relative distance in the connector plane remains fixed, the position of the link body 1725 relative to the magnetic bodies will be uniquely defined. If the magnetic body 1720 moves towards the magnetic body 1730, the link body 1725 will move vertically upwards while remaining parallel to the base 1731 of the magnetic body 1730. If the magnetic body 1720 moves away from the magnetic body 1730, the link body 1725 will move vertically downwards while remaining parallel to the base 1731 of the magnetic body 1730. The relative motion between the connector 1740 and the magnetic bodies together constitute a mechanical linkage: the "ground link" consists of two magnetic bodies, and its length can change as the relative motion between the magnetic bodies. When the positions of the magnetic bodies are fixed, the system can appear like a four-bar linkage in the form of a trapezoid. However, the trapezoid is unstable unless the top and bottom are constrained to be parallel. This can be achieved in the present embodiment if the angle between the connector and the magnetic bodies is defined (i.e. the relative motion between the magnetic bodies is constrained). In the case of the four-bar linkage mechanism of the present embodiment, a spur gear on the connector 1740 can be used to constrain the angle between the connectors.

[0284] In the present embodiment, the connectors 1740a and 40b are identical (this is not essential), but are mounted as mirror images of each other. The connector 1740a has a T-shaped coupler 1741a on the first end into which the structural tube 1743 is inserted and bonded. The stem of the T-shaped coupler acts as a shaft and forms a pin joint with the joint bracket 1722 on the magnetic body 1721. The second end has a T-shaped gear coupler 1742a into which the other end of the structural tube 1743 is configured to be inserted and bonded. As will be further explained in the context of Figure 10F The gear teeth are phased relative to the longitudinal axis of the connector 1740 so that, as can be seen in Figure 10C when the gear teeth are engaged, the link body 1725 remains horizontal. This is found, for example, in a compass, where engaging gears are used on the ends of the link to keep the coupled link in a fixed orientation as the link moves. In various embodiments, the connectors 1740a and 1740b can not be identical. In various embodiments, the T-shaped gear coupler 1742a can be designed so that the shaft that hinges the connector 1740A to the link body 1725 can be concentric with the rotational axis of the gear. Similarly, the T-shaped gear coupler 1742b can have the same concentric property between the gear axis and the hinge axis.

[0285] Figure 10DA joint bracket 1722 designed to be injection molded is shown. The joint bracket has a vertical member 1723 with a circular top and legs 1726a and 1726b for bolting to a magnetic body or top link body 1725. One key feature is that its design takes advantage of the end of the T-shaped coupling shaft of the link mechanism fitting into the bearing journal space 1727 and primarily loading the bracket 1722 in normal use, so that for example bearing surfaces 1724a and 1724b take the load and the bearing preload arm 1725 only preloads the shaft into place. In various embodiments, if a collision between movers (e.g., mover 1710) occurs, the preload arm can flex open and can reduce or avoid damage.

[0286] Figure 10E A connector 1740 is shown, which in the current embodiment includes a T-shaped coupler 1741a, a structural tube 1743, and a T-shaped gear coupler 1742a. The structural tube can be carbon fiber for weight reduction and high stiffness, or a metal that is easy to machine, such as aluminum or other types of high strength materials such as titanium or stainless steel.

[0287] Figure 10F A side view of the T-shaped gear coupling 1742 is shown, where the T-shaped bar forms a shaft 17148 that is connected to a bar 17143. In the embodiment shown, the gear is designed so that the teeth 17147a and 17147b straddle the centerline perpendicular to the bar, so one right-hand wing will mate with a left-hand wing, so that when the gear teeth of two T-shaped gear couplings mate, as they rotate around their shafts, their bars will be forced to move symmetrically around the centerline. On the bar 17143 are half-rings 17146, 17145, and 17144 for receiving a structural tube.

[0288] Figure 10G An isometric view of the T-shaped coupler 1741 is shown. In the embodiment shown, the T-shaped gear coupler can be molded from a simple mold without side pulls. In Figure 10G the bar 17243 has half-rings 17246, 17245, and 17244 for receiving a structural tube. In this isometric view, it can be seen how the part is injection molded using a simple two-part mold pulled along the length of the shaft. The bar 17248 can be used as a shaft, where the ends 17248a and 17248b will be received by the journal space 1727 of the hinge 1722. The shoulders of the ends act as thrust bearing surfaces to define the horizontal axial position of the T-shaped coupler 1741, and thus the corresponding connector 1740.

[0289] As Figures 10A to 10FThe hinge connecting the connector to the link body is referred to as the link hinge; the hinge connecting one of the first and second magnetic bodies to the link body is referred to as the body hinge. In the illustrated embodiment, each of the body or link hinges includes a T-shaped shaft and a bracket.

[0290] As Figure 10E illustrated, the rotation axes of the two hinges connected to the same connector (one body hinge and one link hinge) are parallel.

[0291] Figure 11A Another example embodiment is illustrated in FIG. 11, in which the link body 1825 is configured to rotate. In the illustrated embodiment, two-axis (i.e., rotatable about two axes) hinges 1882a and 1882b are mounted on the magnetic bodies 1820 and 1830, with their rotation axes perpendicular to the plane of motion on which the magnetic bodies are configured to move, via rotation bearings 1883a and 1883b. The key difference between FIG. 11 and FIG. 10 is that each connector is connected to one of the first and second magnetic bodies via a two-axis hinge in FIG. 11 (rather than a cylindrical hinge as in FIG. 10). In the present embodiment, the rotation bearing 1883b is a rotary joint, however, in various embodiments, the rotation bearing 1883b can be a spherical joint or any other suitable type of joint. Furthermore, although the magnetic bodies 1820 and 1830 are rectangular in shape, in other embodiments, the magnetic bodies can have, for example, square footprints or any other suitable footprints. Each two-axis hinge includes a parallel hinge, a perpendicular hinge, and a hinge body. The parallel hinge is made of a unitary joint bracket 18222 mounted on the hinge body and a T-shaped connecting shaft. The joint bracket allows the T-shaped connecting shaft to snap into place. The perpendicular hinge connects the hinge body to one of the two magnetic bodies via a rotation bearing (rotary joint) such that the hinge body can rotate about a rotation axis in the perpendicular direction with respect to the connected magnetic body. In various embodiments, the rotation axis of the perpendicular hinge is perpendicular to the work surface. In various embodiments, the rotation axis of the parallel hinge is parallel to the work surface. If a first magnetic body, such as magnetic body 1820, is then held stationary, and a second magnetic body, such as magnetic body 1830, is rotated about the first magnetic body 1820 in a circle but without rotation of the magnetic body 1830 in the XY plane, the two-axis hinge will rotate about the equidistant point between the two magnetic bodies 1820 and 1830. Such an embodiment can allow the system to have up to three controlled motion translational degrees of freedom and one controlled motion rotational degree of freedom.

[0292] Figure 11BA dual axis hinge 1882 is shown with a base structure 18184 and holes 18183 for receiving bearings (not shown) to support radial, axial, and moment loads. Joint brackets 18222 are mirror images and are snap fit structures and can enable the use of a simpler two part mold. Detained pre-load bearings 18227 and 18224 that must be pried open to enable the shaft to be pressed in are suspended from the main structure. Once the ends 18248a and 18248b of the shaft 18248 are pressed in, 18248a will rest on the main bearing journals 18225 and 18226 for example, and be constrained (i.e. pre-loaded) into place by the pre-load bearings 18227 and 18224. The dual axis hinge structure in this embodiment can be held on a magnetic body such as the magnetic body 1820 when the bearings are inserted for example using thin shoulder screws.

[0293] As to materials, the joint brackets and dual axis hinge can be injection molded from any suitable material such as nylon, and the T-couplers and T-gear couplers can be injection molded from any suitable material such as delrin. By manufacturing these components from different precision molded plastics, the coefficient of friction can be reduced, for example to about 0.05.

[0294] Referring to Figure 11A and 11B The described embodiments can facilitate an automated system with two independent planar movement (MOP) units connected by a planar linkage system of symmetry based revolute joints, whereby relative motion of the MOP units towards or away from each other can actuate the linkage system to move up or down. The linkage elements can be made of modular simple injection molded plastic joint elements and simple beam members connecting the joint elements. Each revolute joint at the coupler can have a spur gear collocated, whereby the spur gears mesh, causing the coupler to remain parallel to the plane on which the MOP units reside. Each revolute joint can include multiple sets of modular molded plastic joint elements, one type containing bearing holes, one type containing shafts. The length of the linkages between the revolute joints can be set by cutting the beam members to length and joining them to the modular molded plastic joint elements. Further, the described embodiments can facilitate an automated system with two independent planar movement (MOP) units connected by a planar linkage system of symmetry based revolute joints, whereby the revolute joints can be mounted on base revolute joints whose axes of motion are perpendicular to the plane on which the MOP units move, such that one MOP unit can rotate about the other, causing the coupler linkages of the linkage system to rotate about the base unit axis of rotation.

[0295] Generally, in various embodiments, a four-bar linkage for moving a coupler link up and down and side to side can include two planar movers, such as magnetic bodies, with a variable length ground link defined by the spacing between them, each mover having a rotational joint bracket and a mirror image connector, each mirror image connector connected to a respective rotational joint bracket on the mover, the link body connected by a pair of rotational joint structures that connect the ends of the connectors that are not connected to the movers. The connectors can include a first T-shaped shaft on a first end of the connector, the top of the T used as a shaft to mate with the rotational joint bracket on the mover, a beam element extending from the stem of the T toward a second end of the connector, a second T-shaped shaft on the second end of the connector, the top of the T used as a shaft to mate with the rotational joint structure on the coupler link, a beam extending from the stem of the T toward the first end of the connector, and a portion of a spur gear at the intersection of the T. The rotational joint structure on the link body can be spaced apart from the pitch diameter of the spur gear such that the spur gear engages and maintains the coupler link parallel to the ground link. The four-bar linkage mechanism can also include a dual-axis hinge on each mover, with one of the rotational joint brackets and mirror image connectors mounted on each dual-axis hinge, with each mirror image connector connected to the link body.

[0296] Figure 12A 、 Figure 12B and Figure 12C together show a non-limiting example of a robotic device 1911 used in conjunction with a work body 1930 according to another embodiment. The robotic device 1911 includes a mover 1910. The mover 1910 includes a first magnetic body 1916I, a second magnetic body 1916II, a third magnetic body 1916III, and a fourth magnetic body 1916IV. Each magnetic body includes a magnetic array, each magnetic array substantially similar to the magnetic array in Figure 8C or another suitable magnet layout described herein. The work body 1930 includes a work body that includes a plurality of electrically conductive elements. Current driven into a suitably selected electrically conductive element in the work body 1930 can interact with the magnetic array components in the magnetic bodies to produce a force to controllably move the robotic device 1911 by connecting the work body 1930 with a suitable amplifier 1970, a suitable controller 1960, and a suitable sensor 1980, such as the sensor shown in Figure 1A and 1B , and operate the system according to a suitable algorithm discussed previously.

[0297] The robotic device 1911 includes a mechanical linkage 1919 that includes a plurality of connectors forming at least two scissor lift linkages connecting each magnetic body with a linkage body 1979, and includes connectors 91A through 91H, hinges 92A through 92P, and linear slides 91I and 91J. Each linear slide can slide along a rail mounted on the linkage body 1917. The mechanical linkage 1919 restricts relative motion between the magnetic bodies (1916I, 1916II, 1916III, 1916IV) in one or more directions / DOF, and allows relative motion between the magnetic bodies in one or more directions / DOF. For example, the mechanical linkage 1919 can constrain relative motion between the magnetic bodies 1916I and 1916II in 3 directions / DOF (Ym, RZm, RXm), and can allow relative motion between the magnetic bodies 1916I and 1916II in 3 directions / DOF (Xm, Zm, RYm); then, the mechanical linkage 1919 also restricts relative motion between the magnetic bodies 1916I and 1916III in 3 directions / DOF (Ym, RZm, RXm), and allows relative motion between the magnetic bodies 1916I and 1916III in 3 directions / DOF (Xm, Zm, RYm). Four magnetic bodies help to increase load capacity compared to only two magnetic bodies. In the illustrated embodiment, the mechanical linkage 1919 can help to convert relative lateral motion in the Xm direction to motion of the linkage body 1917 in the Zm direction, and the Zm direction motion range can be significantly larger than the motion range of each magnetic body. Further, in this embodiment, two fixed support points on the linkage body 1917 are placed at opposite angles, which can make the support structure more stable compared to the case of using magnetic bodies 1916I and 1916I without magnetic bodies 1916III and 1916IV. In various embodiments, the mover 1910 can optionally include one or more brakes (not shown) when the gravity direction is in the -Z direction, similar to the embodiments shown in Figure 8H and Figure 16A (under discussion below), for example, which can save power consumption when holding a component such as a carrying component. The mover 1910 can optionally include one or more elastically deformable components 1921A and 1921B when the gravity direction is in the -Z direction, which can help to reduce power consumption on the working body 1930 by reducing the required lateral force in the Xm direction on the magnetic bodies. In various embodiments, the elastically deformable components can include, for example, springs or other spring elements.

[0298] Figure 13A and 13BAnother embodiment of a magnetic mobile device comprising a mover 2010 and a working body 2030 is shown. The working body 2030 can comprise a plurality of electrically conductive elements, including but not limited to X- and Y- oriented electrically conductive elements in electrically overlaid layers and having a normal direction in the Z direction. The mover 2010 comprises a first magnetic body 2016I and a second magnetic body 2016II. The first magnetic body 2016I comprises four magnetic arrays 2012A-D, which can be substantially similar to the magnetic arrays of the magnetic body 216I in Figure 3A and 3B In the illustrated embodiment, the second magnetic body 2016II is a rotatable cylindrical magnetic body comprising a plurality of linearly elongated magnetized elements around a rotatable rotor frame, as shown in more detail in Figure 9B In various embodiments, the magnetic body 2016II can be a different rotatable shape. Each magnetized element in 2016II is linearly elongated in a direction parallel to a rotation axis 2020 oriented in the Ym direction, and has a magnetization direction orthogonal to its elongation direction. A mechanical linkage 2019, including but not limited to for example a pair of angular contact radial bearings, is mounted between the magnetic bodies 2016I and 2016II, allowing the second magnetic body 2016II to rotate around the rotation axis 2020 fixed to the first magnetic body 2016I. The mechanical linkage 2019 is configured to constrain relative motion between the magnetic bodies 2016I and 2016II in a first set of 5 directions / DOFs (Xm, Zm, Ym, RZm, RXm), and to allow relative motion between the magnetic bodies 2016I and 2016II in a second set of 1 direction / DOF (RYm). In the illustrated embodiment, the second magnetic body 2016II can be configured to interact with appropriate commutated currents flowing in Ys-oriented electrically conductive element traces in the working body 2030 in the vicinity of the magnetic body 2016II, resulting in two independently controllable forces: one in the Z direction to levitate the mover 2010, and a second in the X direction. The X-oriented second force is applied on the second magnetic body 2016II with an offset (i.e., a distance in the Z direction between the working body electrically conductive element top surface 2036 and the rotation axis 2020). Thus, a torque around the Ym-oriented rotation axis 2020 is generated. This torque can be used to control the relative rotational motion between the first magnetic body 2016I and the second magnetic body 2016II in the RYm direction. A sensor system mounted on the working body can be used to measure the rotational position of the magnetic body 2016II. In various embodiments, the mechanical linkage between the first magnetic body 2016I and the second magnetic body 2016II can comprise at least a first shaft and a first brace. The first shaft (e.g., a shaft, etc.) can be rigidly attached to one of the first and second magnetic bodies, and the first brace can be rigidly attached to the other of the first and second magnetic bodies.

[0299] There are several possible applications that can take advantage of the controllable rotational motion of the second magnetic body 2016II relative to the first magnetic body 2016I. As shown in Figure 13C various embodiments, a set of auxiliary conductive elements 2017A configured in one or more phases can be mounted on a body or structure located near the top side of the second magnetic body (opposite to the working body side of the second magnetic body) to generate a back electromotive force voltage. For example, a back iron unit 2017B made of a highly permeable material such as soft magnetic steel can enhance this inductive effect. As a result, the rotational motion of the second magnetic body 2016II can be used as a generator to provide power to the mover-on-device (including but not limited to sensors, actuators, computing units, and communication units).

[0300] As shown in Figure 13D the rotational motion of the second magnetic body 2016II can also be used with a set of gears (2017A and 2017B) to achieve a corresponding rotational motion of the gears (including but not limited to reduced speed and increased torque) around another rotational axis 2020' that is fixed, for example, with the first magnetic body 2016I.

[0301] In various embodiments, the two magnetic bodies can be arranged in a manner similar to that in FIG. 5, and power can be generated by the relative linear motion (including but not limited to reciprocating linear motion) between the magnetic bodies 2016I and 2016II through the installation of suitable components on the magnetic body 2016I (such as conductive elements on the magnetic body 2016I and one or more magnets on the magnetic body 2016II).

[0302] Mover with moving mechanical linkage

[0303] Referring to Figure 14A and 14BAccording to yet another embodiment, a magnetic mobility device 2150 includes a work body 2130, a robotic arrangement 2111, one or more controllers 2160, one or more amplifiers 2170 for driving current through a selective set of electrically conductive elements in the work body 2130, and one or more sensors 2180 for providing position feedback signals. The robotic arrangement 2111 includes a plurality of magnetic bodies 2110. The plurality of magnetic bodies 2110 includes a first magnetic body 2110A and a second magnetic body 2110B. Each magnetic body 2110 is controllably movable relative to the work body 2130 about a working region 2136 of the magnetic mobility device 2150. Each magnetic body 2110 includes one or more magnetic arrays including one or more magnetized elements (e.g., magnets) each having a magnetization direction. The one or more controllers 2160 and the one or more amplifiers 2170 are in electrical communication with each other and with the work body 2130 for selectively and controllably driving current in the plurality of electrically conductive element traces and thereby effecting relative motion between the magnetic bodies 2110 and the work body 2130 as described elsewhere in this specification. A mechanical linkage 2117 including a rotatable arm 2190, a first lever 2192A, and a second lever 2192B connects the first magnetic body 2110A and the second magnetic body 2110B. In various embodiments, the rotatable arm can include a tool holder and an end effector, or any other component, mechanism, or arrangement suitable for a particular operation (e.g., carrying or loading a workpiece).

[0304] In the illustrated embodiment, the first magnetic body 2110A is controllably moved by one or more controllers 2160 in at least 2 in-plane directions / DOFs (X and Y) within its working range, independent of the motion of the second magnetic body 2110B. The second magnetic body 2110B is likewise controllably moved by one or more controllers 2160 in at least 2 in-plane directions / DOFs (X and Y) within its working range, independent of the motion of the first magnetic body 2110A. The rotatable arm (which in various embodiments can include any other rotatable or rotating body) 2190 of the mechanical linkage 2117 is coupled to the first and second magnetic bodies 2110 at bars 2192A and 2192B, and thus the spatial position and orientation of the rotatable arm is entirely determined by the spatial position and orientation of the first and second magnetic bodies 2110A and 2110B. In various embodiments, the range of motion of the rotatable arm in at least one of the Z, Rx, Ry, and Rz directions can be significantly greater than the range of motion of each of the first and second magnetic bodies in at least one of the Z, Rx, Ry, and Rz directions. In various embodiments, each of the first magnetic body 2110A and the second magnetic body 2110B can be capable of controlled motion in 6 directions / DOFs, independent of the other magnetic body. In various embodiments, each of the first magnetic body 2110A and the second magnetic body 2110B can be capable of controlled motion in three in-plane directions / DOFs, independent of the other magnetic body.

[0305] In one embodiment, each of the first magnetic body 2110A and the second magnetic body 2110B can be controllably and independently driven by the working body 2130 in 6 directions / DOFs (X, Y, Z, Rx, Ry, Rz). For example, each of the two magnetic bodies can include a magnetic body substantially similar to the magnetic body illustrated in Figure 8C U.S. Patent No. 6,362,861, or another suitable design, which can operate to interact with a magnetic field generated by a current flowing through the working body 2130 to cause the magnetic body to move in one or more of the 6 directions / DOFs.

[0306] As illustrated in Figure 14A and 14B each of the magnetic body 2110A and the magnetic body 2110B can be independently controlled within its working range, without being constrained by the mechanical linkage 2117. The position and orientation of the rotatable arm 2190 is entirely determined by the position / orientation of the magnetic body 2110A and the magnetic body 2110B. As illustrated in Figure 14AAs shown, the first and second magnetic poles 2192A and 2192B are oriented in the Z direction. In the illustrated embodiment, the rotatable arm 2190 ("first rotatable body," which in other various embodiments can be any suitable rotatable body) is configured to rotate about the first pole 2192A and is slidably engaged with the second pin 2192B (e.g., a "second engagement body," which in various embodiments can be any other suitable engagement body) by, for example, a slot on the rotatable arm 2190. In the illustrated embodiment, the rotatable arm includes a fork at one end thereof (i.e., a first engagement body). The first engagement body (fork) can be configured to detachably engage with the second engagement body (pin). The first and second engagement bodies can be said to be detached when the first and second movers are moved such that the pin slides out of the fork. Thus, when the magnetic body 2110B is moved about the magnetic body 2110A, the rotatable arm 2190 will be driven to rotate about a Z-oriented rotation axis 2120 along the longitudinal axis of the first pole 2192A, which is fixed to the magnetic body 2110A. This rotational motion about the Z-oriented rotation axis 2120 can be significantly greater than the rotational motion that can be achieved by each magnetic body 2110A or 2110B (e.g., which in various embodiments can be on the order of a few degrees). In various embodiments, the rotatable arm 2190 can be capable of rotating up to 360 degrees.

[0307] Figure 15A magnetic moving device 2250 is shown according to another embodiment, comprising a first magnetic body 2210A and a second magnetic body 2210B, both configured to interact with the current flowing through the conductive element traces of the working body 2230 in order to controllably move relative to each other and the working body 2230. Each of the magnetic bodies 2210A and 2210B can be capable of motion in at least 2 directions / DOF (X, Y). In various embodiments, each of the magnetic bodies 2210A and 2210B is capable of controllable motion in at least 6 directions / DOF (X, Y, Z, Rx, Ry, Rz). A mechanical linkage 2299 is installed between the movers 2210A and 2210B. The mechanical linkage 2299 comprises a rotatable body 2293 (configured to rotate around a Z-oriented axis 2220 fixed with the magnetic body 2210A), a four-bar linkage linking the linkage body 2290 and the rotatable body 2293 (comprising connectors 2291A1, 2291A2, rotatable body 93, and linkage body 2290, and respective necessary hinges or cylindrical joints according to various other embodiments disclosed herein), and a connector 2291B connecting the linkage body 2290 and the second magnetic body 2210B through two dual-axis hinges 2292B1 and 2292B2. In various embodiments, the connector 2291B can be a rod, and the hinges 2292B1 and 2292B22 can comprise spherical joints. If the magnetic body 2210A remains stationary, the planar translation of the magnetic body 2210B (in the X and Y directions) can be converted into large stroke motion in the Rz and Z directions. It should be noted that in the present embodiment, the mechanical linkage 2299 does not constrain the relative motion between the magnetic bodies 2210A and 2210B: for example, when the magnetic body 2210A remains stationary, the magnetic body 2210B can still controllably move in 6 directions / degrees of freedom. When the magnetic bodies 10A and 10B are translated together in the X-Y plane, the linkage body 2290 also translates with a long stroke, which is limited only by the dimensions of the working body 2230 in the X-Y plane. In various embodiments, the Rz motion that is achieved can be up to 360 degrees, significantly larger than the few degrees of Rz motion that can be achieved by the magnetic body 2210A and the magnetic body 2210B alone. The motion of the linkage body 2290 in the Z direction can be a fraction of the connector length, and can reach a stroke of a few centimeters to tens of centimeters, significantly larger than the few millimeters of z movement stroke that can be achieved by the magnetic body 2210A and 2210B.

[0308] Self-loading

[0309] According to yet another embodiment, a magnetic mobile device can be configured to load a component onto itself using a first motion and a second motion after the first motion; the second motion can be in a different direction than the first motion. During the first motion, the component to be loaded can be engaged or constrained in a storage system, and the magnetic mobile device can cause the robotic gripper to move in the first direction to gradually engage with the component within the storage system to grasp the component. During the second motion, the magnetic mobile device can cause the component to move out of the storage system in the second direction until the component gradually disengages from the storage system and the constraints imposed by the storage system on the component are completely removed. In various embodiments, the first motion direction can be non-parallel to the second motion direction. In various embodiments, the first motion direction can be opposite to the second motion direction. In various embodiments, the first motion direction can be orthogonal to the second motion direction.

[0310] With specific reference now to the drawings in which identical components are indicated the same, Figure 16A A magnetic mobile device 2350 is shown according to an embodiment configured to load a component. The magnetic mobile device 2350 includes a robotic device 2311, which can include one or more magnetic bodies substantially similar to those magnetic bodies 1016I and 1016II described with reference to Figure 8C or any other suitable magnetic body discussed in this document or elsewhere, and a work body 2330, which is substantially similar to the work body 130 described with reference to FIG. 1. The robotic device 2311 includes a tool 2317 having opposing jaws with an opening, as shown in more detail in Figure 16B In various embodiments, the tool 2317 can be a gripper having, for example, a resilient or elastically deformable opening. One or more components 2393 can be stored in a container 2394 having a side opening at the bottom. In one embodiment, the container 2394 can be tubular and the one or more components can fit in the container similar to coins in a stack of coins. In the illustrated embodiment, the robotic device 2311 is configured to move in a first direction (e.g., the X direction) to engage with the portion at the opening at the bottom of the container 2394, as shown in Figure 16C During the first motion, the engaged component can still be within the container 2394 and can be constrained or engaged with the container 2394, and thus the engagement between the robotic device 2311 and the component 2393 can gradually increase. Once the component 2393 is inside the tool 2317, as shown in Figure 16DAs shown, the robotic device 2311 can then move in a second direction that is not parallel to the first direction of movement, e.g., the Y (or -Y) direction, to remove the engaged component 2393 from the container 2394. As it is removed from the container 2394, the component 2393 remains engaged with the robotic device 2311, but the engagement between the component 2393 and the container 2394 is gradually reduced until the constraints experienced by the container 2394 on the gripped component are overcome. Alternatively, in various embodiments, the second direction of movement can also be parallel and opposite to the first direction of movement, e.g., in the -X direction, to cause the tool 2317 to slide the gripped component out of the container 2394.

[0311] Figure 17A 、 17B and 17C shows another embodiment of a magnetic mobile apparatus comprising one or more robotic devices (2411A, 2411B, 2411C, 2411D) each configured to grasp one or more objects (e.g., vials) from a movable storage system (e.g., a movable screw storage system). Each robotic device has one or more magnetic bodies configured to interact with electrically conductive elements in the work body below the robotic device, as previously described, in order to controllably move each robotic device in at least 2 directions / DOF (e.g., X and Y directions). The movable storage system can move a row of objects along a track in a first direction (e.g., the -Y direction).

[0312] The robotic device (e.g., 2411C) includes a tool 2417C having opposing jaws, e.g., as described above with respect to Figures 16A-16CThe elastic gripper. The robotic device 2411C can use a first motion to approach one or more objects in the screw storage system. The first motion can have a velocity component in the first direction that is synchronized with the movement velocity of the objects in the movable storage system, and a velocity component in the -X direction to gradually engage the one or more objects with the opposing jaws of the tool 2417C. At the end of the first motion, when the tool of the robotic device is fully engaged with the one or more objects, the -X velocity component can be reduced to zero, as shown by the tool 2417B on the robotic device 241 IB. The robotic device can then use a second motion in the first direction to move in synchronization with the movable storage system until the one or more objects are fully removed from the movable storage system, as shown by the tool 2417D on the robotic device 2411D. In various embodiments, the one or more objects can then be transported to another location for further processing or manipulation, including but not limited to filling, weighing, capping, etc. The second motion is only in the first direction, unlike the first motion which is in the X and Y directions. During the first motion, the grasped objects can be constrained by the movable storage system. During the second motion, the grasped objects are engaged with the robotic device, but can also be constrained by the movable storage system. Figure 17B and 17C Cross-sectional views of the robotic devices along lines B-B and C-C are shown, respectively. For example, each robotic device (e.g., the robotic device 2411A in Figure 17C may include two magnetic bodies 2416I and 2416II, which are substantially similar to the magnetic bodies 1316I and 1316II shown in Figure 8F , thereby allowing for a significantly increased range of motion in the Z direction, which can be used for filling and / or weighing and / or capping and / or inspection operations relative to one or more objects.

[0313] Collaborative robots

[0314] Figure 18A magnetic mobile device 2550 according to another embodiment of the present invention is illustrated. The magnetic mobile device 2550 includes a first robotic device 2511A and a second robotic device 2511B. In various embodiments, the first and second robotic devices 2511A and 2511B may each include first and second actuators (not shown). Robotic device 2511A includes an actuator assembly 2595, which includes a first actuator 2594A, and in the illustrated embodiment, includes a second actuator 2594B. In various embodiments, actuator assembly 2595 may include more or fewer actuators. When robotic device 2511B moves toward robotic device 2511A, it may be configured to contact and thereby actuate one of the first and second actuators 2594a and / or 2594b. For example, in various embodiments, actuator assembly 2595 may include a thumb pump, and robotic device 2511B may be configured to push and then release actuator 2594a by moving toward and then away from robotic device 2511A. In various embodiments, this type of actuation can be used to create a vacuum in a vacuum cup (not shown, but in reference, for example). Figure 7C (In the various embodiments described); the vacuum thus created can be used to hold the component 2518 mounted on the vacuum cup, or it can be used to secure the first robot device 2511A against the top surface of the working surface so as to survive in the event of a power failure. In such an embodiment, the second actuator 2595b can be used to release the vacuum by allowing the vacuum cup to be exposed to the atmosphere. The first actuator 2594a can be activated by the robot device 2511B approaching the robot device 2511A in the -X direction; similarly, the second actuator 2594b can be activated by the robot device 2511B approaching the robot device 2511A in the +Y direction. In various embodiments, one or more actuators can be positioned such that movement of the robot device or mover in any suitable direction can actuate the actuators when contact is made between the robot devices or movers.

[0315] In another example embodiment, the actuator assembly 2595 can include a multi-stable mechanism (including but not limited to a bi-stable mechanism) (not shown). As used herein, a "multi-stable mechanism" is a mechanical device that has multiple minimum energy states or stable states, where the device is configured to remain in any stable state. With the aid of an external force, the multi-stable mechanism is configured to switch from one stable state to another. One such example of a bi-stable mechanism is a board under compression. However, any form of multi-stable mechanism can be implemented in various embodiments as contemplated herein. In such embodiments, actuating an actuator such as the first actuator 2594a, for example by bringing the robotic devices into contact with one another so as to push on the actuator 2594a, can trigger the actuator assembly 2595 to cause the multi-stable mechanism to switch from one stable state to another. For example, one stable state can be used to hold the component 2518, and another stable state can be used to release the component 2518.

[0316] Self-actuating robot

[0317] Referring to Figure 19 A magnetic mobility device according to another embodiment includes a robotic device 2611 that includes one or more magnetic bodies configured to interact with electric current driven into electrically conductive elements in a work body to control movement of the robotic device 2611 in at least two directions / DOF, such as X and Y directions. In the illustrated embodiment, the robotic device 2611 includes an actuator assembly 2695 and first, second, and third actuators 2694a, 2694b, and 2694c. In various embodiments, the robotic device 2611 can include more or fewer actuators. The magnetic mobility device also includes an activator 2696. In the illustrated embodiment, the activator 2696 is mounted on the work body frame so that it is stationary relative to the robotic device 2611. In various embodiments, the activator 2696 can be mounted on another robotic device or other suitable movable structure or body, for example. In various embodiments, the device can include more than one activator. The robotic device 2611 can be configured to move toward the activator 2696 to bring the activator 2696 into contact with and thereby actuate one or more of the actuators 2694a, 2694b, and 2694c.

[0318] For example, in various embodiments, an actuation operation can be accomplished by moving the robotic device 2611 so that the first actuator 2694a comes into contact with the activator 2696 to thereby actuate the actuator 2694a and then moving the robotic device 2611 away from the activator 2696 so that the actuator 2694a can be released.

[0319] In various embodiments, actuation of the actuators (e.g., actuators 2694a) can be achieved in a non-contact manner. In such embodiments, the activators 2696 can comprise one or more electrically conductive elements (e.g., with or without a core), and one or more of the actuators 2694 can comprise an armature (e.g., such as iron or a permanent magnet). The armature can be configured to be actuated when in close proximity to an electric current driven through the electrically conductive elements in the activators 2696 to produce mechanical motion. In various embodiments, the armature can comprise a resiliently deformable component, e.g., a spring, that can move the armature to a predetermined position or location when the armature is not actuated by the electric current in the activators. In other embodiments, the actuators 2694 can comprise an actuation mechanism, e.g., an electrostatic actuation mechanism.

[0320] In various embodiments, the actuator assembly 2695 can comprise a vacuum pump (not shown), and the actuators 2694 can be configured for creating and / or releasing a vacuum within the vacuum pump. In various embodiments, the actuator assembly 2695 can comprise a multi-stable mechanism (e.g., a bistable mechanical mechanism) that can be switched from one local stable state to another local stable state by activating one of the actuation handles.

[0321] Although the actuators in some figures are shown outside the footprint of the robotic device, this is not required. For example, the actuators can fall within the footprint of the robotic device; the activators can fall within the footprint of the robotic device when the robotic device is in close proximity to the activators to achieve actuation by mechanical contact or in a non-contact manner.

[0322] Robots with multiple configurations

[0323] According to various embodiments, each robotic device in the magnetic mobility apparatus can be individually configurable into a first configuration and a second configuration. In the first configuration, for example, the mechanical linkages can not constrain the relative motion between the plurality of movers, and the spatial position / orientation of the linkage body can be fully determined by the respective spatial position / orientation of the plurality of movers. In the second configuration, the mechanical linkages can constrain the relative motion between the plurality of movers in one or more directions / DOF. In various embodiments, each of the one or more robotic devices can be individually switched from the first configuration to the second configuration by activating a switching mechanism. Non-limiting examples of switching mechanisms include a lock, a brake, or a pin activated to insert into a pin hole or a face gear, for example. In various embodiments, the mechanical linkages can comprise one or more resiliently deformable components, e.g., springs, that can help create a preload between the elements of the mechanical linkages, and / or reduce the actuation force required to move one or more of the movers.

[0324] With specific reference to Figure 20AFIG. 1 shows an example embodiment of a magnetic mobility device including three movers. Various embodiments can include more or fewer movers. Figure 20A The magnetic mobility device of FIG. 1 includes a robotic apparatus 11 A and a work body 2730. Although Figure 20A Although only one robotic apparatus 2711A is shown in FIG. 2, one skilled in the art will appreciate that other robotic apparatuses (e.g., 2711B, 2711C, 2711D, each of which can be substantially similar to robotic apparatus 2711A) can also be included in the magnetic mobility device, and together they can share work body 2730. The work body includes a plurality of electrically conductive elements. Robotic apparatus 2711A includes a plurality of movers 2710A, 2710B, and 2710C (collectively, “movers 2710”) and a mechanical linkage 2719, which includes a linkage body 2717, connectors 2791A, 2791B, and 2791C, and hinges 2792A1, 2792A2, 2792B1, 2792B2, 2792C1, 2792C2 (collectively, “hinges 2792”). In various embodiments, hinges 2792A1, 2792B1, and 2792C1 can be spherical joints, and hinges 2792A2, 2792B2, 2792C2 can be cylindrical joints or other linear hinge joints. Each of the plurality of movers includes one or more magnetic bodies, which can interact with appropriately driven currents through an appropriately selected set of electrically conductive elements 30 to produce controllable motion for each mover.

[0325] Robotic apparatus 2711A can be configured to include at least two configurations, a first configuration and a second configuration. In the first configuration, each mover 2710A, 2710B, 2710C can have at least two in-plane DOF motions (X and Y). As a result, the position / orientation is fully determined by the position / orientation of the movers 2710A, 2710B, 2710C. In this configuration, the mechanical linkage 2719 does not constrain the relative motion between the movers 2710: for example, the number of directions / DOFs in which any of the three movers can move is not affected by whether the mechanical linkage 2719 is installed or not. In various embodiments, each of the plurality of movers 2710 is capable of moving in 6 directions / DOFs; although the movers 2710 are connected together by the mechanical linkage 2719, each mover can still be controllably moved in 6 directions / DOFs.

[0326] ​​In the second configuration, at least one joint is locked (e.g., the two parts connected by the joint can be forced to be rigidly connected together) by activating a locking / braking mechanism. Thus, the mechanical link 2719 constrains the relative motion between the three pushers 2710; in other words, due to the activation of the locking mechanism, the motion of the three movers is coupled by the mechanical link 2719. For example, in the first configuration, the hinge 2792A1 comprises a spherical joint, which allows a 3-directional / DOF relative motion between the connector 2791A and the mover 2710A; in the second configuration, the spherical joint 2792A1 is locked in a specific position, so that the connector 2791A and the mover 2710A are rigidly connected together. Due to the locking of the spherical joint 2792A1, the relative motion between the movers 2710A and 2710B and 2710C is constrained.

[0327] Non-limiting examples of locking mechanisms include, for example, a brake or a pin driven into a planar gear. In various embodiments, actuation of such a locking mechanism can be by self-actuation as previously described (e.g., by moving the robotic device to interact with an activator), or can be actuated by another robotic device in a cooperative manner as previously described, or can be actuated by relative motion between the movers along the active axis as previously described, or can be actuated by an additional actuator mounted on the mover according to, for example, a wirelessly received command.

[0328] An advantage of the second configuration is to reduce power consumption including but not limited to maintaining a specific position of the carrying plate 17. The first configuration enables flexible motion of the entire robotic device. Allowing the robotic device to switch from one configuration to another provides the advantages of both.

[0329] Although in the previous discussion, the hinges 2792A2, 2792B2, 2792C2 comprise cylindrical joints or linear hinges, and the hinges 2792A1, 2792B1, 2792C1 comprise spherical joints, according to another exemplary embodiment, the hinges 2792A2, 2792B2, and 2792C2 can be spherical joints, and the hinges 2792A1, 2792B1, 2792C1 can be cylindrical joints. In another exemplary embodiment, the hinges 2792A1, 2792A2, 2792B1, 2792B2, 2793C1, 2793C2 can be, for example, all U-joints (a combination of two cylindrical joints whose axes of rotation are not parallel).

[0330] In various embodiments, the robotic device 2711 can comprise one or more elastically deformable elements, for example, springs (e.g., linear springs or rotational springs) mounted in the mechanical link 2719. Figure 20B The addition of the Figure 20Anon-limiting example of a resiliently deformable spring 27103A of robotic device 2711A. When the link body 2717 (which can move in -Z direction in response to coordinated motion of the movers 2710A, 2710B, and / or 2710C) is lowered to a certain position, the lateral actuation force (in X or Y direction) required on the mover 2710A can be larger than the vertical actuation force (in Z direction) required without the resiliently deformable element 27103A. In this way, the inclusion of the resiliently deformable element 27103A with suitable parameters can help reduce the lateral actuation force required on the mover 2710A. For example, such resiliently deformable element can be a linear spring or a torsional spring. Although only one resiliently deformable element is shown in Figure 20B

[0331] In various embodiments, in both configurations, each of the three movers (2710A, 2710B, 2710C) can be suspended away from the work body 2730 with a gap between the work body and the movers. In various embodiments, in both configurations, each of the three movers (2710A, 2710B, 2710C) can be located on the top surface of the work body 2730 and can be moved in X and Y directions by appropriate sliding or rolling bearings.

[0332] Figure 20A Although only three movers are shown in the specific embodiments in

[0333] In various embodiments, the magnetic mobility device can always be configured in the first configuration and there can be no locking mechanism; one or more resiliently deformable elements can be installed in the mechanical linkage, which can help reduce power consumption in certain positions.

[0334] In various embodiments, a magnetic mobility device capable of moving a platform comprises: ​​

[0335] • a work body;

[0336] • at least one mover comprising a first magnetic body and a second magnetic body that move in proximity to a work surface of the work body;

[0337] • wherein the at least one mover is capable of motion in at least two in-plane directions;

[0338] and a relative controllable motion between the first magnetic body and the second magnetic body;

[0339] • a four-bar linkage mechanism comprising two or more connectors attached to respective two or more hinges at a linkage body through another two or more respective hinges on the first magnetic body;

[0340] • a single connector having one end attached to the second magnetic body through a hinge and a second end attached to the linkage body through another hinge.

[0341] In various embodiments, the four-bar linkage mechanism can further comprise at least one locking mechanism on at least one of the hinges between one of the connectors and the first magnetic body. In various embodiments, one or more of the hinges can be a rotary joint. In various embodiments, attaching the single connector to the second magnetic body can further comprise a locking mechanism on the respective hinge between the one connector and the second magnetic body. In various embodiments, the locking mechanism can comprise a toothed or slotted disc and a solenoid actuated locking pin, or an over-center linkage actuated locking pin. In various embodiments, the locking mechanism can comprise a friction brake. In other embodiments, the work body can be planar. In various embodiments, the work body can be cylindrical. Magnetic motion system with multiple work bodies

[0342] According to Figure 21A , 21Band another embodiment generally illustrated in 21C, the magnetic mobility device 2850 includes a plurality of work bodies 2830, a plurality of movers 2810, and a transfer device 2840. Each work body includes a plurality of electrically conductive elements, each of which is operable to receive a controlled current driven through an amplifier into the electrically conductive elements to interact with magnets on the movers to controllably move the movers in at least two in-plane directions / DOFs near a work surface of each work body according to the methods previously described. The plurality of work bodies includes a first work body 2830A and a second work body 2830B. The first work body 2830A and the second work body 2830B overlap in the Z direction: the first work body is located at a first z position, and the second work body is located at a second z position. In various embodiments, there can be more than two overlapping work bodies, and there can be work bodies in the magnetic mobility device that do not overlap with other work bodies. The first work body 2830A has a first work area 2836A, and the second work body 2830B has a second work area 2836B. In this embodiment, the work areas include planar surfaces, but in various embodiments, the work areas can include non-planar surfaces. The transfer device 2840 can travel between the first work body and the second work body to carry one or more movers between the first work body work area 36A and the second work body work area 36B.

[0343] In general, the first (planar) work area 2836A and the second (planar) work area 2836B are disconnected from each other because they are associated with two work bodies located at different Z positions. To transfer one or more movers from one work area to another work area, the system 2850 includes a transfer device 2840. In the illustrated embodiment, the transfer device includes a transfer body 2831 that provides a transfer work area 2837 that includes a surface, which in various embodiments can be planar or non-planar. In the illustrated embodiment, the transfer body is configured to operate like any other work body described herein, in which the transfer body includes a plurality of electrically conductive elements that are operable to conduct electrical current and thereby generate one or more magnetic fields that can exert corresponding forces and / or torques on magnetized elements in one or more movers. The transfer device 2840 can first align the transfer body 2831 with the first work body 2830A in the Z direction, and one or more movers 2810 can be controllably moved from the first work area 2836A to the transfer work area 2837 of the transfer device 2840; afterwards, the transfer device 2840 can travel in the Z direction to align the transfer body 2831 with the second work body 2830B in the Z direction, and thus one or more movers 2810 can be controllably moved from the transfer work area 2837 of the transfer device 2840 to the second work area 2836B of the second work body 2830B.

[0344] Figure 21A An exemplary embodiment of a transfer device 2840 is shown, which includes a transfer body 2831 and a Z-motion transfer stage 2842. In various embodiments, the transfer stage 2842 is operable to transfer one or more movers in other directions (e.g., X and / or Y directions). The transfer stage 2842 is guided by suitable linear guide mechanisms (not shown) and driven by suitable linear drive mechanisms, including but not limited to lead screws and rotary motors and suitable guide mechanisms. The transfer body 2831 can include a plurality of electrically conductive elements and have substantially similar structure to the work bodies 2830A or 2830B, except that the transfer body 2831 is mounted on the Z-motion transfer stage 2842 rather than remaining stationary. The transfer body 2831 provides a transfer work area 2837 to the movers 2810. The transfer work area 2837 moves in the Z direction with the Z transfer stage 2842. In various embodiments, in each work area (2836A, 2836B, 2837), one or more movers 2810 can be controllably moved in at least two in-plane directions / DOFs. In various embodiments, one or more movers 2810 can be controllably moved in 6 directions / DOFs without contacting the work body in each work area (2836A, 2836B, 2837).

[0345] To transfer one or more movers from one work body work area (e.g., 2836A) to another work body work area (e.g., 2836B), the transfer stage 2842 can first move in the Z direction to align the transfer body 2836 with the first work body 2830A, i.e., to align the first work body 2830A and the work area of the transfer body 2836 with respect to the Z direction. As a result, the first work area 2836A and the transfer work area 2837A can form a continuous first extended work area, i.e., the combination of the first work area 2836A and the transfer work area 2837, while the transfer body 2840 is aligned with the first work body 2830A. In the first extended work area, one or more movers 2810 can be controllably moved in up to 6 directions / DOFs from the first work area 2836A to the transfer work area 2837, as shown. Figure 21B Once one or more movers 2810 enter the transfer area 2837, the transfer device can be driven in the Z direction to carry one or more movers as well as the transfer body 2831 to align the transfer body 2831 with the second work body, as shown, which accordingly forms a continuous second extended work area, i.e., the combination of the second work area and the transfer work area, between the transfer work area 2837 and the second work area 2836B. In the second extended work area, one or more movers can be controllably moved in up to 6 directions / DOFs from the second work area 2836B to the transfer work area 2837, as shown. Figure 21A Figure 21A ​The movers (2810G and 2810H) can be controllably moved from the delivery work area 2837 into the second work area 2836B. In this way, the movers can be controllably moved between two non-contiguous work areas (2836A and 2936B).

[0346] Although the illustrated embodiment describes the process of moving the movers from the high level work body 2830A to the low level work body 2830B, those skilled in the art will appreciate that in various embodiments one or more movers can be moved from the low level work body 2830B back to the high level work body 2830A. In various embodiments, the movers can be moved to and from the work bodies in substantially the same plane.

[0347] Figure 21B A cross-sectional view of the magnetic moving apparatus 2850 is shown. Two movers 2810G and 2810H can be batched from one work body to another work body. Although Figure 21B Two movers 2810G and 2810H are shown spaced apart in the X direction, but in other embodiments, when two movers are moved onto the transfer device at the same time, the two movers can be spaced apart in different directions, such as the Y direction. As Figure 21B As shown, during movement between the work bodies, the mover 2810G traverses the first work body 2830A and the transfer body 2831. Figure 21C A situation is shown where the two movers are carried by the transfer device 2840 when the transfer body 2831 is aligned with the second work body 2830B.

[0348] Since one or more movers can be controllably moved in 6 directions / DOF, when the transfer body 2831 is aligned with a work body (e.g. 2830A), the position of the transfer body 2831 in the -z direction does not have to be the same as the position of the work body 2830A in the -z direction. Similarly, the position of the transfer body 2831 in the -Z direction does not need to be the same as the position of the work body 2830B in the -z direction. In general, the position of a work body in the Z direction can be offset by a few degrees from the position of another work body in the Z direction; here the Z direction is the normal direction of the work face of the work body.

[0349] In various embodiments, when the transfer body 2831 is aligned with a work body 2830, it can be necessary to establish bidirectional communication between their respective work body controllers in addition to physically aligning their work planes and their associated work areas in the Z direction. Figure 22AExemplary embodiments are shown in which the transport body controller 2961 and one or more of the workpiece controllers 2960A and 2960B of the workpieces 2930A and 2930B, respectively, are in electrical communication so as to send and receive signals and / or information that can facilitate movement of the mover across the boundary between the transport body 2931 and either of the workpieces 2930A and 2930B. For example, such exchanged information can include, but is not limited to, current feedback, position sensing element output, mover control state, mover control parameters, and current commands. Generally, because the transport body needs to be able to align with at least two separate workpieces, in various embodiments, the transport body can contain a bi-directional communication channel for each workpiece with which the transport body is configured to align. As Figure 22A shown, the transport body is connected to the transport body controller 2961, and the workpiece 2930A is connected to the workpiece controller 2960A. When a workpiece is connected to its respective workpiece controller, e.g., 2930A is connected to 2960A, the workpiece controller can determine the current in the workpiece conductive element and / or can process output signals from position sensing elements in the workpiece. When the transport body 2931 is aligned with the workpiece 2930A, a bi-directional communication channel 2920A is created between 2960A and 2961. When the transport body 2931 is aligned with the workpiece 2930B, a bi-directional communication channel 2920B is created between 2960B and 2961. Such bi-directional communication channels 2920 can be implemented, for example, through industry standard or any other suitable electrical communication means (wired or wireless).

[0350] In various embodiments, the transport body controller 2961 can not be directly linked to each workpiece controller 2960. As Figure 22B shown, the transport body controller 2961 can be directly linked to a router 2925, which further bridges the workpiece controllers to five workpiece controllers 2960A-2960E, where 2930A-2930E are five respective workpieces that overlap in the Z direction, each workpiece being at a different Z position. Each workpiece controller 2960 can have a respective link 2920A-2920E to the router 2925, e.g., workpiece controller 2960A is connected to the router 2925 via link 2920A, and the transport body controller 2961 is connected to the router 2925 via communication channel 2920. When 2931 is physically aligned with a particular workpiece, e.g., 2930C, the router 2925 can be configured to enable data exchange between the transport body controller 2961 and the workpiece controller 2960C through communication channels 2920C and 2920.

[0351] Although only one transporter is shown in the embodiments of Figures 21 and 22, the transport device may include multiple transport working bodies. Figure 23A and 23B A magnetic mobile device 3050 according to another embodiment of the present invention is shown. The magnetic mobile device 3050 includes a plurality of working bodies 3030A, 3030B, 3030C and a plurality of movers 3010A-3010I, each mover 3010A-3010I operating substantially the same as the working bodies and movers described above. Each working body 3030A-3030B provides a corresponding working area 3036A-3036C, each working area having a surface that may be planar or non-planar. The working bodies 3030A, 3030B, and 3030C overlap in the Z-direction. A conveying device 3040 includes a Z-motion conveyor 3042, which includes a plurality of conveying working bodies (two working bodies 3031A and 3031B in the illustrated embodiment). The Z-motion conveyor 3042 is guided and driven by a suitable mechanism such that the Z-motion conveyor 3042 can carry a plurality of working bodies for movement in the Z-direction. The Z-motion conveyor 3042 can simultaneously align one or more conveying workpieces with one or more corresponding workpieces. Figure 23A In this configuration, the conveyor 3031A is aligned with the working body 3030A, and the conveyor 3031B is aligned with 3030B, such that working areas 3036A and 3037A form a continuously extending working area, allowing a first group of one or more movers (e.g., 3010C) to move from 3036A to 3037A or otherwise. Simultaneously, working areas 3036B and 3037B form a continuously extending working area, allowing a second group of one or more movers (e.g., 3010I) to move from working area 3036B to 3037B or otherwise. After mover 3010C moves onto 3037A and mover 3010I moves onto 3037B, the Z-motion conveyor 3042 can carry movers 3010C and 3010I in the -Z direction until the conveyor 3031A is aligned with the working body 3030B and the conveyor 3031B is aligned with the working body 3030C, as shown below. Figure 23BAs shown, the work areas 3036B and 3037A form a continuous extension, allowing the mover 3010C to be controllably moved from 3037A to 3036B, and the work areas 3036C and 3037B form a continuous extension, allowing the mover 3010I to be controllably moved from 3037B to 3036C. In order for both work bodies to be able to align with both transfer work bodies at the same time, the Z-direction offset between the two work bodies (e.g., between 3030A and 3030B) should be substantially equal to the Z-direction offset between the two transfer work bodies (e.g., between 3031A and 3031B). The two transfer work bodies in this example embodiment can help enable simultaneous transfer of movers from one or more work bodies to another or more work bodies, e.g., mover 3010I can be transferred from work body 3030B to 3030C at the same time that mover 3010C is transferred from work body 3030A to 3030B.

[0352] Reference is now made to Figure 32 Magnetic movement apparatus 3950 according to another example embodiment includes a plurality of work bodies (3930A1-3930A3, 3930B1-3930B3, 3930C), a transfer device 3940, and one or more movers 3910A-3910J. Transfer device 3940 includes an X-motion transfer stage 3944, a Z-motion transfer stage 3942, and a transfer body 39130. X-motion transfer stage 3944 is guided by X-direction guides 3945A and 3945B, and is driven by any suitable mechanism (not shown, non-limiting examples of which can include, e.g., a rotary motor plus lead screw, a linear motor, a cable drive system, or a pulley drive system) so that X-motion transfer stage 3944 can travel in the X-direction. Likewise, Z-motion transfer stage 3942 is mounted on X-motion transfer stage 3944 with suitable guiding and driving mechanisms (not shown) so that Z-motion transfer stage 3942 can travel in the Z-direction relative to X-motion transfer stage 3942. Transfer body 39130 is mounted on Z-motion transfer stage 3944 so that transfer body 39130 can move independently in the X and Z directions. In various embodiments, for example, the transfer body can be made to move in any two or more directions, e.g., Y and Z directions or X, Y, and Z directions.

[0353] Each work subject (3930A1-3930A3, 3930B1-3930B3, 3930C, and transfer body 39130) provides a respective work area (3936A1-3936A3, 3936B1-3936B3, 3936C, 39136) that includes an appropriate planar or non-planar surface for controllably moving movers in at least two in-plane directions / DOFs by suitably driving current through the work subject’s conductive elements in accordance with suitable control algorithms and feedback methods as described with reference to previously disclosed embodiments herein. Work subjects 3930A1-3930A3 overlap one another in the Z direction, and work subjects 3930B1-3930B3 overlap one another in the Z direction. In the illustrated embodiment, work subject 3930C1 is a bridging work subject that allows one or more movers to travel between work area 3936A1 and work area 3936B1. Various embodiments can not include a bridging work subject such as work subject 3930C1. By suitably driving X stage 3944 and Z stage 3942, transfer body 39130 can be aligned with another work subject (e.g., 3930A2) such that work area 3936A2 and transfer body work area 39136 form a continuous work area, allowing a mover to move between 3936A2 and 39136, e.g., movers 3910I and 3910J can controllably move from 3936A2 to 39136. The transfer body can then take movers 3910I and 3910J away with X and Z stages and align with another work subject (e.g., 3930B3) such that work area 3936B3 and 39136 form a continuous work area, and movers 3910I and / or 3910J can controllably move from transfer body work area 39136 to work subject work area 3936B3.

[0354] Generally, a transfer body can transfer one or more movers from a first work subject work area to a second work subject work area when the first and second work subject work areas are disconnected from one another and their respective work subjects are at different locations in a particular direction (e.g., the Z direction). Although Figure 32 Work subject 3930C1 illustrated in FIG. 3930C1 can provide a fast transfer passageway for movers to shuttle between 3936A1 and 3936B1, but is not necessary in all embodiments. Although in the illustrated embodiment two movers are carried by transfer body 39130, in various embodiments transfer body 39130 can carry any number of movers from one work subject to another work subject. Although in the illustrated embodiment transfer body 39130 is a single transfer body, in various embodiments two or more transfer bodies can be used in a similar manner as Figure 32 Figure 23A and 23B ​The embodiment shown in FIG. 29 is installed on the Z-motion stage 42 in the manner of the embodiment shown in FIG. 28.

[0355] Figure 24A and 24B Another exemplary embodiment of a magnetic mobility device 3150 is shown that is operable to transfer movers between two workpieces at different Z positions with a transfer device. As shown in FIG. 31, the magnetic mobility device 3150 includes a plurality of workpieces (three workpieces 3130A-3130C in the embodiment shown), one or more movers 3110, and a transfer device 3140. The workpieces 3130A-3130C overlap in the Z direction and each is located at a different Z position. The transfer device 3140 includes a Z-motion stage 3142, and the Z-motion stage 3142 includes an X-direction stage 3143 that is operable to move in the X direction. The Z-motion stage 3142 is driven by a suitable mechanism 3145, such as a lead screw plus a rotary motor, for example, with suitable guide bearings. The X-motion stage 3143 is driven by a suitable mechanism 3144 with suitable guide bearings or rails that constrain the motion of the X-motion stage 3143 in the X direction. When the transfer device 3142 is aligned with a workpiece (e.g., 3130B), the X-motion stage 3143 is extended in the negative X direction so that there is an overlap region 3146B between the workpiece work area 3136B and the work area of the X-motion stage. The X-motion stage 3143 is operable to move the mover 3110 from the workpiece 3130B to the workpiece 3130A, for example, by moving the X-motion stage 3143 in the positive X direction. Figure 24A and 24B The magnetic mobility device 3150 includes a plurality of workpieces (three workpieces 3130A-3130C in the embodiment shown), one or more movers 3110, and a transfer device 3140. The workpieces 3130A-3130C overlap in the Z direction and each is located at a different Z position. The transfer device 3140 includes a Z-motion stage 3142, and the Z-motion stage 3142 includes an X-direction stage 3143 that is operable to move in the X direction. The Z-motion stage 3142 is driven by a suitable mechanism 3145, such as a lead screw plus a rotary motor, for example, with suitable guide bearings. The X-motion stage 3143 is driven by a suitable mechanism 3144 with suitable guide bearings or rails that constrain the motion of the X-motion stage 3143 in the X direction. When the transfer device 3142 is aligned with a workpiece (e.g., 3130B), the X-motion stage 3143 is extended in the negative X direction so that there is an overlap region 3146B between the workpiece work area 3136B and the work area of the X-motion stage. The X-motion stage 3143 is operable to move the mover 3110 from the workpiece 3130B to the workpiece 3130A, for example, by moving the X-motion stage 3143 in the positive X direction. Figure 24A and 24BIn the overlapping region, the mover 3110 can be controllably moved by the work body 3130B and supported magnetically or mechanically by the work body 3130B independent of the X-motion transfer stage 3143. The mover 3110 can also be physically supported by the X-motion transfer stage 3143 independent of the work body 3130B. The mover 3110 can be magnetically levitated and controllably moved into the overlapping region 3146B by the work body 3130B; once the mover 3110 is within the overlapping region 3146B, the mover 3110 can be caused to land on the X-motion transfer stage 3143 by suitably commanding the current flowing into the electrically conductive element of the work body 3136B, for example, by turning off the current through the electrically conductive element across the overlapping region 3146B or by a suitable landing method discussed later in the soft landing operation section. Thus, the X-motion transfer stage 3143 uses components on the carrier (e.g., two protruding prongs on the X-motion transfer stage 3143, shown at 3146B) to carry the mover 3110. Next, the X-motion transfer stage 3143 can retract in the X-direction to fully transfer the mover 3110 out of the overlapping region 3146B, and in addition the Z-motion transfer stage 3142 can then transfer the horizontal transfer stage 3143 with the mover to a different Z-position in alignment with another work body, e.g., 3130C. By reversing the above control sequence of transferring the mover from 3136B to the X-transfer stage 3143, the mover 3110 can be transferred from the X-motion transfer stage 3143 into the working region 3136C of the work body 3130C.

[0356] Although in the illustrated embodiment, the mover 3110 can "land" on the X-motion transfer stage 3143 in order to switch from being supported by the work body to being supported and / or moved by the transfer stage, in various embodiments, the mover can be controllably moved in a levitated mode in the three in-plane directions / DOFs (Rx, Ry, and Z) as it enters the overlapping region 3246 in Figure 25A Figure 25A The overlapping region can be flanked by rails, as shown in 3243 in Figure 25A During the transfer process, the mover can be passively levitated at an initial position in the Z-direction, without feedback control in the out-of-plane directions / DOFs (i.e., Rx, Ry, and Z). As the mover is gradually moved in the -X direction into the overlapping region, it comes into contact with the rails due to the tilt of the rails. Once the mover is fully supported in the Z-direction by the rails, feedback control of the mover in Rz and Y can be turned off, and the mover can be driven in the negative X direction to the transfer stage using X-direction drive forces with open-loop control or using controllable motion in X.

[0357] As used herein, an "overlap region" is an overlap region in the X-Y plane between a work subject work region and a transfer stage work region (where the work region is the location where the transfer stage can direct and transfer a motile object). The motile object can be controllably driven by the work subject from outside the overlap region into the overlap region; then, the transfer stage can bring the motile object out of the overlap region from the work subject work region. In various embodiments, after the motile object moves into the overlap region, the motile object can land on the transfer stage in response to a current flowing into the work subject electrically conductive element, or by a soft landing operation as described in detail below. After the motile object lands on the transfer stage, the transfer stage can bring the motile object out of the overlap region. In various embodiments, the motile object can be controllably driven by the first work subject from outside the overlap region into the overlap region and guided by a mechanical carrier: for example, the motile object can be controlled in a levitation mode in three in-plane directions / DOF, and moved into the overlap region and onto one or more receiving bodies of the transfer stage (e.g., two protruding forks attached to an X-motion transfer stage, as shown in 3143 in FIG. 31). In this case, there is no landing process; after the current in the work subject electrically conductive element that passes through the overlap region is turned off, the motile object can be locked on the transfer stage protruding forks by friction, and then the transfer device can bring the motile object away from the work subject work region. Figure 24A

[0358] In various embodiments, the transfer device can be a mechanical carrier, which can further carry the motile object into a work region of a second work subject. In various embodiments, the second work subject can overlap the first work subject in the Z direction; i.e., the first work subject and the second work subject can be located at different Z positions. The transfer stage can bring the motile object into a second overlap region according to the following exemplary method: the transfer stage is aligned with the second work subject in the Z direction in response to movement of the Z transfer stage in the Z direction; then, the lateral transfer stage extends in the -X direction to bring the motile object into a second overlap region between the second work subject work region and the lateral transfer stage work region; the motile object is magnetically levitated away from the lateral transfer stage in the Z direction in response to an appropriate current being commanded to flow into the electrically conductive element in the second work subject.

[0359] Magnetic movement system including planar motor and conveyor

[0360] ​Generally, in various embodiments of a magnetic mobility device comprising a conveyor and an overlap region according to any of the preceding embodiments, the mover in the overlap region can be controllably driven onto the conveyor first by commanding the current flowing through the work body conductive element, and then the conveyor can convey the mover out of the work body work area. Non-limiting examples of such conveyors include a conveyor belt, a conveyor edge belt, a powered roller, a mechanical moving table, a robotic arm, and a gravity driven conveyor (with a downward sloping conveyor in its carrying surface and a gravity driven mover that slopes downward along the conveyor path). In various embodiments, the mover can be controllably moved into the overlap region by the work body, and then the mover can fall directly onto the conveyor, which then takes the mover away. In various embodiments, the mover can be driven onto the conveyor by the work body along a sliding or rolling guide on the conveyor. In these embodiments, the mover is directly conveyed from the work body to the conveyor.

[0361] In various embodiments, the magnetic mobility device can comprise a mechanical guide and an overlap region, and the overlap region is part of both the work body work area and the work area of the mechanical guide. As previously described, the mover can be controllably moved into the overlap region in response to the current in the work body, and within the overlap region, the mover can be controllably moved towards the conveyor by switching from controllable movement in at least 2 directions / DOF to controllable movement in a single direction / DOF. In various embodiments, the mover falls directly onto the mechanical guide, and the mover is controllably moved towards the conveyor in a single direction / DOF by the work body. In various embodiments, the mover can be driven into the overlap region while being guided by the mechanical guide. In these embodiments, the mover is indirectly conveyed from the work body to the conveyor by the mechanical guide.

[0362] Reference is now made to Figure 25A , 25B , 25C, 25D, 25E, 25F (collectively, FIG. 25), disclosing a magnetic mobility device 3250 comprising a work body 3230, a mover 3210, a conveyance 3244, and a guide 3243, according to another non-limiting embodiment. The mover can be configured to move by current flowing through the work body, according to any of the preceding embodiments. In the illustrated embodiment, the conveyance 3244 comprises a conveyor belt, but in various embodiments, the conveyance can comprise any other mechanical device capable of supporting and moving an object such as the mover 3210. In the illustrated embodiment, the guide 3243 comprises a pair of linear rails: however, in other embodiments, the guide can comprise any other device that guides an object such as the mover 3210 onto the conveyance.

[0363] In the illustrated embodiment, the work body 3230 provides a work area 3236. The system comprises an overlap region 3246 ( Figure 25A (As shown by the dashed line in the diagram), which is part of both the working area of ​​the working body and the working area of ​​the guiding device 3243. The mover 3210 can be controllably moved through the working body 3230 into the overlapping area in at least two in-plane directions / DOF (including but not limited to three in-plane directions / DOF and / or six directions / DOF). In various embodiments, the mover can fall onto the guiding device in response to a current driven by an appropriate working body conductive element within the working body. Within the overlapping area, the mover can be driven towards the conveying device 3244 through the working body 3230 by controllably moving in at least one direction / DOF. In various embodiments, when the mover 3210 is within the overlapping area, the mover 3210 may be limited to movement in one direction / DOF because during the process of the mover 3210 being driven out of the working body working area 3236, there may not be sufficient magnetic array of the working body 3230 to provide the required force and / or torque to move the mover 3210 in more than one direction / DOF. For example, in Figure 25F In this case, only one of the four magnetic arrays (3212A-3212D) is located within the working area of ​​the working body, and this magnetic array 3212D allows the working body to controllably drive the mover in the X direction by correctly commanding the current flowing through the Y-oriented conductive element of the working body; as a result, the mover can be guided and constrained in 5 directions / DOF by the guiding device, and the working body can apply a force in the X direction to the mover and obtain X-direction position feedback as long as the magnetic array 3212D is within the working area of ​​the working body; when the magnetic array 3212D begins to leave the working area of ​​the working body, the conveying device 3244 has achieved sufficient contact area with the mover 3210 so that it can continue to move the mover along the conveying device 3244 (in the -X direction) by friction or other mechanical means.

[0364] The non-limiting sequential process of moving the mover 3210 from the working area of ​​the working body 3230 to the conveying device 3244 can be described as follows:

[0365] i. Such as Figure 25A As shown, in suspension mode, the mover 3210 is controlled by the working body in six directions.

[0366] / DOF can be controllably driven from the outside of the overlapping region 3246 to the inside.

[0367] ii. such as Figure 25B As shown, the mover 3210 falls onto the guide device 3243 in the overlapping area in response to a current driven by a suitable working body conductive element (including but not limited to a shut-off current). Figure 25C It shows along Figure 25B A sectional view of the system with line CC in the middle. Figure 25C The mover 3210 is shown supported by rollers on the guide 3243 rather than levitated by the work body 3230 in the illustrated embodiment. Although the mover 3210 falls onto the guide by moving in the Z direction, the mover 3210 can also maintain a velocity of movement in the -X direction.

[0368] iii. The mover 3210 is driven in the -X direction by the work body 3230, as shown. Figure 25D In embodiments in which the transport 3244 comprises a conveyor belt, the mover 3210 can be controllably driven in the X direction at a speed that approximates or matches the linear speed of the conveyor belt. Alternatively, the mover can be driven with a controllable force. It should be noted that suitable magnetic array layouts, such as but not limited to the magnetic array design in Figure 1 of U.S. Patent 9202719B2, can enable controllable driving of the mover in the -X direction while being guided by the guide, even if half of the mover 3210 extends out of the work body working plane in the -X direction. For example, as shown, Figure 25F half of the mover is already outside the work body working area, but the work body can still obtain X position feedback of the mover 3210 and exert a force on the mover to move it in the X direction.

[0369] iv. The falling curve of the guide 3243 at the end in the -X direction can guide the mover toward the conveyor belt in various embodiments. Once the mover contacts the conveyor belt 3244, the work body 3230 can disallow its control of the mover, and the mover is moved away by the conveyor belt 3244, as shown. Figure 25E

[0370] In various embodiments, the guide can comprise rollers, such as those shown in Figure 25. The rollers can be passive, or can be actively powered and driven by another motor (through a belt, chain, cable, direct drive, gears, or other suitable means) to actively guide the mover as it lands and further along the guide. In this case, if the transport comprises a conveyor belt and the guide comprises active roller elements, the work body can not need to drive the mover along the guide after the mover moves in the -Z direction onto the guide.

[0371] Figure 26A and 26B A magnetic mobility device 3350 according to another embodiment of the application is shown. The magnetic mobility device 3350 comprises a work body 3330, a mover 3310, a powered roller conveyor 3344, such as described with reference to Figure 25A-25F ​The powered roller conveyer includes a linear guide 3343 and has a guiding device of passive rollers. In the illustrated embodiment, the work body 3330 and the mover 3310 are similar to the embodiments previously discussed herein. The work body 3330 provides a work area 3336. The device 3350 includes an overlap area 3346 (indicated by the dashed line in Figure 26A and 26B ) that is part of both the work body work area and the linear guide guide area. Figure 26B The mover 3310 is shown inside the overlap area 3346. The mover 3310 can be transferred from the work body work area 3346 to the conveyer 3344 in a manner substantially similar to the embodiments described with respect to FIG. 25, except that in the present embodiment, the transfer device 3344 includes a powered roller conveyer rather than a conveyor belt. In various embodiments, in the overlap area 3346, the rollers of the guide 3343 can be passive due to space constraints. Outside the overlap area, the rollers on the guide are driven by an external mechanism, such as but not limited to a belt or a cable or a stepper motor.

[0372] In various embodiments, Figure 26A and 26B the rollers of the guide 3343 can be powered rollers, such that after the mover 3310 is switched from being levitated by the work body to being supported by the linear guide 3343, the mover 3310 will be immediately driven away by the powered rollers without the need for the work body to control the mover in the -X direction. In the illustrated embodiment, Figure 26A and 26B the guiding device 3343 and the transfer device 3344 are powered conveyers, and the overlap area 3346 is an overlap area of the work body work area and the powered conveyer work area, and the mover is transferred from the work body to the conveyer directly in the overlap area.

[0373] In various embodiments, all the rollers can be passive, and the guide can have a downward slope towards the -X direction, such that when the mover is sitting on the guide, the mover can be pulled towards the -X direction by gravity (in the case where gravity is substantially in the -Z direction). In this case, the guiding device 3343 and the transfer device 3344 can include passive gravity-driven conveyers, and the overlap area 3346 can be an overlap area of the work body work area and the passive conveyer work area. The mover can be transferred from the work body to the conveyer directly in this overlap area.

[0374] Figure 27A and 27B illustrates a magnetic mobility device 3450 according to another exemplary embodiment, which is substantially similar to the device 3450 described with respect to Figure 26A and 26BThe described embodiments include edge-belt conveyors instead of powered rollers for the transport device 3444 and the guide device 3443. The magnetically mobile device includes a work body 3430, a mover 3410, an edge-belt conveyor 3444, and a guide device 3443 including a linear guide with passive rollers, as shown in Figure 27A The work body 3430 provides a work area 3436. The system includes an overlap area 3446 that is part of both the work body work area and the guide device 3443 work area. The mover 3410 can be controllably moved by the work body 3430 into the overlap area 3446 and can land on the passive roller guide 3443, and can also be driven by the work body 3430 toward the conveyor belt 3444 in either position control mode or force control mode until the mover is brought into frictional contact with the conveyor 3444.

[0375] While the foregoing embodiments describe the process of transporting a mover from a work body work area to a transport device such as a conveyor belt or other conveyor system, those skilled in the art will appreciate that the process can be reversed to transport a mover from a transport device (e.g., a conveyor belt or other conveyor system) to a work body work area.

[0376] Referring to Figure 27A A non-limiting sequential process of moving the mover 3410 from the conveyor belt 3444 to the work body 3430 work area can be as follows:

[0377] i. The conveyor belt 3444 belt can bring the mover 3410 into the guide device (e.g., linear guide) 3443 in the +X direction. Frictional contact between the conveyor belt 3444 and the mover 3410 can allow the mover 3410 to at least partially move onto the linear guide 3443.

[0378] ii. Once the Y-oriented linear magnetic array (e.g., magnetic array 3212D in mover 3210 shown in Figure 25F The work body can controllably move the mover 3410 in the X direction further along the linear guide until the mover 3410 is fully within the overlap area 3446.

[0379] iii. Once the entire mover is within the overlap area, the mover 3410 can be levitated by the work body 3430 and controllably moved in up to three face normal directions / DOFs; the mover 3410 can be driven by the work body 3430 to move the overlap area toward another portion of the work body work area 3436.

[0380] Figure 27B An embodiment is shown utilizing Figure 27AAn example application of the embodiments is shown, wherein the magnetic mobile device 3450 includes a working body 3430, one or more movers 3410, five linear guides 3443A to 3443E, and five edge belt conveyors 3444A to 3444E. In the illustrated embodiment, each linear guide along the respective connecting edge belt conveyor is substantially similar to Figure 27A The embodiments shown differ only in guide rail orientation or position. Each linear guide rail, together with the working body, includes corresponding overlapping areas 3446A to 3446E (by...). Figure 27B (represented by the dashed line in the diagram), which allows the mover to be transferred between the work body and any of the five conveyor edge belts. Figure 27B The magnetic moving part 3450 can be used for multi-port routing in a multi-conveyor system in various embodiments: for example, a mover from one conveyor can first be conveyed to the working area of ​​the work body, and then further conveyed from the working area of ​​the work body to any of the other four conveyors as needed for operations. In various embodiments, the work body 3430 can be mounted on a rotatable conveyor table (e.g., a rotatable conveyor table rotatable about a Z-axis) to change the position and / or orientation of the mover.

[0381] Reference Figure 35A and 35B According to another exemplary embodiment, the magnetic mobile device includes a working body 4230, a mover 4210, and a conveying device (e.g., Figure 35A and 35B The conveyor belt 4244 and the guiding device (e.g., a pair of linear guides) 4243. For example, the illustrated embodiment can be used with respect to... Figure 27A The described embodiments function similarly. The working body 4230 provides a working area 4236. The device includes an overlapping area 4246. Figure 35A(As shown by the dashed line in the diagram), it is part of both the working area of ​​the working body and the working area of ​​the guide device 4243. The mover can be controllably moved into the overlapping area by controllably moving the mover in at least two in-plane directions / DOF, including but not limited to controllably moving the mover in three in-plane directions / DOF in levitation mode, or in three in-plane directions / DOF in seated mode, and / or in six directions / DOF in levitation mode. In the illustrated embodiment, the widened opening at the guide device inlet facilitates the mover's entry into the overlapping area. Within the overlapping area, the mover can be mechanically constrained / supported in the Rz and Y directions by the guide device, and the working body can mechanically support the mover in the Rx, Ry, and Z directions, for example, by suitable sliding or rolling bearings. Within the overlapping region 4246, in various embodiments, the mover 4210 can be driven towards the conveyor by the working body via a switch from controllable movement in at least two directions / DOF to controllable movement in one direction / DOF, such that during the process of driving the mover out of the working area of ​​the working body, there is sufficient magnetic array overlapping with the working body to provide the working body with the necessary force and / or torque to control the mover. The working body may need to drive approximately half of the mover 4210 out of the working area of ​​the working body, after which the conveyor can grasp the mover 4210 and continue moving the mover along the conveyor 4244 (in the -X direction).

[0382] Figure 28A and Figure 28B (Collectively referred to as FIG. 28) illustrates a magnetic mobile device 3550 according to another non-limiting embodiment, which includes a working body 3530, one or more movers 3510, and a conveyor belt 3544. Support mechanisms and drive motors for the conveyor belt are not shown to avoid unnecessarily obscuring the embodiment. The working body 3530 provides a working area 3536. The working body and the conveyor overlap each other in the Z direction. The device 3550 also includes an overlapping area 3546 in the Z direction (shown by dashed lines in FIG. 9), as... Figure 28A As shown, it is both part of the working area of ​​the main working body and part of the working area of ​​the conveyor.

[0383] The non-restrictive sequence of transferring the mover 3510 from the working body 3530 to the conveyor 3544 is as follows:

[0384] i. From the outside via the working body 3530 ( Figure 28A ) to overlapping region 3546 ( Figure 28B Inside the ), the actuator 3510 can be controllably driven in up to 6 directions / DOF in hover mode (or in up to 3 in-plane directions / DOF in hover mode).

[0385] ii.Once the mover is within the overlap region, the mover can come into contact with the conveyor belt in response to the current commanded to be driven into the work body conductive element according to a suitable method including but not limited to turning off the current to the particular conductive element or a soft landing operation as described in detail below. As a result, the mover switches from being supported and driven by the work body to being supported and driven by the conveyor belt. While the mover lands on the conveyor by moving in the Z direction, the mover can be kept at a speed of movement in the X direction that matches the linear speed of the conveyor belt, which can minimize the slippage between the mover and the conveyor belt. After the mover 3510 lands on the conveyor belt, the mover 3510 will be supported by and move with the conveyor belt 3544. Assuming the conveyor belt speed is in the positive X direction, the mover 3510 will be carried away from the overlap region by the conveyor belt.

[0386] Figure 29 A magnetic mobility apparatus 3650 is shown according to another embodiment, which includes a work body 3630, one or more movers 3610A-3610B, and an overhead conveyor 3644, and one or more carriers 3643A-3643C. Each carrier 3643A-3643C is attached to and travels with the overhead conveyor 3644 along its path. In various embodiments, the apparatus 3650 can also include a guide arrangement, such as described with reference to the aforementioned embodiments, and any suitable drive motor for the conveyor 3644. The work body and the conveyor overlap in the Z direction. The work body 3630 provides a work area 3636. The system includes an overlap region 3646 (shown in dashed line in FIG. 36A) that is part of both the work body work area and the carrier support area. In this case, since the carrier (e.g., 3643A) is moving, the overlap region (between the carrier support area and the work body work area) also dynamically changes and moves with the carrier. Figure 29

[0387] A non-limiting sequential process of conveying the mover 3610A to the conveyor system 3644 can be as follows:

[0388] i. The mover 3610 can be controllably driven by the work body from outside to inside of the overlap region 3646, which is the overlap region between the work body work area and the mechanical carrier 3643A support area.

[0389] ​ii. Once the mover 3610 is within the overlap region 3646, the mover can be caused to land on the mechanical carrier 3643A in response to the current driven into the work body conductive elements according to any suitable method including but not limited to turning off the conductive element current. As a result, the mover can be switched from being driven by the work body to being supported and carried by the mechanical carrier 3643A. Although the mover is caused to land on the mechanical carrier by moving in the Z direction, the mover can also be caused to maintain a speed of movement in the X direction that matches the linear speed of the carrier 3643, which can minimize slippage.

[0390] Figure 30 Another magnetic mobile device 3750 is shown according to an example embodiment, which includes a work body 3730, one or more movers 3710A-3710C, and a conveyor 3744. The work body 3730 provides a work area 3736. The support mechanism and drive motor of the conveyor 3744 are not shown to avoid unnecessarily obscuring the embodiment, but one of skill in the art will understand that any suitable method can be applied here. The conveyor 3744 and the work body overlap in the Z direction. In the shown embodiment, the conveyor 3744 runs over the work body 3730 such that the system provides an overlap region 3746 (shown by the dashed line in the middle) that is an overlap region between the work body work area 3736 and the conveyor support area. Figure 30

[0391] A non-limiting sequential process of conveying the mover 3710B from the conveyor 3744 to the work body 3730 and then from the work body 3730 back to the conveyor 3744 can be as follows:

[0392] i. The mover 3710B can be conveyed from outside the overlap region 3746 to inside 3746.

[0393] ii. Once the mover 3710B is within the overlap region 3746, the mover 3710B can be caused to levitate in up to 6 directions / DOF and move within the work body work area in up to 6 directions / DOF in response to controllably driven current in the work body. In various embodiments, for example, the mover can be caused to move in one or more particular directions, such as the X and / or Y directions, in order to accomplish a particular operational task for manufacturing purposes.

[0394] iii. At the end of the work body control process in (ii), the mover 3710 is driven back to the overlap region 3746, and the mover 3710 is caused to return to the conveyor using a suitable method including but not limited to turning off the conductive element current or a soft landing operation as described in detail below by commanding appropriate current to be driven into the work body conductive elements. In various embodiments, the mover 3710 can be caused to move at the same lateral speed as the conveyor, which can minimize slippage.​

[0395] iv. The mover 3710B can then be moved out of the overlap region 3746 by the conveyor, for example for the next operational step.

[0396] Referring to Figure 30 The described embodiments can allow one or more automated steps to be performed directly on a conventional conveyor belt system, without the need for a robotic arm or other tool to pick parts off the conveyor belt for a processing unit, and then move the parts back from the unit to the conveyor belt after processing.

[0397] Figure 31A 、 Figure 31B 、 Figure 31C FIGS. 31A-31C (collectively, FIG. 31) illustrate another exemplary embodiment of a magnetic mobility device 3850, which includes a work body 3830 providing a work body work area 3836, one or more movers (3810A, 3810B), and a conveyor 3844, each of which can function substantially the same as described in the previous embodiments. In the illustrated embodiment, the conveyor 3844 is an adjustable conveyor, in which the spacing between two conveyor belts 3844A and 3844B can be changed to accommodate the needs of the automated process. For example, one belt 3844A can be fixed in the Y direction, while the other belt 3844B is adjustable in the Y direction; or, the Y positions of both belts 3844A and 3844B can be adjustable. Details of the conveyor support mechanisms, drive motors, and Y position adjustment actuators are not shown to avoid obscuring the presentation of the present application, and any suitable existing methods, mechanisms, actuator methods can be employed here with appropriate modifications and substitutions. In this embodiment, the conveyor belts and the work body overlap in the Z direction. The conveyor belts extend over the work body work surface (top surface) such that the system provides an overlap region 3846 (shown in dashed lines in FIG. 31A) between the work body work area and the conveyor support area. Figure 31B Inside the overlap region 3846, movers such as mover 3810A can be supported and driven by both the work body 3830 and the conveyor 3844.

[0398] A non-limiting sequential process of transferring a mover 3810A and / or 3810B from the conveyor 3844 to the work body 3830 and then from the work body 3830 back to the conveyor 3844 can be as follows:

[0399] i. The movers 3810A and 3810B can be moved by the conveyor belts from outside the work body work area 3836 in the -X direction toward the overlap region 3846, as shown in FIG. 31A. Figure 31A

[0400] ​ii. Once the movers 3810A and 3810B are within the overlap region 3846, the movers can be controllably driven by the work body in up to 6 directions / DOF to levitate from the conveyor in the Z direction, as shown in Figure 31B In various embodiments, the movers can be controllably moved in up to 3 in-plane directions / DOF in a passive levitation mode.

[0401] iii. Once the movers are magnetically supported by the work body 3830, the conveyor support is not needed, so the conveyor 3844B can be retracted in the -Y direction to provide more space for the movers to work on the work body work area, which can result in the conveyor no longer being an obstacle / barrier. The movers can be moved with desired X and / or Y motion within the work body work area, for example to accomplish a specific automated task for manufacturing purposes.

[0402] iv. At the end of the work body control process in (iii), the movers can be driven back to the overlap region 3846 shown in Figure 31B and the conveyor 3844B can be extended in the Y direction back to the configuration in Figure 31B Thus, in response to the current being commanded to be driven into the work body conductive elements, the movers can fall back onto the conveyor according to suitable methods including but not limited to turning off the conductive element current or a soft landing operation as described in detail below (while, in various embodiments, maintaining the same lateral velocity as the conveyor, which can minimize the sliding).

[0403] v. The movers can then be carried away from the overlap region 3846 by the conveyor in the -X direction, which can result in the movers being moved to another region for a subsequent operation step in various embodiments.

[0404] The above-described process contemplates conveying two movers 3810A and 3810B together, however, in various embodiments, only one mover can be conveyed according to the process. The process described with reference to FIG. 31 can be only one particular step of an automated or other operation process; for example, the movers can be loaded onto the conveyor 3844 from other suitable devices (e.g. automated devices) prior to being moved as contemplated by the embodiments described with respect to FIG. 31, and the movers can be carried away from the conveyor 3844 to other suitable devices after processing, for example by other conveyors and / or robots or manually.

[0405] Magnetic movement system including isolators

[0406] Reference is made to Figure 33A and 33B(collectively, FIG. 33), shows a magnetic mobile device 4050 including a work body 4030, a mover 4010 carrying one or more objects (e.g., components or samples), e.g., an isolator 4090 and an isolation door 4095, according to another embodiment. The work body and mover can function substantially similar to other work bodies and movers described herein. The work body 4030 provides a work area 4036. The work area 4036 extends into the isolator 4090 and also extends into the surrounding environment 4092. A portion of the work area 4036 is inside the isolator 4090 and a portion of the work area 4036 is outside the isolator. In various embodiments, the isolator 4090 can provide an isolated environment.

[0407] Although only one mover 4010 is shown in FIG. 33, in various embodiments, multiple movers can work within the system, each possibly having independently controllable motion as previously described; the mover 4010 includes a magnetic body including one or more magnetic arrays and the magnetic body can interact with a magnetic field generated by a current flowing through a work body conductive element in the work body 4030 to controllably move the mover 4010 in up to two planar directions / DOF. In various embodiments, the mover can be controllably moved in up to 6 directions / DOF when operating in a levitation mode without contacting the work body 4030.

[0408] The work surface 4036 can be covered with a suitable cover material (e.g., including but not limited to stainless steel, aluminum, metal, glass, and / or plastic) to protect the work body 4030 from the isolated environment within the isolator 4090. In the illustrated embodiment, when the isolation door 4095 is open (e.g., by moving upward), the isolator environment (or equivalently, the "isolated environment") will be connected to the ambient environment 4092. In various embodiments, a seal can be used around the gap between the movable isolation door 4095 and the wall of the isolator 4090, and can also be used at the bottom of the door 4095, for example, such that the contact area between the door and the work body top surface 4036 forms an air-tight seal or any other type of seal. When the isolator 4095 door is closed, the isolator environment will be disconnected from the ambient environment 4092. In various embodiments, the isolator environment within the isolator can be a special environment that is different from the outside environment (e.g., the ambient environment 4092), including but not limited to an environment with high pressure, vacuum, high temperature, low temperature, for example, with chemical reactivity, corrosive, toxic, clean, water-free environment, oxygen-free environment, pure nitrogen environment, inert gas environment, contaminated environment, and / or clean environment. In various embodiments, one or more physical or chemical properties of the isolated environment can be significantly different from one or more physical or chemical properties of the outside environment. Suitable tubing / hoses (not shown) can be connected to the isolator 4090 to maintain the special physical and / or chemical properties of the isolator environment within the isolator 4090. Within the isolator environment, one or more operational tasks, for example, automated tasks, for example, can be performed for purposes related to manufacturing, assembly, testing, inspection, and / or analysis. Non-limiting examples of such tasks are, for example, filling, sputtering, e-beam inspection, lithography, painting, coating, and / or cleaning. Prior to performing one or more tasks in the isolator environment, the mover can be controllably moved into the isolator in the -X direction, after which the isolation door 4095 can be closed. After completion of the one or more tasks, the isolation door can be opened, after which the mover can be controllably moved out of the isolator in the +X direction.

[0409] Figure 33A It is shown that the mover 4010 can be located outside the isolator when the isolation door 4095 is open, for example, in the ambient environment. Figure 33B is a cross-sectional view of the apparatus 4050 when the isolation door 4095 is closed and the mover 4010 is within the isolated environment separate from the ambient environment 4092.

[0410] Referring to Figure 34FIG. 41 illustrates another magnetic mobile device 4150 according to another example embodiment, in which the sidewalls are cut away. The device includes a working body 4130 having a working area 4136, a plurality of movers 4110A-4110H, a plurality of isolators 4190A-4190B (collectively, "4190"), and an isolation buffer 4191. The working area 4136 spans the plurality of isolators 4190, the isolation buffer 4191, and the surrounding environment 4192. Each of the plurality of isolators provides an isolated environment, which can be configured to be switched on and off by a respective isolation door, such as isolation door 4195A corresponding to isolator 4190A, in various embodiments. In the illustrated embodiment, the isolation buffer 4191 provides a buffer environment between the surrounding environment 4192 and the isolated environment. The buffer environment 4191 can be connected or disconnected from the surrounding environment by a buffer door, such as buffer door 4196. Each isolated environment can be significantly different from the surrounding environment 4192 in terms of one or more physical or chemical properties as described above with respect to FIG. 33. Although two isolators are shown in FIG. 41, in various embodiments, the device can include more or fewer isolators. Figure 34 Although two isolators are shown in FIG. 41, in various embodiments, the device can include more or fewer isolators.

[0411] Generally, in embodiments such as those described above, one or more movers can be controllably moved into an isolated region defined by an isolator. An isolation door can be closed to retain the one or more movers within the controlled environment for a particular operation; thereafter, the isolation door can be opened, and the movers can be controllably moved out of the isolator. In some embodiments, the one or more movers can be controllably moved into and out of the isolated region in up to 6 directions / DOF without contacting the same. In some embodiments, the one or more movers include a first mover and a second mover, where the first mover can be controllably moved into the isolated region while the second mover is controllably moved out of the isolated region, or vice versa.

[0412] The movers can be substantially the same as the movers 4010 described with respect to FIG. 33. In the current embodiment, the movers 4110 can be controllably moved back and forth between the surrounding environment 4192 and the isolated environment by appropriate operation of the buffer door 4196 and each relevant isolation door 4195. The buffer door 4196 isolates the buffer environment in substantially similar fashion to the way the isolation doors in the embodiment shown in FIG. 33 isolate each isolated environment.

[0413] A non-limiting example of a process for moving a mover, such as mover 4110G, from the surrounding environment to an isolator, such as 4190A, can be as follows:

[0414] i. The buffer environment 4191 can be adjusted to make the buffer environment 4191 similar to the surrounding environment 4192 compared to the difference between the isolated environment 4190A and the surrounding environment 4192.

[0415] ii. After step i), the buffer door can then be raised to connect the buffer environment 4191 and the surrounding environment 4192, so that the mover 4110G can be controllably moved from the surrounding environment 4192 into the buffer environment 4191.

[0416] iii. Once the mover 4110G is within the buffer environment 4191, the buffer door 4196 can be closed, and the buffer environment can then be adjusted to be substantially similar to the isolation environment 4190A.

[0417] iv. After step iii), the isolation door 4195A can then be raised to connect the isolation environment 4190A and the buffer environment 4191, so that the mover 4110G can be controllably moved from 4191 into the interior of 4190A.

[0418] v. Once the mover 4110G is within 4190A, the isolation door 4195A can be closed, and any objects, e.g., one or more components carried by the mover 4110G, can be processed in 4190A. In various embodiments, the mover 4110G can be configured to perform operations within the isolation environment 4190A, e.g., automated operations.

[0419] In various embodiments, the mover can be moved from the isolator back to the environment by reversing the above process. In various embodiments, the process of moving a mover from the surrounding environment into the isolator can occur simultaneously with the process of moving another mover from the isolator back to the surrounding environment. See, e.g., Figure 34 In various embodiments, during step iv), while 4110G is moved from 4191A to 4190A, another mover (e.g., 4110A) can be simultaneously controllably moved from 4190A to 4191; during step ii), while 4110G is moved from 4192 to 4191, another mover (e.g., 4110E) can be simultaneously controllably moved from 4191 to 4192.

[0420] Magnetic moving device with automated loading / unloading / storage of movers

[0421] In various embodiments, magnetic mobile devices, such as those described earlier herein, may include multiple movers, and the number of movers may range from two or more to one thousand or more. Typically, it may be necessary to store, pack, and / or move so many movers on the working surface of a work body, such as a work unit; handling so many movers safely can be challenging due to the very strong interaction forces that can exist between any two movers in close proximity to each other, given the magnetization elements included in each mover. Furthermore, the required number of movers may vary with manufacturing needs, which may change from time to time; if too many (e.g., more than necessary) movers are located on the working surface of the work body, one or more movers may obstruct the traffic of other movers, and thus may reduce the overall system operating efficiency; if too few (e.g., less than necessary) movers are located on the working surface of the work body, there are not enough movers available to perform operations, and the overall system efficiency may be compromised. To allow for dynamic adjustment of the number of movers in the working area of ​​the work body to meet the time-varying needs of any given process (e.g., a manufacturing process), for example, a storage device may be used as a buffer to hold movers that are not currently present on the work body and / or to supply movers to the work body when necessary.

[0422] Reference Figure 36A and 36B (Collectively referred to as FIG. 36) illustrates a magnetic moving device according to another embodiment, wherein the device has an automatic loading / unloading function. The device includes a plurality of movers 4310A-4310C, a working body 4330, a guide device 4343, and an edge belt conveyor 4344, each of which is substantially similar to the referenced figure. Figure 27A The components described in the embodiments are as follows. In various other embodiments, any combination of the embodiments described above, including the mover, working body, guiding device, and / or conveying device, can be incorporated into a device having such automatic loading / unloading functionality.

[0423] In the illustrated embodiment, the device includes an overlapping region 4346, such as Figure 36A As shown by the dashed line, it is both a part of the working area 4336 of the working body and a part of the working area of ​​the guiding device, wherein the guiding device overlaps with the working body 4330 in the Z direction. One or more movers (e.g., mover 4310C) can be guided by the guiding device 4343 in a manner substantially similar to that described herein (e.g., with respect to...). Figure 27A The method described in the embodiments is substantially similar to that described in the embodiments, in which the work body 4330 is controlled to move to the conveyor belt 4344. Figure 36A The device also includes a storage device 4348 mounted on the Z-motion conveyor 4342, which can be connected to a conveyor previously disclosed herein (e.g., such as...). Figure 23AThe illustrated transfer stage 3042) functions similarly. The Z-motion transfer stage 4342 is guided (not shown) by any suitable moving mechanism (e.g., bearings) and driven by any suitable motor or actuator (not shown) such that the transfer stage 4342 can move in the Z-direction. The transfer stage 4342 can be configured to carry a storage device 4346 to move up and down in the Z-direction. The storage device 4348 includes a plurality of storage bodies 4345A-4345F, and these storage bodies overlap each other in the Z-direction. In various embodiments, the storage device 4348 can be made of non-magnetic materials, such as but not limited to plastic materials, wood, aluminum, copper, and / or ceramics, which can reduce or eliminate undesirable magnetic interactions with the agents stored thereon.

[0424] In the illustrated embodiment, there is a Z-oriented gap between two adjacent storage bodies to allow entry of an agent. In various embodiments, each storage body can include one or more storage surfaces 4349, and each storage surface 4349 can hold one agent. Each storage surface 4349 can include a constraining mechanism to laterally constrain an agent (e.g., in the X and Y directions). For example, the agent 4310A can be held on the storage surface 4349A of the storage body 4345A such that the agent’s movement is limited in the X and Y directions. In various embodiments, each storage body can store one or more agents. For example, the agent 4310A can be stored on the storage body 4345A, and the agent 4310B can be stored on the storage body 4345B. An example constraining mechanism of the storage surface 4349F is illustrated in Figure 36A which the constraining mechanism includes a concave octagonal shape on the storage surface 4349 that, for example, can be configured to mate with a similar but smaller convex octagonal shape on a lower surface of the corresponding agent. In various embodiments, other suitable methods of constraining movement of an agent stored on a storage device can be implemented.

[0425] An example process of transferring the agent 4310C to the storage body 4345C, assuming gravity is in the -Z direction, can be as follows:

[0426] 1) In the levitation mode, the agent 4310C can be controllably moved by the work body in at least 2 directions / DOFs from the work body work area 4336 to the interior of the overlap area 4346;

[0427] 2) The agent 4310C can be caused to land on the guide device 4343;

[0428] 3) The agent 4310C can be controllably moved by the work body 4330 in 1 direction / DOF along the -X direction toward the transfer 4344 until at least half of the agent 4310C is outside the work body work area 4336.

[0429] 4) The mover 4310C can land on the conveyor belt by a soft landing operation or in response to a current flow within the particular conductive element stopping. Due to the friction between the mover and the conveyor belt, the conveyor belt can further move the mover along the conveyor until the mover is laterally aligned with a storage surface 4349C on the storage body 4345C, as shown in Figure 36B FIG. 34B, which shows a cross-sectional side view of the system when the mover 4310C (in the X and Y directions) is laterally aligned with the storage surface 4349C on the storage body 4345C. In various embodiments, if the mover is configured with an extended feature such as a roof edge that can be held by the edge belt conveyor, the mover 4310C can then be vertically supported by the edge belt conveyor 4344.

[0430] 5) Since the Y-direction width of the storage device is less than the Y-direction spacing between the two edge belts of the conveyor, the Z-motion transfer stage carrying the storage device 4348 can be moved in the Z-direction such that the mover 4310C can be lifted off the edge belt conveyor 4344 and constrained on the storage surface 4349C on the storage body 4345C, as shown in the cross-sectional side view of the system in Figure 36C FIG. 34C.

[0431] 6) The Z-motion transfer stage can then be further moved in the Z-direction such that the next storage surface 4349D on the storage body 4345D can be used to store another mover.

[0432] In various embodiments, the above-described process can also be implemented in a reverse working body such that the mover can be transferred from the storage device 4348 to the working body working area 4336, i.e., for loading the mover onto the working body. For example, to load the mover 4310C from the storage device to the working body, an example process can be as follows:

[0433] 1) The storage body 4345C can be lowered from the position shown in Figure 36C FIG. 34A to the position shown in Figure 36B FIG. 34B such that the mover 4310C is lifted off the storage surface 4349C on the storage body 4345C to be supported by the conveyor.

[0434] 2) The conveyor can then transfer the mover 4310C towards the working body 4330 until at least one Y-oriented magnetic array of the mover 4310C is within the working body working area;

[0435] 3) The mover can then be controllably moved in the X-direction by the working body 4330 in 1 direction / DOF while being constrained / guided by the guide 4343 until the mover 4310C is fully within the overlap area 4346.

[0436] 4) Then, the mover 10C can be caused to move upward in the Z direction from the guide 4343 in response to magnetic forces generated by current drive in the working body conductive element in the working body 4330, and can be controllably moved away from the overlap region 4346 and toward the rest of the working body working area 4336 in 6 directions / DOF to perform one or more operations, such as automated tasks.

[0437] In various embodiments, any other suitable conveying device, such as but not limited to a powered roller conveyor as shown in FIGS. 37A and 37B, can be used in the device instead of the edge belt conveyor as shown in FIG. 36. Figure 26A and 26B The powered roller conveyor can be used in the device instead of the edge belt conveyor as shown in FIG. 36.

[0438] Referring to Figure 37 , another magnetic movement device is shown in accordance with an embodiment, in which each storage body includes more than one storage surface. Figure 37 The details of the device of FIG. 37A are substantially similar to the details in the device of FIG. 36, except that Figure 37 Each storage body 4445 in FIG. 37A includes two storage surfaces 4449, which can be used to hold two movers on one storage body. In various embodiments, two movers can be transferred together or one after the other from the working body working area (or from one storage body to the working body working area in another manner) into one storage body. For example, assuming that there are no movers on the other storage bodies of the storage device, the two movers 4410B, 4410C on the storage body 4445A can be transferred one after the other from the storage device 4448 to the working body 4436: by lowering the Z-motion transfer stage in the -Z direction until the movers 4410B and 4410C are lifted completely off their storage surfaces and held by the edge belt conveyor, then the edge belt conveyor can transfer the two movers together in the X direction so that the mover 4410B is laterally aligned with the storage surface occupied by the mover 4410C in Figure 37 ; thereafter, the Z-motion transfer stage can be raised so that the mover 4410B is lifted by the storage body 4445A and held on the aligned storage surface, and the mover 4410C can be further transferred by the conveyor and driven into the overlap region by the working body, and subsequently controllably moved by the working body to the working body working area. In various embodiments, a storage body can include more than two storage surfaces, and can be operable to hold more than two movers.

[0439] In various embodiments, when all or most of the storage surfaces in a storage device, such as storage device 4448, are occupied by motes, the storage device 4448 can be removed from a transfer stage, such as Z-motion transfer stage 4442, via a quick release mechanism, and another empty storage device can be installed on the Z-motion transfer stage 4442. The newly installed empty storage device can be used to store additional motes. The above-described process can be used to move all motes from a work body to a storage device, if necessary, for example, but not limited to, during system maintenance or work body replacement.

[0440] Similarly, in various embodiments, a storage device holding one or more motes can be installed on a Z-motion transfer stage, such as transfer stage 4442, via a quick lock mechanism, so that each mote can be moved from the storage device to the work body work area, as previously described.

[0441] In various embodiments, a storage device can be used to hold one or more motes during shipping. After the one or more motes are placed on the storage surfaces, either automatically or manually, the Z-oriented space between the top surface of the motes and the bottom surface of the storage body described above can be filled with one or more spacer bodies, such as, but not limited to, plastic foam or similar paper or plastic-based packing materials. For example, the entire storage device, along with the motes inside, can be placed in a package for shipping. In various embodiments, the storage device filled with one or more motes can be protected with appropriate magnetic shielding.

[0442] Generally, a mote can carry one or more objects, such as parts, such as, but not limited to, biological samples, devices, medications possibly in suitable containers, products being assembled, raw materials, components, or any other objects needed to fulfill the needs required for the desired operation, automation task, or manufacturing purpose, for example. Suitable tools and / or mechanisms, such as material feeding mechanisms, can be installed or distributed on the work body (e.g., along the sides of the work body, or above the work body from above).

[0443] Work area partitioning

[0444] Generally, as used herein, a work body includes a work surface that can be logically configured into one or more separate work areas, one or more motes can be configured to move in the work areas. Figure 38A and 38BGraphical examples of 2D trajectories of exemplary movers in time domain (38A) and in a working area of a working surface of a working body, such as the working surface of working body (38B), are shown. Generally, in various embodiments, both the length and shape of the 2D trajectories in the working body plane can be configured by modifying the time domain trajectories Xr(t) and Yr(t) of the intended movement path of the movers accordingly. The trajectories can be modified such that a mover (such as any of the movers previously described) is commanded to move from a starting point 1 (having coordinates Xr1, Yr1) to an ending point 2 (having coordinates Xr2, Yr2) over a time span between times tl and t2.

[0445] Figure 39 An exemplary working area 4536 of a magnetic mobile device 4550 is shown, in accordance with another exemplary embodiment. Device 4550 comprises a working body 4530 comprising a working surface defining working area 4536, and a plurality of movers 4510A-4510R. In various embodiments, the overall layout of working body 4530 can be determined by the needs of a particular process (e.g., manufacturing, assembly, processing, or packaging), for example, and working body 4530 can be comprised of modular tiles, in various embodiments.

[0446] In various embodiments, working area 4536 can comprise a plurality of working cells 4521A-4521H. Each working cell can comprise a 2D (two-dimensional) contiguous area within working area 4536 in which a particular operation, process, and / or manufacturing step can be performed, for example. In various embodiments, a working cell can be a dedicated two-dimensional area defined by a user via suitable software means. In various embodiments, the boundaries of a working cell can be rectangular, or can be any other arbitrary shape, such as but not limited to polygonal, circular, or elliptical.

[0447] In various embodiments, two or more working cells can abut one another and can share a boundary, such as working cells 4521B and 4521C, as shown in Figure 39 In various embodiments, two or more working cells can be spaced apart, such as working cells 4521G and 4521F in Figure 39 In various embodiments, the boundaries of a working cell can coincide with the boundaries of the working area, such as working cell 4521F and working area 4536 in Figure 39 In embodiments in which a working cell is located along a working area boundary, a human operator can have convenient access to hardware or components in said working cell, as shown in Figure 39 In various embodiments, one or more working cells can be located entirely within the working area, without sharing any boundary between them.

[0448] Generally, a work cell can correspond to one or more operations, processes, manufacturing steps, or other suitable functions. A workflow can include multiple such operations, processes, manufacturing steps, or other suitable functions. For example, a telephone assembly production facility can include multiple work cells, and in each work cell a certain assembly task can be performed. Each of the multiple movers can be configured to move into a work cell for a given assembly task, and can move from the work cell to another work cell for a subsequent assembly task according to a particular workflow.

[0449] Generally, a portion of the work area can surround or coincide with one or more work cells, and the portion of the work area can serve as a routing area (shown as routing area 4523 in Figure 39 ) for mover traffic, i.e., the routing area 4523 includes a portion of the work area of the work volume in which one or more movers can move toward their respective target locations based on application requirements. By using a suitable routing algorithm configured to drive current through certain conductive elements in the work volume, one or more movers can be controllably moved in the routing area to follow a 2D trajectory generated by one or more controllers, such as the one or more controllers 160 shown in Figure 1A .

[0450] In various embodiments, a device such as the device 4550 can include one or more obstacles, such as the obstacles 4522A-4522C in Figure 39 . In the illustrated embodiment, each obstacle is a two-dimensional region of the work surface that is not allowed or accessible to the movers. In various embodiments, an obstacle can correspond to a tool (or tool holder) that is positioned or mounted such that the movers cannot or should not move into the region occupied by the tool / tool holder because a mechanical collision and / or interference with the normal operation of the tool can otherwise occur. In various embodiments, one or more obstacles such as the obstacle 4522A can be outside of a work cell, one or more obstacles such as the obstacles 4522B and 4522C can be inside a work cell, and one or more obstacles can span the boundary between a work cell and a routing area 4523. In various embodiments, an obstacle can be logically configured by software or by one or more controllers (e.g., the controllers 160 shown in Figure 1A ) such that the one or more controllers can take the obstacle into account during generation of a trajectory for a mover, which can allow the mover to controllably move following a trajectory around the obstacle rather than colliding or crashing into the obstacle.

[0451] In various embodiments, a magnetically mobile device optionally includes a mover buffer system 4547, as shown in Figure 39As shown. In various embodiments, the mover buffer system 4547 may include a mover transfer device 4544 (e.g., but not limited to, e.g., a mover transfer device 4544). Figures 36A-36C The conveyor 4342 shown herein (any of the moving part conveyors described herein, or for example, just a conventional conveyor belt) and the moving part storage device 4546, for example, refer to Figures 36A-36C The mover storage devices 4348 and 4448 described in section 37. Implementing the mover buffering system 4547 allows temporarily unnecessary movers to move from the working area 4536 of the main working body to the mover storage device 4546, so that those temporarily unnecessary movers do not obstruct the mover flow in the working area 4536; when the device needs more movers in the working area 4536 to perform a specific operation or process, the movers stored in the storage device 4546 can be moved back to the working area via the mover transfer device 4544 for further operation or processing. Therefore, the mover buffering subsystem 4547 can help improve system flow efficiency.

[0452] In various embodiments, obstacles may have two states: an active state and a deactivated state. When an obstacle is in the deactivated state, the corresponding area of ​​the obstacle may be used by one or more controllers to route one or more movers and / or command one or more movers to perform one or more operations in the work unit; that is, when the obstacle is in the deactivated state, movers may move into the obstacle area. When an obstacle is in the active state, movers may not be allowed to move into the obstacle area, and one or more controllers may accordingly generate appropriate trajectories to command movers to avoid the active obstacle. Obstacles may be temporarily deactivated: for example, a tool may be temporarily lifted or moved away from the work body so that it does not obstruct movers in the occupied area. In various embodiments, one or more obstacles may be permanently in the active state.

[0453] Controller Architecture

[0454] Typically, the mover moves in response to the magnetic interaction between a magnetizing element in each mover and a magnetic field generated by a current driven by one or more conductive elements in the working body located below the mover. This current can be controlled by one or more controllers. Figure 40A As shown, in various embodiments, controller 4660 (controller 4660 can be used with any other controller described herein) Figure 1A The controller 160 shown (which functions substantially the same) can be divided into multi-level control modules. A non-limiting embodiment describing the implementation of the three control modules in controller 4660 is described below and... Figure 40A The diagram illustrates:

[0455] • The low-level position control module 4662 can be configured to control each controllable axis of the one or more movers using a suitable control algorithm such that the actual position of the one or more movers follows a desired trajectory (e.g., a 2D trajectory, for example).

[0456] • The high-level trajectory control module 4664 can be configured to generate trajectories for the one or more movers such that the one or more movers can move into one or more work cells to perform operations and such that the one or more movers can move from one work cell to another work cell according to a workflow. In various embodiments, the high-level trajectory control module 4664 can include a router module 4666, for example, which can be configured to generate trajectories for the one or more movers in a routing area and / or from one work cell to another work cell. The router module can output routing trajectories for the movers, which can be received by a switching module in the high-level trajectory control module. The switching module can be configured to switch to the routing trajectories when the one or more movers are in the routing area and can switch to host trajectories (explained below) when the movers are in a work cell for a particular operation.

[0457] • The work cell control module 4670 can be configured to control the operation of the one or more movers in a work cell for a particular operation. In various embodiments, each work cell can have a corresponding work cell control module. Each work cell control module 4670 can generate host trajectories for the one or more movers in a work cell simultaneously, one after another.

[0458] In various embodiments, the control modules can be physically implemented in one controller. In other embodiments, the various control modules can be distributed among various controllers. For example, the low-level position control module 4662 can be implemented in a first controller, the high-level trajectory control module 4664 can be implemented in a second controller, and one or more workcell control modules 4670 can be implemented in one or more additional controllers programmed for a particular operation and / or application. In various embodiments, the control modules can be implemented in two controllers: the low-level position control 4662 and the high-level trajectory control 4664 can be implemented in a central controller, and one or more workcell control modules 4670 can be implemented in one or more host controllers programmed for a particular operation and / or application. In other embodiments, the control modules can be implemented in two controllers in a different manner: the low-level position control module 4662 can be implemented in a zone controller, and the high-level trajectory control module 4664 and the workcell control module 4670 can be implemented in a central controller. In general, the control modules can be implemented using suitable software running on any suitable computer hardware, such as but not limited to central processing units (“CPUs”), graphics processing units (“GPUs”), microprocessors, microcontrollers, digital signal processors, programmable logic controllers (“PLCs”), and / or industrial PCs (“IPCs”), etc., or can be implemented directly as hardware in a field programmable gate array (“FPGA”), or a combination of any of the above. In various embodiments, bidirectional electrical communication channels can exist between or across one or more of the control modules in the controllers.

[0459] Figure 40B A non-limiting example of a low-level position control module is shown, for example Figure 40A As previously mentioned, the movement of the mover can be controlled in at least 2 directions / DOFs (typically X, Y, Z, Rx, Ry, and Rz directions) in response to feedback sent to the controller; thus, it can be said that the mover is capable of controlled movement in at least 2 directions / DOFs. In the illustrated embodiment, the low-level position control module 4662 includes a feedback controller module 4663 configured to take as input the trajectory from the high-level trajectory control module 4664 and the position feedback signals generated by one or more sensors such as the sensors 180 shown. Figure 1A Figure 1A ​one or more amplifiers 170 are shown to drive the desired conductive elements in current according to current command signals. A 2D trajectory of the mover (Xr, Yr) is computed by the advanced trajectory control module 4664. The feedback controller 4663 can be configured to control the ...

Claims

1. An apparatus for moving a magnetically movable device, the apparatus comprising: a working body comprising a plurality of electrically conductive coils and a working surface on which the magnetically movable device is configured to be controllably moved within at least two degrees of freedom, wherein the magnetically movable device and the plurality of electrically conductive coils are on opposite sides of the working surface; a guiding device at least partially overlapping the working body, thereby defining with the working body an overlapping region associated with the guiding device and the working body; a conveying device for moving the magnetically movable device away from or towards the overlapping region; and one or more controllers configured to controllably move the magnetically movable device on the working surface to or away from the overlapping region by driving one or more currents through at least one of the plurality of electrically conductive coils in order to adjust one or more magnetic fields to controllably magnetically levitate the magnetically movable device, wherein the guiding device is configured to guide movement of the magnetically movable device between the overlapping region and the conveying device, and wherein the one or more controllers are further configured to control the conveying device to move the magnetically movable device away from or towards the overlapping region. the one or more controllers are further configured to, after moving the magnetically movable device to the overlapping region, move the magnetically movable device towards the working surface and subsequently drop the magnetically movable device on the guiding device.

2. The apparatus of claim 1, wherein, the one or more controllers are further configured to, after moving the magnetically movable device to the overlapping region, controllably move the magnetically movable device towards the working surface.

3. The apparatus of claim 2, wherein, the one or more controllers are further configured to, after moving the magnetically movable device towards the working surface, controllably drop the magnetically movable device on the guiding device.

4. The apparatus of claim 2, wherein, the one or more controllers are further configured to drive one or more currents through at least one of the plurality of electrically conductive coils in order to adjust the one or more magnetic fields to controllably move the magnetically movable device between the overlapping region and the conveying device, wherein the movement of the magnetically movable device between the overlapping region and the conveying device is guided by the guiding device.

5. The apparatus of claim 1, wherein, the movement of the magnetically movable device between the overlapping region and the conveying device occurs within one degree of freedom.

6. The apparatus of claim 5, wherein, the at least two degrees of freedom include a Z-axis extending perpendicular to the working surface.

7. The apparatus of claim 1, wherein, the at least two degrees of freedom include at least two in-plane degrees of freedom.

8. The apparatus of claim 1, wherein, the at least two degrees of freedom include at least three degrees of freedom.

9. The apparatus of claim 1, wherein, the at least two degrees of freedom include six degrees of freedom.

10. The apparatus of claim 1, wherein, the conveying device comprises a conveyor.

11. The apparatus of claim 1, wherein, the guiding device comprises one or more rollers for guiding movement of the magnetically movable device between the overlapping region and the conveying device.

12. The apparatus of claim 1, wherein, the guiding device comprises one or more rails for guiding movement of the magnetically movable device between the overlapping region and the conveying device.

13. The apparatus of claim 1, wherein, ​ 14. The apparatus of claim 1, wherein, The guiding device is a first guiding device, wherein the conveying device is a first conveying device, wherein the overlapping region is a first overlapping region, and wherein the apparatus further comprises: a second guiding device at least partially overlapping with the workpiece, thereby defining with the workpiece a second overlapping region associated with the second guiding device and the workpiece, wherein the second overlapping region is different from the first overlapping region; a second conveying device for moving the magnetically movable device away from or towards the second overlapping region, wherein, after the magnetically movable device has been moved to the first conveying device, the one or more controllers are configured to control the first conveying device to move the magnetically movable device away from the first overlapping region in a first direction, and wherein, after the magnetically movable device has been moved to the second conveying device, the one or more controllers are further configured to control the second conveying device to move the magnetically movable device away from the second overlapping region in a second direction different from the first direction.

15. The apparatus of claim 1, wherein, The magnetically movable device comprises: a first pair of landing surfaces for contacting the guiding device, wherein the first pair of landing surfaces is located on a first opposite side of the magnetically movable device, and wherein the first opposite side is located on both sides of a first vertical plane passing through a center of the magnetically movable device; and a second pair of landing surfaces for contacting the guiding device, wherein the second pair of landing surfaces is located on a second opposite side of the magnetically movable device, and wherein the second opposite side is located on both sides of a second vertical plane perpendicular to the first vertical plane and passing through the center of the magnetically movable device.

16. The apparatus of claim 15, wherein, The first opposite side extends perpendicular to the second opposite side.

17. The apparatus of claim 1, wherein: the magnetically movable device comprises a plurality of arrays of magnets; when moving the magnetically movable device from the overlapping region towards the conveying device in a first horizontal direction, the one or more controllers are further configured to: drive one or more currents through at least one of the plurality of electrically conductive coils so as to adjust the one or more magnetic fields, thereby controllably moving the magnetically movable device by causing the one or more magnetic fields to interact with a plurality of the arrays of magnets, wherein the at least one of the plurality of electrically conductive coils is oriented in a second horizontal direction perpendicular to the first horizontal direction, and wherein each of the plurality of the arrays of magnets comprises one or more magnetized elements elongated in the second horizontal direction; and the one or more controllers are further configured to: drive one or more currents through at least one of the plurality of electrically conductive coils so as to adjust the one or more magnetic fields, thereby controllably moving the magnetically movable device by causing the one or more magnetic fields to interact with a plurality of the arrays of magnets, wherein the at least one of the plurality of electrically conductive coils is oriented in a second horizontal direction perpendicular to the first horizontal direction, and wherein each of the plurality of the arrays of magnets comprises one or more magnetized elements elongated in the second horizontal direction; and Subsequently, when a portion of the magnetically movable device no longer overlaps the work surface, driving one or more electric currents through at least one of the plurality of electrically conductive coils to adjust the one or more magnetic fields to controllably move the magnetically movable device by interacting the one or more magnetic fields with a single one of the array of magnets, wherein the at least one of the plurality of electrically conductive coils is oriented in the second horizontal direction, and wherein the single one of the array of magnets comprises one or more magnetized elements elongated in the second horizontal direction.

18. The apparatus of claim 17, wherein, The single one of the array of magnets is offset relative to a center of the magnetically movable device.

19. The apparatus of claim 1, wherein, The guide device is part of the transport device.

20. The apparatus of claim 1, wherein, The transport device does not form part of the work body.

21. The apparatus of claim 1, wherein, The one or more controllers are further configured to control the transport device to move the magnetically movable device away from or towards the overlap region by moving the magnetically movable device laterally away from or towards the overlap region, wherein the lateral movement of the magnetically movable device away from or towards the overlap region is constituted in a plane parallel to the work surface.

22. A method of moving a magnetically movable device, comprising: controllably moving the magnetically movable device on a work surface of a work body in at least two degrees of freedom by magnetic levitation to or away from an overlap region associated with a guide device and the work body, wherein the overlap region is defined by the guide device at least partially overlapping the work body; controllably moving the magnetically movable device between the overlap region and a transport device while guiding movement of the magnetically movable device with the guide device; and controllably moving the magnetically movable device away from or towards the overlap region from the transport device. Controllably moving the magnetically movable device away from or towards the overlap region comprises moving the magnetically movable device laterally away from or towards the overlap region, wherein the lateral movement of the magnetically movable device away from or towards the overlap region is constituted in a plane parallel to the work surface.

23. The method of claim 22, wherein, 24. An apparatus for moving a magnetically movable device, the apparatus comprising: a work body comprising a plurality of electrically conductive coils and a work surface on which the magnetically movable device is configured to be controllably moved in at least two degrees of freedom, wherein the magnetically movable device and the plurality of electrically conductive coils are on opposite sides of the work surface; a transport device overlapping a portion of the work body, thereby defining an overlap region associated with the transport device and the work body; and a non-overlap region associated with the work body only. ​ one or more controllers configured to controllably move the magnetically movable device into or out of the overlap region by driving one or more currents through at least one of the plurality of electrically conductive coils to adjust one or more magnetic fields to controllably levitate the magnetically movable device, wherein the one or more controllers are further configured to control the transport device to move the magnetically movable device out of or into the overlap region.

25. The apparatus of claim 24, wherein, The one or more controllers are further configured to control the transport device to move the magnetically movable device laterally out of or into the overlap region, wherein the lateral movement of the magnetically movable device out of or into the overlap region is constituted in a plane parallel to the work surface.

26. The apparatus of claim 24, wherein, The one or more controllers are further configured to move the magnetically movable device out of the overlap region and into the non-overlap region after controlling the transport device to move the magnetically movable device into the overlap region.

27. The apparatus of claim 26, wherein, The one or more controllers are further configured to move the magnetically movable device towards the work surface after moving the magnetically movable device out of the overlap region and into the non-overlap region.

28. The apparatus of claim 24, wherein, The one or more controllers are further configured to move the magnetically movable device over the transport device after controllably moving the magnetically movable device out of the non-overlap region and into the overlap region.

29. The apparatus of claim 24, wherein, The transport device comprises one or more carriers attached to a conveyor.

30. The apparatus of claim 24, wherein, The transport device comprises at least two conveyors and a spacing between the at least two conveyors is adjustable.

31. The apparatus of claim 30, wherein, The one or more controllers are further configured to: control the transport device to reduce the spacing between the at least two conveyors after moving the magnetically movable device into the overlap region; and move the magnetically movable device towards the work surface and subsequently drop the magnetically movable device on the transport device after reducing the spacing between the at least two conveyors.

32. The apparatus of claim 24, wherein, The at least two degrees of freedom comprise a Z-axis extending perpendicular to the work surface.

33. The apparatus of claim 24, wherein, The at least two degrees of freedom comprise at least two in-plane degrees of freedom.

34. The apparatus of claim 24, wherein, The at least two degrees of freedom comprise at least three degrees of freedom.

35. The apparatus of claim 24, wherein, The at least two degrees of freedom comprise six degrees of freedom.

36. The apparatus of claim 24, wherein, The magnetically movable device comprises: a first pair of landing surfaces for contacting the transport device, wherein the first pair of landing surfaces is located on a first opposing side of the magnetically movable device; and a second pair of landing surfaces for contacting the transport device, wherein the second pair of landing surfaces is located on a second opposing side of the magnetically movable device.

37. The apparatus of claim 36, wherein, The first opposing side extends perpendicular to the second opposing side.

38. A method of moving a magnetically movable device, comprising: controllably moving the magnetically movable device in and out of an overlap region associated with the transport device and the work body by magnetic levitation in at least two degrees of freedom, wherein the overlap region is defined by the overlap of the transport device and a portion of the work body; and controllably moving the magnetically movable device between the overlap region and the transport device; and controllably moving the magnetically movable device in and out of the overlap region using the transport device.

39. The method of claim 38, wherein, controllably moving the magnetically movable device in and out of the overlap region includes moving the magnetically movable device laterally in and out of the overlap region, wherein the lateral movement of the magnetically movable device in and out of the overlap region is made in a plane parallel to the work surface.

40. The apparatus of claim 24, wherein, the portion of the work body that overlaps the transport device only overlaps a portion of the transport device.

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