System and method for strain and acceleration based analysis in standalone cart system

Abstract

Systems and methods for strain and acceleration based analysis in standalone cart systems are provided. A system and method for monitoring forces exerted at multiple locations on a moving member includes a plurality of sensors, where each sensor is mounted at one of the locations. Each sensor detects operating conditions of the moving member at the location on the moving member where the sensor is mounted. The sensors can include accelerometers, strain gauges, or combinations thereof. Each strain gauge is mounted proximate to a region of interest on the moving member. Each strain gauge generates a feedback signal corresponding to a deformation of the material measured at the location of the sensor. From the deformation of the material measured, the force acting on the moving member at the location of the sensor can be determined. The forces exerted at different locations on the moving member can be monitored in real time to determine bearing performance, or monitored over a duration of time to observe changes in bearing performance over the duration of time.

Description

Technical Field

[0001] The topics disclosed in this paper relate to systems and methods for monitoring the health of a vehicle with a stand-alone trolley system. More specifically, multiple sensors, such as strain gauges and accelerometers, are mounted at different locations on the vehicle to provide performance and health information for the vehicle or subsystems at different locations on the vehicle. Background Technology

[0002] Motion control systems utilizing independent trolleys and linear motors can be used in a variety of processes (e.g., packaging, manufacturing, and processing) and offer advantages over conventional conveyor systems, including enhanced flexibility, extremely high-speed motion, and mechanical simplicity. The motion control system comprises a group of independently controlled vehicles or trolleys (referred to herein as “moving parts”), each supported on a track for movement along the track. The track consists of multiple track segments, and a linear drive system controls the operation of the moving parts, causing them to travel along the track. Sensors can be located at fixed positions along the track and / or spaced apart on the moving parts to provide information about the position and velocity of the moving parts.

[0003] Numerous differences between different moving parts, or even differences in individual moving parts over time, can affect how a moving part travels along the track. For example, variations between moving parts due to manufacturing tolerances can lead to differences in the physical engagement between the moving part and the track. Variations in physical engagement may cause one of the bearings on the moving part to experience greater pressure and / or friction than other bearings. The bearing experiencing the greatest pressure and / or friction may wear out faster than other bearings. Similarly, variations in the orientation of the track will cause different forces to be applied to the moving parts due to gravity. As each moving part travels along the track, variations in the load on each moving part will result in varying forces applied to each moving part. All variations in manufacturing, orientation, load, etc., affect the external forces experienced by the moving parts and will similarly cause one of the bearings on the moving part to experience greater pressure and / or friction than other bearings.

[0004] Therefore, it is desirable to monitor the forces applied at multiple locations on the moving part.

[0005] Furthermore, wear on bearings or rollers over time can increase variations between different moving parts or change the orientation of individual moving parts over time. Wear on the track (e.g., dents on the guide rail) or variations in the transition distance between track sections can also affect how moving parts travel along the track.

[0006] Therefore, it is desirable to have real-time feedback corresponding to bearing performance and to monitor changes in bearing performance over time. Summary of the Invention

[0007] According to one embodiment of the present invention, a system for monitoring the state of moving parts in an independent trolley system includes a plurality of sensors, a control circuit, and a transmitter. The independent trolley system includes a plurality of moving parts configured to travel along a track. Sensors are mounted on the moving parts, and each sensor is configured to generate at least one feedback signal corresponding to an operating condition of the moving part. The control circuit is mounted on the moving parts. The control circuit is configured to receive at least one feedback signal from each of the sensors and generate a data packet including a value corresponding to an operating condition monitored from each of the sensors. The transmitter is mounted on the moving parts. The transmitter is configured to receive the data packet from the control circuit and transmit the data packet to a receiver located outside the moving parts.

[0008] According to another embodiment of the invention, a system for monitoring the status of multiple bearings on a moving part in a trolley system includes multiple sensors, control circuitry, and a transmitter. Sensors are mounted on the moving part, and each sensor is mounted near one of the bearings on the moving part. Each sensor is configured to generate at least one feedback signal corresponding to the operating condition of a corresponding bearing mounted near each of the sensors. Control circuitry is mounted on the moving part. Control circuitry is configured to receive at least one feedback signal from each of the sensors and generate a data packet including the value of at least one feedback signal corresponding to the operating condition of the corresponding bearing monitored from each of the sensors. Transmitter is mounted on the moving part. Transmitter is configured to receive the data packet from the control circuitry and transmit the data packet to a receiver located outside the moving part.

[0009] According to another embodiment of the invention, a method for monitoring the state of a moving part in a stand-alone trolley system includes generating at least one feedback signal from each of a plurality of sensors mounted on the moving part. The at least one feedback signal corresponds to an operating condition of the moving part, and at least one feedback signal from each of the sensors is received at a control circuit mounted on the moving part. The control circuit generates a data packet including at least one value corresponding to the operating condition monitored by each of the sensors. The data packet is transmitted from a transmitter mounted on the moving part to a receiver located outside the moving part.

[0010] These and other advantages and features of the invention will become apparent to those skilled in the art from the detailed description and accompanying drawings. However, it should be understood that while the detailed description and drawings indicate preferred embodiments of the invention, they are given by way of illustration rather than limitation. Many changes and modifications can be made within the scope of the invention without departing from its spirit, and the invention encompasses all such modifications. Attached Figure Description

[0011] The accompanying drawings illustrate various exemplary embodiments of the subject matter disclosed herein. Throughout the drawings, the same reference numerals denote the same parts, and in the drawings:

[0012] Figure 1 This is a perspective view of an exemplary linear trolley system incorporating multiple moving parts that travel along a closed curved track, according to an embodiment of the present invention.

[0013] Figure 2 This is a perspective view of an exemplary linear trolley system incorporating multiple moving parts that travel along a closed curved track, according to another embodiment of the present invention.

[0014] Figure 3 yes Figure 2 A partial side view of the linear trolley system;

[0015] Figure 4 It comes from Figure 1 A three-dimensional view of the moving parts of the transportation system;

[0016] Figure 5 yes Figure 1 A partial cross-sectional view of the transportation system;

[0017] Figure 6 It comes from Figure 2 A side view of the moving parts of the transportation system;

[0018] Figure 7 yes Figure 2 A partial cross-sectional view of the transportation system;

[0019] Figure 8 yes Figure 1 A partial side view of a segment of one embodiment of a linear trolley system, showing activation coils distributed along a surface of a track segment;

[0020] Figure 9 This is an exemplary control system for a linear trolley system incorporating one embodiment of the present invention;

[0021] Figure 10 yes Figure 9 A block diagram representation of the control system;

[0022] Figure 11 It comes from Figure 2 A perspective view of a moving component of a transportation system, showing multiple sensors and control circuits mounted to the moving component according to an embodiment of the present invention;

[0023] Figure 12 It is used as Figure 11 A schematic representation of an exemplary strain gauge, one of the sensors;

[0024] Figure 13 yes Figure 11 A block diagram representation of an exemplary control circuit;

[0025] Figure 14 This is a front view of an exemplary track in which the main axis of the track is positioned in a vertical orientation.

[0026] Figure 15 This is a front view of an exemplary track installed in a horizontal orientation; and

[0027] Figure 16 This is a front view of an exemplary track in which the short axis of the track is positioned vertically for installation.

[0028] In describing the various embodiments of the invention illustrated in the accompanying drawings, specific terminology will be used for clarity. However, this is not intended to limit the invention to the specific terminology chosen, and it should be understood that each specific term includes all technical equivalents that operate in a similar manner to achieve similar purposes. For example, the terms "connection," "attachment," or similar terms are frequently used. This is not limited to direct connections but includes connections via other elements, which are considered equivalent by those skilled in the art. Detailed Implementation

[0029] Various features and advantageous details of the subject matter disclosed herein will be more fully described with reference to non-limiting embodiments detailed in the following description. The subject matter disclosed herein describes a system and method for monitoring forces applied at multiple locations on a moving part. Multiple sensors are mounted at multiple locations on each moving part. Each sensor detects the operating conditions of the moving part at the location on which it is mounted. According to one embodiment of the invention, at least one accelerometer and at least one strain gauge are mounted to the moving part. According to one aspect of the invention, multiple strain gauges may be mounted to the moving part, wherein each strain gauge is mounted near one of the bearings of the moving part. Each strain gauge generates a feedback signal corresponding to the deformation of the material measured at the sensor location. Based on the measured deformation of the material, the force acting on the moving part at the sensor location can be determined. Therefore, strain gauges can be used to monitor forces applied at multiple locations on the moving part. According to one aspect of the invention, forces applied at multiple locations on the moving part can be monitored in real time to determine bearing performance. Forces can also be monitored over a duration to observe changes in bearing performance over that duration.

[0030] Each sensor is configured to generate a feedback signal corresponding to the measured strain. It is envisioned that the feedback signal, additional processing signal, or a combination thereof can be transmitted from each moving part to a remote device. Each moving part travels along a track of an independent trolley system. The remote device is preferably a fixed device mounted outside the track and, for example, can provide a user with a visual interface displaying the real-time forces experienced at each location on the moving part. On smaller tracks, a communication bus can be mounted around the track, and each trolley can include brushes configured to slide along the communication bus and establish a “wired” communication path between the trolley and the remote device. However, as the branch and / or track size increases, a wired communication path becomes impractical, and a wireless communication path is preferred. Each moving part can include a wireless communication device that communicates with the sensors and the remote device to transmit data directly from the sensors to the remote device. Alternatively, intermediate communication nodes can be periodically established along the track, allowing the wireless communication device on each moving part to communicate with one of the nodes. Each node can then be connected to the remote device via a wired connection, a wireless connection, or a combination thereof. Each node can serve as a gateway for transmitting data between the trolley and the remote device.

[0031] In one embodiment of the invention, it is envisioned that each sensor and communication device be powered by a battery mounted on a trolley. According to another embodiment of the invention, it is envisioned that each sensor and communication device be powered via a wireless power transmission system. The wireless power transmission system may use, for example, inductive or optical coupling between power sources mounted on or near a track, wherein the power sources are configured to transmit energy to a pickup device mounted on the trolley. The pickup device is configured to receive the transmitted energy when it is within range of the power source. Multiple power sources may be arranged around the track, or alternatively, power rails may be continuously mounted along the track, and power pickups may be inductively coupled to the power rails to continuously receive power from the wireless power transmission system on the trolley. The trolley may have an energy storage device in which the energy delivered to the trolley is stored until the sensor, control circuitry, or communication device requires energy for activation.

[0032] First go to Figures 1 to 3Two embodiments of an exemplary transport system for moving articles or products are shown. The transport system includes a track 10 composed of a plurality of segments 12, 14. According to the illustrated embodiment, the segments define a generally closed loop supporting a group of moving members 100 capable of moving along the track 10. Each of the illustrated tracks 10 includes four straight segments 12, wherein two straight segments 12 are positioned along each side of the track and spaced apart from another pair of straight segments. The track 10 also includes four curved segments 14, wherein a pair of curved segments 14 are located at each end of the track 10 to connect the pairs of straight segments 12. The four straight segments 12 and the four curved segments 14 form a generally elliptical track and define a closed path on which each of the individual moving members 100 can travel. It should be understood that track segments of various sizes, lengths and shapes can be joined together to form the track 10 without departing from the scope of the invention.

[0033] exist Figure 1 In this configuration, track 10 is oriented in a horizontal plane and supported on the ground by a base 15 extending vertically downward from track 10. The base 15 includes a pair of generally planar support plates 17 located on opposite sides of track 10, each support plate 17 having mounting feet 19 for securing track 10 to the surface. Figure 2 The image shows a track 10 without a base. It is envisioned that the track 10 can be installed in different orientations, such as inclined or vertical, and that the track includes segments of different shapes, including but not limited to straight segments, inwardly curved segments, outwardly curved segments, upwardly inclined segments, downwardly inclined segments, and various combinations thereof. For convenience, the terms used herein will refer to... Figure 1 The horizontal orientation of track 10 shown herein is discussed. Terms such as up, down, inside, and outside are used relative to the shown track orientation. These terms relate to the shown track and are not intended to be limiting. The moving part 100 will travel along the track and take various orientations depending on the configuration of track 10, and the relationships discussed herein may be changed accordingly.

[0034] Each track segment 12, 14 includes a plurality of independently attached guide rails 20, on which each moving member 100 runs. According to the illustrated embodiment, the guide rails 20 extend generally along the outer periphery of the track 10. A first guide rail 20 extends along the upper surface 11 of each segment, and a second guide rail 20 extends along the lower surface 13 of each segment. It is contemplated that each guide rail 20 may be a single component, which may be molded, extruded, or machined into a single guide rail component, or that each guide rail 20 may be assembled and formed from multiple components. It is also contemplated that, without departing from the scope of the invention, the cross-section of the guide rail 20 may be circular, square, rectangular, or any other desired cross-sectional shape. The guide rails 20 generally conform to the curvature of the track 10, thus extending along straight track segments 12 in straight paths and along curved track segments 14 in curved paths. The guide rails 20 may be relatively thin relative to the dimensions of the track 10 and only span a portion of the width of the surface of the track 10 to which they are attached.

[0035] Also refer to Figure 5 A first embodiment of the guide rail 20 includes a base portion 22 mounted to a track section and a track portion 24 along which a moving member 100 travels. Each moving member 100 includes a complementary roller 110 for engaging with the track portion 24 of the guide rail 20 to move along the track 10. Each side of the track portion 24 is wedge-shaped, and each roller 110 includes a complementary groove configured to receive the wedge-shaped side of the track portion.

[0036] Also refer to Figure 7 A second embodiment of the guide rail 20 includes two track portions 26 and 28, wherein the first track portion 26 and the second track portion 28 each have a generally rectangular cross-sectional area. The first track portion 26 of the upper guide rail 20 is located on the top surface 11 of the track, and a first roller and a second roller 110 engage each side of the first track portion 26 of the upper guide rail. The second track portion 28 of the upper guide rail 20 protrudes from a side of the track portion orthogonal to the orientation of the first track portion 26. A third roller 110 engages a surface of the second track portion 28 of the upper guide rail. Similarly, the first track portion 26 of the lower guide rail 20 has a generally rectangular cross-sectional area and is oriented on the lower surface 13 of the track, and a fourth roller and a fifth roller 110 engage each side of the first track portion 26 of the lower guide rail. The second track portion 28 of the lower guide rail 20 protrudes from a side of the track portion orthogonal to the orientation of the first track portion 26, and a sixth roller 110 engages a surface of the second track portion 28 of the lower guide rail.

[0037] One or more movable parts 100 are mounted to guide rails 20 on track 10 and are capable of moving along guide rails 20. See again... Figure 4 and Figure 5A first embodiment of an exemplary movable member 100 is shown. Each movable member 100 includes a side member 102, a top member 104, and a bottom member 106. The side member 102 extends at least a height across the distance between a guide rail 20 located on the top surface 11 of the track 10 and a guide rail 20 located on the bottom surface 13 of the track 10, and is oriented generally parallel to the side surface 21 when mounted to the track 10. The top member 104 extends generally orthogonally to the side member 102 at its top end and extends beyond the guide rail 20 located on the top surface 11 of the track 10. The top member 104 includes a first segment 103 extending orthogonally from the side member 102 across the width of the guide rail 20, the width of which is generally the same as the width of the side member 102. A set of rollers 110 is mounted on the underside of the first section 103, and this set of rollers 110 is configured to engage with the track portion 24 of the guide rail 20 mounted to the upper surface 11 of the track section. According to the illustrated embodiment, two pairs of rollers 110 are mounted on the underside of the first section 103, wherein the first pair of rollers is positioned along a first edge of the track portion 24 of the guide rail, and the second pair of rollers is positioned along a second edge of the track portion 24 of the guide rail 20. The first and second edges, and thus the first and second pairs of rollers 110, are located on opposite sides of the guide rail 20 and reliably (positively) retain the moving member 100 relative to the guide rail 20. The bottom member 106 extends substantially orthogonally to the side member 102 at the bottom end of the side member 102, and the bottom member 106 extends along the bottom of the moving member 100 a distance sufficient to receive a third pair of rollers 110. The third pair of rollers 110 engages with the outer edge of the track portion 24 of the guide rail 20 mounted to the lower surface 13 of the track section. Thus, the moving member 100 rides along the guide rail 20 on the rollers 110 mounted to both the top member 104 and the bottom member 106 of each moving member 100. The top member 104 also includes a second section 120 that protrudes from the first section 103 beyond the guide rail 20 by an additional distance and is configured to hold the position magnet 130. According to the illustrated embodiment, the second section 120 of the top member 104 includes a first portion 122 that extends generally parallel to the guide rail 20 and tapers to a width smaller than that of the first section 103 of the top member 104. The second section 120 also includes a second portion 124 that extends downward from the first portion 122 and extends generally orthogonally to the first portion 122. The second portion 124 extends downward by a distance less than the distance to the upper surface 11 of the track section, but this distance is sufficient to allow the position magnet 130 to be mounted to the second portion 124. According to the illustrated embodiment, the position magnet 130 is mounted in a recess 126 on the second portion 124, and the position magnet 130 is configured to align with a sensor 150 mounted in the top surface 11 of the track section.

[0038] Refer again Figure 7 A second embodiment of an exemplary moving member 100 is shown. Each moving member 100 includes a side member 102, a top member 104, and a bottom member 106. The side member 102 extends at least a height across the distance between the guide rail 20 located on the top surface 11 of the track 10 and the guide rail 20 located on the bottom surface 13 of the track 10, and is oriented generally parallel to the side surface 21 when mounted to the track 10. The top member 104 extends generally orthogonally to the side member 102 at the top end of the side member 102, and extends beyond the guide rail 20 located on the top surface 11 of the track 10. A first set of rollers 110 is mounted on the underside of the top member 104 and configured to engage either side of a first track portion 26 of the track 20 mounted to the upper surface 11 of the track segment. According to the illustrated embodiment, two pairs of rollers 110 are mounted to the underside of the top member 104, wherein the first pair of rollers is positioned along a first side of the first track portion 26, and the second pair of rollers is positioned along a second side of the first track portion 26 of the upper guide rail 20. A third pair of rollers 110 is mounted on the side member 102 and extends below the second track portion 28 of the upper guide rail. A bottom member 106 extends substantially orthogonally to the side member 102 at the bottom end of the side member 102, and extends along the bottom of the moving member 100 by a distance sufficient to receive the fourth and fifth pairs of rollers 110. The fourth and fifth pairs of rollers 110 each engage one side of the first track portion 26 of the lower guide rail 20. A sixth pair of rollers 110 is mounted on the side member 102 and extends above the second track portion 28 of the lower guide rail. Rollers 110 work together to engage the various surfaces of guide rail 20, thereby allowing the moving member 100 to travel along guide rail 20 while maintaining the orientation of the moving member 100 relative to track 10. According to the illustrated embodiment, position magnet 130 is mounted within top member 104 and configured to align with sensor 150 mounted within top surface 11 of track section.

[0039] Reference Figure 5 and Figure 7 Both, the linear drive system is partially integrated onto each moving member 100 and partially integrated within each track section 12, 14 to control the movement of each moving member 100 along the section. A coil 50 (see also) is mounted along the length of the track 10. Figure 8The first driving member is used. Each moving member 100 includes a second driving member 140, which is configured to interact with the electromagnetic field generated by the coil 50 to propel the moving member 100 along the track 10. It is contemplated that the driving member 140 on each moving member 100 may be a driving magnet, a steel guard and teeth, a conductor, or any other suitable member that will interact with the electromagnetic field generated by the coil 50. Typically, the driving member 140 on each moving member 100 includes a permanent magnet that emits a magnetic field. Compared to a magnetic salient pole structure without a magnetic field, the magnetic field generated by the driving member 140 on each moving member 100 improves the interaction between the moving member and the electromagnetic field generated by the coil 50. For convenience, the invention will be discussed with respect to the driving magnet 140, which serves as a driving member within each moving member 100. However, it should be understood that other magnetic salient pole structures may be employed without departing from the scope of the invention.

[0040] Reference Figure 8 A series of coils 50 are positioned along the length of track 10. Each moving element 100 includes at least one drive magnet 140 configured to interact with an electromagnetic field generated in the coils. Successive activation of the coils 50 establishes a moving electromagnetic field that interacts with the magnetic field generated by each permanent magnet 140 mounted on the moving element 100, and causes the moving element 100 to travel along track 10. A controlled voltage is applied to each coil 50 to achieve the desired moving element operation. The drive magnets 140 are mounted on the inner surface of the side member 102 and, when mounted to track 10, are spaced apart from the series of coils 50 extending along track 10. Figure 5 and Figure 7 As shown, an air gap 141 is provided between each set of drive magnets 140 and the coils 50 along the track 10. According to the illustrated embodiment, each coil 50 is placed in a channel 23 extending longitudinally along a surface of the track segment 12. The electromagnetic field generated by each coil 50 crosses the air gap 141 and interacts with the drive magnets 140 mounted to the moving member 100 to control the operation of the moving member 100.

[0041] Next, turn to Figure 9 This illustrates a portion of another exemplary freestanding trolley transport system for moving items or products. The system shown includes a track 310 composed of multiple segments 312. The moving component 100 shown is not as... Figure 1Instead of traveling along the side of the track, the movement 100 travels along a channel in track 310. This channel is defined by a bottom surface 316 and a pair of opposing sidewalls 313. Guide rails 314 are placed along the length of the upper surface of each sidewall 313 and are configured to support and engage the movement 100 as it travels along track 310. Power is delivered to section 312 via a DC bus 320 extending along track 310. The DC bus 320 includes a positive rail 322 and a negative rail 324, wherein any suitable voltage or potential is provided between the positive and negative rails to excite coil 50.

[0042] Figure 9 The system shown includes two straight sections 312, and an exemplary control system connected to an independent trolley transport system is also shown. A section controller 51 is provided within each track section 312 to regulate the current flowing to a coil 50, which forms part of the linear drive system in each track section 312. Optionally, each section controller 51 may also be responsible for all or part of the motion control of each moving part 100 as it travels along the corresponding section 312. According to one embodiment of the invention, the section controllers 51 may be mounted together in a control cabinet. Cables, multiple cables, individual conductors, or combinations thereof extend from the control cabinet to each section 12, 14 to deliver current to the coil 50 and receive feedback signals, for example, from a position sensor 150. In smaller systems, each section controller 51 and the industrial controller 200 may be included in a single control cabinet. Depending on the size and layout of the track 10, additional control cabinets may be distributed around the track, with a portion of the section controller 51 located within the control cabinet close to the track section 12, 14 it controls. The controller within the cabinet and the separate control cabinet are communicatively connected via network medium 160. Although in Figure 9 The block shown is an external part of track segment 312, but this illustration is for the purpose of showing the interconnection between controllers. According to another embodiment, each segment controller 51 is envisioned to be mounted in the lower part 319 of track segment 312. Each segment controller 51 communicates with adjacent segment controllers 51 and the central controller 170, which in turn communicates with the industrial controller 200. According to yet another embodiment, the central controller 170 can be removed, and its functions can be integrated into the segment controllers 51, the industrial controller 200, or a combination thereof, and each segment controller 51 can communicate directly with the industrial controller 200.

[0043] For example, the industrial controller 200 may be a programmable logic controller (PLC) configured to control elements of a processing pipeline arranged along track 10. The processing pipeline may be configured, for example, to fill and mark boxes, bottles, or other containers loaded onto or held by the moving part 100 as it travels along the pipeline. In other embodiments, the robotic assembly platform may perform various assembly and / or processing tasks on workpieces carried by the moving part 100. This exemplary industrial controller 200 includes: a power supply 202 having a power cable 204 connected, for example, to a public power supply; a communication module 206 connected to other controllers 51, 170 via a network medium 160; a processor module 208; an input module 210 receiving input signals 211 from sensors or other devices along the processing pipeline; and an output module 212 transmitting control signals 213 along the processing pipeline to controlled devices, actuators, etc. Processor module 208 can identify when movement 100 is needed at a specific location and can monitor sensors (e.g., proximity sensors), position switches, etc., to verify that movement 100 is in the desired position. Processor module 208 transmits the desired position of each movement 100 to central controller 170 or a corresponding section controller 51, wherein it receives commands to generate the required current in each coil 50 of the corresponding section controller 51 to control the movement of each movement 100. Optionally, industrial controller 200 may include a module that is in a slot in one of the base frames or embedded as a routine executed within processor module 208 to perform command generation, and processor module 208 may transmit a current command instead of the desired position to the section controller.

[0044] Also refer to Figure 10 Each module in the industrial controller 200 may include its own memory and processor, and is configured to execute one or more routines corresponding to the desired operation of the respective module. Figure 10 The illustrated portion of the industrial controller shows a first processor 207 and a first memory device 209 located in processor module 208, and a second processor 203 and a second memory 205 located in communication module 206. A backplane connects each module within the industrial controller 200, and backplane connectors 201a and 201b are shown connecting these two modules. Although shown as a direct connection between two modules, the backplane is a communication bus extending along the chassis of the industrial controller, and each backplane connector 201 for a module engages a complementary backplane connector on the communication bus, which aligns with a slot on the chassis into which the module is inserted. A communication interface 199 within communication module 206 is configured to connect to an industrial network 160.

[0045] The central controller 170 includes a processor 174 and a memory device 172. It is envisioned that the processor 174 and memory device 172 may each be a single electronic device or may be formed by multiple devices. The processor may be a microprocessor. Optionally, the processor 174 and / or memory device 172 may be integrated on a field-programmable array (FPGA) or application-specific integrated circuit (ASIC). The memory device 172 may include volatile memory, non-volatile memory, or a combination thereof. An optional user interface 176 may be provided to the operator to configure the central controller 170 and to load or configure the desired motion trajectory of the moving part 100 on the central controller 170. Optionally, this configuration may be performed via a remote device connected to the central controller 170 via a network and communication interface 178. It is envisioned that the central controller 170 and user interface 176 may be a single device, such as a laptop computer, notebook computer, tablet computer, or other mobile computing device. Optionally, the user interface 176 may include one or more individual devices, such as a keyboard, mouse, display, touchscreen, interface port, removable storage medium, or media reader, for receiving information from and displaying information to the user. Optionally, the central controller 170 and the user interface may be an industrial computer installed in a control cabinet and configured to withstand harsh operating environments. It is contemplated that other combinations of computing devices and peripheral devices, as will be understood in the art, may still be utilized in or incorporated into the system controller 170 and user interface 176 without departing from the scope of the invention.

[0046] The central controller 170 includes one or more programs stored in storage device 172 and executed by processor 174. The central controller 170 can receive instructions for coordinating with industrial processes or machines. In one aspect, referred to as “centralized” control, the central controller 170 can determine one or more motion trajectories for the moving part 100 to follow along track 10. The program executing on processor 174 communicates via network medium 160 with each segment controller 51 on each track segment. The central controller 170 can transmit command signals to the segment controller 51 in each track segment to control the excitation of coil 50. The central controller 170 can receive feedback signals corresponding to the identification and / or position of the moving part 100 along each track segment and control the movement of the moving part 100 directly from the central controller 170. In one embodiment of the invention, it is contemplated that the central controller 170 can be implemented within industrial controller 200 as part of a control program executed in processor module 208, or as a dedicated motion control module inserted into one of the slots of industrial controller 200.

[0047] In another aspect, referred to as “distributed” control, the central controller 170 can be configured to transmit desired motion commands, or portions thereof, from the central controller 170 to each of the section controllers 51. The motion command identifies one or more desired moving parts 100 to be positioned at or along each track section 312. The central controller 170 can distribute the motion command to each section controller 51 based on the moving part 100 located at or near the track section 312. The corresponding section controller 51 for each track section 312 can then determine the appropriate command signal for each moving part 100 and transmit that command signal to one or more electrical sections within each track section to control the excitation of the coil 50. By allowing the section controllers 51, rather than the central controller 170, to control the driving of each moving part 100 along the track 310, distributed control minimizes the amount of communication in the system. In one embodiment of the invention, it is envisioned that the central controller 170 may be implemented within the industrial controller 200 as part of a control program executed in the processor module 208, or as a dedicated motion control module inserted into one of the slots of the industrial controller 200.

[0048] The position feedback system provides the section controller 51 with information on the position of each moving part 100 along the length of track sections 12, 14. In one embodiment, the position feedback system may include an array of one or more position magnets 130 mounted to the moving part 100 and sensors 150 spaced apart along the track sections 12, 14. (Refer to again...) Figure 1 For simplicity, only a few position sensors 150 are shown along one track segment 12. It is envisioned that the position sensors 150 will continue along each track segment 12, 14 and over the entire length of track 10. The sensors 150 are positioned such that each of the position magnets 130 approaches the sensor as the moving part 100 passes over it. The sensors 150 are suitable magnetic field detectors, including, for example, Hall effect sensors, magnetic diodes, anisotropic magnetoresistive (AMR) devices, giant magnetoresistive (GMR) devices, tunneling magnetoresistive (TMR) devices, fluxgate sensors, or other microelectromechanical systems (MEMS) devices configured to generate an electrical signal corresponding to the presence of a magnetic field. The magnetic field sensors 150 output feedback signals, which are provided to a segment controller 51 for the corresponding track segment 12 on which the sensor 150 is mounted. The feedback signals can be analog signals provided to a feedback circuit 58, which in turn provides signals to a processor 52 corresponding to the magnet 130 passing over the sensor 150.

[0049] The section controller 51 also includes a communication interface 56, which receives communications from the central controller 170, adjacent section controllers 51 along the path, and the industrial controller 200. The communication interface 56 extracts data from message packets on the communication network and transmits the data to a processor 52 executing within the section controller 51. The processor may be a microprocessor. Optionally, the processor 52 and / or memory device 54 within the section controller 51 may be integrated on a field-programmable array (FPGA) or application-specific integrated circuit (ASIC). It is envisioned that the processor 52 and memory device 54 may each be a single electronic device or formed by multiple devices. The memory device 54 may include volatile memory, non-volatile memory, or a combination thereof. The section controller 51 receives the motion trajectory or desired motion of the moving member 100 and controls the moving member 100 along the track section 312 controlled by the section controller 51 using motion commands.

[0050] Each section controller 51 generates a switching signal to produce a desired current and / or voltage at each coil 50 in the track section 312, thereby achieving the desired movement of the moving part 100. The switching signal 72 controls the operation of the switching device 74 of the section controller 51. According to the illustrated embodiment, the section controller 51 includes a dedicated gate driver module 70, which receives command signals (e.g., desired voltage and / or current to be generated in each coil 50) from the processor 52 and generates the switching signal 72. Optionally, the processor 52 may incorporate the functions of the gate driver module 70 and directly generate the switching signal 72. The switching signal 72 is provided to a power conversion section in each track section 312, wherein each power conversion section includes a plurality of power switching devices 74. The switching devices 74 may be solid-state devices activated by the switching signal, including but not limited to transistors, thyristors, or silicon controlled rectifiers.

[0051] In one embodiment, the processor 52 may also receive feedback signals from sensors that provide indications of current operating conditions within the power section or of current operating conditions of coils 50 connected to the power section. According to the illustrated embodiment, the power section includes a voltage sensor 62 and a current sensor 60 at the input of the power section. The voltage sensor 62 generates a voltage feedback signal, and the current sensor 60 generates a current feedback signal, wherein each feedback signal corresponds to an operating condition on the main track 322. The section controller 51 also receives feedback signals corresponding to the operation of coils 50 connected to the power section. A voltage sensor 153 and a current sensor 151 are connected in series with coils 50 at each output of the power section. The voltage sensor 153 generates a voltage feedback signal, and the current sensor 151 generates a current feedback signal, wherein each feedback signal corresponds to an operating condition of the corresponding coil 50. The processor 52 executes a program stored in the memory device 54 to regulate the current and / or voltage supplied to each coil, and the processor 52 and / or the gate driver 70 generate a switching signal 72 that selectively enables / disables each of the switching devices 74 to achieve the desired current and / or voltage in each coil 50. The energized coil 50 generates an electromagnetic field that interacts with the drive magnet 140 on each moving member 100 to control the movement of the moving member 100 along the track segment 12.

[0052] Next, turn to Figure 11 Multiple sensors 360 can be mounted to each moving part 100 to monitor the state of the moving part during operation. According to the illustrated embodiment, each sensor 360 is mounted near one of the rollers 110 of the moving part 100. The sensor 360 is configured to generate a feedback signal 365 corresponding to a force applied to the corresponding roller 110 near which the sensor is mounted. The sensor 360 can be, for example, an accelerometer, a gyroscope, or a strain gauge. The force applied to the moving part 100 via the linear drive system will produce acceleration or deceleration of the moving part, which can be measured by an accelerometer. Forces experienced by the moving part 100 during travel (e.g., from the linear drive system, from friction along the guide rails, or from loads applied to the moving part 100) may cause certain rotational movements of the moving part 100, which can be measured by a gyroscope and are typically provided as roll, pitch, and yaw of the moving part. The force applied to the moving part 100 via the linear drive system may cause some deflection (expansion or contraction) of the material constituting the moving part 100 at the location where the sensor 360 is mounted, and this can be measured by a strain gauge. Therefore, sensors are placed at these locations to generate feedback signals corresponding to the forces applied to the moving part as seen at the sensor locations.

[0053] For example Figure 11As shown, it is envisioned that one or more coordinate systems can be defined for an independent trolley system. The first coordinate system 420 can be a primary reference coordinate system having a first x-axis (X), a first y-axis (Y), and a first z-axis (Z). This primary reference coordinate system can be used by all devices within the independent trolley system, or alternative coordinate systems can be used depending on application requirements. For example, each moving part 100 can have a moving part coordinate system 425 assigned to it. The origin of the moving part coordinate system 425 is located at the desired position relative to the moving part, and the second x-axis (X)... m The second y-axis Y m Second z-axis Z m The origin of the moving part coordinate system 425 is defined relative to the origin. Furthermore, each sensor 360 may have a sensor coordinate system 430 defined relative to its position. The origin of the sensor coordinate system 430 is located at the location where the sensor is mounted, and as shown, can be at the center of each sensor. A third x-axis is defined relative to the origin of the sensor coordinate system 430. s The third y-axis Y s and the third z-axis Z s The feedback signal 365 generated by each sensor can be assigned to one of the coordinate systems and transformed between coordinate systems according to the defined offset between the origins of the coordinate systems.

[0054] As previously indicated, according to one aspect of the invention, sensor 360 may be strain gauge 400. Also refer to... Figure 12 An exemplary circuit of sensor 360 as strain gauge 400 is shown. The illustrated embodiment is an electrical strain gauge constructed from a Wheatstone bridge 405 with four resistors. One resistor is a variable resistor, wherein the resistance varies with the strain present at that location. A conductive trace 404 applied to foil material 402 is mounted at the location of interest. If strain causes deformation at the location of interest, the foil 402 mounted at that location elongates or compresses due to the deformation. The elongation or compression of the foil 402 causes a similar change in the conductive trace 404 mounted on the foil 402. The elongation and compression of the conductive trace 404 will change the length and width of the conductive trace 404, thereby changing the resistance along the length of the trace 404. The voltage applied to the variable resistor is provided to amplifier 410, which in turn generates a feedback signal 365 corresponding to the strain present at that location. The changing resistance in strain gauge 400 will cause a changing output voltage V corresponding to the changing resistance, the measured strain, and the force applied at that location. out .

[0055] Refer again Figure 11Each sensor 360 generates a feedback signal 365 provided to the control circuit 370 mounted on the moving part 100. A housing may be provided around the control circuit 370 to protect it from contamination from the manufacturing environment. See also... Figure 13 The control circuitry 370 includes an interface 385 to receive each feedback signal 365. The interface 385 is envisioned to include an analog-to-digital (A / D) converter, amplifier, buffer, multiplexer, etc., to convert the voltage signal output from each sensor 360 into a digital value. Optionally, each sensor 360 may be configured to transmit data as a serial bit stream or as part of a data packet. The interface 385 may include a complementary communication interface to receive digital data and provide data values ​​to the controller 375.

[0056] Controller 375 is configured to assemble data received from each sensor into data packets for transmission from moving part 100. Controller 375 may be a microcontroller, microprocessor, field-programmable gate array (FPGA), application-specific integrated circuit (ASIC), etc. Controller 375 is envisioned to execute a series of instructions stored in a memory, either on the controller itself or an external device. Controller 375 may be configured to directly assemble data into data packets for transmission according to a desired communication protocol. Optionally, controller 375 may be configured to perform some initial processing, such as converting the measured strain into force (as described below). Controller 375 can then assemble the processed data into data packets for transmission according to a desired communication protocol.

[0057] Data packets are provided to a transmitter 390 and antenna 395 mounted on the moving part to transmit data from sensor 360 to a controller located remotely from the moving part 100. One or more receivers 350 (see also...) Figures 9 to 10 The receiver 350 can be positioned along track 10. In some applications, a single receiver 350 may have sufficient range and bandwidth to communicate with each moving part 100 traveling along track 10. In other applications, multiple moving parts 100 may generate a large number of data packets exceeding the bandwidth of a single receiver 350, or the distance traveled along track 10 may exceed the range of the receiver. Figure 9 As shown, each section controller 51 may include or have a receiver 350 connected to the section controller 51. Transmitter 390 sends a data packet containing a measured value from a feedback signal or a processed data value corresponding to the measured value to the receiver 350 of the section controller 51 closest to the moving part 100. Receiver 350 then sends the data to the section controller 51 or a central controller 170 or industrial controller 200 communicating with the section controller 51.

[0058] The control circuit 370 also includes a power supply circuit 380 mounted on the moving part 100. The power supply circuit 380 is configured to power the sensor 360, the controller 375, and the transmitter 390. According to one embodiment of the invention, the power supply circuit 380 may include a battery configured to be powered. One or more voltage regulators receive power from the battery and supply regulated DC voltages, such as 3.3VDC, 5VDC, 12VDC, 24VDC, any other desired DC or AC voltage, or combinations thereof. Optionally, the moving part 100 includes a pickup device configured to travel with the moving part and receive power from a power source external to the moving part. The power source may be, for example, a power supply coil or power supply rail that receives current that generates an electromagnetic field. The pickup device may be a coil mounted on the moving part, wherein a secondary current is induced when the moving part travels through an electromagnetic field. The secondary current is provided to the voltage regulator circuitry to provide the desired voltage to each device on the moving part, or to an energy storage device to store excess energy not needed by the device. If more power is needed than that supplied by the pickup device, the energy stored in the energy storage device can supplement the energy supplied by the pickup coil.

[0059] Feedback signal 365 is sent to a controller located away from the moving part 100. The controller may be a section controller 51 that controls the section of the track where the moving part is located. Alternatively, the controller may be a central controller 170 for a stand-alone trolley system or an industrial controller 200 that controls the operation of the track and external actuators. It is also envisioned that dedicated receivers 350 or more may be positioned around the track 10 to receive feedback signal 365 from each moving part 100, and that dedicated receivers 350 may relay information to one of the controllers. The feedback signal may be used to monitor bearing wear and / or predict the remaining life of the bearings at each roller 110 on the moving part.

[0060] During operation, the forces applied to the moving part 100 and the operating conditions of the moving part are monitored at multiple locations by sensors 360 mounted at each location on the moving part. Each sensor 360 mounted on the moving part 100 generates one or more feedback signals 365 corresponding to the forces applied to the moving part 100. Each sensor 360 may be a single-axis sensor, generating a feedback signal 365 corresponding to one of the axes of the sensor coordinate system 430, or each sensor 360 may be a multi-axis sensor, generating feedback signals 365 corresponding to two or all three axes of the sensor coordinate system 430.

[0061] According to one embodiment of the invention, sensor 360 is strain gauge 400, which is configured to monitor the deflection of moving member 100 at the location where the strain gauge is mounted. Feedback signal 365 corresponding to the strain measured by the sensor can be used to determine the force experienced by moving member 100 at the sensor location. Using Equation 1, the measured strain can first be converted into stress experienced by moving member 100. Young's modulus is a material property of moving member 100 and is a known value based on the moving member's construction. The value of Young's modulus for each moving member 100 can be stored in the memory of one of the controllers and used to convert the measured strain into a stress value.

[0062] σ n =Eε n (1)

[0063] in:

[0064] σ n The stress is determined at sensor "n".

[0065] ε n It is the strain measured at sensor "n", and

[0066] E is the Young's modulus of the material at the location of sensor "n".

[0067] After determining the stress using Equation 1, the stress can be converted into the force experienced by the moving part at the sensor location using Equation 2. Multiplying the previously determined stress value by the cross-sectional area of ​​the moving part at the sensor location determines the force observed at the sensor location.

[0068]

[0069] in:

[0070] σ n The stress is determined at sensor "n".

[0071] F n The force observed at the location of sensor "n" is...

[0072] A is the cross-sectional area of ​​the moving part at position "n".

[0073] After determining the forces present at each bearing, a controller can be used to monitor the real-time performance of the moving part 100 or track its performance over time. According to one aspect of the invention, the controller monitoring performance is envisioned as a segment controller 51, which monitors the performance of each moving part 100 as it travels along the segment controller 51. The segment controller 51 monitors the forces in real time and can generate a warning or fault message to be sent to the central controller 170 or the industrial controller 200 if the forces exceed a predetermined threshold. Optionally, the segment controller 51 can store the observed force values ​​for each moving part in its memory 54. Initial values ​​can be stored during commissioning, and changes in these values ​​over time can be monitored. When the difference between the measured force values ​​(observed under consistent operating conditions) exceeds a predetermined threshold, the segment controller 51 can generate a warning or fault message to be sent to the central controller 170 or the industrial controller 200.

[0074] According to another aspect of the invention, the controller for monitoring performance can be a central controller 170 or an industrial controller 200. If a receiver 350 is connected to each segment controller 51, the segment controller 51 can be configured to retransmit data packets containing data from the sensor 360 to the central controller 170 or the industrial controller 200. Alternatively, the receiver 350 can be directly connected to the central controller 170 or the industrial controller 200, and the corresponding controller can directly receive data from the sensor 360 from each moving part 100. The central controller 170 or the industrial controller 200 can be configured to store data from each of the plurality of moving parts 100 in the independent trolley system. The controller can monitor the data in real time or over a period of time in a manner similar to that discussed above for each segment controller.

[0075] A controller configured to monitor the performance of a moving part 100 in an independent trolley system can detect multiple different operating conditions based on feedback signals from a sensor 360. According to a first aspect of the invention, the controller can be configured to determine misalignment between adjacent track segments 12. When each moving part 100 transitions between first track segments 12, 14 and second track segments 12, 14 (where the second track segment is adjacent to the first track segment), the operating performance between the track segments should change little or no. Ideally, each track segment is manufactured identically to each other, and the operating performance does not change when the moving part transitions between track segments. However, variations do exist between adjacent track segments due to manufacturing tolerances, assembly tolerances, etc. In some cases, adjacent track segments 12, 14 may have some misalignment between the two segments. When the moving part 100 transitions between misaligned segments, the moving part will experience a rapid increase in acceleration and strain. If the acceleration and / or strain rises sharply beyond a predefined threshold, the controller can generate a warning or fault message to alert technicians to misalignment between adjacent track sections.

[0076] According to another aspect of the invention, the controller can be configured to determine the remaining life of the bearing on each roller 110. Each roller 110 may include a ball bearing, roller bearing, or other suitable bearing, depending on application requirements. The controller can be configured to monitor values ​​detected by the strain gauge 400 to determine the force applied to the bearing and also provide an indication of the remaining bearing life. (Refer to...) Figures 14 to 16 The orientation of track 10 may affect bearing life. See also... Figure 6 and Figure 11 It can be observed that the rollers 110 engage different portions 26 and 28 of the guide rail 20 with different orientations. The combination of the orientation of each roller 110 on the moving member 100 and the orientation of the track 10 will cause different rollers 110 to withstand a greater gravitational force g than other rollers. Figure 14 and Figure 16 As shown, when the track is installed in a vertical orientation, in Figure 6 The horizontally oriented roller 110 will experience a greater force due to gravity g than the vertically oriented roller 110 in the same diagram. For example... Figure 15 As shown, when the track is installed in a horizontal orientation, Figure 6The roller 110, which is vertically oriented and located below the moving member 100, engages the upper surface of the portion 28 of the guide rail 20 that protrudes from the track section and experiences the greatest force due to gravity g. Without any other force applied, the bearings on the roller 110, which experiences the greater force due to gravity, will wear faster than the bearings on the other rollers 110. Measurements of the strain observed on the moving member for each roller 110 provide an indication of the force experienced by each roller 110, and consequently, an indication of the force experienced by the bearing on each roller.

[0077] The controller can monitor the condition of rollers 110, observe maximum forces, and determine the remaining life of each roller and / or the bearing on each roller. In addition to the forces generated by gravity, forces due to the acceleration and load of the moving part 100 will also be applied to it. The controller's memory may include a lookup table corresponding to the expected life of the bearings due to the various applied forces. The controller can maintain records of the operation of each moving part 100 and the measured forces to determine the remaining life of each bearing. When the remaining life drops below a first threshold, a warning message can be generated to alert technicians that preventative maintenance is needed. If the remaining life drops below a second threshold, a second warning message or fault message indicating that the bearing and rollers 110 may be about to fail can be generated.

[0078] According to another aspect of the invention, the orientation of the track can be determined by monitoring the feedback signal 365 from each sensor 360. When the moving part is stationary, the force generated by gravity will produce a reading from the accelerometer that is -9.8 m / s² in the direction of gravity. 2 The corresponding reading. If the multi-axis accelerometer is mounted on the moving part 100, the controller can detect -9.8 m / s along its path based on the accelerometer. 2 The axis of the reading determines the orientation of track 10.

[0079] According to another aspect of the invention, the feedback signal 365 from the sensor 360 can be used to determine the presence of a payload on the moving member 100. Referring again... Figure 11The illustrated movable member 100 includes an opening 101 on its upper surface. The opening 101 is envisioned to have a threaded inner surface, and a fastener (not shown) can be secured to the opening 101 using bolts, screws, or other threaded fasteners. The fastener may be a platform on which a load can be placed. Alternatively, the fastener may include a clamp, vacuum member, jig, or other such clamping member to secure the load to the movable member 100. The weight of the payload mounted on the movable member 100 will exert a downward force on the top member 104 of the movable member and a torque on the bolts 105 that secure the top member 104 to the side member 102. This force can cause deflection on the top member 104 and / or the side member 102, and particularly near the edge of each member where the top and side members intersect. Strain gauges mounted near each roller 110 along the top of the side member 102 or on the roller 110 along the inner side of the top member 104 will detect the deflection caused by the presence of the load on the movable member 100. Furthermore, a larger load will result in a larger deflection. A controller (section controller 51, central controller 170, or industrial controller 200) configured to receive feedback signals 365 from strain gauge 400 can use a lookup table or perform calculations to determine the weight of the effective load based on the additional strain measured when the load is present. Therefore, each strain gauge can be used not only to detect the presence of a load on each moving part, but also to determine the amount of load present on the moving part 100.

[0080] In another aspect of the invention, feedback signal 365 can be used to monitor wear in the independent trolley system. During commissioning or early operation of the moving part 100, a first value of feedback signal 365 can be stored during a specific operation. For example, as the moving part 100 travels through a specific location, strain, stress, or acceleration can be monitored and stored in memory. Optionally, multiple values ​​of feedback signal 365 can be stored as the moving part 100 travels along the length of the track. During subsequent operation of the moving part 100, measurements of strain, stress, or acceleration observed in feedback signal 365 can be compared with the stored values. Changes in feedback values ​​over time exceeding a predetermined threshold can indicate excessive wear or damage to the moving part 100 or the track segments 12, 14 on which the moving part 100 travels. Warning or fault messages can be generated to alert technicians to changes in values ​​and the moving part 100 and / or track segments 12, 14 on which the values ​​have changed, thereby providing an indication of wear or damage in the independent trolley system.

[0081] Another aspect of the invention allows the controller to determine improvements to the motion trajectory performed by the moving parts 100. As described above, each moving part 100 is controlled by a linear drive system to travel along a track. An industrial controller 200, a central controller 170, a section controller 51, or a combination thereof are operable to generate the motion trajectory of each moving part. The section controller 51 controls the operation of coils 50 spaced apart along the track to achieve the desired motion of each moving part 100. As the moving part 100 travels along the track 10, feedback signals 365 from each sensor 360 can be periodically stored to obtain a corresponding measured acceleration trajectory, velocity trajectory, stress trajectory, or strain trajectory corresponding to the motion trajectory generated by the controller. One of the controllers analyzes the feedback signals 365 stored in the memory to identify the maximum value of acceleration, velocity, stress, or strain. This maximum value of the measured feedback can be compared with a first predetermined threshold. Optionally, the controller can analyze the feedback signals 365 to identify the duration along the trajectory during which the value exceeds a second predetermined threshold. When the measured performance of the moving part 100 exceeds an instantaneous maximum value or when the measured performance of the moving part 100 exceeds a second maximum value for a predetermined duration, the controller can generate a message to alert the technician about the performance. Optionally, the controller can also be configured to adjust the generated motion trajectory to reduce the maximum value or the sustained value over a shorter period, thereby reducing the total stress or total strain on the system.

[0082] It should be understood that the invention is not limited in its application to the details of the construction and arrangement of the components described herein. The invention can have other embodiments and can be practiced or implemented in various ways. All the foregoing variations and modifications are within the scope of the invention. It should also be understood that the invention disclosed and defined herein extends to all alternative combinations of two or more individual features mentioned in or apparent from the text and / or drawings. All these different combinations constitute various alternative aspects of the invention. The embodiments described herein illustrate the best mode known for carrying out the invention and will enable others skilled in the art to utilize the invention.

[0083] Various embodiments have been described in the foregoing specification with reference to the accompanying drawings. However, it will be apparent that various modifications and alterations can be made to these embodiments, and other embodiments can be implemented, without departing from the broader scope of the invention as set forth in the appended claims. Therefore, the specification and drawings should be considered illustrative rather than restrictive.

Claims

1. A system for monitoring the status of moving parts in an independent trolley system, wherein, The independent trolley system includes multiple moving parts configured to travel along a track, and the system includes: A plurality of sensors are mounted on the moving part, wherein each of the plurality of sensors is configured to generate at least one feedback signal corresponding to the operating conditions of the moving part; A control circuit mounted on the moving part, wherein the control circuit is configured to receive the at least one feedback signal from each of the plurality of sensors and generate a data packet, the data packet including a value corresponding to the operating condition monitored from each of the plurality of sensors; and A transmitter mounted on the movable component, wherein the transmitter is configured to receive the data packet from the control circuitry and transmit the data packet to a receiver located outside the movable component. in: The moving component includes multiple bearings; Each of the plurality of sensors is installed near one of the plurality of bearings; and The at least one feedback signal corresponds to the force present on the corresponding bearing near each of the plurality of sensors.

2. The system according to claim 1, wherein, At least one of the plurality of sensors is a strain gauge, and at least one of the plurality of sensors is an accelerometer.

3. The system according to claim 1, wherein, Each of the plurality of sensors is a strain gauge.

4. The system of claim 1 further includes a controller configured to receive the at least one feedback signal from each of the plurality of sensors and determine the remaining life of the corresponding bearing in which each of the plurality of sensors is mounted.

5. The system according to claim 1, further comprising: A battery mounted on the movable component, wherein the battery is configured to provide power to each of the plurality of sensors, the control circuitry, and the transmitter; and At least one voltage regulator circuit is mounted on the movable part and configured to deliver power from the battery to each of the plurality of sensors, the control circuit, and the transmitter.

6. The system according to claim 1, further comprising: At least one power pickup device mounted on the moving member, wherein the power pickup device is configured to travel with the moving member and receive power from a fixed power source installed along the track of the independent trolley system; and At least one voltage regulator circuit is mounted on the movable part and configured to deliver power from the at least one power pickup device to each of the plurality of sensors, the control circuit, and the transmitter.

7. The system according to claim 1, wherein, The operating condition corresponding to the at least one feedback signal is selected from one of the following: The misalignment between the first segment and the second segment of the track, with the second segment positioned adjacent to the first segment; The remaining life of the bearing of at least one roller mounted on the moving part; The orientation of the track; The presence of a payload on the moving component; Determining the wear on the moving part or the track; and The trajectory of the moving component.

8. A system for monitoring the status of multiple bearings on a moving part in an independent trolley system, the system comprising: A plurality of sensors are mounted on the moving part, wherein each of the plurality of sensors is mounted near one of the plurality of bearings on the moving part, and each of the plurality of sensors is configured to generate at least one feedback signal corresponding to the operating conditions of the corresponding bearing in which each of the plurality of sensors is mounted; A control circuit mounted on the moving part, wherein the control circuit is configured to receive the at least one feedback signal from each of the plurality of sensors and generate a data packet including the value of the at least one feedback signal corresponding to the operating conditions of the corresponding bearing monitored from each of the plurality of sensors; and A transmitter mounted on the movable component, wherein the transmitter is configured to receive the data packet from the control circuit and transmit the data packet to a receiver located outside the movable component.

9. The system according to claim 8, wherein, At least one of the plurality of sensors is a strain gauge, and at least one of the plurality of sensors is an accelerometer.

10. The system according to claim 8, wherein, Each of the plurality of sensors is a strain gauge.

11. The system according to claim 10, wherein, The at least one feedback signal corresponds to the force present on the corresponding bearing near each of the plurality of sensors.

12. The system of claim 11, further comprising a controller configured to receive the at least one feedback signal from each of the plurality of sensors, and configured to determine the remaining life of the corresponding bearing in which each of the plurality of sensors is mounted.

13. The system according to claim 8, further comprising: A battery mounted on the movable component, wherein the battery is configured to provide power to each of the plurality of sensors, the control circuitry, and the transmitter; and At least one voltage regulator circuit is mounted on the movable part and configured to deliver power from the battery to each of the plurality of sensors, the control circuit, and the transmitter.

14. The system according to claim 8, further comprising: At least one power pickup device mounted on the moving member, wherein the at least one power pickup device is configured to travel with the moving member and receive power from a fixed power source installed along the track of the independent trolley system; and At least one voltage regulator circuit is mounted on the movable part and configured to deliver power from the power pickup device to each of the plurality of sensors, the control circuit, and the transmitter.

15. A method for monitoring the state of a moving part in an independent trolley system, the method comprising the steps of: At least one feedback signal is generated from each of a plurality of sensors mounted on the moving part, wherein the at least one feedback signal corresponds to the operating conditions of the moving part; The control circuit mounted on the moving part receives at least one feedback signal from each of the plurality of sensors; The control circuit generates a data packet, wherein the data packet includes at least one value corresponding to the operating condition monitored by each of the plurality of sensors; and The data packet is transmitted from a transmitter mounted on the moving part to a receiver located outside the moving part. in: The moving component includes multiple bearings; Each of the plurality of sensors is installed near one of the plurality of bearings; and The at least one feedback signal corresponds to the force present on the corresponding bearing near each of the plurality of sensors.

16. The method of claim 15, further comprising the step of receiving the data packet at a controller located remotely from the location of the moving part.

17. The method according to claim 15, wherein, Each of the plurality of sensors is a strain gauge.

18. The method of claim 15, further comprising the step of: Using a controller configured to receive the at least one feedback signal from each of the plurality of sensors, the remaining life of the corresponding bearing in which each of the plurality of sensors is mounted is determined.

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