Electromagnetic motor conveyor track section with modular electronics

Abstract

An electromagnetic motor, such as a linear motor or planar motor, can be used in a conveyor system. The control electronics of the electromagnetic motor conveyor system can include a backplane arranged in a track section that has a coil power connection for connecting to a power source providing electrical power to the plurality of coils of the motor, and a plurality of coil driver board power connections. A plurality of coil driver boards that can control power delivered to the plurality of coils with each of the coil driver boards individually removable from the track section.

Description

ELECTROMAGNETIC MOTOR CONVEYOR TRACK SECTION WITH MODULAR ELECTRONICSRELATED APPLICATIONS

[0001] The current application claims priority to US Provisional Patent Application 63 / 570,388 filed March 27, 2024 and entitled “Electromagnetic Motor Conveyor Track Section with Modular Electronics,” the entire contents of which are incorporated herein by reference in their entirety for all purposes.TECHNICAL FIELD

[0002] The current description relates to track sections for an electromagnetic motor conveyor, and in particular to modular electronics for the track sections.BACKGROUND

[0003] A linear motor conveyor system uses electromagnetic coils arranged along a track to controllably move a shuttle on the track. The track may be formed into a number of separate sections, with coils and electronics for powering the coils in each section. The number of coils arranged along the track determines, at least in part, the precision of the movement control of the shuttle. That is, increasing the number of coils in the same length of track can allow more precise movement control of the shuttle. Further, by increasing the voltage and current supplied to the coils can increase the force that the coils can apply to the shuttle and as such can increase the possible acceleration, and speed, of the shuttle.

[0004] Increasing the number of coils, and their power, in a track section requires increased electronics for controlling the increased coil density as well as possibly increased cooling capacity in order to cool both the coils and the electronics. The increased electronics and the cooling requirements can be difficult to provide within the confines of a track section without developing specific electronics and cooling solutions.BRIEF DESCRIPTION OF THE DRAWINGS

[0005] Further features and advantages of the present disclosure will become apparent from the following detailed description, taken in combination with the appended drawings, in which:

[0006] FIG. 1 depicts a linear motor conveyor system;

[0007] FIG. 2A depicts a top view of a block diagram of a linear motor conveyor system;

[0008] FIG. 2B depicts a front view of the linear motor conveyor system of FIG. 2A;

[0009] FIG. 3A depicts a cross-sectional view of the linear motor conveyor system of FIG. 2B;

[0010] FIG. 3B depicts details of the modular electronics of a track section of a linear motor conveyor system;

[0011] FIG. 4 depicts further modular electronics of a track section of a linear motor conveyor system;

[0012] FIGs. 5A, 5B depict rear views of a track section of a linear motor conveyor system;

[0013] FIG. 5C depicts a front view of the track section of the linear motor conveyor system of FIGs. 5A, 5B;

[0014] FIG. 6 depicts the modular electronics of the track section of FIGs. 5A, 5B;

[0015] FIG. 7 depicts a section of the modular electronics of FIG. 6;

[0016] FIG. 8 depict backplane sections of the modular electronics of FIG. 6;

[0017] FIG. 9 depicts details of a coil driver board;

[0018] FIG. 10 depicts a cross-section view of the track section;

[0019] FIG. 11 depicts details of a gateway board;

[0020] FIG. 12 depicts a cross-section view of a track section and electronics;

[0021] FIG. 13A depicts a rear view of a track section;

[0022] FIG. 13B depicts a cross-sectional of the track section of FIG. 13A;

[0023] FIG. 14 depicts a cross-section view of the track section with electronics;

[0024] FIG. 15 depicts a robotic arm with a linear motor track section;

[0025] FIG. 16 depicts an illustrative embodiment of a planar motor conveyor system using modular electronics; and

[0026] FIG. 17 depicts an implementation of a planar motor conveyor system using modular electronics.DETAILED DESCRIPTION

[0027] In accordance with the present disclosure there is provided a section for an electric motor conveyor system comprising: a plurality of electromagnetic coils of the electric motor arranged adjacent a shuttle surface of the track section; a plurality of electrical connections to the plurality of coils; at least one backplane comprising: a coil power connection for connecting to a power source providing electrical power to the plurality of coils; a plurality of coil driver board power connections; and a plurality of coil driver boards controlling power delivered to the plurality of coils, each of the coil driver boards individually removable from the track section.

[0028] In a further embodiment of the section, the plurality of electrical connections to the plurality of coils are located on the at least one backplane.

[0029] In a further embodiment of the section, the plurality of electrical connections to the plurality of coils are located on respective ones of the plurality of coil driver boards.

[0030] In a further embodiment of the section, each of the plurality of coil driver board power connections provide a connection to a respective coil driver board between the coil power connection and the electrical connection to a respective coil controlled by the respective coil driver board.

[0031] In a further embodiment of the section, the at least one backplane further comprises: a communication connection providing a connection to control signals; and a plurality of board communication connections.

[0032] In a further embodiment of the section, the power connection and the board communication connection of a respective coil driver board are provided as a single physical connectors.

[0033] In a further embodiment of the section, the power connection and the board communication connection of a respective coil driver board are provided as separate physical connectors.

[0034] In a further embodiment of the section, at least one of the power connection and the board communication connection of a respective one of the plurality of coil driver boards provide a mechanical interface for mounting the respective coil driver board to the backplane.

[0035] In a further embodiment of the section, the plurality of coil driver boards are secured in place by the mechanical interface.

[0036] In a further embodiment of the section, the plurality of coil driver boards are secured in place by removable panel of the track section.

[0037] In a further embodiment of the section, the plurality of coil driver boards are accessible from an opening in a side of the track section.

[0038] In a further embodiment of the section, the plurality of coil driver boards are individually installable and removable from the opening.

[0039] In a further embodiment of the section, the power connection and the board communication connection provide the only electrical connections that need to be connected or disconnected in order to install or remove a respective coil driver board from the track section.

[0040] In a further embodiment of the section, each of the coil driver boards further comprise respective control circuitry controlling power delivered through the releasable power connection to a respective subset of the plurality of coils according to control signals.

[0041] In a further embodiment of the section, each of the coil driver boards controls power delivered to at least one coil.

[0042] In a further embodiment of the section, each of the coil driver boards controls power delivered to between 1 and 10 coils.

[0043] In a further embodiment of the section, each of the coil driver boards further comprise a respective thermal cooling component for cooling at least a portion of the control circuitry of the respective coil driver board, each of the respective thermal cooling component coupled to a section cooling component.

[0044] In a further embodiment of the section, the respective thermal cooling component of the respective coil driver boards comprises a cooling strip and the section cooling component comprises a thermal heat sink exposed to an exterior environment.

[0045] In a further embodiment of the section, the thermal heat sink comprises a removable panel of the track section covering a plurality of the coil driver boards.

[0046] In a further embodiment of the section, the at least one backplane comprises: a power backplane comprising the electrical connections to the plurality of coils, the coil power connection and the power connections of the plurality of coil driver board connections; and a communication backplane comprising the communication connection and the board communication connection of the plurality of coil driver board connections.

[0047] In a further embodiment of the section, the power backplane is formed as two or more separate power backplane printed circuit boards (PCBs) with inter-board power connections connecting the two or more separate power backplane PCBs.

[0048] In a further embodiment of the section, the communication backplane is formed as two or more separate communication backplane printed circuit boards (PCBs) with inter-board communication connections connecting the two or more separate communication backplane PCBs.

[0049] In a further embodiment of the section, the backplane further comprises at least one of: an output coil power connection for connecting to an adjacent track section; and an output communication connection for connecting to an adjacent track section.

[0050] In a further embodiment of the section, the backplane further comprises a plurality of thermistors mounted to a side of the backplane facing the electromagnetic coils, each of the thermistors in contact with a portion of the track section in order to monitor a temperature of the track section.

[0051] In a further embodiment of the section, the at least one backplane is mounted within an internal cavity of the track section behind the plurality of electromagnetic coils.

[0052] In a further embodiment of the section, each of plurality of coil driver boards are arranged within the internal cavity and are approximately perpendicular to the at least one back plane.

[0053] In a further embodiment of the section, each of the plurality of coil driver boards are arranged approximately parallel to each other.

[0054] In a further embodiment of the section, the section is a track section of a linear motor conveyor system.

[0055] In a further embodiment of the section, the section is a section of a planar motor conveyor system.

[0056] In accordance with the present disclosure there is further provided a linear motor conveyor system comprising: at least one lineartrack section comprising a section as described above; and a plurality of shuttles arranged on the at least one track section, respective positions of each of the plurality of shuttles are independently controllable along 1 axis of the at least one linear track section

[0057] In a further embodiment of the linear motor conveyor system, the at least one linear track section comprises a plurality of interconnected track sections.

[0058] In a further embodiment of the linear motor conveyor system, the plurality of interconnected track sections are arranged to form a closed loop.

[0059] In a further embodiment of the linear motor conveyor system, the plurality of interconnected track sections are arranged in an open-ended configuration.

[0060] In a further embodiment of the linear motor conveyor system, the system further comprises a robotic arm having at least one degree of freedom, wherein the at least one linear track section is connected at an effector end of the robotic arm.

[0061] In accordance with the present disclosure there is further provided a planar motor conveyor system comprising: a plurality of interconnected sections arranged in a planar configuration, each of the sections comprising a section as described above; and a plurality of shuttles arranged on the planar configuration of interconnected sections, respective positions of each of the plurality of shuttles on the interconnected sections independently controllable about 2 axes.

[0062] In a further embodiment of the planar motor conveyor system, the shuttle is independently controllable along between 2 and 6 axes.

[0063] A track section of a linear motor section conveyor uses a modular electronic design that allows for a spatially efficient design that facilitates increased coil density within a track section. The modular design uses a backplane to distribute power to a plurality of coil driver boards that control power distribution to a subset of coils in the track section. Each coil driver board can be mounted approximately perpendicular to the backplane to provide increased electronics density within the track section. Further, the modular design can easily scale to increase the density of the coils without requiring the complete redesign of the electronics. As described in further detail below, the coil driver boards may be individually removed from the backplane without any significant disassembly of the track section or electronics. Further details of the track sections with modular electronics are described further below.

[0064] FIG. 1 depicts a linear motor conveyor system. The conveyor system 100 comprises a plurality of track sections, including one or more straight sections 102a..102d (referred to collectively as straight sections 102) and curved sections 104a, 104b (referred to collectively as curved sections 104) connected together. As depicted in FIG. 1 the straight sections 102 and curved sections are arranged in order to provide a continuous loop of track. There are a wide range of possible configurations of a conveyor system that include both inside and outside corner sections of different radiuses, straight sections, etc. The conveyor system may be configured as a closed loop of track sections or may be open ended.

[0065] Regardless of the exact configuration of the track sections, one or more moveable shuttles, or sometimes referred to as shuttles, are mounted on the track one of which is indicated by reference number 106. The track sections house electromagnetic coils which are controlled to provide a motive force to the individual shuttles. By controlling the power supplied to individual coils, it is possible to independently control the motion of the plurality shuttles on the track. Although not described in detail herein, the conveyor system includes a positioning system that can determine the location of individual shuttles on the track.

[0066] Each track section has a number of coils arranged along the track section in order to drive the shuttles. Increasing the number of coils in a section may be desirable as it can provide a smaller pitch between shuttles. As the shuttle-to-shuttle pitch decreases, the size of the coilsmust also decrease, and so the coil density increases, in order to allow independent control of the shuttles. The increased coil density can allow a lower shuttle-to-shuttle pitch of a linear motor conveyor system. Further, the increased coil density, as well as the compact modular electronics associated with the coils, can be used in other applications, including for example in planar motor conveyor systems that allow multiple degrees of freedom for the movement of shuttles, including translations along 2 orthogonal axis ad rotations. While increasing the number of coils may have various advantages, there may be downsides as well, including an increased cost as a result of the increased number of coils and associated components. It may not be necessary to provide the increased coil density in all applications. The modular electronic design described further below allows the coil density used on track sections to be easily changed, either increasing or decreasing the density of the coils, without having to significantly modify the designs of the electronics or other components of the track section.

[0067] FIG. 2A depicts a top view of a block diagram of a linear motor conveyor system. The system 200 is depicted as a linear motor conveyor system in which one or more shuttles are moved along a track under electromagnetic power. The track may be formed from a number of connected track sections including, straight track sections 202, and curved sections 204. It will be appreciated that the particular track configuration depicted in FIG. 2A is only illustrative and other configurations are possible. The shuttle 206 can be controllably moved along the track in order to move a part or component through one or more processing steps or stations.

[0068] FIG. 2B depicts a front view of the linear motor conveyor system of FIG. 2A. FIG. 2B depicts schematically the plurality of coils 208a..208n (referred to collectively as coils 208) arranged on the track section. Controlling the power supplied to individual coils 208 controls the motion of the shuttles on the track. The electronics for controlling the individual coils is generally housed within the track sections. The modular electronics described herein provides a spatially efficient solution that allows the electronics to be fit in a volume of the track section behind the coils 208. Details of the internals of the track section and the modular electronics are depicted in FIG. 3A.

[0069] FIG. 3A depicts a cross-sectional view of the linear motor conveyor system of FIG. 2B. FIG. 3B depicts details of the modular electronics of a track section of a linear motor conveyor system. As depicted, the shuttle 206 comprises a body 310 that supports a magnet array 312. The interaction between the magnet array 312 and the magnetic field generated by the coils208a provides the motive force for moving the shuttle along the track section 202. A plurality of bearings 314a, 314b, may be mounted to the shuttle in order maintain a distance between the shuttle 206 and track 202. The bearings 314a, 314b may be provided in various ways including as wheels.

[0070] Within the track section, the plurality of coils are mounted within the track section adjacent a shuttle surface in order to be in close proximity to the shuttles and their magnet arrays. Each coil, such as coil 208a, comprises a winding of a conductor and is driven by applying power to the coil. The power supplied to the coil, whether the voltage or the current, can be varied in order to control the resulting force applied to the shuttle 206. Driving of each coil is controlled individually. A backplane 316 is mounted within the track section. The backplane 316 includes a connection 318 to a power source that can supply the power for driving all of the coils 208a of the track section. Each of the coils is electrically connected to the backplane via a respective coil connection 320. FIG. 3B depicts a single conductor connecting the coil 208a to the coil connection 320 for simplicity of the drawing; however, each coil connection 320 comprises two electrical connections for the positive and negative electrical connections to the coils as depicted in FIG. 3A. In order to control the power supplied to the coil, each coil is associated with a coil driver board 322. As depicted in FIG. 3B there are a plurality of coil driver boards 322 that are individually connected to the backplane 316. The individual coil driver boards 322 are generally arranged perpendicular to the backplane 316 and parallel to each other. The backplane 322 includes a plurality of power connections 324 for connecting each of the coil driver boards 322 to the backplane. The power connections 324 allow each coil driver board 322 to control the power, supplied from the power source connection 318, that is delivered to the respective coil. In addition to providing the required electrical connections for controlling the coil’s power, the power connection 324 may also provide a mechanical interface for mounting the coil driver boards to the backplane.

[0071] Each of the coil driver boards 322 include control circuitry 326 that controls the electrical power supplied to respective coils. The control circuitry may include various electronic components for driving the electrical coils as well a processor or microprocessor for generating control signals for the various electronic components. The microprocessor may receive instructions or signals from external components that specify how the coils should be driven. The instructions may be provided over wired and / or wireless communication channels (notshown). Regardless of the control signals, it will be appreciated that the plurality of individual coil driver boards 322 are capable of driving the associated coils in order to move the shuttles as required or desired.

[0072] The coil driver boards may be secured to the backplane 316 in various ways. For example, the power connection 324 may provide the mechanical connection that connects the coil driver board to the backplane 316 can include a releasable lock that secures the coil driver board to the backplane. Additionally or alternatively, the coil driver board may be secured in place by a force applied by a rear cover or panel 328 that can be secured to the track section, such as be screws or bolts, although any appropriate mechanism may be used to secure the rear cover. The rear cover 328 may include one or more features 332a, 332b that contact the coil driver board and push the board into the connector or the backplane.,

[0073] One or more electrical components of the control circuit 326 may generate heat. In order to dissipate the heat generated by coil driver boards, each board may have an associated cooling component 334 that can be thermally coupled to an external cooling component to dissipate the heat from the coil driver boards into an external environment. The cooling components 334 of the individual coil driver boards may comprise for example heat transfer materials, a heat pipe, or heat transfer components, that are thermally coupled to one or more heat producing components on the coil driver boards. The external cooling component may comprise a heat sink that is exposed to the external environment. The heat sink may be provided by the rear cover panel 328 which may formed from a heat transfer material such as aluminum or copper.

[0074] The rear cover may cover an opening in the rear of the track. The cover panel can be removed in order to provide easy access to the coil driver boards, each of which can be easily removed from the backplane. The modular design allows individual coil driver boards to be removed and replaced if a board is damaged or malfunctions. Additionally or alternatively, the coil driver boards can be replaced with different versions to provide different features or functionality. For example, it could be possible to provide a high power coil driver board version for certain applications, and low power coil driver board versions for other applications. Although depicted as being removed from the back of the track section, it is possible for openings to be provided on the top or bottom of the track section and have the coil driver boards removable from the top or bottom openings. Such an arrangement may require repositioningof the backplane within the track section so that the perpendicularly mounted coil driver boards can be removed from the opening.

[0075] The above has described a modular electronics for a track section of a linear motor conveyor. The arrangement of the backplane and separate coil driver boards provides a spatially efficient arrangement of the components that can be fitted into a wide range of track sections without requiring significant modification to the layout. For example, the same or similar backplane and coil driver boards may be fitted in both the straight sections of the track as well as the curved track sections. It will be appreciated that the different track sections can be physically connected together, and electrical connections made between the sections. For example, a coil power source can be connected to connection 318. A separate power connection 336 may be arranged at the opposite end of the backplane 316 which can be used to connect the power source to an adjacent backplane. The power source can be daisy chained across the adjacent track sections in order to simplify the installation of the conveyor system.

[0076] Further, in addition to providing flexibility to the physical layout, the modular electronics also provide flexibility for providing different coil densities in track sections. While the above has described each coil driver board as controlling a single associated coil, the design is easily expandable to have a coil driver board control multiple coils.

[0077] FIG. 4 depicts further modular electronics of a track section of a linear motor conveyor system. The track section electronics 400 are similar to that described above with reference to FIGs. 2, 3A and 3B; however, the coil driver boards control 2 coils each. Further, the backplane depicted in FIG. 4 includes control connections and has been split into two physically separate backplanes.

[0078] The modular electronics 400 are depicted as controlling the same number of coils 208a, 208b as the electronics described above; however there are half as many coil driver boards 422. Each of the coil driver boards is depicted in FIG. 4 as controlling two coils, however each coil driver board may control additional coils such as 3, 4, 5, 6, etc. Further, although each coil driver board is depicted as controlling the same number of coils, it is possible that different coil driver boards can control different number of coils. The backplane includes a power backplane portion 416a and a communication backplane portion 416b. The power backplane 416a includes a power source connection 418a for connecting to a power source for driving the coils.An additional power connection 436a may be arranged at the opposite end of the power backplane which may be used to connect the power source to adjacent backplanes. The power backplane includes a plurality of power connections 424a for connecting the coil driver boards to the power backplane 416a. The coils are electrically connected to the power backplane 416a by way of respective coil connections 420a, 420b. The electrical connection for each coil controlled by a respective board passes through the coil board connection 424 and the coil connections 420a, 420b so that the coil driver board can control the power delivered to the coils from the power source.

[0079] In addition to the power side of the modular electronics, the backplane includes communication backplane 416b that provides communication and control paths between all of the coil driver boards. The communication and control paths may include connections 418b, 436b arranged at opposite ends of the communication backplane that allow the communication and control path to be connected to adjacent communication planes. The communication backplane may include a plurality of communication connections 424b for connecting each of the coil driver boards to the communication and control paths.

[0080] The power connections 424a and communication connections 424b for connecting the coil driver boards to the respective backplanes may provide the required electrical connections as well as a mechanical interface that mounts the coil driver boards to the backplanes. While it is possible to provide both the power connections 424a and the communication connections 424b with a mechanical interface to support the coil drivers, it is possible to have the mechanical interface only on one of the connections, or it is possible to have the mechanical interface separate from the electrical interfaces provided by the respective power and communication connections.

[0081] The communication and control signals provided to the individual coil driver boards may be provided by one or more remote control devices. Additionally or alternatively, a gateway controller 438 may be mounted to the communication backplane and can provide the communication and control signals to the respective coil driver boards that are connected to the communication and control path. The gateway controller 438 may receive control signals from one or more remote locations either by wired or wireless connections. The communication and control signals may include high speed serial links for data including for example, voltage values, set-point currents, among other data and instructions. The communication and controlsignals may also include discrete input / output (I / O) signals such as safety signals and / or high speed triggers.

[0082] Separating the backplane into two separate backplanes can make installation of the backplanes into the track sections easier as well possibly simplifying the electrical design or layout of the boards. Further, with the coil power separated from the communications, heat transfer between components can be reduced. Additionally, the separation of the power and communication can also reduce electrical noise.

[0083] The modular electronics described above may also provide flexibility to increase or decrease the coil density of track sections without having to alter the control electronics in the track section. For example, if the number of coils was reduced, such as halved, the same electronics depicted in FIG. 4 could be used but only half as many coil driver boards would be needed. Further, increase density can be provided by simply adding more coil driver boards to the back planes. Additionally or alternatively, slight modifications of the power planes can be made to allow a single driver board to control additional coils. Since the modular electronics provide a spatially efficient configuration of the electronics, a similar electronics design may be used even as the coil density is increased, which can reduce the cost of implementing different versions of the tracks.

[0084] The above has described various details of modular electronics for a linear motor conveyor system. The details described above can be implemented in a wide range specific applications. One particular implementation of a track section for a linear motor conveyor using the modular electronics is described further below with respect to FIGs. 5A - 10.

[0085] FIGs. 5A, 5B depict rear views of a track section of a linear motor conveyor system. FIG. 5C depicts a front view of the linear motor conveyor system. FIG. 6 depicts the modular electronics of the track section of FIGs. 5A, 5B. FIG. 7 depicts a section of the modular electronics of FIG. 6. FIG. 8 depict backplane sections of the modular electronics of FIG. 6. FIG. 9 depicts details of a coil driver board. FIG. 10 depicts details of a gateway board.

[0086] As depicted in FIGs.5A, 5B and 5C, a track section 500 houses the electronics used to move a shuttle along the track. The shuttle is moved by electromagnetic forces applied to the shuttle via a plurality of coils 502 arranged within the track section in close proximity to a shuttlesurface as seen in FIG. 50. The shuttle surface may be located on what may be referred to as the front of the track section. The track section 500 may have an interior volume within which the control electronics are located. The track section may include a number of openings that may be covered by respective panels or covers 504a, 504b. Each track section 500 may be mounted on a surface by one or more stands 506a, 506b which are depicted as being located at opposite ends of the track section. The stands 506a, 506b may include openings or passage ways connected to the interior volume of the track section that can allow power and communication connections to be easily passed from one section to an adjacent section. As depicted, a power pass-through connector 508a and a communication pass-through connection 508b allows the power and communication connections to be easily made between track sections.

[0087] As depicted in FIG. 5B, the plurality of coil driver boards, one of which is labelled 524a, are accessible when the rear panels 504a, 504b are removed. The coil driver boards, as well as the backplanes, are split into two sections 510a, 510b. The coil driver boards are perpendicularly mounted to the backplanes mounted in the track section. The track section 500 includes 60 individually controllable coils 502 in FIG. 5C that are controlled by 30 coil driver boards arranged in two groups of 15 coil driver boards. The coil driver boards include a heat transfer component 526a, most clearly shown in FIG. 7 and FIG. 9, that have connection points extending past the edge of the coil driver boards so that they can make contact with the rear cover panels 504a, 504b when closed. A thermal tape 572a, 572b is depicted as being applied across the connection points of the heat pipes. The thermal tape can improve the heat transfer between the heat pipes and the rear panel cover that acts as a heat sink or cooler that dissipates the heat from the coil driver boards into the external environment.

[0088] As can be seen in FIG. 6, the coil driver boards are mounted on two substantially identical sections 510a, 510b. Each section 510a, 510b includes a power backplane section 512a, 512b and a communication backplane section 514a, 514b. Each of the power back planes comprise an inter-board power connection 516a, 516b and 518a, 518b. As depicted, the power inter-board connections can be connected together by an electrical connection provided by PCB boards, which may include a fuse holder. The inter-board power connections can be connected between boards in the same track section, as well as between different track sections, using for example the power interconnect 508a. One or more of the powerconnections of a power backplane can be connected to a power source for providing the coil driving power.

[0089] In addition to the power backplane, the electronics include communication backplanes 514a, 514b. The communication backplanes 514a, 514b may include inter-board communication connections 520a, 520b, 522a, 522b that allow the separate backplanes to be communicatively coupled together. The communication connection may be made between the backplanes within the same track section. The communication between track sections may be provided through a different communication path.

[0090] Each of the coil driver boards are connected to both the power backplane and the communication back plane by respective board power connections 528a and board communication connections 530a. The connections 528a, 530a may provide both electrical and mechanical interfaces for securing the coil driver boards to the backplanes. The communication backplane may include an additional connection 536 for securing a section gateway controller board 538. The gateway controller board may control communication with the individual coil driver boards in order to provide the necessary control signals to the coil driver boards. If the communication backplanes, either within the same track section, or possibly in adjacent track sections, are connected together via the inter-board communication connections 520a, 520b, 522a, 522b, only a single gateway controller is need for the connected boards. As depicted in FIG. 6, only a single gateway controller 538 is provided for the two sections 510a, 510b. It is noted that a communication ribbon connecting connector 522a and 520b is omitted in FIG. 6 for clarity of the figure.

[0091] The gateway controller 538 may receive control instructions or information from a remote location, which may be another gateway controller, or a conveyor controller that the gateway controller uses to determine what control signals to provide to the individual coil driver boards. In order to control the shuttles, the gateway controller, and possibly the coil driver boards, may use information from one or more sensors. For example, positioning sensors may be arranged along the track section in order to determine the location of shuttles on the track. The communication board 514a, 514b may include one or more sensors on the board, such as temperature sensors or may include sensor connectors 540 that allow separate sensors, such as positioning sensors to be connected to the communication backplane. The backplane mayinclude one or more processors or microprocessors 542 that can process the sensor information and communicate the sensor data to the gateway controller 538.

[0092] FIG. 7 depicts one of the electronic modules 510a. As is clear in FIG. 7, each of the coil driver boards 524 are secured to the power backplane and the communication backplane by respective board power connections 528h, and board communication connections 530h. The connections provide both the physical and mechanical interface for the coil driver boards. Each of the coils are electrically connected to the power board, and through the power board to the respective coil driver board, via coil connections 532h, 534h. Alternatively, each of the coils may be connected directly to the coil driver boards by releasable connectors. Any of the coil driver boards, or the gateway controller can be easily removed without requiring significant disassembly, unhooking, etc. of components. All that is required is to remove the cover panel and pull the board out either for repair or replacement.

[0093] The electronics module 510a is depicted as having a gateway controller 536 mounted to the board. The gateway controller 536 can control the coil driver boards that are connected to the same communication backplane as the gateway controller, as well as those connected to a communication board that is communicatively coupled to the backplane via communication inter-board connection 520a, 520b, 522a, 522b.

[0094] FIG. 8 depicts the power backplane 512a and the communication backplane 514a.The power backplane provides the electrical connections to a power source as well as other power backplanes 516a, 518a. The power can be distributed from the power connections to the coil driver boards through the board power connections 528a..528o. Each of the coil driver boards is associated with electrical connections 532a, 534a..532o, 534o to the respective coils.

[0095] The communication backplane 514a includes the inter-board communication connections 520a, 522a as well as the communication connections 530a..530o to the coil driver board. Although the power and communication connections are described as being separate, it is noted that the power of the backplane may be a higher voltage for the coils such as 24V or 48V. The communication connections may include power for the coil driver board circuitry however it may be lower power compared to the coil driving power. The communication backplane may include a communication connection to a gateway controller 538. The communication backplane may also include one or more connections to external components540 such as external position sensors for the shuttle. The backplane may include one or more microprocessors 542 which may process sensor data and provide the sensor data to the gateway controller.

[0096] The communication backplane may receive power from an external power source, or it may receive power from the power backplane. The power backplane and the communication backplane may have an electrical connection 544a, 546a between the two backplanes to supply power from the power backplane to the communication backplane.

[0097] FIG. 9 depicts a schematic of a coil driver board 524. The coil driver board may be formed on a PCB 550 that includes tabs that provide the power connection interface. It is noted that the electrical contacts are not depicted in FIG. 9. The PCB may include tabs for the communication interface 554. The PCB tabs, in addition to providing the electrical connections, can also provide the mechanical interface for supporting the coil driver board on the backplanes. The coil driver board includes two driving circuits for respective coils. It will be appreciated that the electronics in the FIG. 9 are only illustrative and various electrical circuits for providing the coil driving functionality is possible. The electrical components are depicted as comprising fuses 556a, 556b, capacitors 558a, 558b, 560a, 560b, power MOSFETs 562a, 562b, 564a, 564b and H-bridge coil drivers 566a, 566b. The electrical components can be controlled by a processor or microprocessor 574.

[0098] The heat transfer component 526a is depicted as a strip is clearly depicted in FIG. 9. The heat transfer component may comprises a copper strip 568 that is thermally coupled to the MOSFETs, which may produce significant heat. The strip of copper can bend and have arms extending outwards with thermal connecting pads 570a, 570b arranged to be pressed against the back panel when the back panel is closed. The heat transfer component 526a can transfer the heat from the MOSFETs to the back panel which in turn can dissipate the heat to the external environment. Although the heat transfer component 526a is described as being a copper strip, it may comprise other material such as aluminum or other heat transfer materials. Further, the heat transfer component may comprise a solid strip as depicted or may comprise other heat transfer devices such as a heat pipe.

[0099] The electromagnetic coils 502 may be arranged on a front of the track section as depicted in FIG. 10. The coils 502 may comprise a plurality of overlapping coils, depicted inFIG. 10 as coils 502a, 502b. Each of the coils is electrically connected to the respective coils connectors 532a, 534a. Although FIG. 10 depicts a single wire connection between the respective coil connectors 532a, 534a and coils 502a, 502b, each of the coils are connected to the respective coil connectors by two wires. The electromagnetic coils 502 used to drive the shuttles on the track section can generate significant heat. The heat generated by the coils can be dissipated by a coil cooling system. The coils may be thermally coupled to the structure of the track section and cooling channels can be formed within the track section in proximity to the coils. The cooling channels may carry a cooling fluid and may have input and output ports 594a, 594b. The coil cooling is described in further detail below with reference to FIGs. 11 -13.

[0100] FIG. 11 depicts a gateway controller board 524. The gateway controller comprises a PCB 576 that provides one or more tabs 578 for the communication connections for communicating with the coil driver boards as well as the power connections for powering the gateway controller. The controller may include a processor 580 and other support electronics. The gateway controller may include additional communication connections 582, 584 which are depicted as fiber optic communication connections. The additional communication connections 582, 584 allow the gateway controllers to be daisy chained together as well as to a central controller for the overall conveyor system. For example, one of the communication connections 582 may provide bi-directional communication to a central controller or another gateway controller and communication connection 584 may provide bi-directional communication with another gateway controller.

[0101] FIG. 12 depicts a cross-section view of a track section and electronics. As described above, the coils 1202 can generate significant heat that needs to be expelled from the track. As depicted in FIG. 1212, the coils can be mounted to the front of the track section. The coils may be secured to the track section with a potting material (not shown) to provide good thermal conductance between the coils and the thermal mass of the track section. The track section includes an upper cooling channel 1204a and a lower cooling channel 1204b. These cooling channels are each connected to an input port 594a and an output port 594b which are arranged at one end of the track section. At the end of the track section opposite the ports 594a, 594b, the channels are connected together by a tube 1206, although the connection could be provided as an internal feature of the track section. A cooling fluid passes through the cooling channels1204a, 1204b and heat from the coils is transferred to the cooling fluid through the track section.The cooling fluid can then be cooled and recirculated through the track sections.

[0102] The operation of the coils and the electronics may depend upon their temperature. In order to monitor temperatures in the vicinity of the coils, a plurality of thermistors can be used to measure the temperatures at various locations on the track section.

[0103] FIGs. 13A - 14 depicts details of the temperature monitoring for a track section. FIG. 13A depicts a rear view of a track section. FIG. 13B depicts a cross-sectional of the track section of FIG. 13A. FIG. 14 depicts a cross-section view of the track section with electronics. The track section 1300 may include a plurality of temperature monitoring points 1302a..1302j. Each of the monitoring points provide a protrusion from the track section which provides a location at which temperature can be monitored. The cross section of one of the temperature monitoring points 1302a is depicted in detail in FIG.13B. As can be seen, the temperature monitoring point provides a protrusion of the thermal mass of the track section. A thermistor can be placed on the temperature monitoring point in order to monitor the temperature at the particular location. FIG. 13B depicts the track section without the electronics in order to more clearly see the temperature monitoring point. FIG. 14 depicts the same cross sectional view with the electronics. The communication backplane can include a plurality of thermistors 1402 arranged on the backside of the communication backplane 514. With the thermistors arranged on the back of the communication backplane, when the backplane is installed, the thermistor is in contact with, or at least close proximity to, the temperature monitoring point 1302a. Having the thermistors arranged on the communication backplane allows the sensors to be easily connected to the gateway controller, or other components that use the temperature. The monitored temperatures may be used for various reasons.

[0104] The modular electronics for the linear motor conveyor described above provide flexible electronics modules that can be used in a wide range of physical configurations as well as a wide range of coil densities and power levels for the track sections. The modular electronics allow the scaling, both up and down, of the coil density, and power of the coils using the same or similar components. Not only does the modular electronics provide advantages in terms of flexibility noted above, it can also decrease parts cost as the same part, such as the coil driver boards, back planes, power planes can be re-used in various different applications.

[0105] The linear motor conveyor system is described above as a plurality of interconnected track sections. The track sections may be connected in various arrangements to provide a closed loop, or open ended conveyor arrangement. Other applications of a linear track section with the modular electronics are possible.

[0106] FIG. 15 depicts a robotic arm with a linear motor track section effector. A robotic arm or similar system 1502 may have one or more moveable connections providing one or more degrees of freedom, depicted by arrows 1504a, 1504b, 1504c, 1504d. A linear motor track section 1506 may be mounted to an effector end of the robotic arm 1502. A plurality of shuttles 1508a..1508e are located on the linear motor track section and can be independently controlled to move on the track section, which may be useful in a range of applications including in transferring components and particularly re-pitching the components.

[0107] The above has described a linear motor conveyor system that uses compact modular electronics. The modular electronics described above can be used in other applications.

[0108] FIG. 16 depicts a planar motor conveyor system 1600. The planar motor conveyor comprises a plurality of coils, one of which is labelled as coil 1602, arranged in a matrix. The coils 1602 are depicted as being arranged in a plurality of columns 1604a, 1604b, 1604c, 1604d. Each of the columns of coils may be arranged as a section similar to the linear track sections described above. The coils 1602 can be controlled in order to control movement of a shuttle 1606 on the planar arrangement. The planar motor conveyor system can allow the shuttle 1606 to be moved along multiple axes as depicted by arrows 1608. In addition to the translations along the perpendicular axes, the coils may also be controlled to cause the shuttle to rotate. The shuttle may have up to 6 degrees of freedom, including translation along X, Y, Z, axes as well as yaw, pitch and roll. The increased coil density possible with the modular electronics design described above can also be used in the planar motor conveyor system.

[0109] FIG. 17 depicts the modular electronics arranged for a planar motor conveyor system. As depicted, each of the columns 1602a..1602d may comprise a plurality of respective coils 1704a, 1704b, 1704c, 1704d connected coil driver boards 1706a, 1706b, 1706c, 1706d coupled to respective backplanes as described above. The backplanes may be provided as separate communication backplanes 1708a, 1708b, 1708c, 1708d and power backplanes 1710a, 1710b, 1710c, 171 Od. The compact modular design of the electronics described above with regard tothe linear motor conveyor system allows the coils to be arranged adjacent each other in the planar arrangement.

[0110] The above has described a plurality of columns of coils with the same number of coils in each column of coils. It is possible to have different number of coils in each column.

[0111] It will be appreciated by one of ordinary skill in the art that the system and components shown in FIGs. 1 - 17 may include components and / or steps not shown in the drawings. For simplicity and clarity of the illustration, elements in the figures are not necessarily to scale, are only schematic and are non-limiting of the elements structures. It will be apparent to persons skilled in the art that a number of variations and modifications can be made without departing from the scope of the invention as defined in the claims.

[0112] Although certain components and steps have been described, it is contemplated that individually described components, as well as steps, may be combined together into fewer components or steps or the steps may be performed sequentially, non-sequentially or concurrently. Further, although described above as occurring in a particular order, one of ordinary skill in the art having regard to the current teachings will appreciate that the particular order of certain steps relative to other steps may be changed. Similarly, individual components or steps may be provided by a plurality of components or steps. One of ordinary skill in the art having regard to the current teachings will appreciate that the components and processes described herein may be provided by various combinations of software, firmware and / or hardware, other than the specific implementations described herein as illustrative examples.

[0113] The techniques of various embodiments may be implemented using software, hardware and / or a combination of software and hardware. Various embodiments are directed to apparatus, e.g. a node which may be used in a communications system or data storage system. Various embodiments are also directed to non-transitory machine, e.g., computer, readable medium, e.g., ROM, RAM, CDs, hard discs, etc., which include machine readable instructions for controlling a machine, e.g., processor to implement one, more or all of the steps of the described method or methods.

[0114] Some embodiments are directed to a computer program product comprising a computer- readable medium comprising code for causing a computer, or multiple computers, to implementvarious functions, steps, acts and / or operations, e.g. one or more or all of the steps described above. Depending on the embodiment, the computer program product can, and sometimes does, include different code for each step to be performed. Thus, the computer program product may, and sometimes does, include code for each individual step of a method, e.g., a method of operating a communications device, e.g., a wireless terminal or node. The code may be in the form of machine, e.g., computer, executable instructions stored on a computer-readable medium such as a RAM (Random Access Memory), ROM (Read Only Memory) or other type of storage device. In addition to being directed to a computer program product, some embodiments are directed to a processor configured to implement one or more of the various functions, steps, acts and / or operations of one or more methods described above. Accordingly, some embodiments are directed to a processor, e.g., CPU, configured to implement some or all of the steps of the method(s) described herein. The processor may be for use in, e.g., a communications device or other device described in the present application.

[0115] Numerous additional variations on the methods and apparatus of the various embodiments described above will be apparent to those skilled in the art in view of the above description. Such variations are to be considered within the scope of the current disclosure.

Claims

WHAT IS CLAIMED IS:1 . A track section for an electric motor conveyor system comprising: a plurality of electromagnetic coils of an electric motor arranged adjacent a shuttle surface of the track section; a plurality of electrical connections to the plurality of coils; at least one backplane comprising: a coil power connection for connecting to a power source providing electrical power to the plurality of coils; and a plurality of coil driver board power connections; and a plurality of coil driver boards controlling power delivered to the plurality of coils, each of the coil driver boards individually removable from the track section.2 The section of claim 1 , wherein the plurality of electrical connections to the plurality of coils are located on the at least one backplane.3 The section of claim 1 , wherein the plurality of electrical connections to the plurality of coils are located on respective ones of the plurality of coil driver boards.4 The section of claim 2 or 3, wherein each of the plurality of coil driver board power connections provide a connection to a respective coil driver board between the coil power connection and the electrical connection to a respective coil controlled by the respective coil driver board.5 The section of any one of claims 1 to 4, wherein the at least one backplane further comprises: a communication connection providing a connection to control signals; and a plurality of board communication connections.6 The section of claim 5, wherein the power connection and the board communication connection of a respective coil driver board are provided as a single physical connectors.

7. The section of claim 5, wherein the power connection and the board communication connection of a respective coil driver board are provided as separate physical connectors.

8. The section of any one of claims 5 to 7, wherein at least one of the power connection and the board communication connection of a respective one of the plurality of coil driver boards provide a mechanical interface for mounting the respective coil driver board to the backplane.9 The section of claim 8, wherein the plurality of coil driver boards are secured in place by the mechanical interface.10 The section of any one of claims 1 to 9, wherein the plurality of coil driver boards are secured in place by removable panel of the track section.11 The section of any one of claims 1 to 10, wherein the plurality of coil driver boards are accessible from an opening in a side of the track section.12 The section of claim 11 , wherein the plurality of coil driver boards are individually installable and removable from the opening.13 The section of claim 12, wherein the power connection and the board communication connection provide the only electrical connections that are connected or disconnected in order to install or remove a respective coil driver board from the track section.14 The section of any one of claims 1 to 13, wherein each of the coil driver boards further comprise respective control circuitry controlling power delivered through the releasable power connection to a respective subset of the plurality of coils according to control signals.15 The section of claim 14, wherein each of the coil driver boards controls power delivered to at least one coil.16 The section of claim 14, wherein each of the coil driver boards controls power delivered to between 1 and 10 coils.

17. The section of any one of claims 14 to 16, wherein each of the coil driver boards further comprise a respective thermal cooling component for cooling at least a portion of the control circuitry of the respective coil driver board, each of the respective thermal cooling component coupled to a section cooling component.

18. The section of claim 17, wherein the respective thermal cooling component of the respective coil driver boards comprises a cooling strip and the section cooling component comprises a thermal heat sink exposed to an exterior environment.

19. The section of claim 18, wherein the thermal heat sink comprises a removable panel of the track section covering a plurality of the coil driver boards.

20. The section of any one of claims 1 to 19, wherein the at least one backplane comprises: a power backplane comprising the electrical connections to the plurality of coils, the coil power connection and the power connections of the plurality of coil driver board connections; and a communication backplane comprising the communication connection and the board communication connection of the plurality of coil driver board connections.21 . The section of claim 20, wherein the power backplane is formed as two or more separate power backplane printed circuit boards (PCBs) with inter-board power connections connecting the two or more separate power backplane PCBs.

22. The section of claim 20 or 21 , wherein the communication backplane is formed as two or more separate communication backplane printed circuit boards (PCBs) with inter-board communication connections connecting the two or more separate communication backplane PCBs.

23. The section of any one of claims 1 to 22, wherein the backplane further comprises at least one of: an output coil power connection for connecting to an adjacent track section; and an output communication connection for connecting to an adjacent track section.

24. The section of any one of claims 1 to 23, wherein the backplane further comprises a plurality of thermistors mounted to a side of the backplane facing the electromagnetic coils, each of the thermistors in contact with a portion of the track section in order to monitor a temperature of the track section.

25. The section of any one of claims 1 to 24, wherein the at least one backplane is mounted within an internal cavity of the track section behind the plurality of electromagnetic coils.

26. The section of claim 25, wherein each of plurality of coil driver boards are arranged within the internal cavity and are approximately perpendicular to the at least one back plane.

27. The section of claim 26, wherein each of the plurality of coil driver boards are arranged approximately parallel to each other.

28. The section of any one of claims 1 to 27, wherein the section is a track section of a linear motor conveyor system.

29. The section of any one of claims 1 to 28, wherein the section is a section of a planar motor conveyor system.

30. A linear motor conveyor system comprising: at least one linear track section comprising a section according to any one of claims 1 to 27; and a plurality of shuttles arranged on the at least one track section, respective positions of each of the plurality of shuttles are independently controllable along 1 axis of the at least one linear track section31 . The linear motor conveyor system of claim 30, wherein the at least one linear track section comprises a plurality of interconnected track sections.

32. The linear motor conveyor system of claim 30, wherein the plurality of interconnected track sections are arranged to form a closed loop.

33. The linear motor conveyor system of claim 30, wherein the plurality of interconnected track sections are arranged in an open-ended configuration.

34. The linear motor conveyor system of claim 30, further comprising a robotic arm having at least one degree of freedom, wherein the at least one linear track section is connected at an effector end of the robotic arm.

35. A planar motor conveyor system comprising: a plurality of interconnected sections arranged in a planar configuration, each of the sections comprising a section according to any one of claims 1 to 27; and a plurality of shuttles arranged on the planar configuration of interconnected sections, respective positions of each of the plurality of shuttles on the interconnected sections independently controllable about 2 axes.

36. The planar motor conveyor system of claim 35, wherein the shuttle is independently controllable along between 2 and 6 axes.

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