Suspended Carrier Top Gap Control to Prevent Tilt and Dust
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Solution Overview
Problem
Suspended carrier devices driven by linear motors face challenges in maintaining the top gap between the magnet plate and the moving control coil unit, leading to potential tilting during start or stop operations and dust generation due to contact-based posture holding mechanisms, especially in clean environments.
Innovation Solution
A carrier device with a non-contact mechanism using top gap control coil units and a controller to manage the interval between the magnet plate and the top gap control coil units, generating attractive or repulsive forces to maintain the top gap and prevent tilting, while suppressing dust generation by avoiding contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a contact-type posture holding mechanism (roller) is arranged, then the top gap can be maintained, but dust is generated at the contact location
Solution Approach 1:
The patent replaces the mechanical contact-type roller mechanism with a non-contact magnetic field-based control coil mechanism. The control coil generates a magnetic field that interacts with the magnet plate to maintain the top gap without physical contact, thereby eliminating dust generation while preserving gap maintenance functionality.
Solution Approach 2:
The patent introduces a magnetic field as an intermediary between the control coil and the magnet plate. This magnetic field mediator enables force transmission and gap control without direct mechanical contact, solving the dust generation problem while maintaining precise top gap control.
2Manufacturing precision
If a contact-type posture holding mechanism (roller) is arranged, then the top gap can be maintained, but the moving body tilts during start or stop due to inertia
Solution Approach 1:
The patent replaces the mechanical roller system with a magnetic field-based control system that can apply forces more smoothly and responsively. The control coil generates magnetic forces that can counteract inertial effects during acceleration and deceleration, preventing tilting while maintaining the top gap.
Solution Approach 2:
The patent employs a dynamic control system where the control coil actively adjusts the magnetic field strength to maintain the top gap constant during various motion states. This dynamic adjustment capability allows the system to compensate for inertial forces during start and stop operations, preventing posture instability.
3Object-generated harmful factors
If a non-contact mechanism is used, then dust generation is suppressed, but the top gap control becomes more complex
Solution Approach 1:
The control coil serves multiple functions: it generates the magnetic field for levitation, controls the top gap distance, and maintains posture stability. By consolidating these functions into a single electromagnetic component, the patent reduces overall system complexity despite using a non-contact mechanism.
Solution Approach 2:
The patent implements a feedback control system where the controller continuously monitors the top gap and adjusts the control coil current accordingly. This closed-loop control simplifies the management of the non-contact mechanism by using automated feedback rather than complex mechanical linkages.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively maintains the posture of the moving body with greater accuracy and reduces dust generation by maintaining a non-contact state between the magnet plate and the top gap control coil units, enhancing the reliability and cleanliness of the carrier device.
Implementation Method 1
When a drive current is supplied to the exciting coils, a magnetic field is generated in the top gap, and the moving body moves in a predetermined direction along the magnet plate.
Implementation Method 2
at least two top gap control coil units including a plurality of exciting coils which are arranged on the upper surface of the moving body along a magnet plate the same as or different from the predetermined magnet plate among the at least one magnet plate and separated from the magnet plate
Data Source
AI summary
A carrier device is provided, which includes: a moving body; a top plate arranged above and separated from the moving body; a magnet plate including a plurality of permanent magnets arranged parallel to a predetermined moving direction on a lower surface of the top plate in a manner that adjacent polarities are different; a moving control coil unit including a plurality of exciting coils arranged on an upper surface of the moving body along and separated from the magnet plate; top gap control coil units including a plurality of exciting coils arranged on the upper surface of the moving body along and separated from the magnet plate; and a controller supplying drive currents respectively to the moving control coil unit and the top gap control coil units to make the moving body move along the moving direction, and controlling a top gap.