Independent Cart Track Segmentation for Section Safety Control
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Solution Overview
Problem
Independent cart systems face challenges in ensuring safety during human interaction, as powering down the system to prevent motion is not feasible due to the need for motion in other sections, and mechanical brakes do not entirely prevent unintended motion from other movers entering the interaction area.
Innovation Solution
A safety controller is introduced to receive input signals and execute safety functions by disabling current flow to specific track segments, allowing safe operation in one section while permitting motion in others, using segment controllers to regulate coil power and prevent or restrict mover motion within designated sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If power is removed from the entire system to prevent unintended motion, then safety is improved, but productivity deteriorates because motion cannot occur in any section
Solution Approach 1:
The track is divided into multiple independently controllable sections, each with its own segment controller that can regulate current flow to coils in that specific section. This allows the safety function to be applied only to the section where human interaction occurs, while other sections remain operational and can continue moving carts.
2Reliability
If mechanical brakes are applied to stop movers in a section, then unintended motion is prevented, but additional movers can still enter the section from other parts of the track
Solution Approach 1:
The harmful factor (electromagnetic force from energized coils that could accelerate movers into the safety zone) is removed by disabling current flow to coils in the protected section. This extraction of the propulsive capability, combined with mechanical braking, ensures that no additional movers can be propelled into the section where human interaction is occurring.
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
This solution effectively prevents unintended motion in specific sections of the track, ensuring operational safety during human interaction while maintaining motion in other sections, thereby enhancing overall safety and operational flexibility in independent cart systems.
Implementation Method 1
The track is made up of a number of track segments that, in turn, hold individually controllable electric coils. Successive activation of the coils establishes a moving electromagnetic field that interacts with the movers and causes the mover to travel along the track.
Implementation Method 2
Each of the movers may be independently moved and positioned along the track in response to the electromagnetic fields generated by the coils.
Implementation Method 3
Sensors may be spaced at fixed positions along the track and/or on the movers to provide information about the position and speed of the movers.
Data Source
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AI summary
An independent cart system with safety functions that prevent unintended motion independently within different sections of the track while permitting motion along other sections of the track is disclosed. A safety controller receives one or more input signals corresponding to operating conditions along the track. A safety program executing in the safety controller monitors the state of the input signals to determine whether a safety function is to be executed. When a safety program is executed, the safety controller transmits an output signal to one or more segment controllers present in one section along the track. Each segment controller is responsible for regulating current flow to the coils mounted to the corresponding track segment In response to the signal from the safety controller, each segment controller in the section controls the power output to the coils along that section of track to achieve the safe operation desired in that segment.