Contactless Conveyance With Coil-Based Orientation Control
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Solution Overview
Problem
Conveyance systems using linear motors face productivity losses and reduced lifetime due to contamination and increased friction from mechanical contact, particularly in high-speed applications, and existing magnetic levitation systems have complex structures that complicate orientation control.
Innovation Solution
A conveyance system employing a movable element with coil groups and magnetic bodies, where electric currents generate forces for contactless movement and orientation control, reducing the need for physical guides and simplifying the system configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a guide apparatus such as a linear guide is used in a conveyance system, then the conveyance system can provide mechanical support and guidance, but contaminants such as wear fragments and lubricants are generated from the sliding portion, decreasing productivity and lifetime
Solution Approach 1:
The patent replaces the mechanical contact-based linear guide with a magnetic field-based positioning system. Coils generate magnetic forces to levitate and position the movable element without physical contact, eliminating wear fragments and lubricant contamination while maintaining support and guidance functions.
Solution Approach 2:
The patent extracts and removes the guide apparatus (linear guide) from the conveyance system entirely. By using magnetic fields for positioning and support, the system eliminates the source of contaminants (sliding portion) while maintaining the necessary support and guidance functions through alternative means.
2Reliability
If a guide apparatus such as a linear guide is used in a conveyance system, then the conveyance system can provide mechanical support and guidance, but friction increases during high-speed conveyance, decreasing productivity
Solution Approach 1:
The patent replaces friction-based mechanical guidance with magnetic field-based positioning. The coils generate magnetic forces that provide support and guidance without physical contact, eliminating friction and enabling high-speed conveyance without productivity loss.
3Reliability
If permanent magnets and coils are disposed in multiple rows for magnetic levitation control, then contactless conveyance can be achieved, but the system structure becomes complex
Solution Approach 1:
The patent makes the coils multi-functional by using them for both levitation control and orientation control. The same coil array that provides magnetic lift also generates torques for rotational control, eliminating the need for separate permanent magnet rows and simplifying the overall system structure.
Solution Approach 2:
The patent merges the levitation function and orientation control function into a single coil system. By controlling the current distribution in the coils, the system achieves both vertical levitation and rotational orientation control without requiring separate magnetic components, thereby reducing structural complexity.
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 system achieves contactless conveyance and precise orientation control without increasing system size or complexity, enhancing productivity and extending the lifetime of components by minimizing friction and contamination risks.
Implementation Method 1
in a case where electric current is applied to the first coil group or the second coil group, a force is generated between the movable element and the plurality of magnetic bodies
Implementation Method 2
the movable element is capable of moving in the first direction along the plurality of magnetic bodies while an orientation of the movable element is controlled by the generated force
Data Source
AI summary
A conveyance system comprising a movable element including a first coil group and a second coil group, and a stator including a plurality of magnetic bodies disposed along the first direction so that the plurality of magnetic bodies are capable of facing the first coil group and the second coil group. The first coil group includes a plurality of first coils disposed along a first direction, and the second coil group includes a plurality of second coils disposed along a second direction intersecting with the first direction. In a case where electric current is applied to the first coil group or the second coil group, a force is generated between the movable element and the plurality of magnetic bodies. The movable element is capable of moving in the first direction along the plurality of magnetic bodies while an orientation of the movable element is controlled by the generated force.