Electromagnetic Pinning for Linear Drive Mover Position Holding
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Solution Overview
Problem
Existing motion control systems in linear drive systems face challenges in maintaining precise position of movers at stations without mechanical coupling, as they are prone to movement due to external disturbances, electronic noise, and position drift, which can lead to overheating and damage.
Innovation Solution
A control system that utilizes electromagnetic pinning by regulating current in the linear drive system's coils to provide a holding force, using a d-axis current to resist movement and maintain position, independent of mechanical structures, and immune to noise and drift in position feedback signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mechanical structure (pin) is used to lock the mover in place, then the mover position is retained reliably, but the system complexity and cost increase
Solution Approach 1:
The patent replaces the mechanical pin locking system with an electromagnetic holding force generated by the linear drive coils. The controller applies a holding current to the coils to create an electromagnetic force that counteracts external disturbance forces, eliminating the need for mechanical locking structures and their associated complexity.
Solution Approach 2:
The linear drive system's own electromagnetic field is utilized to provide the holding force, rather than requiring a separate mechanical locking mechanism. The system uses its inherent capability to generate electromagnetic forces to maintain mover position during external interactions.
2Reliability
If a mechanical structure (pin) is used to lock the mover in place, then the mover position is retained reliably, but the system maintenance requirements increase
Solution Approach 1:
The mechanical pin that requires periodic maintenance and wear replacement is replaced with an electromagnetic holding field. The electromagnetic system has no moving parts that wear, eliminating maintenance requirements associated with mechanical coupling and pin engagement.
3Measurement precision
If the motor control attempts to return the mover to position when mechanically coupled, then position accuracy is maintained, but excessive current is generated causing overheating
Solution Approach 1:
The controller applies a holding current to the coils before mechanical coupling occurs, creating an electromagnetic force that preemptively counteracts external disturbance forces. This prevents the need for reactive current increases that would occur if the controller tried to correct position after disturbance, thereby avoiding excessive current and overheating.
4Reliability
If the motor control remains active during mechanical coupling, then position can be maintained, but it cannot be used with mechanical structures
Solution Approach 1:
The patent merges the electromagnetic holding function with the mechanical coupling system. The controller remains active and applies holding current to the coils while the mechanical pin is engaged, creating a hybrid system where electromagnetic and mechanical methods work together to maintain position during external interactions.
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 maintains precise positioning of movers at stations, reducing the risk of overheating and damage, while eliminating the need for mechanical coupling, thus enhancing system reliability and reducing maintenance costs.
Implementation Method 1
a linear drive system that utilizes a stator to drive a mover along a track... regulating flux and torque producing components of current with a stator of a linear drive system to resist movement of a stopped vehicle
Data Source
AI summary
A system and method for holding position of a mover in an independent cart system includes receiving a current feedback signal corresponding to a current present in at least one coil for a linear drive system in the independent cart system. A motion command for the mover is received, where the motion command defines a desired position along a track of the independent cart system to which the mover is to travel. An electromagnetic pinning control mode is disabled while controlling operation of the at least one mover to the desired position and enabled when the at least one mover is at the desired position.