Linear Motor Conveyor Reconfiguration for Faulty Part Separation
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Solution Overview
Problem
Conventional linear motor conveyor systems face inefficiencies in handling parts with voids or faulty components, as they lack the flexibility to reconfigure parts effectively, leading to reduced system efficiency.
Innovation Solution
A system and method utilizing a linear motor conveyor with independently positionable moving elements and a control system to reconfigure parts from a first configuration to a second, including a pick and place device that moves selected parts to the conveyor, allowing for efficient handling and processing of good parts while separating or removing faulty ones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional linear motor conveyor systems use cabling to attach moving elements, then power and control can be provided to moving elements, but cable management becomes complex and flexibility for reconfiguring parts is reduced
Solution Approach 1:
The patent removes cabling from the moving elements entirely, extracting the power and control functions from the mechanical connection. Instead of cables attached to moving elements, the system uses a cableless linear motor system where power and control signals are transmitted through the track infrastructure, eliminating cable management complexity while maintaining adaptability for part reconfiguration
Solution Approach 2:
The patent replaces the mechanical cabling system with an electromagnetic field-based linear motor system. The linear motor track generates electromagnetic fields that directly drive the moving elements without physical cable connections, substituting a mechanical power transmission system with an electromagnetic one that provides both propulsion and control without cable entanglement
2Productivity
If parts are moved in a fixed configuration through the conveyor system, then system operation is simplified, but the ability to handle voids and faulty parts efficiently is reduced
Solution Approach 1:
The patent implements dynamic reconfiguration of parts during conveyor operation. The control system detects voids and faulty parts, then dynamically adjusts the positions of moving elements and redirects parts to different configurations or destinations, allowing the system to maintain high throughput while adaptively handling defective parts without disrupting overall productivity
Solution Approach 2:
The patent incorporates feedback mechanisms where sensors detect the presence, position, and quality of parts on the conveyor. This feedback information is used by the control system to make real-time decisions about reconfiguring parts, routing good parts to continue processing, and diverting faulty parts for removal or separate handling, thereby maintaining productivity while improving adaptability
3Adaptability or versatility
If moving elements are independently positioned along the linear motor track, then flexible reconfiguration of parts is enabled, but control system complexity increases
Solution Approach 1:
The patent divides the conveyor system into independently controllable moving elements along the linear motor track. Each moving element can be individually positioned and controlled, allowing flexible reconfiguration of parts. The control system manages these segmented elements through coordinated control algorithms that optimize part routing while handling the complexity of independent positioning
Solution Approach 2:
The patent designs the linear motor track and moving elements as universal components that can perform multiple functions: transporting parts, reconfiguring part arrangements, isolating faulty parts, and routing to different destinations. This multi-functionality reduces the need for separate specialized mechanisms, managing control complexity while maximizing reconfiguration flexibility
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 approach enables efficient reconfiguration of parts, improving throughput by allowing for flexible handling and processing of parts in a different configuration, reducing the need for cable management and enhancing overall system efficiency.
Implementation Method 1
a linear motor conveyor including a linear motor track and a plurality of moving elements wherein the plurality of moving elements can be independently positioned along the linear motor track
Data Source
AI summary
A system and method for parts handling including: a plurality of parts arranged in a first configuration; a linear motor conveyor including a linear motor track and a plurality of moving elements; a pick and place device configured to move at least a subset of the parts from the first configuration to the linear motor conveyor system; and a control system configured to: determine locations of the parts within the first configuration; control the linear motor conveyor to move the moving elements to positions related to the locations of the parts within the first configuration; control the pick and place device to move the parts generally simultaneously to the corresponding moving elements; and after receiving the parts, move the moving elements such that the parts are in a second configuration that is different from the first configuration.