Linear Drive Conveyor With Magnetic Right-Angle Transfers
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Solution Overview
Problem
Conventional conveyor systems, such as roller and belt conveyors, require complex mechanical designs with numerous moving parts, necessitating frequent maintenance, calibration, and adjustments, and right-angle transfers involve intricate mechanical components that complicate service and installation.
Innovation Solution
A linear drive conveyor system utilizing guide tracks, carriages, and a magnetic induction motor system with minimal moving parts, enabling precise control and transfer of goods within a warehouse facility without mechanical lifts, and incorporating a warehouse management system for efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional roller or belt conveyors are used, then goods can be transported, but the system requires complex mechanical designs with numerous moving parts requiring frequent maintenance and calibration
Solution Approach 1:
The patent replaces conventional mechanical conveyor systems with a magnetic field-based propulsion system. The driver generates a moving magnetic field that interacts with a magnetic array on the carriage to propel it along guide tracks, eliminating the need for mechanical rollers, belts, and associated moving parts while maintaining goods transport capability
Solution Approach 2:
The patent extracts and removes the complex mechanical components (rollers, belts, bearings, motors) from the conveyor system, retaining only the essential guide tracks and magnetic propulsion elements. This extraction of unnecessary components directly reduces maintenance requirements while preserving the core transport function
2Productivity
If conventional conveyor systems with multiple components are used, then goods transport is achieved, but development, installation, and commissioning time are high
Solution Approach 1:
The guide tracks serve multiple functions simultaneously: they provide structural support, guide the carriage movement, and interact with the magnetic field for propulsion. This multi-functionality eliminates the need for separate components, thereby reducing development time and accelerating installation and commissioning processes
3Adaptability or versatility
If right-angle transfers with lifting components are used, then goods can be transferred between conveyor lines, but the design requires complex mechanical components and height adjustment
Solution Approach 1:
The patent enables goods transfer between conveyor lines at the same elevation level, eliminating the need for lifting components. The carriage can be redirected from one guide track to another at identical height through magnetic propulsion control, achieving transfer capability without mechanical height adjustment mechanisms
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 provides a low-maintenance, cost-effective, and efficient conveyor solution with reduced installation time, enabling precise control and transfer of goods, and can integrate with various material handling systems, including automated storage and retrieval systems, sorters, and robotic workstations.
Implementation Method 1
a linear induction motor system having a drive coil coupled to the guide track and configured to magnetically push and/or pull the magnetic array of the carriage in order to propel the carriage along the guide tracks
Data Source
AI summary
A conveyor system for transporting goods within a warehouse facility. The system includes an array of guide tracks and carriages moveable along the guide tracks for transporting goods within the warehouse facility. A drive system includes drivers spaced along the guide tracks. The drivers may utilize linear induction motors, propels the carriages along the guide tracks. The linear induction motors utilize stepper motors, and optionally microstepping motors. A warehouse management system controls the linear drive system to transport goods throughout warehouse facility for storage and order fulfilment. The linear driver conveyor system includes perpendicular transfers at which carriages can be transferred from one conveyor line to another, without the need for mechanical processes, such as lift or buffers, to move the carriage between conveyor lines.