Linear Motor Conveyor for Liquid Container In-Line Testing
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Solution Overview
Problem
In-line testing of liquid-filled containers using conventional conveyor systems requires frequent acceleration and deceleration, leading to high dynamic forces and energy consumption, and is often limited by the duration of the testing step, which hampers throughput efficiency.
Innovation Solution
The method employs an electric linear motor to convey and stationarily hold liquid-filled containers during testing, allowing for high acceleration and speed while decoupling the throughput rate from the testing duration, using multiple movers and testing stations, and employing electromagnetic sensing and spinning techniques for particle detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional conveyor systems are used for in-line testing, then devices can be conveyed continuously, but frequent acceleration and deceleration lead to high dynamic forces and energy consumption
Solution Approach 1:
The conveyor system is segmented into multiple independent linear motor modules, each capable of independent control. This allows individual sections to be accelerated or decelerated without affecting the entire system, reducing the total dynamic forces and energy consumption required for throughput control.
Solution Approach 2:
The linear motor system provides dynamic control of conveyor speed and acceleration through electronic control, replacing mechanical drive systems with fixed characteristics. This enables optimization of acceleration profiles to minimize energy consumption while maintaining required throughput rates.
2Productivity
If the conveyer operates in stop and go stepwise mode for testing, then devices can be tested in-line, but high dynamic forces act upon drives, gears and bearings
Solution Approach 1:
The conventional mechanical conveyor system with drives, gears, and bearings is replaced by a linear motor system that directly propels devices along a guide rail. This eliminates mechanical transmission components and reduces dynamic forces by providing direct electromagnetic propulsion with precise force control.
Solution Approach 2:
The acceleration and deceleration parameters are optimized through electronic control of the linear motor, allowing smooth transitions that minimize dynamic forces. The system can adjust acceleration profiles dynamically based on device characteristics and testing requirements.
3Measurement precision
If the testing step duration is increased for accurate inspection, then measurement precision improves, but the overall throughput rate decreases
Solution Approach 1:
The testing process is segmented into multiple parallel inspection stations, each performing specific measurement functions. This allows continuous flow of devices through different testing stages simultaneously, maintaining high throughput while providing comprehensive inspection coverage with sufficient measurement time at each station.
Solution Approach 2:
The linear motor system maintains continuous motion of devices through the testing line, eliminating complete stops. Devices are conveyed at controlled speeds through inspection zones, allowing continuous non-contact measurement (e.g., optical sensing) to be performed without interrupting the flow, thereby maintaining both precision and throughput.
4Productivity
If high acceleration and speed movement is achieved with linear motor, then throughput rate increases, but the mover requires precise positioning control
Solution Approach 1:
The linear motor system incorporates feedback sensors (e.g., encoders, position sensors) that continuously monitor mover position and velocity. This feedback is processed by control systems that adjust motor commands in real-time to maintain precise positioning during high-speed operation, enabling high throughput with accurate device placement at each inspection station.
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 significantly increases throughput rates by minimizing the impact of testing duration on overall processing speed and enables efficient detection of solid particles within the liquid, reducing the operational stress on conveyor systems and optimizing energy use.
Implementation Method 1
conveying the selected liquid filled containers by means of a electric linear motor... The mover is moved along the stator of a linear motor by so called 'travelling electromagnetic waves'
Implementation Method 2
employing electromagnetic sensing and spinning techniques for particle detection
Data Source
Figure 1~2
Figure 3(a)~4
AI summary
A method of testing devices (1) comprising the steps of: conveying (L1, L2) devices (1) towards, into and from a testing station (13) on a mover (7) of a linear motor (9), performing on a selected device (1') a testing step in and by said testing station (13), wherein said selected device (1') is a liquid filled container (1'), wherein a wall of the container (1') and the liquid being transparent to electromagnetic radiation, keeping said selected device (1') in said testing station (13) stationary with respect to a translatory movement relative to said testing station (13), by holding said selected device (1') in said testing station during said testing step on the mover (7) of the linear motor (9), sensing an electromagnetic radiation from said selected device (1') by single or multiple subsequent stand still picturing sensitive to said radiation.