Linear Motor Mover Sensing for Precise Position Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing linear motor systems in industrial applications, such as packaging assemblies, face challenges with imprecise position control of movable members due to mechanical play, leading to potential handling errors and premature degradation, which can result in defective products and sterility issues.
Innovation Solution
A linear motor system with integrated movement detectors, including inertial sensors and magnetometers, monitors the real-time movements and positions of movable members, allowing for precise control and early detection of faults or errors, thereby facilitating correct operation and reducing defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If movement detectors are integrated into movable members to monitor real-time movements and positions, then position control precision is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple sensing functions (inertial sensors for acceleration/velocity, magnetometers for position, encoders for rotational position) into an integrated movement detection system within each movable member. This merging of multiple sensors and functions into a unified system achieves precise position control while managing complexity through integration rather than separate independent systems.
Solution Approach 2:
The movement detectors continuously monitor the actual position, velocity, and acceleration of movable members and feed this information back to the control system. The control system compares this feedback with the desired trajectory and adjusts motor commands in real-time to correct deviations, thereby achieving high position control precision through closed-loop feedback control.
2Reliability
If real-time monitoring of movable members is implemented, then reliability is improved, but use of energy increases
Solution Approach 1:
The movement detectors operate continuously throughout the operational cycle of the movable members, providing uninterrupted real-time monitoring of position, velocity, and acceleration. This continuous operation ensures that any deviations or faults are detected immediately, maintaining high reliability without requiring periodic checks or interruptions in the monitoring function.
Solution Approach 2:
Each movable member is equipped with its own movement detectors and processing unit that autonomously monitor its own operational parameters. The system self-diagnoses its own status and reports anomalies to the central control, enabling self-monitoring and self-reporting functionality that improves reliability without requiring additional external monitoring infrastructure.
3Manufacturing precision
If processing units calculate movements and detect faults in real-time, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent divides the control system into distributed processing units, with each movable member having its own processing unit that independently calculates its movement parameters and detects faults. This segmentation allows each unit to focus on specific local calculations and fault detection, improving handling precision for that particular member while distributing the overall system complexity across multiple independent units rather than requiring one complex centralized processor.
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 enables precise monitoring of movable member movements, reduces handling of defective products, and detects mechanical issues early, ensuring accurate positioning and operation of packaging assemblies.
Implementation Method 1
The inertial sensor may be configured to detect an acceleration of the movable member (2) or of the at least one element (20, 21)
Implementation Method 2
The rotation sensor may be configured to detect an angular velocity of the movable member (2) or of the at least one element (20, 21)
Implementation Method 3
The magnetometer may be configured to detect a magnetic field and the processing unit (5, 23) may be configured to calculate a position of the second element (21) with respect to the first element (20) as a function of a signal (M3) from the magnetometer
Data Source
AI summary
A linear motor system includes a track and at least one movable member coupled to the track and configured to move along the track. The at least one movable member includes a first element, a second element relatively movable with respect to the first element, and at least one movement detector configured to transmit a movement signal. A processing unit is configured to calculate a movement of the movable member, the second element and/or the first element as a function of the movement signal received from the movement detector.