Linear Transporter Magnetic Shield Molding for Accurate Position Detection
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Solution Overview
Problem
Existing linear transporters face accuracy issues in position detection due to magnetic interference and manufacturing variations, particularly in forming magnetic shields with precise corner portions, leading to irregularities in magnetic flux and reduced detection accuracy.
Innovation Solution
A linear transporter design with a magnetizer and magnetic shield formed by integral molding using a resin containing magnetic material powder, where the magnetic shield blocks magnetic lines of force on end and top surfaces, and a correction value storage corrects positions using common values for multiple carriers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the magnetic shield is formed by bending a plate-shaped magnetic body or cutting a block of magnetic material, then the magnetic shield can be manufactured, but the corner portion cannot be formed with high accuracy, creating spaces between the magnet and magnetic shield
Solution Approach 1:
The magnetic shield is formed by injecting magnetic material into a resin, creating a composite material structure. This allows the magnetic shield to be molded into complex shapes including precise corner portions that maintain tight contact with the magnet, eliminating the manufacturing difficulties associated with bending plates or cutting blocks while achieving high corner portion accuracy.
2Reliability
If spaces exist between the magnet and magnetic shield due to dimensional tolerance, then the magnetic shield can be manufactured, but irregularities occur in magnetic flux and position detection accuracy decreases
Solution Approach 1:
By forming the magnetic shield as a composite material of magnetic material injected into resin, the shield can be precisely molded to maintain tight contact with the magnet without spaces. This eliminates magnetic flux irregularities caused by gaps while maintaining manufacturing feasibility, thereby improving position detection accuracy.
3Measurement precision
If individual correction values are stored for each transport body to compensate for manufacturing variations, then position detection accuracy is maintained, but the system complexity and storage requirements increase
Solution Approach 1:
By forming all magnetic shields using the same composite material injection process, manufacturing variations are minimized and made homogeneous across different transport bodies. This allows a single common correction value to be used for all transport bodies, reducing system complexity and storage requirements while maintaining position detection accuracy.
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 design suppresses irregularities in magnetic flux, reduces manufacturing variations, and enhances position detection accuracy by ensuring tight contact between the magnet and shield, minimizing the need for individual correction values and lowering manufacturing costs.
Implementation Method 1
a magnetic shield that is a magnetic body and is formed of a resin containing a magnetic material powder, where the magnetic shield blocks magnetic lines of force originating from the magnet
Implementation Method 2
a magnetizer installed on each of the transport bodies configured to generate a magnetic field for use in position detection
Implementation Method 3
a magnetic detection element installed on the transport path to detect the magnetic field
Data Source
AI summary
A linear transporter includes: a transport path including a stator; multiple transport bodies that move along the transport path; a magnetizer that is installed on each of the transport bodies and generates a magnetic field for use in position detection; a magnetic detection element that is installed on the transport path and detects the magnetic field; a calculator that calculates the position of each of the transport bodies on the basis of the magnetic field detected by the magnetic detection element; and a correction value storage that stores a correction value set, which is a combination of correction values for correcting the position of each of the transport bodies. The magnetizer includes a magnet in which magnetic poles of different polarities are arranged alternately along a moving direction of the transport bodies.