Magnetic Tray Shuttle Routing With Linear-Motor Pusher Transfer
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Solution Overview
Problem
Existing tray conveyors face challenges in efficiently routing trays between different conveying lines, particularly due to the need for precise control and efficient transfer mechanisms to ensure smooth movement and alignment.
Innovation Solution
A tray shuttle system utilizing a tray holder with a track supported by a first mover and a pusher movable along the track, connected via a linkage to a second mover, combined with a linear-motor stator to propel the tray shuttle, enabling bidirectional movement and precise tray transfer between conveyor sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a traditional mechanical linkage system is used to route trays between conveying lines, then the structure is simple and easy to manufacture, but the precision of tray alignment and positioning is insufficient
Solution Approach 1:
The patent replaces traditional mechanical linkage systems with a linear motor-driven pusher mechanism. The linear motor provides precise positional control through electromagnetic fields, eliminating the need for complex mechanical linkages while achieving high alignment precision. The pusher is moved along the tray holder by electromagnetic force rather than mechanical connection, resolving the contradiction between precision and complexity.
Solution Approach 2:
The patent introduces a linear motor as an intermediary between the control system and the pusher mechanism. This intermediary converts electrical signals into precise mechanical motion, enabling accurate tray positioning without direct mechanical linkages. The linear motor acts as a mediator that translates control commands into precise physical displacement, achieving high positioning accuracy while maintaining system simplicity.
2Speed
If a linear motor system is used to propel the tray shuttle, then the speed control and positioning precision are improved, but the energy consumption increases
Solution Approach 1:
The linear motor operates in periodic cycles, accelerating the tray shuttle to transfer speed, maintaining it during the transfer, then decelerating and stopping. The motor is activated only during these periodic transfer operations rather than continuous operation, reducing overall energy consumption while achieving high speed control precision during active transfer phases.
Solution Approach 2:
The tray shuttle system uses the magnetic field from the linear motor to both propel and brake the shuttle. During deceleration, the motor acts as a regenerative brake, converting kinetic energy back into electrical energy that can be recovered or dissipated, reducing net energy consumption while maintaining precise speed control throughout the transfer cycle.
3Measurement precision
If a Scott-Russell linkage is used to move the pusher along the track, then the movement precision is improved, but the device complexity increases
Solution Approach 1:
The patent replaces the Scott-Russell mechanical linkage with a linear motor-driven pusher system. The linear motor provides direct electromagnetic propulsion along the track, eliminating the need for complex mechanical linkages. Position sensing systems (such as encoders or magnetic sensors) provide precise position feedback without mechanical linkages, resolving the contradiction between positioning precision and mechanical complexity.
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
Enables efficient and precise routing of trays between conveyor sections by leveraging a Scott-Russell linkage and linear synchronous motors for controlled tray movement, ensuring seamless transitions and alignment.
Implementation Method 1
A transfer linear-motor stator (140) extends along the travel direction and produces an electromagnetic flux wave that interacts with the magnetic field of the permanent-magnet array in the first mover to propel the tray shuttle in the travel direction
Implementation Method 2
A first mover (22, 92) that extends in a width direction (24) perpendicular to a bidirectional travel direction (25) from a first side (26) to a laterally opposite second side (27). The first mover (22, 92) includes four wheels (29) and a permanent-magnet array (28, such as a Halbach array), at or near the mover's bottom side
Implementation Method 3
A linkage (48, 100) connects the first and second movers (22, 46). The linkage (48, 100) moves the pusher (58, 110) along the track between the rails (76, 77) by the movement of the pusher mover (46) relative to the holder mover (22, 92) in the bidirectional travel direction (25)
Data Source
Figure 1~2
Figure 3A~3D
Figure 4A~4D
AI summary
A tray shuttle and a tray conveyor using the tray shuttle to route magnetic conveyor trays from one conveyor section to another. The trays and the shuttles are propelled by linear-motor stators that produce electromagnetic flux waves that interact with the magnetic fields of permanent-magnet arrays in movers in each tray. Each shuttle has a main holder mover and one or more other movers connected to a linkage that operates one or more pushers that push trays off a tray holder on the shuttles.