Planar Motor Carrier Path Control for Collision Avoidance
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Solution Overview
Problem
Planar motor systems in packaging lines face challenges with malfunctions, collisions between carriers, and the need to rapidly adapt to operational changes to prevent production stoppages and ensure efficient container handling.
Innovation Solution
A method and system for controlling planar motor systems that dynamically adjust carrier movement paths based on event signals, using a graph-based algorithm to optimize paths and avoid collisions, and a control unit to manage carrier movements and obstacles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the planar motor system operates at constant speed to maintain production flow, then productivity is improved, but the system becomes vulnerable to malfunctions and collisions when events occur
Solution Approach 1:
The control unit dynamically adjusts carrier speeds and trajectories in response to events. When an event is detected, the control unit modifies the movement parameters of affected carriers while maintaining constant speed for unaffected carriers, allowing the system to adapt to malfunctions while preserving overall productivity.
Solution Approach 2:
The control unit continuously monitors the system for events and uses this feedback to adjust carrier movements. The feedback mechanism detects malfunctions and triggers appropriate responses, such as slowing down or rerouting carriers, to prevent collisions while maintaining production flow.
2Reliability
If the control unit rapidly responds to events to restore operability, then reliability is improved, but the risk of collisions between carriers increases due to sudden movements
Solution Approach 1:
When an event is detected, the control unit proactively adjusts the trajectories and speeds of carriers that may be affected, before collisions can occur. This preliminary anti-action prevents harmful effects by modifying carrier movements in advance based on predicted collision risks.
Solution Approach 2:
The control unit implements protective measures by reducing speeds and creating safety buffers around affected carriers before actual collisions can happen. This cushioning approach allows the system to respond rapidly to events while minimizing the risk of harmful collisions.
3Ease of operation
If carriers maintain fixed trajectories to ensure predictable operation, then ease of operation is improved, but the system cannot adapt to operational changes or malfunctions
Solution Approach 1:
The system maintains predictable operation for carriers not affected by events, while dynamically adjusting the trajectories of affected carriers. This selective dynamic approach preserves ease of operation for the majority of carriers while enabling adaptability when needed.
Data Source
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AI summary
It is disclosed a method for controlling a planar motor system (1), the planar motor system (1) comprising a base element (2) and a plurality of carriers (3A,3B,3C,3D), movable independently over the base element (2); the method comprising the following phases: - receiving an event signal indicative an event related to the operation of the carriers (3A,3B,3C,3D) and / or of the base element (2), and performing the following operation, as a function of the event signal: - determining, for each carrier (3A,3B,3C,3D), a starting point (P1) and an arrival point (P2), - generating a graph (G) defined by a plurality of potential movement points over the base element (2), including the starting point (P1) and the arrival point (P2), - calculating a movement path (P) from the starting point (P1) to the arrival point (P2), which connects a portion of the potential movement points of the graph (G) .