Independent Mover Track Drive With Sequential Pinion Engagement
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Solution Overview
Problem
Current track systems for driving vehicles, such as those using linear synchronous motors, are limited in speed and magnetic thrust force, making them less effective for high-speed converting applications, as they can only convey vehicles at velocities up to 2.5-5 meters/second and experience significant reductions in thrust force as velocity increases.
Innovation Solution
A controlled motion system comprising a track with movers that have driven members engaged by drive elements like pinions or timing belts, where rotary motors drive these elements to provide independent and controlled motion along the track, allowing for higher speeds and forces by sequential engagement and synchronized control of the movers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If linear synchronous motor (LSM) systems are used to drive vehicles along a track, then independent movement of vehicles is achieved, but the maximum velocity is limited to 2.5-5 meters/second and magnetic thrust force drops off considerably as velocity increases
Solution Approach 1:
The track is divided into multiple zones with discrete drive elements (pinions, timing belts, chains) positioned at specific intervals. Each drive element can independently engage with the mover's driven member, allowing selective acceleration and velocity control at different track positions. This segmentation enables the system to overcome the velocity limitations of LSM by using mechanical drive elements that can provide high thrust at various speed ranges.
Solution Approach 2:
The system dynamically transitions between different drive mechanisms based on velocity requirements. Rotary motors drive the mechanical elements (pinions, timing belts, chains) to provide high thrust at lower velocities, while the system can smoothly transition to maintain independent velocity control at higher speeds. This dynamic adaptation allows the system to maintain both high speed capability and sufficient thrust force throughout the velocity range.
2Productivity
If linear synchronous motor (LSM) systems are used, then vehicles can be conveyed along the track, but the magnetic thrust force generated drops off considerably as velocity increases
Solution Approach 1:
The patent replaces the electromagnetic drive system (LSM) with a mechanical drive system consisting of rotary motors coupled to mechanical transmission elements (pinions, timing belts, chains). These mechanical elements directly engage with the mover's driven member through meshing or friction contact, providing reliable thrust force transmission that does not suffer from the velocity-dependent force drop-off characteristic of magnetic systems. The mechanical substitution enables maintaining high thrust force across a broader velocity range.
3Speed
If rotary motors drive pinions or timing belts to engage driven members, then higher speeds and forces are achieved, but the system complexity increases with multiple drive elements and sequential engagement requirements
Solution Approach 1:
The drive elements (pinions, timing belts, chains) are designed to be universally applicable across different track positions and mover types. Each drive element follows a closed-loop path and can engage with standard driven members on various movers. This universality reduces overall system complexity by using standardized components rather than custom-designed drive mechanisms for each position, despite having multiple drive elements distributed along the track.
Solution Approach 2:
The drive elements are positioned and configured to automatically engage with the mover's driven member as the mover passes through the engagement zone. The sequential engagement is self-regulating based on the mover's position and velocity, reducing the need for complex active control mechanisms. The mechanical geometry of the drive elements and driven members ensures proper engagement timing, allowing the system to manage its own operation with minimal external coordination.
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 independent control of movers at higher speeds and forces, enhancing performance in high-speed converting operations by maintaining thrust force and velocity control, overcoming the limitations of existing systems.
Implementation Method 1
The drive elements are configured to sequentially engage the driven member of a plurality of the movers to provide controlled motion of the movers independently around the track. The drive elements may each be driven by a rotary motor.
Data Source
AI summary
A system and an apparatus capable of independently driving movers are described herein. The system and apparatus includes: a track that forms a path for movers; a plurality of movers movably mounted on the track for moving along the path; and a plurality of drive elements fixedly arranged along the track. The drive elements each have a surface that is oriented to contact a driven member of the movers. The drive elements are configured to sequentially engage the driven member of a plurality of the movers to provide controlled independent motion of the movers along the track. The drive elements may be driven by rotary motors. A method of independently driving movers is also described herein.