Sequential Rotary Track Drive for Independent High-Speed Movers
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Solution Overview
Problem
Current track systems for high-speed conveying applications, such as those using linear synchronous motors, are limited by low maximum velocities and significant drops in magnetic thrust force as velocity increases, making them unsuitable for high-speed converting operations.
Innovation Solution
A controlled motion system comprising a track with parallel lanes and rotary motor-driven drive elements that sequentially engage with movers to provide independent and controlled motion, allowing for variable velocities and forces along the track, utilizing gear pinions and timing belts for mechanical engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If linear synchronous motors are used for track systems, then electromagnetic propulsion is achieved, but maximum velocity is limited and magnetic thrust force drops significantly at higher velocities
Solution Approach 1:
The track system is divided into multiple independent drive zones, each with its own rotary motor and drive elements. This segmentation allows different portions of the track to operate at different velocities and forces simultaneously, enabling high-speed operation in some zones while maintaining high thrust in others, thus resolving the contradiction between maximum velocity and magnetic thrust force.
Solution Approach 2:
The patent replaces the electromagnetic linear motor system with a mechanical drive system using rotary motors, drive elements (such as friction wheels or gears), and mechanical transmission components. This substitution eliminates the velocity-dependent thrust degradation inherent in electromagnetic systems, allowing maintainment of high force at high velocities through mechanical advantage and optimized friction/gear engagement.
2Productivity
If linear synchronous motors are used, then electromagnetic force propulsion is achieved, but the system is unsuitable for high-speed converting operations
Solution Approach 1:
The system employs dynamically adjustable drive elements that can modify their engagement characteristics, rotational speed, and positioning in real-time based on operational requirements. This dynamic control allows the mechanical drive system to optimize performance for high-speed converting operations, adjusting forces and velocities to match production demands while maintaining suitability for such operations.
Solution Approach 2:
By replacing the electromagnetic propulsion system with a mechanical drive system using rotary motors and drive elements, the patent enables high-speed converting operations that were previously unachievable with linear synchronous motors. The mechanical system provides better control over force and velocity relationships, making it suitable for high-productivity converting applications.
3Adaptability or versatility
If multiple movers are driven independently, then individual velocity control is achieved, but system complexity increases
Solution Approach 1:
The patent merges multiple drive functions into a unified track-based system where rotary motors and drive elements serve multiple movers simultaneously. The drive elements travel along the track and can engage with different movers at different positions, providing independent velocity control to multiple movers through a shared infrastructure rather than requiring separate drive systems for each mover, thus reducing overall system complexity.
Solution Approach 2:
The drive elements are designed with multi-functionality, capable of engaging with different movers, adjusting their velocities independently, and operating at various positions along the track. This universal design allows a single type of drive element to serve multiple purposes and multiple movers, reducing the variety of components needed and simplifying the overall system structure while maintaining independent control capabilities.
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 high-speed and high-force conveying capabilities, overcoming the limitations of existing systems by allowing independent control of movers' velocities and forces, enhancing performance in high-speed converting operations.
Implementation Method 1
wherein the drive elements are each driven by a rotary motor
Implementation Method 2
the drive elements each comprising a surface that is oriented to contact the driven member of the movers
Data Source
Figure 1
Figure 2A~2C
Figure 3A~3D
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.