Linear Motor Slider Transfer Monitoring at Guide Rail Joints

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Solution Overview

Problem

Conveyance devices with guide rails face challenges in accurately aligning connecting positions due to environmental temperature changes and wear over time, leading to potential impacts and damage to the platform car and guide rails.

Innovation Solution

A conveyance device equipped with a controller that monitors vibration and driving electric power at the connecting portions between guide rails, allowing for predictive maintenance and notification of potential issues before damage occurs, thereby reducing impact-related damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the conveyor operates continuously over time, then productivity is improved, but the alignment accuracy of guide rail connecting portions deteriorates due to wear and thermal expansion

Engineering Contradiction:

Improvecontinuous operation capabilityVSAvoidalignment accuracy of guide rail connecting portions

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The system performs preliminary detection of alignment deviations at guide rail connecting portions before they cause damage to the slider. The vibration detection mechanism continuously monitors for abnormal vibrations that indicate misalignment, allowing maintenance to be performed proactively rather than reactively after damage occurs.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system implements feedback through continuous vibration monitoring at the guide rail connecting portions. When abnormal vibrations indicating misalignment are detected, the system generates alerts that feed back to operators for corrective action, creating a closed-loop system that maintains alignment accuracy over time.

Inventive Principle:

Principle #23Feedback

2Manufacturing precision

If the guide rails are rigidly fixed to maintain alignment, then manufacturing precision is improved, but the system becomes vulnerable to damage from thermal expansion and bimetallic effects

Engineering Contradiction:

Improvealignment accuracy of guide railsVSAvoiddamage from thermal expansion and bimetallic effects

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The system introduces vibration detection as an intermediary mechanism between the guide rails and the slider. Rather than trying to prevent all sources of misalignment (thermal expansion, bimetallic effects), the system detects the resulting vibrations as an intermediate indicator and uses this information to prevent final damage to the slider.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system replaces mechanical alignment maintenance (such as frequent manual realignment or complex compensation mechanisms) with a sensing-based approach. Vibration sensors detect misalignment conditions, and electronic monitoring systems track alignment degradation, substituting mechanical intervention with sensor-based detection and information processing.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Strength

If the slider is designed to be robust to withstand impacts, then strength is improved, but the device complexity and cost increase

Engineering Contradiction:

Improveimpact resistance of sliderVSAvoidslider design complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The system converts the potentially harmful impact forces into useful information through vibration detection. By monitoring vibrations at the guide rail connecting portions, the system detects misalignment conditions before they generate damaging impacts, effectively converting what would be harmful mechanical stress into diagnostic information that enables preventive maintenance.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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

The solution effectively reduces or prevents damage to guide rails and sliders by enabling proactive maintenance based on vibration and power state monitoring, ensuring accurate alignment and extending the lifespan of the conveyance system.

Implementation Method 1

a conveyor including a linear motor and a plurality of guide rails over which the slider is transferable

Methodology Applied

Scientific EffectLinear motor: Linear Motor

Implementation Method 2

acquire, based on a vibration in a connecting portion between the plurality of guide rails, a transfer state of the slider between the guide rails

Methodology Applied

Scientific EffectVibration detection: Vibration

Data Source

PatentUS11738954B2Conveyance device

Publication Date: 2023.08.29 YAMAHA MOTOR CO LTD

AI summary

A conveyance device includes a slider, and a conveyor including a linear motor and a plurality of guide rails over which the slider is transferable, and being configured to convey the slider. The conveyance device further includes a controller configured or programmed to acquire, based on a vibration in a connecting portion between the plurality of guide rails or driving electric power of the linear motor in the connecting portion between the plurality of guide rails, a transfer state of the slider between the guide rails.