Track Mover Transport with Sequential Rotary Drive Zones
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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 unsuitable for high-speed converting applications, where higher speeds and forces are required.
Innovation Solution
A controlled motion system with a track and movers that utilize a plurality of rotationally free drive elements, driven by rotary motors, allowing for independent control of velocity profiles along the track, enabling sequential engagement and synchronized motion of movers to achieve higher speeds and forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If linear synchronous motor (LSM) based systems are used for track transport, then electromagnetic force propulsion is achieved, but speed and magnetic thrust force are limited
Solution Approach 1:
The track system is divided into multiple independent drive zones, each with its own LSM capable of independent control. This segmentation allows different sections to operate at different speeds and forces simultaneously, enabling high-speed transport in certain zones while maintaining control in others, thus resolving the contradiction between speed and thrust force limitations.
Solution Approach 2:
The system dynamically adjusts the operational parameters of each LSM zone based on real-time requirements. By making the drive system dynamic rather than static, the track can optimize speed and force distribution across different zones, allowing high-speed converting operations to occur in specific segments while other segments maintain lower speeds for loading/unloading or precise positioning.
2Productivity
If higher speeds and forces are implemented in track systems, then high-speed converting operations are enabled, but control precision and synchronization become more difficult
Solution Approach 1:
Each LSM zone is equipped with feedback mechanisms that continuously monitor position, speed, and force parameters. This feedback is used to dynamically adjust operational parameters, ensuring precise velocity control even at high speeds. The feedback loops enable real-time correction of any deviations, maintaining synchronization across multiple drive zones despite high-speed operations.
Solution Approach 2:
The control system is designed to universally manage multiple LSM zones with different operational requirements through a centralized coordination mechanism. This multi-functional control architecture can simultaneously handle high-speed transport, precise positioning, acceleration, and deceleration across different zones, maintaining measurement precision regardless of the operational mode or speed level in any given zone.
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 system enables independent control of movers' velocities and forces, enhancing performance for high-speed converting operations by maintaining tangential velocity control and reducing acceleration and jerk stresses, thus overcoming the limitations of existing systems.
Implementation Method 1
wherein the drive elements may each be driven by a rotary motor
Implementation Method 2
engaging the first mover mechanically with the first drive element at a first position on the path, wherein the first drive element is moving with a first rotational velocity, and the first rotational velocity of the first drive element prescribes the tangential velocity of the first mover
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.