Motion Trajectory Switching for Bump-Less Cart Control
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Solution Overview
Problem
Transitioning between centralized and distributed control methods in independent cart systems results in abrupt changes in motion commands, leading to vehicle vibrations and reduced throughput due to the need for vehicles to be stopped during transitions.
Innovation Solution
A method and system that allows for smooth operation by maintaining a record of operating conditions and blending motion commands between controllers, enabling transitions while the vehicle is moving.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If transitioning between centralized and distributed control methods is implemented, then control flexibility and system scalability are improved, but motion command abrupt changes and vehicle vibrations occur
Solution Approach 1:
The patent applies preliminary action by having the second controller receive and process the first motion trajectory data before the transition occurs. The second controller uses the operating state data (position, velocity, acceleration) from the first controller to generate a continuous motion trajectory, ensuring that the transition between control methods does not cause abrupt changes or vibrations in the vehicle motion.
Solution Approach 2:
The patent implements feedback by using the operating state data (position, velocity, acceleration) from the first controller as input to the second controller. This feedback mechanism ensures that the second controller can generate motion commands that are consistent with the current vehicle state, maintaining smooth and continuous motion during the transition between centralized and distributed control methods.
2Adaptability or versatility
If transitioning between control methods is implemented, then control flexibility is improved, but system throughput decreases due to vehicle stops
Solution Approach 1:
The patent applies continuity of useful action by enabling the transition between centralized and distributed control methods while the vehicle is in motion. The second controller receives the first motion trajectory and uses the current operating state to generate continuous motion commands, eliminating the need to stop the vehicle during controller transitions and thereby maintaining system throughput.
3Stability of the object's composition
If a central controller is used, then coordination of vehicle motion is improved, but system size and complexity are limited
Solution Approach 1:
The patent applies segmentation by dividing the control system into multiple independent controllers (first controller and second controller) that can each manage specific track segments. This allows the system to scale to larger sizes by adding more track segments and controllers while maintaining coordinated vehicle motion through the transition mechanism that shares motion trajectory data between controllers.
4Device complexity
If distributed control is used, then system scalability is improved, but coordination between controllers is difficult
Solution Approach 1:
The patent applies the intermediary principle by using the motion trajectory data and operating state information as a mediator between the first and second controllers. The second controller receives the first motion trajectory and uses it to generate continuous motion commands, ensuring smooth coordination during transitions while maintaining the scalability benefits of distributed control architecture.
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
Ensures continuous and smooth motion control during transitions between different control structures, enhancing system throughput by avoiding abrupt changes and vehicle stops.
Implementation Method 1
The track is made up of a number of track segments that, in turn, hold individually controllable electric coils. Successive activation of the coils establishes a moving electromagnetic field that interacts with the movers and causes the mover to travel along the track.
Data Source
AI summary
A system and method of transitioning between motion trajectories in an independent cart system includes controlling motion of a mover along a track segment with a segment controller responsive to a first motion trajectory. At least one operating state for the first motion trajectory is received at an external controller as the segment controller is controlling motion of the mover responsive to the first motion trajectory. A second motion trajectory for the mover is generated with the external controller, where the second motion trajectory includes the at least one operating state as an initial condition for the second motion trajectory. While the segment controller is controlling motion of the mover along the track segment responsive to the first motion trajectory, the second motion trajectory is transmitted from the external controller to the segment controller, and the segment controller switches from the first motion trajectory to the second motion trajectory.