Virtual Path Control for Timed Trackless Movers
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Solution Overview
Problem
Existing mover systems lack the ability to adjust paths dynamically and ensure precise, timed arrivals at destinations, particularly in complex environments with varying obstacles, leading to inefficiencies and inaccuracies in object transportation.
Innovation Solution
A trackless mover system with independently controlled movers that follow a predefined virtual vector path, adjusted by a master controller using communication networks and tracking sensors to ensure timely arrivals, and can modify paths in real-time to avoid obstacles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If chain based systems or magnet moving systems are used, then movers can be transported along a fixed path, but the path cannot be easily reconfigured and all movers must operate at the same line speed
Solution Approach 1:
The patent implements dynamic path planning where each mover has an independently adjustable virtual vector path that can be modified in real-time based on system conditions, object destinations, and obstacles. This allows the path to adapt dynamically rather than being fixed mechanically, resolving the contradiction between path reconfigurability and system rigidity.
Solution Approach 2:
The system changes the operational parameters of each mover independently, including path coordinates, velocity profiles, and timing parameters. This allows different movers to travel at different speeds and follow different paths simultaneously, enabling path reconfiguration without mechanical redesign while maintaining system coordination through the master controller.
2Productivity
If all movers operate at the same line speed to maintain synchronization, then coordinated operation is achieved, but flexibility in individual mover timing and speed adjustment is lost
Solution Approach 1:
The patent segments the control of each mover into independent virtual axis entities, where each mover's path and speed parameters can be individually defined and adjusted. This segmentation allows independent speed control for each mover while the master controller coordinates their operations to achieve overall system productivity and synchronization when needed.
Solution Approach 2:
The system implements dynamic speed adjustment where each mover's velocity profile can be modified in real-time based on its specific destination, load conditions, and system requirements. The master controller dynamically coordinates these individual adjustments to maintain coordinated operation, allowing both individual flexibility and collective synchronization.
3Manufacturing precision
If mechanical pinning systems are used to precisely position objects, then position accuracy is achieved, but the system must stop the mover and requires additional mechanical components
Solution Approach 1:
The patent replaces mechanical pinning systems with a virtual positioning system that uses calculated position data from tracking sensors and master controller computations. The mover maintains continuous motion while the system achieves precise positioning through digital coordinate control and path adjustment, eliminating the need for mechanical stopping and pinning components.
Solution Approach 2:
The system implements continuous feedback through tracking sensors that monitor each mover's actual position and the master controller compares this with the scheduled position. This feedback loop enables real-time path and speed adjustments to achieve precise positioning accuracy without mechanical intervention, maintaining continuous motion while achieving manufacturing precision.
4Reliability
If network cables are used for control connections, then data reliability is maximized, but system flexibility and ease of reconfiguration is reduced
Solution Approach 1:
The patent implements a dynamic communication architecture where the control system can adapt its connection methods based on requirements. The master controller can coordinate movers using wireless communications for flexible reconfiguration while maintaining reliable data transmission through protocol management and error handling, allowing the system to achieve both reliability and adaptability through intelligent communication management rather than fixed physical connections.
Data Source
AI summary
A moving system comprising a master controller for monitoring and controlling a master operation comprising one or more individual movers such that each mover arrives at predefined end point at selected times. Each mover includes a mover control system that interacts with the master controller and has a predefined virtual vector path with one or more defined end points. The predefined virtual vector path comprises a plurality of discrete points, wherein each discrete point has a vector axis for use by the master controller and the mover control system to direct the mover to move such that it arrives at each defined end point at a selected time. In operation, the master controller functions to modify the predefined virtual path and sends commands to the mover control system in response to changes in the master operations.