Rockwell Automation Technologies Incorporated

Magnemotion, Inc.

Rockwell Automation, Inc.

Eric J Wildi

Yuhong Huang

Robert H Schmidt

Brian M Perreault

Oliver C Haya

Neil R Bentley

Mark R Cooper

A system automatically calibrates gains and/or offsets for each position feedback signal in order to reduce variations between position feedback signals for each sensor in a linear drive system. As a mover travels along a track segment, the segment controller records the position feedback signal output from each position sensor corresponding to a magnet on the mover passing the position sensor. The segment controller periodically monitors the position feedback values generated by one mover as it travels along the track segment and automatically updates the sensor gains as a function of a ratio of a target peak value to a measured peak value of the position feedback signal. The segment controller also records the position feedback signal from each sensor when no mover is traveling past the sensor. The segment controller periodically monitors the position feedback values received when no mover is present and automatically updates sensor offset values.

System and method for automatic runtime position sensor offset calibration in a linear motion system

A system to automatically calibrate gains and/or offsets for each position feedback signal in order to reduce variations between position feedback signals for each sensor in a linear drive system is disclosed. As a mover travels along a track segment, the segment controller records the position feedback signal output from each position sensor corresponding to a magnet on the mover passing the position sensor. The segment controller determines peak values for each position feedback signal and compares the peak values against a target peak value. The segment controller then adjusts a gain value for each sensor by a ratio of the target peak value to a measured peak value. The segment controller periodically monitors the position feedback values generated by one mover as it travels along the track segment and automatically updates the sensor gains as previously described.

System and method for automatic runtime position sensor gain calibration in a linear motion system

A controller for an independent cart system simplifies programming and automatically adapts operation each mover travelling along a track. The controller includes a configuration table defining segments of the track, which includes a maximum velocity and/or a maximum acceleration for each mover within the segment. A motion command for a mover commands motion across multiple segments between the starting point and the ending point. As the mover travels, the controller receives a position feedback signal corresponding to the present location of the mover. The controller obtains the maximum velocity and/or maximum acceleration for the mover corresponding to the segment in which it is located. The controller automatically adjusts the speed and/or acceleration of the mover along the segment in which it is presently located. As the mover transitions between segments, the controller automatically adjusts the speed and/or acceleration according to the new segment in which the mover is located.

System and method for limiting motion in an independent cart system

An improved system and method for monitoring operation of movers in an independent cart system reduces the required communication bandwidth for monitoring operation of movers in a system where control is distributed among multiple controllers spaced along the track. As the mover is travelling along the track segment, each distributed controller monitors at least one operating characteristic of the mover. As a mover travels along the track, each distributed controller transmits the operating characteristic to a successive distributed controller, such the monitored operating characteristic is transmitted along the track as the mover travels along the track. At a reduced rate or upon request from a central controller, each distributed controller may transmit the status of a mover present on the corresponding track segment controlled by that distributed controller to the central controller.

System and method for monitoring mover status in an independent cart system

A linear drive system provides a combination of distributed control to increase the number of movers which may be supported in the system and centralized control to reduce the separation distance between movers by grouping movers together and placing a reference mover of the group under central control with remaining movers of the group under distributed control. In addition, in precise working locations, or 'synchronization zones,' each of the movers can be temporarily placed under central control to further reduce the separation distance and allow improved coordination with industrial processes or machines in the system.

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Lexington, MA, United States of America

Eric J Wildi