Rockwell Automation Technologies Incorporated

Oliver C Haya

Peter M Smit

Mark R Cooper

Xikai Sun

Nanwei Yao

John Floresta

Peter J Bruder

Robert H Schmidt

Yuhong Huang

Patrick E Ozimek

Neil R Bentley

Eric J Wildi

Marc Koeppel

Paul Jerome Grosskreuz

Juan A Fernandez

Shankernarayan Ramanarayanan

Rui Zhou

Linglai Li

Aderiano M Da Silva

A linear motor system may include a plurality of track sections that may enable a mover to traverse a track formed by the plurality of track sections. The system may also include a plurality of connection modules, such that each connection module of the plurality of connection modules may physically couple two respective adjacent track sections of the plurality of track sections and communicatively couple the two respective adjacent track sections of the plurality of track section. Each connection module may also electrically couple the two respective adjacent track sections of the plurality of track section.

Track connection module for linear motor tracks

A system and method for providing power to independent movers traveling along a track in a motion control system without requiring a fixed connection between the mover and a power source external to the mover. In one embodiment, a sliding transformer transfers power between the track and each mover. In another embodiment, an optical transmitter transfers power between the track and an optical receiver mounted on each mover. In yet another embodiment, a generator includes a drive wheel engaging the track as each mover travels along the track. A power converter on the mover receives the power generated on and/or transmitted to the mover to control an actuator or a sensor mounted on the mover or to activate drive coils mounted on the mover to interact with magnets mounted along the track and, thereby, control motion of each mover.

Method and system for contactless power transfer in a linear drive system

An improved system for determining the identification of movers in a motion control system is disclosed, where the motion control system includes multiple movers traveling on a track. The physical construction of at least one element of one of the movers is different on one mover than on each of the other movers. The control system for the movers detects the difference in construction and identifies the unique mover as a first mover. Each of the other movers along the track are assigned an identifier based on their relative position to the first mover. According to one embodiment, a position sensing system is utilized to identify the first mover. According to another embodiment, the drive system for the movers is utilized to identify the first mover. In still another embodiment, a combination of the position sensing system and the drive system is utilized to identify the first mover.

Method and apparatus for identifying a mover on a track

A linear motor system has multiple modular track sections joined end-to-end to form a track along which movers may be displaced by the control of magnetic fields generated by coils disposed in each track section. A curved track section is provided that includes a curved portion, an integral straight portion, and a fit spline transition between the curved portion and the straight portion. The integration of the straight portion smooths the transition between the curved and straight areas of the track, and allows for improved performance.

Curvilinear motor

Method and apparatus for power transfer to an independent moving cart during travel along a track

A system and method for wirelessly providing power to independent movers traveling along a track includes a sliding transformer to transfer power between the track and each mover. The sliding transformer includes a primary winding extending along the track and a secondary winding mounted to each mover. Each of the primary and secondary windings may be formed of a single coil or multiple coils. The primary and secondary windings are generally aligned with each other and extend along the track and along the mover in the direction of travel with an air gap present between the windings. A power converter on the mover may regulate the power supplied to the mover to control an actuator or a sensor mounted on the mover or to activate drive coils mounted on the mover to interact with magnets mounted along the track and, thereby, control motion of each mover.

Method and apparatus for wireless power transfer to an independent moving cart

A linear motor system has multiple modular track sections joined end-to-end to form a track along which movers may be displaced by the control of magnetic fields generated by coils disposed in each track section. A curved track section is provided that includes a non-constant radius of curvature that is a non-linear function of the run length along the curved track section. The curved track section may have a number of different radii of curvature, and one or more of them may be based on a non-linear function of the run length. The resulting curvature provides improved dynamic performance of movers driven along the curved track section.

Linear motor curve module with improved geometry

An improved system for determining the identification of movers in a motion control system is disclosed, where the motion control system includes multiple movers traveling on a closed track. The physical construction of at least one element of one of the movers is different on one mover than on each of the other movers. The control system for the movers detects the difference in construction and identifies the unique mover as a first mover. Each of the other movers along the track are assigned an identifier based on their relative position to the first mover. According to one embodiment, a position sensing system is utilized to identify the first mover. According to another embodiment, the drive system for the movers is utilized to identify the first mover. In still another embodiment, a combination of the position sensing system and the drive system is utilized to identify the first mover.

Method and apparatus for identifying a mover on a closed track

A curvilinear encoder is provided in which an incremental or absolute position for a cart can be detected on a track by applying one or more excitation signals and receiving one or more pick up signals. Analogous to a transformer arrangement, an encoder mover can be placed on the cart moving along the track, and an encoder stator can be placed on the track separated by a gap. The one or more excitation signals can be applied to the one or more excitation coils on the mover or the stator to generate one or more magnetic fields, and the one or more pick up signals can be received by one or more pick up coils on the mover or the stator for sensing changes in the magnetic fields produced by motion of the mover on the track.

Curvilinear encoder system for position determination

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.

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Milwaukee, WI, United States of America

Oliver C Haya