Rockwell Automation Technologies Incorporated

Xikai Sun

Peter M Smit

Mark R Cooper

Oliver C Haya

Nanwei Yao

Jadav Das

John Floresta

Tracy M Clark

Peter J Bruder

Robert H Schmidt

Gennadi Sizov

Dayin Xu

Neil R Bentley

Shankha S Seal

Lixiang Wei

Richard Lukaszewski

Yuan Xiao

Haihui Lu

Jingbo Liu

Michael J Melfi

Wei Qian

Jiangang Hu

Linglai Li

Aderiano M Da Silva

Kun Wei

Shaofeng Zhang

Michaela R Kaufmann

A system and method of determining orientation of a physical location on a cart or end effector located on the cart in an independent cart system receives a feedback signal from a sensor on the cart. A multi-axis device may generate three or more signals corresponding to X, Y, and Z axes orientations. Processing may be performed on the signals to generate a value of yaw, pitch, or roll of the cart. The feedback or processed signals are transmitted from the mover to a remote device external from the track. The real-time orientation information may be used to implement closed-loop control of an actuator mounted on or external to each cart as the cart travels along the track. Power for the devices on the mover may be provided by a battery mounted on the cart or by a wireless power transfer system.

System and method for determining real-time orientation on carts in an independent cart system

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

A system for wirelessly transmitting power between a track and independent movers in a motion control system includes a pick-up coil provided proximate to the magnets on the movers. The fundamental component of the voltage applied to the drive coils interacts primarily with the magnetic field generated by the permanent magnets on the movers and not with the pick-up coil. Consequently, the pick-up coil does not interfere with desired operation of the movers but rather, interacts primarily with the harmonic components and has current and voltages induced within the pick-up coil as a result of the harmonic components. The energy captured by the pick-up coil reduces the amplitude of eddy currents on the mover. After harvesting the harmonic content, the pick-up coil may be connected to another circuit on the mover and serve as a supply voltage for the other circuit.

System and method for wireless power transfer in a linear cart system

An independent cart system includes an inductive link for contactless power transfer between a track and each mover as the mover travels along the track. A system for contactless data transmission between movers and a controller in the independent cart system includes a transmitter and/or receiver mounted on each mover and a complementary receiver and/or transmitter mounted on a track. The transmitter receives data to be transmitted across the inductive link and modulates a voltage present on either the primary or secondary winding to which it is coupled. The modulated voltage present on one winding induces a corresponding modulation on the voltage present on the other winding. A receiver operatively connected to the other side of the inductive link detects the modulated voltage and decodes the data from the modulated voltage received across the inductive link.

Method and apparatus for data transmission over an inductive link for an independent cart system

A system to reduce eddy currents and the resulting losses in a synchronous motor includes at least one pick-up coil mounted to the rotor. Each pick-up coil may be located proximate a pole on the rotor. A voltage applied to the stator to control the synchronous motor includes both a fundamental component and harmonic components. The fundamental component interacts with a magnetically salient structure in each pole on the rotor to cause rotation of the rotor. The harmonic components induce a voltage in the pick-up coil. The portion of the harmonic components that induce a voltage in the pick-up coil no longer generate eddy currents within the motor. The energy harvested by the pick-up coil may also be utilized in a function other than driving the motor, such as powering a sensor mounted on the rotor.

System and method for wireless power transfer to a rotating member in a 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

By configuring an encoder scale as a varying scale with successively increasing or decreasing pitch, sensors in a travel path of the scale can detect a phase difference to determine an absolute position of the scale for use in an industrial control system. Due to the successively increasing or decreasing pitch, each sensor can detect successively increasing or decreasing properties (such as magnetic fields) from the scale in a uniquely identifiable pattern. By taking the difference between readings of adjacent sensors, each sensor detecting properties of the scale, an absolute position of the scale between the sensors can be determined. The principle for feedback for the encoder system is analogous to a Nonius or Vernier principle to determine absolute position.

Encoder system for position determination with varying scale

By configuring an encoder scale as an angled or inclined magnet or pair of oppositely arranged, adjacent magnets, a magnetic field sensor in a travel path of the scale can detect an absolute position of the scale for use in an industrial control system. Due to the angle or incline, when a first side of the scale is proximal to the sensor, the sensor can detect an angle of &#x2212;180&#xb0;. As the scale moves to center with respect to the sensor, the sensor can detect an increasing angle to 0&#xb0;. Then, as a second side of the scale becomes proximal to the sensor, the sensor can detect an increasing angle to +180&#xb0;. The angle changes linearly with position. In one aspect, the pair of oppositely arranged magnets can be rotated with respect to the travel path to provide the angle. In another aspect, the pair of oppositely arranged magnets can be magnetized diagonally to provide the angle.

Encoder system for position determination with inclined scale

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

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Shanghai, China

Xikai Sun