Abstract: A linear motor conveyor system including: a track including: at least one guide rail, including a first portion and a second portion; and a plurality of moving elements, each moving element including: a body; and at least one set of bearings supported by the body, including a first bearing configured to move along the first portion and a second bearing configured to move along the second portion, wherein the second bearing and second portion are offset in relation to the first bearing and first portion such that the second bearing overlaps along the direction of the track with a first bearing of an adjacent moving element to provide a reduced tooling pitch between the moving elements. In some cases each of the plurality of moving elements further includes: a second set of bearings; and a bearing suspension system to provide a suspension to the second set of bearings.

Abstract: A method and system for wireless communication with accessories on moving elements in a conveyor system, the conveyor system including a conveyor controller for independently controlling the moving elements. The method includes: configuring two or more track wireless hubs to cover respective wireless zones, each providing wireless coverage for a portion of the conveyor system; configuring two or more moving elements on the conveyor system with pallet wireless hubs configured to communicate with the track wireless hubs; communicating between the conveyor controller and at least one of the track wireless hubs when one of the moving elements having a predetermined identification is entering the respective wireless zone; performing a simplified connection between the track wireless hub and the respective pallet wireless hub based on the predetermined identification; and controlling an accessory on the entering moving element using communications via the track wireless hub and the pallet wireless hub.

Abstract: A transporting system and method for a linear motor conveyor system, wherein the conveyor system includes at least one moving element and at least one track on which the moving element moves, the transporting system including: a rotatable element; a motor for rotating the rotatable element; a coupler connected to the rotatable element, wherein the coupler is configured to engage with the moving element when the coupler is positioned in a predetermined relationship with the moving element; and a controller configured to: operatively connect with the linear motor conveyor system; and control at least one of the moving element and the rotatable element so that the coupler is positioned in the predetermined relationship with the moving element on the track such that the coupler strips the moving element off the track.

Abstract: A linear motor conveyor system including: a moving element comprising at least one magnetic element and at least one bearing; a first track comprising a first linear motor, the first track configured to have a first rail on which the at least one bearing of the moving element runs and the first linear motor is configured to generate a dynamic magnetic field which acts on the magnetic element; a second track having at least a transfer region positioned adjacent the first track, the second track configured to have a second rail on which the same at least one bearing runs while in the transfer region.

Abstract: A system and method for tracking a location of a moving element on a conveyor system. The system including: magnetic sensors; a magnetic encoder strip that is readable by the magnetic sensors; and a processor for receiving and processing the sensor readings to determine a location of the moving element. The method including: sensing a current location of the moving element, wherein at least one of the magnetic sensors and magnetic encoder are associated with the moving element; and providing a current location to a conveyor system controller. The system may further include: color sensors; and a color gradient encoder strip that is readable by the color sensors, wherein the color gradient encoder strip and color sensors provide moving element location at start up and the magnetic sensors and magnetic encoder strip track moving element location during operation. In this case, the method is adjusted accordingly.

Abstract: A linear motor conveyor system including: a track comprising a shaped guide rail; a plurality of moving elements, each moving element having: a body; at least two bearings supported by the body and configured to match with the shaped guide rail, wherein the bearings are mounted to the moving element such that the moving elements overlap along the direction of the track providing a reduced tooling pitch between the moving elements. A moving element for moving on a track of a conveyor system, the moving element including: a first set of bearings shaped to match with a first shaped guide rail; a second set of bearings configured to abut against a second guide rail; and a body supporting the first and the second bearing, wherein the body is shaped to allow the first bearing to at least partially overlap the body of an adjacent moving element.

Abstract: A linear motor conveyor system including: at least one track section comprising: electronic circuitry housed within the track section; and a rotatable segment comprising an end profile that abuts another track section to form a stepped groove sealed by a gasket. A moving element for a linear motor conveyor system including: a body; a first set of bearings attached to the body and angled to abut against a first guide rail of a conveyor system having a protrusion with opposing angled profiles; a second set of bearing attached to the body and designed to abut against a flat profile of a second guide rail of the conveyor system. A dry lubricant provided to the body and configured to lubricate a bearing surface of the linear motor conveyor system supporting the first set of bearings.

Abstract: A linear motor conveyor system having a moving element comprising a first and a second magnetic element on opposite sides; a first track comprising a first linear motor configured to generate a dynamic magnetic field which acts on the first magnetic element to provide a first dynamic lateral force and a first dynamic longitudinal force; a second track with a transfer region positioned adjacent to the first track, the second track configured to generate a magnetic field that acts on the second magnetic element to provide a second lateral force; and a controller to control the first linear motor such that the first dynamic lateral force is configured to bias the moving element toward the first linear motor until the moving element reaches a switch point in the transfer region, after which the dynamic lateral forces are selectively adjusted to bias the moving element toward the first or second track.

Abstract: A linear motor conveyor system including: at least one track section comprising: electronic circuitry housed within the track section; and a rotatable segment comprising an end profile that abuts another track section to form a stepped groove sealed by a gasket. A moving element for a linear motor conveyor system including: a body; a first set of bearings attached to the body and angled to abut against a first guide rail of a conveyor system having a protrusion with opposing angled profiles; a second set of bearing attached to the body and designed to abut against a flat profile of a second guide rail of the conveyor system. A dry lubricant provided to the body and configured to lubricate a bearing surface of the linear motor conveyor system supporting the first set of bearings.

Abstract: Various systems and methods for optimizing operation at a manufacturing assembly line are disclosed. A method for optimizing operation at a manufacturing assembly line having a track on which a plurality of shuttles travel, the track including one or more stations at which a production task occurs and one or more track areas defined relative to the one or more stations, includes monitoring shuttle operation data associated with the plurality of shuttles on the track, and track sensor data associated with an operation state of the track; detecting an operation variation at the manufacturing assembly line based on the shuttle operation data; in response to detecting the operation variation, analyzing the shuttle operation data and the track sensor data to determine one or more degradation causes resulting in the operation variation; and generating an operation recommendation for resolving at least one degradation cause of the one or more degradation causes.

Abstract: A linear motor conveyor system including: a plurality of track sections including a track and an interior area; a track cover covering the track of the plurality of track sections; a top plate covering at least a portion of the interior area of the plurality of track sections; at least one top cover covering at least a portion of the top plate and any uncovered portions of the interior area; and a plurality of gaskets providing a seal between the track cover and track, top cover and top plate such that the interior area of the plurality of track sections are sealed. The track cover may be a strong, flexible material configured to wrap along or around the track to cover any joints between track sections and provide a sealed, easy to clean cover.

Abstract: A transporting system and method for a linear motor conveyor system, wherein the conveyor system includes at least one moving element and at least one track on which the moving element moves, the transporting system including: a rotatable element; a motor for rotating the rotatable element; a coupler connected to the rotatable element, wherein the coupler is configured to engage with the moving element when the coupler is positioned in a predetermined relationship with the moving element; and a controller configured to: operatively connect with the linear motor conveyor system; and control at least one of the moving element and the rotatable element so that the coupler is positioned in the predetermined relationship with the moving element on the track such that the coupler strips the moving element off the track.

Abstract: A curvilinear track section of a linear motor system including: a straight track portion; a curvilinear track portion coupled to the straight track portion; at least one motor unit for driving a moving element along the straight track portion and the curvilinear track portion; wherein the curvilinear track portion has a clothoid transition region adjacent to the straight track portion. In some cases, the curvilinear track portion includes a first slot grouping formed in an exterior edge of the curvilinear track portion, wherein the first slot grouping is at a predetermined angle relative to the exterior edge; a second slot grouping formed in the exterior edge of the curvilinear track portion, wherein the second slot grouping is at a second predetermined angle; and motor units inserted into the first and second slot groupings.

Abstract: A linear motor conveyor system including: a track comprising a shaped guide rail; a plurality of moving elements, each moving element having: a body; at least two bearings supported by the body and configured to match with the shaped guide rail, wherein the bearings are mounted to the moving element such that the moving elements overlap along the direction of the track providing a reduced tooling pitch between the moving elements. A moving element for moving on a track of a conveyor system, the moving element including: a first set of bearings shaped to match with a first shaped guide rail; a second set of bearings configured to abut against a second guide rail; and a body supporting the first and the second bearing, wherein the body is shaped to allow the first bearing to at least partially overlap the body of an adjacent moving element.

Abstract: A joint system and method for managing alignment tolerances in a track section of a conveyor, the system including: a plurality of track sections, each track section including at least one end to be joined with an adjacent track section and one or more rails on which bearings of moving elements move; and wherein, at the end of each track section, the one or more rails each comprise a finger such that rails from adjacent track sections form an interlaced connection between fingers from each track section and both fingers are angled such that a non-alignment of the rails will not jar a bearing moving over the joint.

Abstract: A linear motor conveyor system including: at least one track section comprising: electronic circuitry housed within the track section; and a rotatable segment comprising an end profile that abuts another track section to form a stepped groove sealed by a gasket. A moving element for a linear motor conveyor system including: a body; a first set of bearings attached to the body and angled to abut against a first guide rail of a conveyor system having a protrusion with opposing angled profiles; a second set of bearing attached to the body and designed to abut against a flat profile of a second guide rail of the conveyor system.

Abstract: A curvilinear track section of a linear motor system for use with a moving element including a machine readable medium, the track section including: a curvilinear track portion having a predetermined curved shape; a plurality of sensors provided to the track portion such that each of the plurality of sensors is oriented perpendicular to the direction of motion while the plurality of sensors are placed along the direction of motion and the plurality of sensors are configured such that the machine readable medium will overlap at least two of the plurality of sensors at the same time; and a processor configured to determine a position of the moving element on the curvilinear track section based on the readings from the sensors.

Abstract: A linear motor conveyor system having a moving element comprising a first and a second magnetic element on opposite sides; a first track comprising a first linear motor configured to generate a dynamic magnetic field which acts on the first magnetic element to provide a first dynamic lateral force and a first dynamic longitudinal force; a second track with a transfer region positioned adjacent to the first track, the second track configured to generate a magnetic field that acts on the second magnetic element to provide a second lateral force; and a controller to control the first linear motor such that the first dynamic lateral force is configured to bias the moving element toward the first linear motor until the moving element reaches a switch point in the transfer region, after which the dynamic lateral forces are selectively adjusted to bias the moving element toward the first or second track.

Abstract: A linear motor conveyor system including: a track comprising a shaped guide rail; a plurality of moving elements, each moving element having: a body; at least two bearings supported by the body and configured to match with the shaped guide rail, wherein the bearings are mounted to the moving element such that the moving elements overlap along the direction of the track providing a reduced tooling pitch between the moving elements. A moving element for moving on a track of a conveyor system, the moving element including: a first set of bearings shaped to match with a first shaped guide rail; a second set of bearings configured to abut against a second guide rail; and a body supporting the first and the second bearing, wherein the body is shaped to allow the first bearing to at least partially overlap the body of an adjacent moving element.

Abstract: A linear motor conveyor system including: at least one track section comprising: electronic circuitry housed within the track section; and a rotatable segment comprising an end profile that abuts another track section to form a stepped groove sealed by a gasket. A moving element for a linear motor conveyor system including: a body; a first set of bearings attached to the body and angled to abut against a first guide rail of a conveyor system having a protrusion with opposing angled profiles; a second set of bearing attached to the body and designed to abut against a flat profile of a second guide rail of the conveyor system. A dry lubricant provided to the body and configured to lubricate a bearing surface of the linear motor conveyor system supporting the first set of bearings.