Abstract: A system for identifying movers in an independent cart system includes movers having at least one magnet and sensors generating a feedback signal responsive to detecting a magnetic field from the magnet as each mover travels past the sensor. A memory stores an identifier and a corresponding digital fingerprint for each mover. The stored digital fingerprint is generated as a function of the magnetic field generated by the magnet on each mover. A controller receives the feedback signal from each sensor and determines a run-time digital fingerprint for each mover corresponding to the magnetic field generated by the magnet on each mover as a function of the feedback signal. The run-time digital fingerprint is matched to one of the stored digital fingerprints, and the identifier, corresponding to the stored digital fingerprint matching the run-time fingerprint, is read from memory.

Abstract: A system and method for detecting integrity of a position for a mover in an independent cart system, includes receiving multiple first position feedback signals at a first processing core and receiving multiple second position feedback signals at a second processing core. Each of the first and second position feedback signals are generated by first and second position sensors, respectively, by detecting a magnet array mounted on the mover. A first value of the position of the mover is generated with the first processing core responsive to the first position feedback signals, and a second value of the position of the mover is generated with the second processing core responsive to the second position feedback signals. The first and second values of the position of the mover are compared with either the first or second processing core to verify operation of the first and second position sensors.

Abstract: A system for identifying movers in an independent cart system includes movers having at least one magnet and sensors generating a feedback signal responsive to detecting a magnetic field from the magnet as each mover travels past the sensor. A memory stores an identifier and a corresponding digital fingerprint for each mover. The stored digital fingerprint is generated as a function of the magnetic field generated by the magnet on each mover. A controller receives the feedback signal from each sensor and determines a run-time digital fingerprint for each mover corresponding to the magnetic field generated by the magnet on each mover as a function of the feedback signal. The run-time digital fingerprint is matched to one of the stored digital fingerprints, and the identifier, corresponding to the stored digital fingerprint matching the run-time fingerprint, is read from memory.

Abstract: A system for zero radius direction changes in an independent cart system includes a drive magnet array movably mounted to a mover. The drive magnet array includes at least one drive magnet configured to engage an electromagnetic field generated by coils extending along a track and a first engagement member for selectively positioning the drive magnet array between at least a first position and a second position. A switch track segment defines at least a first and second path for the mover. The first path includes coils to generate the electromagnetic field along the first path, and the second path includes coils to generate the electromagnetic field to along the second path. The drive magnet array is aligned with the first path when the drive magnet array is in the first position and with the second path when the drive magnet array is in the second position.

Abstract: Virtual slots are provided to coordinate traffic flow in an independent cart system. Multiple virtual slots are defined along a length of a track for the independent cart system. The track includes multiple track segments, and the independent cart system includes a linear drive system to propel movers along the track. Each of the virtual slots are controlled to travel along the length of the track. The virtual slots are spaced apart at a first distance and are controlled to travel synchronously at a desired speed. Each of the movers is controlled to travel within one of the virtual slots at the desired speed, and each of the movers has a minimum stopping distance greater than the first distance when travelling at the desired speed.

Abstract: A method for real-time path planning in an independent cart system includes generating a first route for a mover to travel from among multiple paths in the independent cart system and transmitting the first route to a segment controller. The mover is controlled along a portion of the track segments in the first route, and a first weighting value is determined for a remainder of the first route as the mover is travelling along the first route. At least one additional route for them mover is generated as the mover is travelling along the first route, and a second weighting value is assigned to the additional route. The weighting values for the remainder of the first route and for the additional route are compared to determine whether the mover will continue along the first route or transition to the different route.

Abstract: An independent cart system includes multiple track segments, multiple movers, multiple position sensors, and a controller. Each track segment includes multiple coils along a length of the track segment and a segment controller operative to selectively energize the coils to generate an electromagnetic field. Each mover includes a magnet array having multiple magnets, where the magnet array generates a magnetic field that interacts with the electromagnetic field generated by the coils to propel the mover along the track segments. The position sensors are spaced apart along the length of each track segment and generate a position feedback signal with a waveform as a function of the magnetic field generated by the magnet array on each mover. The controller is operative to receive the position feedback signal from each position sensor and to determine a unique identifier for each mover as a function of the waveform of the position feedback signal.

Abstract: Virtual slots are provided to coordinate traffic flow in an independent cart system. Multiple virtual slots are defined along a length of a track for the independent cart system. The track includes multiple track segments, and the independent cart system includes a linear drive system to propel movers along the track. Each of the virtual slots are controlled to travel along the length of the track. The virtual slots are spaced apart at a first distance and are controlled to travel synchronously at a desired speed. Each of the movers is controlled to travel within one of the virtual slots at the desired speed, and each of the movers has a minimum stopping distance greater than the first distance when travelling at the desired speed.

Abstract: A system for zero radius direction changes in an independent cart system includes a drive magnet array movably mounted to a mover. The drive magnet array includes at least one drive magnet configured to engage an electromagnetic field generated by coils extending along a track and a first engagement member for selectively positioning the drive magnet array between at least a first position and a second position. A switch track segment defines at least a first and second path for the mover. The first path includes coils to generate the electromagnetic field along the first path, and the second path includes coils to generate the electromagnetic field to along the second path. The drive magnet array is aligned with the first path when the drive magnet array is in the first position and with the second path when the drive magnet array is in the second position.

Abstract: An independent cart system includes multiple track segments, multiple movers, multiple position sensors, and a controller. Each track segment includes multiple coils along a length of the track segment and a segment controller operative to selectively energize the coils to generate an electromagnetic field. Each mover includes a magnet array having multiple magnets, where the magnet array generates a magnetic field that interacts with the electromagnetic field generated by the coils to propel the mover along the track segments. The position sensors are spaced apart along the length of each track segment and generate a position feedback signal with a waveform as a function of the magnetic field generated by the magnet array on each mover. The controller is operative to receive the position feedback signal from each position sensor and to determine a unique identifier for each mover as a function of the waveform of the position feedback signal.

Abstract: A system for identifying movers in an independent cart system includes movers having at least one magnet and sensors generating a feedback signal responsive to detecting a magnetic field from the magnet as each mover travels past the sensor. A memory stores an identifier and a corresponding digital fingerprint for each mover. The stored digital fingerprint is generated as a function of the magnetic field generated by the magnet on each mover. A controller receives the feedback signal from each sensor and determines a run-time digital fingerprint for each mover corresponding to the magnetic field generated by the magnet on each mover as a function of the feedback signal. The run-time digital fingerprint is matched to one of the stored digital fingerprints, and the identifier, corresponding to the stored digital fingerprint matching the run-time fingerprint, is read from memory.

Abstract: A system for detecting linear drive system faults includes a track, a calibrated inspection apparatus, and processing circuitry. The track includes track segments defining a path along which movers travel. Drive coils induce travel of the movers along the track. The calibrated inspection apparatus includes (i) a calibrated inspection mover that travels along the track and/or (ii) a calibrated inspection station including one or more of the track segments. The processing circuitry obtains feedback signals from controllers for the track segments. The feedback signals characterize relative motion between the calibrated inspection apparatus and (i) the track segments and/or (ii) the movers. The processing circuitry determines a fault based on the feedback signals and calibrated characteristics of the calibrated inspection apparatus. The fault includes at least one of (i) a track segment fault in the track segments or (ii) a mover fault in the movers.

Abstract: A system and method for detecting integrity of a position for a mover in an independent cart system, includes receiving multiple first position feedback signals at a first processing core and receiving multiple second position feedback signals at a second processing core. Each of the first and second position feedback signals are generated by first and second position sensors, respectively, by detecting a magnet array mounted on the mover. A first value of the position of the mover is generated with the first processing core responsive to the first position feedback signals, and a second value of the position of the mover is generated with the second processing core responsive to the second position feedback signals. The first and second values of the position of the mover are compared with either the first or second processing core to verify operation of the first and second position sensors.