Abstract: A motor controller executes an axis module for each of multiple motors coupled to a shared load. A first control module passes at least one state variable to a second control module without experiencing communication delays between the axis modules. In order to decouple interaction between axes, the first control module determines the desired state variable at a periodic update rate and stores the desired state variable in memory. The first control module provides an indication to the second control module that the desired state variable is available. Within the same period at which the desired state variable is determined, the second control module receives the indication that the desired state variable is available and reads the state variable from the memory of the controller. The second control module executes using the desired state variable to reduce coupling between the two control modules.

Abstract: Systems and methods for synchronizing motion connection communication to time-aware network for industrial systems. One system includes an electronic processor configured to determine a controller Qbv configuration for an industrial controller included in a TSN. The electronic processor is also configured to determine, based at least in part on the controller Qbv configuration, a first start of a Qbv slot for isochronous traffic for an industrial device included in the TSN. The electronic processor is also configured to adjust, based at least in part on the first start of the Qbv slot for isochronous traffic for the industrial device, network scheduling for the industrial device. The electronic processor is also configured to deploy the adjusted network scheduling to the industrial device.

Abstract: Systems and methods for accurate network traffic flow for time-sensitive networking in industrial systems. One configuration provides a system for controlling network traffic flow for time-sensitive networking in industrial systems. The system includes an electronic processor configured to receive, from an industrial controller of an industrial system, queuing data associated with a first queue of the industrial controller. The electronic processor is also configured to determine, based on the queuing data, a distribution of network traffic within the industrial system. The electronic processor is also configured to generate a network traffic model for display, the network traffic model including the distribution of network traffic within the industrial system.

Abstract: An independent cart system with safety functions prevents unintended motion independently within different sections of the track while permitting motion along other sections of the track. A safety controller receives one or more input signals corresponding to operating conditions along the track. A safety program executing in the safety controller monitors the state of the input signals to determine whether a safety function is to be executed. When a safety program is executed, the safety controller transmits an output signal to one or more segment controllers present in one section along the track. Each segment controller is responsible for regulating current flow to the coils mounted to the corresponding track segment. In response to the signal from the safety controller, each segment controller in the section controls the power output to the coils along that section of track to achieve the safe operation desired in that segment.

Abstract: 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.

Abstract: A method and system for motion control of movers in an independent cart system is disclosed. In one implementation, the independent cart system includes a plurality of track segments, each section having a respective controller. One of the controllers receives a motion command for a plurality of carts, respectively. The controller generates a force command for each of the plurality of carts and transmits the respective commands to the track segments commutating the plurality of carts.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: An independent cart system with safety functions that prevent unintended motion independently within different sections of the track while permitting motion along other sections of the track is disclosed. A safety controller receives one or more input signals corresponding to operating conditions along the track. A safety program executing in the safety controller monitors the state of the input signals to determine whether a safety function is to be executed. When a safety program is executed, the safety controller transmits an output signal to one or more segment controllers present in one section along the track. Each segment controller is responsible for regulating current flow to the coils mounted to the corresponding track segment. In response to the signal from the safety controller, each segment controller in the section controls the power output to the coils along that section of track to achieve the safe operation desired in that segment.

Abstract: An independent cart system with safety functions prevents unintended motion independently within different sections of the track while permitting motion along other sections of the track. A safety controller receives one or more input signals corresponding to operating conditions along the track. A safety program executing in the safety controller monitors the state of the input signals to determine whether a safety function is to be executed. When a safety program is executed, the safety controller transmits an output signal to one or more segment controllers present in one section along the track. Each segment controller is responsible for regulating current flow to the coils mounted to the corresponding track segment. In response to the signal from the safety controller, each segment controller in the section controls the power output to the coils along that section of track to achieve the safe operation desired in that segment.

Abstract: A mover is configured to be electromagnetically propelled along a track in a linear motor track system with a force that is calculated to include compensation for gravity. A multi-axis accelerometer arranged in each segment of the track can detect an orientation or angle of the track segment for determining gravity with respect to the particular section. As a result, if the track is at an incline, such as a ramp, a desired force for moving a mover along the track can be compensated to include gravity due to the incline for achieving a desired motion result. In addition, the detected orientation of the track can be compared to an expected orientation stored by a control program to avoid a loss of performance due to physical changes in the track not matching an expected/programmed configuration of the track.

Abstract: A method and system for motion control of movers in an independent cart system is disclosed. In one implementation, the independent cart system includes a plurality of track segments, each section having a respective controller. One of the controllers receives a motion command for a plurality of carts, respectively. The controller generates a force command for each of the plurality of carts and transmits the respective commands to the track segments commutating the plurality of carts.

Abstract: A method and system for motion control of movers in an independent cart system is disclosed. In one implementation, the independent cart system includes a plurality of track segments, each section having a respective controller. One of the controllers receives a motion command for a plurality of carts, respectively. The controller generates a force command for each of the plurality of carts and transmits the respective commands to the track segments commutating the plurality of carts.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: A mover is configured to be electromagnetically propelled along a track in a linear motor track system with a force that is calculated to include compensation for gravity. A multi-axis accelerometer arranged in each segment of the track can detect an orientation or angle of the track segment for determining gravity with respect to the particular section. As a result, if the track is at an incline, such as a ramp, a desired force for moving a mover along the track can be compensated to include gravity due to the incline for achieving a desired motion result. In addition, the detected orientation of the track can be compared to an expected orientation stored by a control program to avoid a loss of performance due to physical changes in the track not matching an expected/programmed configuration of the track.