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: 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 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 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: A linear and curvilinear encoder is provided in which absolute mechanical position and high resolution position determination can be obtained using a cart having a mover with “hybrid” teeth, configured in a curvilinear profile or shape, moving along a curvilinear track with a stator having teeth. The absolute mechanical position and high resolution position determination can be detected on the track by applying an excitation signal to a coil surrounding particular teeth of the stator to produce an electromagnetic (EM) field which can be influenced by the profile or shape of the teeth of the mover. A resulting pick-up signal can then be detected in a pick-up coil surrounding particular teeth of the stator with different harmonics in the pick-up signal corresponding to harmonics of the profile or shape of the teeth.

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: A linear drive system provides a combination of distributed control to increase the number of movers which may be supported in the system and centralized control to reduce the separation distance between movers by grouping movers together and placing a reference mover of the group under central control with remaining movers of the group under distributed control. In addition, in precise working locations, or “synchronization zones,” each of the movers can be temporarily placed under central control to further reduce the separation distance and allow improved coordination with industrial processes or machines in the system.

Abstract: A system and method for cooling an enclosed position feedback device mounted to a motor is disclosed. An active cooling device is mounted between the position feedback device and the housing enclosing the position feedback device. A compliant mount is provided to accommodate vibration in the position feedback device. The compliant mount may be a compliant thermal pad positioned between the feedback device and the active cooling device. Optionally, the compliant mount may be provided between the motor and the position feedback device.

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 linear drive system provides a combination of distributed control to increase the number of movers which may be supported in the system and centralized control to reduce the separation distance between movers by grouping movers together and placing a reference mover of the group under central control with remaining movers of the group under distributed control. In addition, in precise working locations, or “synchronization zones,” each of the movers can be temporarily placed under central control to further reduce the separation distance and allow improved coordination with industrial processes or machines in the system.

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: The present invention provides a mover traveling along a track, the mover system having a mover frame supporting a mover sensor element and a track frame providing a path for which the mover frame travels and supporting track sensor elements for interacting with the mover sensor element of the mover frame. The interaction between the mover sensor element and track sensor elements provides an identification signal of each mover and the identification signal of each mover on the track is arranged according to a cyclic sequence where unique contiguous substrings occur only once within the sequence.

Abstract: The present invention provides a mover traveling along a track, the mover system having a mover frame supporting a mover sensor element and a track frame providing a path for which the mover frame travels and supporting track sensor elements for interacting with the mover sensor element of the mover frame. The interaction between the mover sensor element and track sensor elements provides an identification signal of each mover and the identification signal of each mover on the track is arranged according to a cyclic sequence where unique contiguous substrings occur only once within the sequence.

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 he 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 linear and curvilinear encoder is provided in which absolute mechanical position and high resolution position determination can be obtained using a cart having a mover with “hybrid” teeth, configured in a curvilinear profile or shape, moving along a curvilinear track with a stator having teeth. The absolute mechanical position and high resolution position determination can be detected on the track by applying an excitation signal to a coil surrounding particular teeth of the stator to produce an electromagnetic (EM) field which can be influenced by the profile or shape of the teeth of the mover. A resulting pick-up signal can then be detected in a pick-up coil surrounding particular teeth of the stator with different harmonics in the pick-up signal corresponding to harmonics of the profile or shape of the teeth.

Abstract: A system and method for cooling an enclosed position feedback device mounted to a motor is disclosed. An active cooling device is mounted between the position feedback device and the housing enclosing the position feedback device. A compliant mount is provided to accommodate vibration in the position feedback device. The compliant mount may be a compliant thermal pad positioned between the feedback device and the active cooling device. Optionally, the compliant mount may be provided between the motor and the position feedback device.

Abstract: A distributed motor drive system includes a power management module and multiple inverter modules integrated with the motors and located on a machine or process remote from the power management module. The power management module distributes DC voltage and command signals to each of the inverters, where the DC voltage is distributed between modules via a DC link cable. The integrated inverters execute switching routines to convert the DC voltage to an AC voltage suitable for controlling the motor. Each of the power management module and the inverters includes a portion of the DC bus. The current on the DC link cable is monitored and general bus utilization as well as overload conditions are reported.

Abstract: A distributed motor drive system includes a power management module and multiple inverter modules integrated with the motors and located on a machine or process remote from the power management module. The power management module distributes DC voltage and command signals to each of the inverters. The DC voltage is distributed between modules via a DC link cable. The integrated inverters execute switching routines to convert the DC voltage to an AC voltage suitable for controlling the motor. Each of the power management module and the inverters includes a portion of the DC bus capacitance. The distributed motor drive system also includes a link inductance between the power management module and the inverters to limit the amount of reactive current generated by the inverters.