Transport system powered by short block linear synchronous motors

• US 8,616,134 B2
• Filed: 01/23/2009
• Issued: 12/31/2013
• Est. Priority Date: 01/23/2009
• Status: Active Grant

• Current Assignee: Rockwell Automation, Inc.
• Original Assignee: Magnemotion Incorporated (Rockwell Automation, Inc.)
• Inventors: King, Nathanael N., Perreault, Brian M., Clark, Tracy M., Thornton, Richard D., Young, Jason, Bottasso, Michael W.
• Primary Examiner(s): MCCARRY JR, ROBERT J
• Application Number:
  US12/359,022
• Publication Number:
  US 20100186618A1
• Time in Patent Office: 1,803 Days
• Field of Search: 104281-284, 191/2, 191/6, 191/22.R, 191/33.R
• US Class Current: 104/284
• CPC Class Codes: B60L 13/003 Crossings; Points
• CPC Class Codes: B60L 13/03 Electric propulsion by linear motors
• CPC Class Codes: B60L 13/10 Combination of electric propulsion and magnetic suspension or levitation
• CPC Class Codes: B60L 2200/26 Rail vehicles
• CPC Class Codes: B65G 19/02 for articles, e.g. for containers
• CPC Class Codes: B65G 35/06 comprising a load-carrier moving along a path, e.g. a closed path, and adapted to be engaged by any one of a series of traction elements spaced along the path effecting drive at two or more points spaced along the length of an endless conveyor B65G23/32
• CPC Class Codes: B65G 54/02 electrostatic, electric, or magnetic
• CPC Class Codes: H02K 41/031 of the permanent magnet type

Abstract

Aspects of the invention provide a transport system powered by short block Linear Synchronous Motors (LSMs). The use of short blocks allows vehicles to move under precise control even when they are in close proximity to each other. The design allows the vehicles to be propelled and guided while negotiating sharp turns and negotiating merge and diverge switches. A coreless LSM can be used to create propulsive force without attractive force so as to allow a relatively high drag vehicle suspension, such as a vehicle sliding on a smooth surface.

Claims

1. A transport system, comprising

A. a guideway including a plurality of propulsion coils disposed along a region in which vehicles are to be propelled,

B. plural vehicles disposed on the guideway, each containing a magnetic flux source,

C. electronic power and control circuitry that excites the propulsion coils independently so as to propel the plural vehicles independently of one another along the guideway, and

D. one or more sensors that monitor positions of the vehicles moving on the guideway.

2. The transport system of claim 1, wherein one or more of the vehicles are slidingly disposed on the guideway.

3. The transport system of claim 1, comprising guidance structure on any of the guideway and one or more of the vehicles that inhibit the one or more vehicles from moving off the guideway.

4. The transport system of claim 3, wherein the guidance structure comprises one or more rails that are disposed on the guideway.

5. The transport system of claim 1, wherein the magnet flux source of at least one of the vehicles comprises one or more magnets.

6. The transport system of claim 5, wherein the plurality of coils are disposed in the guideway for close proximity to the one or more magnets of passing vehicles.

7. The transport system of claim 5 wherein the one or more magnets comprise a Halbach magnet array.

8. The transport system of claim 1, wherein the propulsion coils are mounted on one or more printed circuit boards.

9. The transport system of claim 8, wherein the guideway comprises a plurality of coupled modules.

10. The transport system of claim 9, wherein one or more of the modules include one or more of the printed circuit boards with propulsion coils mounted thereon.

11. The transport system of claim 10, wherein one or more of the modules comprise one or more power controllers that form part of the electronic power and control circuitry and that are selectively electrically coupled to one or more of the propulsion coils.

12. The transport system of claim 11, wherein the one or more power controllers are selectively electrically coupled to the propulsion coils of the associated module for independent control thereof.

13. The transport system of claim 12, wherein one or more of the modules comprise one or more microprocessors and one or more switches that provide electrical coupling between the power control circuitry and the propulsion coils.

14. The transport system of claim 1, comprising wheels, bearings or other rolling elements for suspension of at least one of the vehicles.

15. The transport system of claim 1, wherein the one or more position sensors are located close enough together that they can identify individual vehicles.

16. The transport system of claim 15, wherein the one or more position sensors are located close enough together that they can identify individual vehicles even when the vehicles are closely spaced.

17. The transport system of claim 1, wherein one or more of the propulsion coils are coreless.

18. A transport system, comprising

A. a guideway comprising a plurality of propulsion coils,

B. plural vehicles disposed on the guideway, each of the plural vehicles containing a magnetic flux source,

C. control circuitry that excites the propulsion coils so as to propel the plural vehicles independently of one another along the guideway,

D. sensors that monitor positions of the plural vehicles moving on the guideway, and

E. wherein one or more of the propulsion coils are mounted on a printed circuit board.

19. The transport system of claim 18, wherein the guideway comprises a plurality of coupled modules.

20. The transport system of claim 19, wherein one or more of the modules include one or more of the printed circuit boards with propulsion coils mounted thereon.

21. The transport system of claim 20, wherein one or more of the modules comprise one or more power controllers that are selectively electrically coupled to the propulsion coils on that module.

22. The transport system of claim 21, wherein the power controller is selectively electrically coupled to the one or more propulsion coils of the associated module for independent control thereof.

23. The transport system of claim 22, wherein one or more of the power controllers each contain a microprocessor.

24. The transport system of claim 18, wherein the one or more position sensors are located close enough together that they can identify individual vehicles.

25. The transport system of claim 24, wherein the one or more position sensors are located close enough together that they can identify individual vehicles even when the vehicles are closely spaced.

26. A transport system, comprising

A. a guideway that guides plural vehicles and that includes at least one of a merge region and a diverge region,

B. plural vehicles disposed on the guideway, each containing a magnetic flux source,

C. electronic power and control circuitry that excites a plurality of propulsion coils so as to propel the plural vehicles independently of one another along the guideway, and

D. one or more sensors that monitor positions of the vehicles moving on the guideway.

27. The transport system of claim 26, wherein the guideway comprises a straight-away region, along with at the least one of a merge region and a diverge region.

28. The transports system of claim 27, wherein any of the merge region and the diverge region include a mechanically actuated switch that alters a course of a vehicle passing thereon.

29. The transport system of claim 27, wherein any of the merge region and the diverge region include a magnetically actuated switch that alters a course of a vehicle passing thereon.

30. The transport system of claim 26, wherein one or more of the vehicles are slidingly disposed on the guideway.

31. The transport system of claim 30, wherein one or more of the vehicles that are slidably disposed on the guideway have a low coefficient of friction therewith.

32. The transport system of claim 31, wherein the coefficient of friction is less then substantially 0.2.

33. The transport system of claim 26, wherein one or more of the vehicles are disposed for rolling motion on the guideway.

34. The transport system of claim 26, wherein one or more of the vehicles are disposed on wheels for rolling motion on the guideway.

35. The transport system of claim 26, wherein at least one of said merge regions and diverge regions comprises a plurality of coreless propulsion coils disposed along a region in which the course of passing vehicles is altered.

36. The transport system of claim 26, wherein at least one of said merge regions and diverge regions comprises a plurality of coreless propulsion coils disposed along a corner, curve and/or branch defining the merge or diverge, respectively, so as to propel the vehicles therethrough.

37. The transport system of claim 26, comprising wheels, bearings or other rolling elements for suspension of at least one of the vehicles.

38. The transport system of claim 26, wherein the one or more position sensors are located close enough together that they can identify individual vehicles.

39. The transport system of claim 38, wherein the one or more position sensors are located close enough together that they can identify individual vehicles even when the vehicles are closely spaced.

40. A transport system comprising

a guideway comprising one or more rails that guide a vehicle;

a plurality of vehicles, each that interacts with the guideway rails for guidance and each containing one or more magnet arrays that can be used for propulsion;

a multiplicity of coils that are mounted in close proximity to the magnets of passing vehicles and can be excited independently so as to provide forces on the vehicle magnets so as to propel the vehicles independently of one another;

functionality that interconnects the coils to electronic power control circuitry and that includes switching devices and one or more microprocessors;

one or more position sensors that monitor the position of vehicles moving on the guideway;

microprocessors that control the coil currents in response to commands and synchronized to the motion of the vehicles;

and an energy source that provides power for the propulsion of the vehicles.

41. A transport system comprising

a guideway comprising one or more rails that guide a vehicle in at least two dimensions;

a plurality of vehicles that interact with the guideway rails for guidance and that each include one or more magnet arrays that can be used for propulsion;

a surface on the lower side of each of the plurality of vehicles that slides with a low coefficient of friction on a surface on the guideway;

a multiplicity of coils that are mounted in close proximity to the magnets of passing vehicles and can be independently excited so as to provide forces on the vehicle magnets that propel the vehicles independently of one another;

functionality that interconnects the coils to electronic power control circuitry that includes switching devices and one or more microprocessors;

position sensors that monitor the position of vehicles moving on the guideway;

one or more microprocessors that control the coil currents in response to commands and synchronized to the motion of the vehicles;

and an energy source that provides power for the propulsion of the vehicles.

42. A transport system comprising

a guideway comprising one or more rails that guide a vehicle in at least two dimensions;

a plurality of vehicles, at least one that is approximately 50 mm square, that interact with the guideway rails for guidance and that each include one or more magnet arrays that can be used for propulsion;

a surface on the lower side of each of the the plurality of vehicles that slides with a coefficient of friction of less than 0.2 on a surface on the guideway;

a multiplicity of coils that are mounted within a few mm of the magnets of passing vehicles and can be independently excited so as to provide forces on the vehicle magnets that propel the vehicles independently of one another and where at least three coils can be used create a propulsive force on a single vehicle;

functionality that interconnects the coils to electronic power control circuitry and that includes switching devices and one or more microprocessors;

position sensors that monitor the position of vehicles moving on the guideway;

one or more microprocessors that control the coil currents in response to commands and synchronized to the motion of the vehicles;

and an energy source that provides power for the propulsion of the vehicles.

43. A guideway module for use in a transport system, the guideway module comprising

A. one or more coreless propulsion coils disposed along a region in which plural vehicles that include magnetic flux sources are to be propelled,

B. electronic power and control circuitry that excites the one or more propulsion coils independently of one or more other propulsion coils in any of

(a) the guideway module, and

(b) a guideway in which that guideway module is incorporated,

so as to control movement of the plural vehicles passing over the guideway module independently of one another, and

C. one or more position sensors that monitor the position of vehicles moving on the guideway.

44. The guideway module of claim 43 adapted for sliding motion of one or more vehicles thereon.

45. The guideway module of claim 43, comprising guidance structure that inhibits motion of vehicles off the guideway.

46. The guideway module of claim 45, wherein the guidance structure comprises one or more rails.

47. The guideway module of claim 46, wherein the one or more propulsion coils are disposed for close proximity to the one or more magnets defining flux sources on the plural vehicles passing over the module.

48. The guideway module of claim 43, wherein the propulsion coils are mounted on one or more printed circuit boards.

49. The guideway module of claim 43, arranged for interlocking coupling with one or more such modules.

50. The guideway module of claim 43, comprising one or more power controllers that form part of the electronic power and control circuitry and that are selectively electrically coupled to one or more of the propulsion coils.

51. The guideway module of claim 50, wherein the one or more power controllers are selectively electrically coupled to the propulsion coils of the associated module for independent control thereof.

52. The guideway module of claim 43 comprising one or more position sensors that monitor the position of vehicles moving thereon.

53. The guideway module of claim 43 adapted for rolling motion of one or more vehicles thereon.

54. A guideway module defining any of a merge and a diverge for use in a transport system, the guideway module altering a course of a vehicle passing thereover, comprising

A. one or more propulsion coils disposed along a region in which plural vehicles that each include one or more magnetic flux sources are to be propelled,

B. electronic power and control circuitry that excites the one or more propulsion coils independently of one or more other propulsion coils in any of

(a) the guideway module, and

(b) a guideway in which that guideway module is incorporated,

so as to independently propel plural vehicles passing over the guideway module independently of one another, and

C. one or more position sensors that monitor the position of vehicles moving on the guideway.

55. The guideway module of claim 54, comprising a mechanically actuated switch that alters a course of a vehicle passing thereon.

56. The guideway module of claim 54, comprising a magneticaly actuated switch that alters a course of a vehicle passing thereon.

57. The guideway module of claim 54, comprising a plurality of coreless propulsion coils disposed along a region in which the course of passing vehicles is altered.

58. The guideway module of claim 54, comprising a plurality of coreless propulsion coils disposed along a corner, curve and/or branch defining the merge or diverge, respectively, so as to propel the vehicles therethrough.

59. A guideway for use in a transport system, the guideway comprising one or more couplable modules, each including

A. one or more coreless propulsion coils disposed along a region in which plural vehicles that each include one or more magnetic flux sources are to be propelled,

B. electronic power and control circuitry that excites the one or more propulsion coils independently of one or more other propulsion coils in any of

(a) the guideway module, and

(b) a guideway in which that guideway module is incorporated,

so as to propel plural vehicles passing over the guideway module independently of one another, and

C. one or more position sensors that monitor the position of vehicles moving on the guideway.

60. A vehicle for use in a transport system, comprising a flux source and adapted to be propelled along a guideway comprising

A. one or more coreless propulsion coils disposed along a region in which plural vehicles that each include one or more magnetic flux sources are to be propelled,

B. electronic power and control circuitry that excites the one or more propulsion coils independently of one or more other propulsion coils so as to propel the vehicle independently of other vehicles on the guideway, and

C. one or more position sensors that monitor the position of vehicle and other vehicles moving on the guideway.

61. A transport system, comprising

A. a guideway including a plurality of propulsion coils disposed along a region in which one or more vehicles are to be propelled,

B. plural vehicles disposed on the guideway, each containing a magnetic flux source,

C. electronic power and control circuitry that excites the propulsion coils independently so as to propel the plural vehicles independently of one another along the guideway, and

D. one or more sensors that monitor positions of the vehicles moving on the guideway,

E. microprocessors that are coupled to the electronic power and control circuitry and to the propulsion coils, and at provide electrical coupling therebetween.