Versatile control of a linear synchronous motor propulsion system

• US 8,863,669 B2
• Filed: 06/07/2012
• Issued: 10/21/2014
• Est. Priority Date: 06/07/2011
• Status: Active Grant

• Current Assignee: Rockwell Automation, Inc.
• Original Assignee: Magnemotion Incorporated (Rockwell Automation, Inc.)
• Inventors: Young, Jason A., Malkowski, P. Eric, Perreault, Brian M., Onorato, Michael F.
• Primary Examiner(s): LE, MARK T
• Application Number:
  US13/490,995
• Publication Number:
  US 20130008336A1
• Time in Patent Office: 866 Days
• Field of Search: 246/182.R, 246/182.A, 246/187.R, 246/187.A, 246/34.A, 104/290, 104/292, 318/38, 318/295, 318/297, 318/135
• US Class Current: 104/292
• CPC Class Codes: B60L 15/005 for control of propulsion for vehicles propelled by linear motors
• CPC Class Codes: B60L 2200/26 Rail vehicles
• CPC Class Codes: B60L 2220/14 Synchronous machines
• CPC Class Codes: H02P 25/06 Linear motors
• CPC Class Codes: H02P 25/064 of the synchronous type
• CPC Class Codes: H02P 6/006 Controlling linear motors
• CPC Class Codes: Y02T 10/64 Electric machine technologies in electromobility

Abstract

Control of Linear Synchronous Motors involves a number of low level issues of motor control—such as sensing precise position, controlling current in stator windings, and obeying commands from high level controllers—and high level vehicle control—such as stopping and starting, switching and merging, limiting speed and acceleration, synchronizing relative motion, preventing collisions and accidents, and dealing with failures. In most cases there is a master controller that directs vehicles based on simple commands but in other cases it is desirable to allow an external agent to provide more detailed control—such as synchronizing motion between a vehicle and a robot or allowing human operator control. This patent describes a versatile control scheme that allows both simplified high level control and, when or where necessary, control by an external agent. The result is a transport system and method that provides efficient and precise movement of vehicles on a guideway.

Claims

1. 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) one or more 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 one or more vehicles along the guideway,

(d) a first set of one or more controllers and a second set of one or more controllers, wherein the first set of one or more controllers is coupled to the second set of one or more controllers, and wherein the second set of one or more controllers is coupled to the electronic power and control circuitry,

(e) the guideway comprising at least (i) a first zone in which motion of vehicles thereon is commanded by application of set point-based parameters to the second set of controllers, and (ii) a second zone in which motion of vehicles thereon is commanded by application of limit-based parameters to the second set of controllers,

(f) the first set of one or more controllers generates set point-based parameters for application to the second set of one or more controllers in order to control motion of vehicles in the first zone,

(g) the first set of one or more controllers generate limit-based parameters for application to the second set of one or more controllers to control motion of vehicles in the second zone, and the second set of controllers generate set point parameters from those limit-based parameters,

(h) the second set of controllers apply control signals to the electronic power and control circuitry based on set point parameters to control motion of vehicles in the first and second zones.

2. The transport system of claim 1, wherein the magnetic flux source comprises one or more Halbach or other magnet arrays.

3. The transport system of claim 1, wherein the limit-based parameters comprise one or more of final-position, max-velocity, max-acceleration, and/or jerk.

4. The transport system of claim 1, wherein the set point-based parameters comprise one or more of current or desired position, current or desired velocity and/or current or desired acceleration.

5. The transport system of claim 1, wherein the plurality of propulsion coils comprise an LSM motor and in which the guideway additionally comprises one or more of position sensing logic and power electronic components.

6. A method of transport, comprising

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

(b) providing one or more vehicles on the guideway,

(c) exciting the propulsion coils independently so as to propel the one or more vehicles along the guideway

(d) providing a first set of one or more controllers and a second set of one or more controllers, wherein the first set of one or more controllers is coupled to the second set of one or more controllers, and the second set of one or more controllers is coupled to the electronic power and control circuitry,

(e) commanding motion of one or more of the vehicles in a first zone of the guideway by application of set point-based parameters to the second set of controllers,

(f) commanding motion of one or of the vehicles in a second zone of the guideway by application of limit-based parameters to the second set of controllers,

(g) generating, with the first set of one or more controllers, set point-based parameters for application to the second set of one or more controllers in order to control motion of vehicles in the first zone,

(g) generating, with the first set of one or more controllers, limit-based parameters for application to the second set of one or more controllers to control motion of vehicles in the second zone, and the second set of controllers generate set point parameters from those limit-based parameters,

(h) applying, with the second set of controllers, control signals to the electronic power and control circuitry based on set point parameters to control motion of vehicles in the first and second zones.

7. The method of claim 6, wherein one or more of the vehicles comprise one or Halbach arrays, other magnet arrays, and/or other magnetic flux sources.

8. The method of claim 6, wherein step E includes commanding motion of one or more of the vehicles in the second zone using limit-based parameters that comprise one or more of final-position, max-velocity, max-acceleration, and/or jerk.

9. The method of claim 6, wherein step D includes commanding motion using set point-based parameters that comprise one or more of current or desired position, current or desired velocity and/or current or desired acceleration.

10. The method of claim 6, wherein step A includes providing the guideway such that the plurality of propulsion coils comprise an LSM motor and such that the guideway additionally comprises one or more of position sensing logic and power electronic components.

11. The method of claim 10, wherein step E includes generating one or more of the limit-based parameters utilizing the central controller that is coupled to the one or more block controllers.