Transport system powered by short block linear synchronous motors

• US 9,346,371 B2
• Filed: 12/30/2013
• Issued: 05/24/2016
• Est. Priority Date: 01/23/2009
• Status: Active Grant

• Current Assignee: Magnemotion Incorporated (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:
  US14/143,802
• Publication Number:
  US 20140182478A1
• Time in Patent Office: 876 Days
• Field of Search: 104281-284, 191/2, 191/6, 191/22.R, 191/33.R
• US Class Current: 1/1
• 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 so as to propel the plural vehicles independently of one another along the guideway,

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

E. wherein any of

(i) one or more of the vehicles are slidingly disposed on the guideway, and/or

(ii) the propulsion coils are mounted on one or more printed circuit boards.

2. The transport system of claim 1, further comprising a 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.

3. The transport system of claim 2, wherein the guidance structure comprises one or more rails that are disposed on the guideway.

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

5. The transport system of claim 4, wherein the plurality of coils are disposed in the guideway for close proximity to the one or more magnets of passing vehicles.

6. The transport system of claim 4, wherein the one or more magnets comprise a Halbach magnet array.

7. The transport system of claim 1, wherein the guideway comprises a plurality of coupled modules.

8. The transport system of claim 7, wherein one or more of the modules include one or more of the printed circuit boards with propulsion coils mounted thereon.

9. The transport system of claim 8, 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.

10. The transport system of claim 9, wherein the one or more power controllers are selectively electrically coupled to the propulsion coils of the associated module for independent control thereof.

11. The transport system of claim 10, 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.

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

13. The transport system of claim 12, wherein the one or more sensors are located close enough together that they can identify individual vehicles even when the vehicles are closely spaced.

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

15. The transport system of claim 1, wherein the guideway includes at least one of a merge region and a diverge region.

16. The transport system of claim 15, wherein the guideway comprises a straight-away region, along with at the least one of a merge region and a diverge region.

17. The transports system of claim 16, wherein any of the merge region and the diverge region include a mechanically actuated switch that alters a course of a vehicle passing thereon.

18. The transport system of claim 16, wherein any of the merge region and the diverge region include a magnetically actuated switch that alters a course of a vehicle passing thereon.

19. The transport system of claim 15, wherein one or more of the vehicles that are slidably disposed on the guideway have a coefficient of friction with the guideway of less than about 0.2.

20. The transport system of claim 15, wherein at least one of said merge regions and diverge regions includes a plurality of coreless propulsion coils disposed along a region in which the course of passing vehicles is altered.

21. The transport system of claim 15, wherein at least one of said merge regions and diverge regions includes 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.

22. 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;

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

wherein any of

(i) one or more of the vehicles are slidingly disposed on the guideway and

(ii) the propulsion coils are mounted on one or more printed circuit boards.

23. The transport system of claim 22, wherein a surface on the lower side of each of the plurality of vehicles slides with a coefficient of friction of less than about 0.2 on a surface on the guideway.

24. The transport system of claim 22, wherein at least one of the plurality of vehicles is approximately 50 mm square.

25. 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,

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

D. the propulsion coils are mounted on one or more printed circuit boards.

26. The guideway module of claim 25 adapted for sliding motion of one or more vehicles thereon.

27. The guideway module of claim 25, further comprising a guidance structure that inhibits motion of vehicles off the guideway.

28. The guideway module of claim 25 adapted for interlocking coupling with one or more such modules.

29. The guideway module of claim 25, 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.

30. The guideway module of claim 25, wherein the guideway module defines any of a merge and a diverge that alters a course of a vehicle passing thereon.