A stator segment for a linear motor-based transport system is developed to the effect that a transmitter for cyclic transmission of a control data record in a first clock cycle also transmits, in addition to transmitting the control data record, a position value in a clock-synchronized manner, wherein a plurality of positions are available as a sequence with a quantity of elements and an element with an index corresponds to a position, where the transmitter unit is configured such that, upon every first clock cycle, the index is incremented commencing from a starting value and an element is transmitted after the control data record, where the transmitter unit is furthermore configured to transmit all elements in one transmission interval, and where the transmission interval corresponds to a multiple of the first clock cycle.

In order to improve control of a long-stator linear motor, a first measured value is ascertained in a first measurement section and a second measured value is ascertained in a second measurement section, in each case along a transport path in a movement direction. The first measurement section overlaps, in the movement direction, the second measurement section in an overlap region, and the first measured value and the second measured value represent the same actual value of a physical quantity. An operating parameter of the long-stator linear motor determined based on a deviation occurring between the first measured value and the second measured value.

The invention provides in some aspects a transport system comprising a guideway with a plurality of propulsion coils disposed along a region in which one or more vehicles are to be propelled. One or more vehicles are disposed on the guideway, each including a magnetic flux source. The guideway has one or more running surfaces that support the vehicles and along which they roll or slide. Each vehicle can have a septum portion of narrowed cross-section that is coupled to one or more body portions of the vehicle. The guideway includes a diverge region that has a flipper and an extension of the running surface at a vertex of the diverge. The flipper initiates switching of vehicle direction at a diverge by exerting a laterally directed force thereon. The extension continues switching of vehicle direction at the diverge by contacting the septum. Still other aspects of the invention provide a transport system, e.g., as described above, that includes a merge region with a flipper and a broadened region of the running surface. The flipper applies a lateral force to the vehicle to alter an angle thereof as the vehicle enters the merge region, and the broadened region continues the merge by contacting the septum of the vehicle, thereby, providing further guidance or channeling for the merge. The flipper, which can be equipped for full or partial deployment, is partially deployed in order to effect alteration of the vehicle angle as the vehicle enters the merge.

In order to implement a secure monitoring function for a long-stator linear motor or planar motor, the invention proposes that at least one first measurement value of a first sensor is compared to a predefined plausibility threshold value, and in the event of said plausibility threshold value being exceeded by the first measurement value, an error is identified and an action is triggered.

An improved system for preventing collisions between movers while improving throughput in a linear drive system utilizes a continually variable vehicle length for each mover. A vehicle length is assigned to each mover, where the vehicle length is a minimum track length required by the vehicle to avoid physically contacting a neighboring vehicle along the track. The vehicle length for each mover is then determined for each location along the track based on both the track geometry and the mover geometry. The vehicle length is continually variable along the length of the track allowing movers to be positioned as close together as possible for each location along the track based on both the track geometry and the mover geometry. The continually variable vehicle length provides collision prevention between movers while increasing throughput of movers along segments of the track that do not require the largest spacing between movers.

A system and method for varying an amplitude of voltage on a DC bus by track segment in a linear drive system for an independent cart system according to application requirements is disclosed. The track includes at least a first portion and a second portion, where a DC voltage at a first amplitude is provided to the first portion of the track, and a DC voltage at a second amplitude is provided to the second portion of the track. The first amplitude of the DC voltage is selected to permit movers traveling along the track to travel at full rated speed with a full rated three applied to the mover. The second amplitude of the DC voltage is selected to permit the movers to travel at a reduced speed with full or increased three applied or to travel at full rated speed with a reduced force applied to the mover.

A mover includes a body, an axle, a drive wheel, a motor, a speed reducer, and a shaft coupling. The wheel is arranged rotatably around the axle. The reducer is attached to the axle to reduce and transmit rotational power of the motor and includes an output shaft aligned with a center axis of the axle. The coupling transmits the rotational power of the reducer to the wheel and includes a cylindrical portion having an annular shape when viewed along the center axis and housing the reducer at least partially inside. The cylindrical portion includes an input portion and an output portion at first and second ends, respectively, along the center axis. The cylindrical portion further includes an absorber between the input and output portions to absorb deviation and an angle of deviation between respective rotational center axes of the output shaft and the drive wheel.

A method for determining an air gap between a transport rotor and a stator segment, wherein an acceleration run of the transport rotor is performed and, here, the present stator current is measured and actual speed values are determined, from which a change in speed per time unit is determined, and from which an acceleration is determined, where the present propulsion force is determined from the product of the force constant and the present stator current, where the present propulsion force and the acceleration are used to determine a virtual mass of the transport rotor, and where for a statement about the currently prevailing air gap a relationship between an increase in the virtual mass and an enlargement of the air gap is used and a size value for the air gap is calculated therefrom.

The invention provides in some aspects a transport system comprising a guideway with a plurality of propulsion coils disposed along a region in which one or more vehicles are to be propelled. One or more vehicles are disposed on the guideway, each including a magnetic flux source. The guideway has one or more running surfaces that support the vehicles and along which they roll or slide. Each vehicle can have a septum portion of narrowed cross-section that is coupled to one or more body portions of the vehicle. The guideway includes a diverge region that has a flipper and an extension of the running surface at a vertex of the diverge. The flipper initiates switching of vehicle direction at a diverge by exerting a laterally directed force thereon. The extension continues switching of vehicle direction at the diverge by contacting the septum. Still other aspects of the invention provide a transport system, e.g., as described above, that includes a merge region with a flipper and a broadened region of the running surface. The flipper applies a lateral force to the vehicle to alter an angle thereof as the vehicle enters the merge region, and the broadened region continues the merge by contacting the septum of the vehicle, thereby, providing further guidance or channeling for the merge. The flipper, which can be equipped for full or partial deployment, is partially deployed in order to effect alteration of the vehicle angle as the vehicle enters the merge.

External interaction with a mover in an independent cart system is allowed at known locations along the track. The mover is initially propelled along the track in a first operating state. When the mover arrives at a station, the controller generates a signal to alert the external actuator of the presence of a mover at the station. After waiting at the station for a first predefined time interval, the controller switches to a second operating state, in which the coils are de-energized or the controller is reconfigured to operate in a less responsive manner than in the first operating state. The controller remains in the second operating state for a second predefined interval, during which the external actuator interacts with the mover or a load on the mover. After the second predefined interval, the controller enters a third operating state, and the controller propels the mover away from the station.