Control architecture for use with transport systems, such as linear drive systems, rotary drive systems, or a combination thereof, comprising a computer system having a controller for operating control system software for receiving input commands and protocols for creating a motion profile for each transport element, and a gateway for receiving the motion profile from the control system software and for operating gateway drive software that functions to select the appropriate drives to move each transport element along one or more tracks in accordance with their motion profiles.

Magnetic levitation transport using a parallel dipole line track system is provided. In one aspect, a magnetic levitation transport system includes: a dipole line track system having: i) multiple segments joined together, each of the multiple segments having at least two diametric magnets, and ii) at least one diamagnetic object levitating above the at least two diametric magnets. A method for operating a magnetic levitation transport system is also provided.

In an electromagnetic transport system, a transport route is divided into transport sections, each including at least one transport segment. A section control unit is assigned to each transport section, and a segment controller is assigned to each transport segment. A logistics unit, specifies a destination of the transport units to the section control units via the logistics network. Section control units are connected to the segment controllers of associated transport segments via a segment network and are designed to; determine a track section for the associated transport section from the destination, determine target values using the track section and to transmit the target values to the segment controllers via the segment network. Segment controllers supply current to drive coils using target values and occurring actual values to generate a magnetic field which interacts with drive magnets of the transport units to move the transport units.

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 method and system for characterizing performance of a mover operating in a linear drive system is disclosed, where the linear drive system includes multiple track segments and where each track segment includes a segment controller. Each segment controller is configured to obtain an in-system frequency response for a mover present along the track segment. An injection sequence is generated within the segment controller, where the injection sequence includes harmonic content across a range of frequencies to be evaluated. The injection sequence is added to a control module within the segment controller, and the segment controller samples and records motion of the mover in response to the injection sequence. A frequency response corresponding to the recorded motion of the mover resulting from the injection sequence is obtained, and may be utilized to identify a resonant operating point or an undesirable level of the harmonic content present in the sampled data.

Control architecture for use with transport systems, such as linear drive systems, rotary drive systems, or a combination thereof, comprising a computer system having a controller for operating control system software for receiving input commands and protocols for creating a motion profile for each transport element, and a gateway for receiving the motion profile from the control system software and for operating gateway drive software that functions to select the appropriate drives to move each transport element along one or more tracks in accordance with their motion profiles.

A method of operating a transport system, in particular a multi-carrier system, which comprises a plurality of linear motors, which are arranged in a row and have a guide track, and a plurality of transport elements that are movable along the guide track by means of the linear motors, has the following steps: generating a travel job for a first one of the transport elements for travelling along at least a part section of the guide track, generating a first movement profile of the first transport element for the travel job based on predetermined movement characteristic values, matching the first movement profile with a second movement profile of a second transport element directly in front of the first transport element and determining whether a predetermined minimum distance between the first transport element and the second transport element is fallen below during the execution of the travel job, updating the first movement profile to maintain the minimum distance if it has been determined that the minimum distance is fallen below, and controlling the linear motors to move the first transport element in accordance with the first movement profile.

Systems and methods for energy storage and management may be useful for a variety of applications, including launch devices. A system can include a direct current (DC) bus configured to operate within a predetermined range of voltages. The system can also include an array comprising a plurality of ultra-capacitors connected to the DC bus and configured to supply the DC bus with energy. The system can further include an input configured to receive energy from a power grid, wherein the power grid is configured to supply fewer than 250 amps of power. The system can additionally include an output configured to supply more than 250 amps of power. The system can also include a controller configured to control charging and discharging of the array of ultracapacitors and configured to control the DC bus to remain within the predetermined range of voltages.

Methods for determining an absolute position of a moving travel unit of a stationary transport system, the travel unit movable along a travel path inside the system. The travel unit is driven by at least one linear motor along the path. The linear motor is a synchronous motor including a plurality of stator units installed along the travel path configured to provide a magnetic field traveling along the travel path. At least one rotor unit is attached to the travel unit and is configured to be driven along the travel path by the traveling magnetic field. Wherein respectively by analysis of regulating parameters of a vector regulation of the linear motor an active stator unit is determined from the plurality, which presently provides the magnetic field driving the rotor unit and a relative position of the rotor unit in relation to the active stator unit is computed.

A method and system for detecting and reporting component failures in a linear drive system may identify failed position sensors, failed position magnets, and failed drive coils in the linear drive system. As a mover travels along a track segment in the linear drive system, signals corresponding to the position of the mover and to the current commanded in each drive coil are stored. Analysis of the stored signals identifies whether one of the position sensors along the track segment, one of the position magnets on the movers, or one of the drive coils, used to propel the movers along the track, has failed.