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.

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.

Present example embodiments relate generally to a ground transportation system for interacting with one or more vehicles, the vehicle comprising at least one magnetic element fixedly attached to the vehicle, each magnetic element operable to generate a magnetic field having a first magnitude and a first direction, the system comprising a magnetic coil assembly fixedly positioned near an area traversable by the vehicle and comprising a core and a magnetic wire coil wrapped around the core, the magnetic coil assembly operable to generate a magnetic field having a second magnitude and a second direction; and an energy storage unit operable to release energy to and store energy from the magnetic coil assembly.

The invention provides in some aspects a transport system comprising a guideway having a plurality of regions in which one or more vehicles are propelled, where each such vehicle includes a magnet. Disposed along each region are a plurality of propulsion coils, each comprising one or more turns that are disposed about a common axis, such that the respective common axes of the plurality of coils in that region are (i) substantially aligned with one another, and (ii) orthogonal to a direction in which the vehicles are to be propelled in that region. The plurality of coils of at least one such region are disposed on opposing sides of the magnets of vehicles being propelled along that region so as to exert a propulsive force of substance on those magnets. In at least one other region, the plurality of coils disposed on only a single side of the magnets of vehicles being propelled in that region exert a propulsive force of substance thereon-regardless of whether the plurality of coils in that region are disposed on a single or multiple (e.g., opposing sides) of those magnets.

A magnetic levitation conveying system conveys products on trays and measures the weight of the product without requiring removal of the product or tray. A track below the trays has magnetic levitation coils that generate a magnetic field when energized. The trays include magnets or other levitation elements that interact with the magnetic levitation coils to generate a propulsive levitating force on the tray. A sensor measures a parameter in the system to correlate the parameter with the weight of the conveyed product. The parameter can be a floating height of the tray above the track, an amount of energy necessary to maintain a particular floating height of the tray above the track, a force resulting from accelerating or decelerating the tray, a force required to maintain a desired curve radius when the tray moves around a curve, a force that counteracts an acceleration caused by an incline or other suitable indicator of weight.

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.

A system and method for wirelessly providing power to independent movers traveling along a track includes a sliding transformer to transfer power between the track and each mover. The sliding transformer includes a primary winding extending along the track and a secondary winding mounted to each mover. Each of the primary and secondary windings may be formed of a single coil or multiple coils. The primary and secondary windings are generally aligned with each other and extend along the track and along the mover in the direction of travel with an air gap present between the windings. A power converter on the mover may regulate the power supplied to the mover to control an actuator or a sensor mounted on the mover or to activate drive coils mounted on the mover to interact with magnets mounted along the track and, thereby, control motion of each mover.

In order to improve the adaptation of a long stator linear motor to requirements or conditions of individual transport units or of the transport track it is foreseen, that a movement profile is preset for the transport unit (Tx), which is followed by the transport unit (Tx), in doing so at least one system parameter of a model of the control system (21) is determined by means of a parameter estimation method, and the value of the system parameter over time is collected and from the variation over time a wear condition of the transport unit (Tx) and/or of the transport track is deduced.

In order to improve the adaptation of a long stator linear motor to requirements or conditions of individual transport units or of the transport track it is foreseen, that the control variables (StG) of a driving coil (7, 8) of long stator linear motor are superimposed with an excitation signal (AS) with a predetermined frequency band, wherein actual variables (IG) of the driving coil control are determined, from the control variables (StGAS) superimposed with the excitation signal (AS) and from the determined actual variables (IG) a frequency response is determined and from the frequency response the control parameters (RP) for this transport unit (Tx) are determined and the transport unit (Tx) is controlled using these determined control parameters (RP) for movement along the transport track.

A controller for an independent cart system simplifies programming and automatically adapts operation each mover travelling along a track. The controller includes a configuration table defining segments of the track, which includes a maximum velocity and/or a maximum acceleration for each mover within the segment. A motion command for a mover commands motion across multiple segments between the starting point and the ending point. As the mover travels, the controller receives a position feedback signal corresponding to the present location of the mover. The controller obtains the maximum velocity and/or maximum acceleration for the mover corresponding to the segment in which it is located. The controller automatically adjusts the speed and/or acceleration of the mover along the segment in which it is presently located. As the mover transitions between segments, the controller automatically adjusts the speed and/or acceleration according to the new segment in which the mover is located.