Magnetic movement using offset magnetic arrays with electromagnets
12570484 ยท 2026-03-10
Assignee
Inventors
Cpc classification
H02N15/00
ELECTRICITY
B65G43/00
PERFORMING OPERATIONS; TRANSPORTING
B65G54/02
PERFORMING OPERATIONS; TRANSPORTING
B65G2812/99
PERFORMING OPERATIONS; TRANSPORTING
International classification
B65G54/02
PERFORMING OPERATIONS; TRANSPORTING
B65G43/00
PERFORMING OPERATIONS; TRANSPORTING
H02K41/03
ELECTRICITY
Abstract
A system provides a work surface, a configuration space unit, and a magnetic movement system. The work surface has a configuration space associated therewith. In this regard, the configuration space unit is positionable within the associated configuration space of the work surface. The magnetic movement system has unit cells arranged in cooperation with the work surface, where each unit cell comprises an actuator, a magnet coupled to the actuator such that the actuator causes movement of the magnet defining an actuated magnet, and an electromagnetic coil. Moreover, the magnetic movement system is configured such that a magnetic field produced by at least one unit cell performs at least one operation that affects a position of the configuration space unit within the configuration space of the work surface.
Claims
1. A system comprising: a work surface having a configuration space associated therewith; a configuration space unit, the configuration space unit positionable within the associated configuration space of the work surface; and a magnetic movement system having unit cells arranged in cooperation with the work surface, each unit cell comprising: an actuator; a magnet coupled to the actuator such that the actuator causes movement of the magnet defining an actuated magnet; and an electromagnetic coil; wherein the magnetic movement system is configured such that a magnetic field produced by at least one unit cell performs at least one operation that affects a position of the configuration space unit within the configuration space of the work surface.
2. The system of claim 1 further comprising: a controller operatively programmed to control the unit cells of the magnetic movement system to perform the at least one operation to levitate, tilt, spin/orient, move, propel, thrust, pull, push, or combinations thereof, the configuration space unit relative to the work surface, wherein the controller is programmed to carry out each operation based issuing commands to at least one unit cell to: selectively control the actuator to adjust a position of the actuated magnet relative to the work surface; selectively communicate a signal to the electromagnetic coil to control a field generated thereby; or selectively control both the actuator and the communicated signal to the electromagnetic coil.
3. The system of claim 2, wherein: each unit cell of the magnetic movement system further comprises a sensor node that is configured to measure at least one kinematical aspect of the configuration space unit; and the controller is further operatively programmed to: collect measurements from at least one sensor node; detect an instability of the configuration space unit based at least in part, from the collected measurements; and provide a command to the magnetic movement system to output a time-varying magnetic field which reacts to the detected instability based upon the collected measurements to provide a magnetic field which counters the instability.
4. The system of claim 3, wherein: at least one sensor node measures position, velocity, acceleration, or a combination thereof.
5. The system of claim 3, wherein: at least one sensor node measures position; and the controller: detects the instability based upon a sensed position determined from the collected measurements; determines the configuration space unit to be drifting from a desired position; and provides the command to the magnetic movement system to apply a countering force to the magnet of the levitated configuration space unit.
6. The system of claim 2, wherein: the controller is operatively programmed to control at least one unit cell such that: the controller operates the electromagnetic coil at a first frequency; and the controller operates the actuator at a second frequency; where the first frequency is greater than the second frequency.
7. The system of claim 2, wherein: the controller is operatively programmed to control at least one unit cell such that: the controller operates the actuator and hence, the actuated magnet in the Z direction to control a magnetic force applied to the configuration space unit; and the controller controls the electromagnetic coil to control X and Y direction forces, and x, y and z torques to control stability of the configuration space unit.
8. The system of claim 2, wherein: the controller is operatively programmed to control at least one unit cell such that: the controller operates the actuator and hence, the actuated magnet in the Z direction to control a magnetic force applied to the configuration space unit; and the controller controls at least one of the actuator and the electromagnetic coil to control X and Y direction forces, and x, y and z torques to control stability of the configuration space unit.
9. The system of claim 2, wherein: the controller is operatively programmed to control at least one unit cell such that: the actuated magnet of at least one unit cell provides levitation forces (Z forces) of the configuration space unit, whereas the electromagnetic coil provide high frequency lateral force adjustments (X and Y) needed to maintain levitation and keep the levitated configuration space unit on a desired path.
10. The system of claim 1, wherein for at least one unit cell: the electromagnetic coil is situated in line with movement of the actuated magnet via the actuator; and a controller is operatively programmed to selectively operate the actuator to facilitate a magnetic force applied to the configuration space unit, and to selectively modify properties of the electromagnetic coil to affect the stability of the configuration space unit.
11. The system of claim 1, wherein for at least one unit cell: the electromagnetic coil is on a printed circuit board, which is coupled to a select one of the actuated magnet or a moveable component of the actuator.
12. The system of claim 11, wherein: the electromagnetic coil on the printed circuit board comprises a coil that is part of a set of electromagnetic coils.
13. The system of claim 1, wherein for at least one unit cell: the actuated magnet is moveable by the associated actuator relative to the work surface; and the electromagnetic coil is stationary relative to the work surface.
14. The system of claim 1, wherein for at least one unit cell: the actuated magnet and the electromagnetic coil are both moveable by the associated actuator relative to the work surface.
15. The system of claim 1, wherein for at least one unit cell: the magnet is part of a set of magnets arranged in a first pattern; and the electromagnetic coil is part of a set of electromagnetic coils arranged in a second pattern different from the first pattern.
16. The system of claim 1 further comprising a cryogenic cooling system to cool the electromagnetic coil.
17. The system of claim 1, wherein the configuration space unit is implemented as a conveyance system that includes at least one of wheels, rollers, casters, or bearings, so that complete levitation is not strictly required to effect movement of the conveyance system within the configuration space by the magnetic movement system.
18. The system of claim 17, wherein a weight of a load on the conveyance system is carried in a manner that is split between an assist provided by the magnetic movement system and the conveyance system.
19. The system of claim 1, wherein: the actuated magnet of each unit cell is varied in at least one of default height or magnetic strength.
20. The system of claim 1, wherein: at least one actuator comprises a select one of: a linear actuator; an actuator that affects rotating the corresponding permanent magnet on a cylinder or disc; or an actuator that selectively covers and uncovers the corresponding permanent magnet with a magnetically permeable material.
21. The system of claim 1, wherein: the configuration space unit comprises a magnet; the actuated magnet and/or the electromagnetic coil of at least one unit cell generates a magnetic field that interacts with the magnet of the configuration space unit to carry out each operation.
22. A system comprising: a configuration space unit; a magnetic movement system that is configured to perform at least one operation to levitate, tilt, spin/orient, move, propel, thrust, pull, or push the configuration space unit, the magnetic movement system having unit cells, each unit cell comprising: an actuator; a magnet coupled to the actuator such that the actuator causes movement of the magnet; and an electromagnetic coil; a controller operatively programmed to control the unit cells of the magnetic movement system to perform the at least one operation, wherein the controller is programmed to carry out each operation based issuing commands to at least one unit cell to: selectively control the actuator to adjust a position of the actuated magnet relative to the work surface; selectively communicate a signal to the electromagnetic coil to control a field generated thereby; or selectively control both the actuator and the communicated signal to the electromagnetic coil.
23. A system comprising: a configuration space unit having a magnet and a conveyance system on a bottom thereof; a magnetic movement system that is configured to utilize magnetic forces in cooperation with the magnet on the bottom of the configuration space unit to move the configuration space unit across a floor, the magnetic movement system having unit cells that cooperate with the floor, each unit cell comprising: at least one of: an actuator; and a permanent magnet coupled to the actuator such that the actuator causes movement of the permanent magnet; and an electromagnetic coil; a controller that is communicably coupled to unit cells, wherein the controller is operatively programmed to control select unit cells to carry out the movement of the configuration space unit across the floor.
24. The system of claim 23, wherein: the conveyance system does not touch the floor when being levitated.
25. The system of claim 23, wherein: the configuration space unit further comprises bumpers along the bottom edges thereof, that may touch the work surface as a configuration space unit starts to tilt beyond a certain x or y angle.
Description
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
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DETAILED DESCRIPTION
(39) Aspects herein provide a magnetic movement system that can lift, stabilize, move, orient, or otherwise position objects, including very heavy objects. Moreover, such magnetic movement systems can operate with a manageable amount of power and heat, and do not require rails or other physical restraints.
INTRODUCTION
(40) Aspects herein disclose a system in which magnets provide magnetic forces that operate on a configuration space unit positioned relative to a work surface. For instance, where the work surface is a horizontal bed, the magnetic forces operate on a configuration space unit positioned above the horizontal bed to affect a position of the configuration space unit, e.g., to spin, orient, tilt, stabilize, move, thrust, pull, push, lift, levitate, etc., the configuration space unit. Moreover, aspects of the disclosure expand on such magnetic movement systems and provide alternatives and improvements.
(41) In this regard, aspects herein define a configuration space. As used herein, the configuration space includes a space associated with the work surface to which a controller can control a magnetic movement system to perform work, e.g., to sense, identify, locate, position, or otherwise interact with an object (i.e., a configuration space unit) in the configuration space. In this regard, a configuration space can comprise an area, volume, regular volume, irregular volume, etc.
(42) As used herein, a configuration space unit (CSU or CSUs-plural) is an object positionable within a configuration space of a work surface that can be manipulated by a corresponding magnetic movement system as described more fully herein. By way of non-limiting example, a configuration space unit can comprise a mobility unit (an object that can move or is otherwise movable), such as a mover, cart, sled, moveable pallet or platform, automatic guided vehicle, operator-assisted vehicle, pedestrian (e.g., via an object worn, carried or otherwise attached to the pedestrian), etc. A configuration space unit can also comprise an object that is fixedly positioned relative to the configuration space, which may have components capable of limited movement, such as a stationary robot with a moveable end effector, a machine, etc.
(43) Moreover, as used herein, the term levitate and derivatives thereof (e.g., levitates, levitating, levitation, etc.) means to provide a force that acts on an object, such as a configuration space unit. For instance, an example force can comprise a magnetic force that opposes the effect of gravity. By way of illustration, in the example case of a configuration space unit such as a mover, levitation may comprise lifting the mover from a work surface so as to rise into the air sufficient to avoid physical contact with the work surface. As another example, the levitation force may be insufficient to physically cause the configuration space unit to lift completely from the work surface, but the levitation force opposes gravity sufficient to reduce friction when moving or orienting a configuration space unit. As an example, a configuration space unit such as a cart may not physically lift off the work surface. However, the magnetic movement system applies a sufficient force acting on the configuration space unit to assist overcoming static friction, to assist the cart in rolling along the work surface, to help brake a rolling cart, etc. Levitation can also include tilting, or otherwise imparting a lifting force, whether the lifting force is sufficient to overcome the weight of the object/gravity.
(44) In order to levitate a system of magnets, a magnetic control system must provide two essential elements 1) a force, to overcome the attractive force of gravity (e.g., to lift (Z direction), to pull and/or push (e.g., in any combination of X, Y, and Z directions, etc.), and 2) stability. Magnetic levitation where an object rises completely off a surface is inherently unstable according to Earnshaw's theorem, and therefore a static arrangement of permanent magnets generally cannot be used for stable levitation.
(45) Instead, levitation control systems herein are configured to provide a time-varying magnetic field which reacts to any instability and provides a magnetic field which counters the instability. This can be implemented, for example, using an active feedback scheme in which some kinematical aspect of the magnets are measured (e.g. position, velocity and acceleration). If the sensed position, for example, is determined to be drifting from its desired position, then countering forces are applied to the magnets. The determination of the position, velocity etc., can be accomplished using any variety of sensors (e.g., optical, hall effect, etc.). Moreover, in the case of actuated permanent magnets, the countering forces can be affected by physically moving the actuated magnets in response to the readings of the various sensors.
(46) In addition to lift and stability, if motion of the magnets is desired, then the levitation control system can also be adapted to provide forces/torques to the magnets while maintaining stability. According to aspects herein, for full control of a array of magnets, the control system may be able to provide control in six separate degrees of freedom. The six degrees of freedom implementation requires the control system to provide forces, for example, in the X, Y and Z directions as well as torques about the X, Y and Z axes. It should be noted that the same system that provides stability may also provide lateral forces, e.g., to attract and/or repel configuration space unit magnets to spin/orient, move, propel, thrust, pull, push (or any combination thereof) a configuration space unit.
(47) Aspects herein provide a movement system that creates repulsive and/or attractive magnetic forces by lifting and lowering magnets (referred to herein as actuated magnets) from a bed of such magnets, e.g., which may be arranged in unit cells, as will be described more fully herein. Moreover, aspects herein provide details for enabling the incorporation of electromagnets with the actuated permanent magnets in a bed of magnets. In an example implementation, a wire coil of an electromagnet is co-located with each actuated magnet. In some implementations, each actuated magnet travels up and optionally through, its associated wire coil. In another implementation, each actuated magnet is paired with an electromagnet having a coil, e.g., which can be printed on a PCB (printed circuit board), and each PCB coil can be located above the highest level of its associated actuated magnet. The electromagnetic coils can be cooled to enable superconductivity.
(48) The actuated magnets and electromagnets can be configured to work together in various relationships and geometries. In an example implementation, the actuated permanent magnets are used to support loads, and the electromagnets are used to provide stability adjustments. Both types of magnets (permanent magnet and electromagnet) can be used to control the movement, spin/orientation, tilt, stability, combinations thereof, etc., of levitated objects. Each electromagnet is able to cause both attractive and repulsive magnetic force using the same hardware.
(49) In an example implementation, permanent magnets and electromagnets can be configured at a 1:1 ratio. In another example, permanent magnet arrays can be placed in a first regular density, and electromagnets can be placed in a second regular density that is more or less dense than the first density. The densities of each group of magnets can vary based upon the environment and expected activities in different areas of an installation. Permanent magnets can be placed throughout a work surface such as a floor, and electromagnets can be placed at strategic locations where extra stability and control is needed. In the example of a floor, electromagnets can be located in an area such as near a loading dock. As yet another example, a path of permanent magnets can be flanked by electromagnets which provide forces to keep objects on the path.
(50) The forces exerted by the permanent magnets on configuration space units can be altered by moving each individual magnet up and down with a linear actuator, or by rotating each magnet on a cylinder or disc, or by covering and uncovering each magnet with magnetically permeable material. An entire array of permanent and electromagnets can be moved up and down together by linear actuators. Also, a superconducting surface can provide levitation forces.
(51) As described in patent applications PCT/US2021/045457 and PCT/US2021/072947, the disclosures of which are incorporated by reference, individual permanent magnets can be lifted up in a coordinated fashion to interact with permanent magnets, which are attached underneath a configuration space unit, creating repulsive and attractive magnetic forces which can lift and nudge the configuration space unit in any direction. Alternatively, electromagnets or a combination of electromagnets and actuated permanent magnets can be used to change the magnetic field in the X, Y, and/or Z direction, causing the same type of repulsive and attractive magnetic forces. Aspects herein can further utilize the methods for controlling levitation and building a levitation control system, as described in U.S. patent application Ser. No. 18/425,978 having the title, Position Sensing System which is incorporated by reference herein in its entirety, and U.S. provisional patent application 63/382,533 filed Nov. 6, 2022, and corresponding non-provisional Ser. No. 18/503,154 filed Nov. 6, 2023, the disclosures of which are incorporated by reference in their entirety.
(52) In an example implementation of a movement system, a common mechanism is used to provide both the lift and the stability. For example in an actuated permanent magnet system, the actuated magnets can provide both the lift and the stability, provided that the magnets can respond and move fast enough. There is a limit however to the speed of mechanical motions, so that depending on the details of the actuators employed in the system, mechanical actuations alone may not be sufficient. In this regard, it is possible to implement lift and stability using two different systems.
(53) Hybrid System ComponentsThe Unit Cell
(54) A magnetic movement system can be constructed using an array of hybrid system components, implemented as an array or bed of unit cells.
(55) Referring now to the drawings, and in particular, to
(56) The electromagnetic coil 101 comprises for example, conductive wire that is wrapped into a square tube or hollow cylinder tube. In the illustrated example, the electromagnetic coil 101 is wrapped with a large enough opening such that the permanent magnet 102 may be actuated through the center of the tube. Thus for example, the electromagnetic coil 101 can be positioned in-line with the arm of the linear actuator 103 so as to allow the permanent magnet 102 to reciprocate at least partially, through the opening/hole of the electromagnetic coil 101. An electric current is driven through the looped wire creating a magnetic field.
(57) In other example implementations, the electromagnetic coil 101 can comprise one or more electromagnetic coils either in-line with the magnet 102, offset from the magnet 102, or in a pattern in cooperation with the magnet 102.
(58) Thus, although described generally as an electromagnetic coil 101, in practice, the electromagnetic coil 101 can comprise one or more electromagnetic coils, each being the same or different, e.g., in size, wire gauge, number of turns, etc., each being driving by the same current or each electromagnetic coil being driven by a different current.
(59) Likewise, the magnet 102 can be implemented by one or more magnets, for example, a permanent magnet or magnets (in any pattern or configuration), an arrangement of magnets, such as a Halbach array, a mix of permanent magnets having the same or different physical properties, orientations, magnetic properties, etc., an electromagnetic coil or electromagnetic coils (in any pattern or configuration), a mix of permanent magnets and electromagnetic coils, or combinations thereof, etc.
(60) The actuator 103 is schematically illustrated as a linear actuator for sake of clarity of explanation. In this regard, the actuator 103 includes a drive mechanism and an arm that linearly extends and retracts (reciprocates) a programmable distance from the drive mechanism, up to a predetermined maximum extension. Movement of the arm of the actuator 103 causes corresponding movement of the magnet 102. Other actuator configurations are described more fully herein.
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(62) In example implementations, the magnet 102 reciprocates with the arm of the actuator 103. In this regard, the magnet 102 is also referred to herein as an actuated magnet to characterize its ability to move in cooperation with the actuator.
(63) In some example implementations, the electromagnetic coil 101 may be fixedly positioned. For instance, as illustrated, the magnet 102 moves independently of the electromagnetic coil 101. Moreover, in some implementations, the electromagnetic coil 101 remains fixed and the magnet 102 is capable of movement relative to the electromagnetic coil 101. In other implementations, the electromagnetic coil 101 can move with the movement of the magnet 102, e.g., via an arm of the actuator 103.
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(65) Referring to
(66) As illustrated, the configuration space unit 201 has a magnet 203 (e.g., a permanent magnet) positioned thereon. In practical applications, the magnet 203 can be positioned on a bottom surface of the configuration space unit 201, e.g., so as to be positioned as close to the unit cell 100 as possible.
(67) In an example implementation, the magnet 203 of the configuration space unit 201 is placed above or otherwise in proximity to the electromagnetic coil 101 and/or permanent magnet 102 of the unit cell 100. Here, the electromagnetic coil 101 and/or the actuated magnet 102 can be utilized to provide a magnetic force that interacts with the magnet 203 to act on the configuration space unit 201.
(68) For instance, the force can affect a position of the configuration space unit 201, e.g., to perform at least one operation to levitate, tilt, spin/orient, move, propel, thrust, pull, push, stabilize, etc., the configuration space unit 201 relative to a work surface and the corresponding unit cell 100.
(69) Moreover, the amount of force generated between the actuated magnet 102 of the unit cell 100 and the magnet 203 of the configuration space unit 201 can be determined/controlled/established based upon the distance between the actuated magnet 102 and the magnet 203, as adjusted by the actuator 103. Correspondingly, the electromagnetic coil 101 can be used to provide a force, e.g., for repulsive levitation, attraction, stability adjustments, or a combination thereof to the magnet 203. Here, the strength of the field can be controlled by controlling an amount of current passing through the electromagnetic coil 101. Likewise, the electromagnetic coil 101 can be in an energized state where current passes through the conductive coil of the electromagnetic coil 101, or the electromagnetic coil 101 can be in an de-energized state where no current passes through the conductive coil of the electromagnetic coil 101. As such, a magnetic field generated by the electromagnetic coil 101 can by dynamic, and can even reverse in polarity, based upon the current driven through the electromagnetic coil 101.
(70) Analogous to
(71) Some implementations can incorporate bumpers 210 along the bottom edge(s) of the configuration space units. Each bumper 210 is any shape and/or configuration that may touch the floor as a configuration space unit starts to tilt beyond a certain Ox or Oy angle, indicating instability. These bumpers 210 effectively slow down the unstable motion, allowing the actuators more time to make required force adjustments. Bumpers 210 can be included on any implementation described more fully herein.
(72) Example configurations can further incorporate springs into the bumpers, which apply a counteracting force to offset the forces of the unstable configuration space unit, thereby slowing down instability.
(73) Referring to
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(75) For instance, the unit cell 300 can include an electromagnetic coil 101, a permanent magnet 102, and an actuator 103, implemented as a linear actuator as illustrated. The actuator 103 is illustrated in
(76) The unit cell 300 is also illustrated as having a sensor node 304. The sensor node 304 is configured to measure at least one kinematical aspect of the configuration space unit, e.g., alone or in combination with the controller (e.g., see controller 104,
(77) The unit cell 300 can further include other components, e.g., a housing/frame, mounting hardware, etc.
(78) Referring to
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(80) In an example implementation, on the PCB, a copper trace is printed, e.g., in a spiral pattern. Current flows through the spiral to create a magnetic field. The magnetic field created in a coil increases with the number of turns of the wire or PCB trace. Generally speaking, the number of turns that can be created on a PCB is limited as compared to a wire wrapped coil, as there is limited space to print the spiral on the PCB surface. A multilayer PCB could be used to increase the number of turns, but this is limited by the number of PCB layers that can be economically fabricated.
(81) Given that the PCB coil sits above the actuated magnets, its geometry need not match that of the actuators.
(82) Referring to
(83) In
(84) In
(85) Configuration Space Unit and Work Surface
(86) An array of hybrid actuated magnet/electromagnet coils can be used as (or in combination with) a work surface, e.g., a floor to impart forces on a configuration space unit. The configuration space unit can comprise, for example, an object as described more fully herein. In an example implementation, the configuration space unit is lined with permanent magnets such that magnetic force between the magnetic fields generated by the unit cells and the magnets of the configuration space unit are repulsive, attractive, or a combination thereof, in order to act on the configuration space unit, e.g., to affect its position, to impart movement to the configuration space unit, etc.
(87) Configuration Space Unit
(88) As noted above, at least one configuration space unit is within an environment (e.g., within a configuration space) of a work surface. Referring to
(89) In order to identify, orient, levitate, stabilize, move, etc., the configuration space unit 601, a surface of a configuration space unit 601 is equipped with magnets, e.g., permanent magnets 602. In the example implementation, the magnets 602 are located on an underside surface of the configuration space unit 601 and are arranged in a pattern similar to a checkerboard, omitting every second magnet and (correspondingly) adding space between magnets 602. Other patterns, or arrangements can alternatively be implemented. By comparison, a corresponding work surface can integrate an array of unit cells, e.g., a full grid pattern of unit cells 100. In an example implementation, the configuration space unit magnets 602 are arranged and spaced such that the configuration space unit magnets 602 cannot all simultaneously be positioned directly above the same floor unit cell 100.
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(91) A square shaped configuration space unit 601 (analogous to the configuration space unit 601,
(92) In an example implementation, the actuated magnets 102 are dynamically adjusted via corresponding actuators 103 to provide a levitation force. The faster responding electromagnetic coils 101 provide stability, which may involve repulsive and/or attractive forces, e.g., depending on whether to achieve stability, the configuration space unit needs to be pushed or pulled relative to the location of each electromagnet coil 101. In an example implementation, the actuated magnets 102 provide the Z forces, whereas the electromagnet coils 101 provide the X, Y, and Ox, Oy and Oz forces. The actuated magnets 102 may be updated at a first frequency to maintain desired Z forces, while the faster responding electromagnet coils may be updated at a higher frequency to maintain the configuration space unit's desired position and provide stability.
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(94) In an example implementation, a movement system comprises a configuration space unit 601 having a magnet, such as one or more permanent magnets 602 (e.g., see
(95) In an example implementation, a system comprises a work surface (e.g., the work surface 701 implemented as a floor in
(96) In some implementations, a controller 104 is operatively programmed to control the unit cells 100 of the magnetic movement system to perform the at least one operation to levitate, tilt, spin/orient, move, propel, thrust, pull, push, or combinations thereof, the configuration space unit 601 relative to the work surface 701. In this implementation, the controller 104 can be programmed to carry out each operation based issuing commands to at least one unit cell 100 to selectively control the actuator 103 to adjust a position of the actuated magnet 102 relative to the work surface 701, selectively communicate a signal to the electromagnetic coil 101 to control a field generated thereby, or selectively control both the actuator 103 and the communicated signal to the electromagnetic coil 101.
(97) Moreover, in some implementations, each unit cell 100 of the magnetic movement system can further comprise a sensor node 304 (sensor node 304,
(98) As another example, the sensor node 304 (
(99) In still another example, the sensor node 304 (
(100) Yet further, the controller 104 can be operatively programmed to control at least one unit cell such that the controller operates the electromagnetic coil at a first frequency, and the controller operates the actuator at a second frequency, where the first frequency is greater than the second frequency.
(101) As another example, the controller 104 can be operatively programmed to control at least one unit cell 100 such that the controller 104 operates the actuator 103 and hence, the actuated magnet 102 in the Z direction to control levitation of the configuration space unit 601, and the controller 104 controls the electromagnetic coil 101 to control X and Y direction forces, and x, y and z torques to control stability of the configuration space unit 601.
(102) In still another example, the controller 104 can be operatively programmed to control at least one unit cell 100 such that the controller 104 operates the actuator 103 and hence, the actuated magnet 102 in the Z direction to control levitation of the configuration space unit 601. Also, the controller 104 controls at least one of the actuator 103 and the electromagnetic coil 101 to control X and Y direction forces, and x, y and z torques to control stability of the configuration space unit 601.
(103) In a further example, the controller 104 can be operatively programmed to control at least one unit cell 100 such that the actuated magnet 102 of at least one unit cell 100 provides levitation forces (Z forces) of the configuration space unit 601, whereas the electromagnetic coil 101 provide high frequency lateral force adjustments (X and Y) needed to maintain levitation stability and keep the configuration space unit 601 on a desired path.
(104) In some implementations, for at least one unit cell, the electromagnetic coil is situated in line with movement of the magnet via the actuator, and a controller is operatively programmed to selectively operate the actuator to facilitate levitation of the configuration space unit, and to selectively modify properties of the electromagnetic coil to affect the stability of the configuration space unit.
(105) As noted more fully herein, in some implementations, the electromagnetic coil is on a printed circuit board (e.g., see electromagnetic coil 401,
(106) In some implementations, for at least one unit cell, the actuated magnet 102 is moveable by the associated actuator 103 relative to the work surface 701 and the electromagnetic coil 101 is stationary relative to the work surface 701 (e.g., fixed below, within, as part of the unit cell, dissociated from the unit cell, etc.). As an alternative, the actuated magnet 102 and the electromagnetic coil 101 can both be moveable by the associated actuator 103 relative to the work surface 701. As another example, the actuated magnet 102 can be part of a set of magnets arranged in a first pattern, and the electromagnetic coil 101 is part of a set of electromagnetic coils arranged in a second pattern different from the first pattern.
(107) In some implementations, the movement system can further comprise a cryogenic cooling system to cool the electromagnetic coil. For instance, a cooling system 705 can provide the necessary conditioning to implement efficient operation.
(108) As will be described in greater detail herein, e.g., with reference to
(109) In some example implementations, the actuated magnet 102 of each unit cell 100 is varied in at least one of default height or magnetic strength.
(110) In further implementations, at least one actuator comprises a select one of a linear actuator, an actuator that affects rotating the corresponding permanent magnet on a cylinder or disc, or an actuator that selectively covers and uncovers the corresponding permanent magnet with a magnetically permeable material, as will be described in greater detail herein.
(111) In some systems, the configuration space unit 601 can comprise a magnet 602 (
(112) According to further aspects herein, a system comprises a configuration space unit 601, a magnetic movement system, and a controller 104. The magnetic movement system is configured to perform at least one operation to levitate, tilt, spin/orient, move, propel, thrust, pull, or push the configuration space unit 601. In this regard, the magnetic movement system has unit cells 100, where each unit cell 100 comprises an actuator 103, a magnet 102 coupled to the actuator 103 such that the actuator 103 causes movement of the magnet 102 (thus defining an actuated magnet), and an electromagnetic coil 101. The controller 104 is operatively programmed to control the unit cells 100 of the magnetic movement system to perform the at least one operation. More particularly, the controller 104 is programmed to carry out each operation based issuing commands to at least one unit cell 100 to selectively control the actuator 103 to adjust a position of the actuated magnet 102 relative to the work surface 701, selectively communicate a signal to the electromagnetic coil 101 to control a field generated thereby, or selectively control both the actuator 103 and the communicated signal to the electromagnetic coil 101.
(113) As still another example, a system comprises a configuration space unit 601, a magnetic movement system, and a controller 104. The configuration space unit 601 has a magnet 602 (
(114) In this example, the configuration space unit 601 may be levitated, e.g., to not touch the work surface 701 (e.g., a floor in this example).
(115) As another example, the configuration space unit may further comprise bumpers (e.g., bumpers 210,
(116) Yet further, although a single controller 104 is schematically shown, in practice, the controller 104 and/or its functions can be distributed. For instance, depending upon the size of the movement system 700, it may be desirable to allocate a sub-controller 104 to a cluster, e.g., a group, array, section, etc., of unit cells. Where multiple controllers 104 are utilized, the various sub-controllers 104 can be controlled by a supervisory controller 104 (or controllers) in any practical hierarchy.
(117) The combined actuated magnet/electromagnetic coil system is incorporated into an active feedback loop in which the position of the configuration space unit 601 is compared to a target position, e.g., by the controller 104. By way of example, each unit cell 100 can include a Hall effect sensor or suitable device for detecting the configuration space unit 601 (or configuration space units 601).
(118) In some implementations, the controller 104 is operatively programmed to control the configuration space unit 601, e.g., to control and or establish a position of the configuration space unit 601, an orientation of the configuration space unit 601, movement of the configuration space unit 601 across the floor, combinations thereof, etc. If the sensed position of the configuration space unit 601 deviates from its target position, then the controller 104 controls one or more select unit cells 100 to apply restoring forces to keep the configuration space unit 601 in a stable position/orientation. Various approaches can be implemented.
(119) In an example approach, for each unit cell 100, the electromagnetic coils 101 are used exclusively for the lateral stability, and the actuated magnets 102 are used exclusively to vertically support the load. In this scheme the magnet actuations are controlled by the controller 104 in such a way that they do not respond to any small changes in lateral position of the configuration space unit 601. This reduces unnecessary wear on the mechanical actuators in the system.
(120) In another approach to active feedback by the controller 104, both the actuated magnets 102 and the electromagnetic coils 101 are used to provide lateral stability. In this case, the actuated magnets 102 and the coils 101 respond to any lateral deviations of the configuration space unit 601 from its target position. In such a system, care must be taken so that the two systems do not interfere with each other as unnecessary power consumption could be induced (e.g. the permanent magnets are pulling while the electromagnet is pushing).
(121) In some configurations, the work surface 701 implements a false floor, which can be added between the configuration space unit 601 and the electromagnet coils 101. This hybrid system can be compared to a system that uses only electromagnetic coils 101. In a coils-only floor system, the levitation force and the stability are provided by electromagnetic coils in the floor. However, the power consumed by an electromagnetic coil dominated by resistive losses is given by the expression P=RI.sup.2 where R is the coil resistance and I is the coil current.
(122) The expression shows that the power consumption, P, increases with the square of the current. Therefore, doubling the levitation force requires a factor of four increase in power. The hybrid system has an advantage in that the levitation force is provided by the permanent magnets, which requires no power except the power consumed by the mechanical actuators. Thus, the hybrid actuated magnet/electromagnet coil system consumes less power to levitate relatively heavy loads as compared to an electromagnet coil-only system.
(123) Some implementations can utilize a cryogenic cooling system 705, e.g., a system of jets that utilize a cryogenic coolant, to cool the coils 101 in the above configuration to cryogenic temperatures where the coil conductor becomes superconducting. In this case, the current flows in the coils without resistance, mitigating the P=RI.sup.2 losses in a conventional conductor.
(124) However, power will be consumed in keeping the system at the extremely low temperatures, and extensive insulation would be required to isolate the cooled coils from the rest of the system.
(125) Referring to
(126) In
(127) Countering gravity has an effect of reducing friction. Reduced friction is of interest, e.g., where a configuration space unit is not completely levitated. In a frictionless system, there would be no need to counter gravitya goal of movement can be accomplished with pushing and/or pulling forces in X and Y and z.
(128) The false floor 701 is assumed to be sufficiently smooth and clean, creating a low friction surface for the bearings to roll across. Lateral forces created by the combined system of permanent magnets 102 and coils 101 within the floor can be used to transport the configuration space unit across the false floor 701. The configuration space unit 601 schematically illustrated in
(129) Referring to
(130) In
(131) Since all or a part of the load of the configuration space unit 601 is supported by the conveyance system 801, this system is lower power than a fully levitated coil-based system.
(132) Referring to
(133) In
(134) In another configuration, wheels are placed on configuration space units 601, but while the configuration space unit is levitated, the wheels do not touch the work surface 701, e.g., the false floor. Instead, these wheels only come in contact with the floor: (1) when the actuated magnet system is non-functional, or when part of the actuated magnet system is non-functional, allowing the configuration space unit to be manually relocated; over the non-functioning portion; or (2) to allow configuration space units to be pushed over surfaces that do not contain the floor of actuated magnets.
(135) The wheeled system of the configuration space unit 601 can be designed to support and transport a target load. A load exceeding the target load may be placed on the configuration space unit, and in this implementation, the system adjusts the magnetic forces from the actuated permanent magnets and electromagnets such that the target load rests on the wheels of the configuration space unit, while the remaining load is supported by the actuated permanent magnets and/or electromagnets. Load balancing can be described as Total Load=Target load on Configuration space unit Wheels+Load supported by Magnetic Forces.
(136) The load placed on the configuration space unit 601 can be determined prior to or after being placed on the configuration space unit. The movement system then has the information it needs to supply constant levitation forces sufficient to levitate a load of magnitude=Total LoadTarget Load on Configuration space unit Wheels.
(137) Referring to
(138) A scenario is illustrated where the weight of a levitated load can be determined using the described movement systems. The system incorporates a proximity sensor which detects the distance from the configuration space unit 601 with the levitated load 1101 to the sensor. The sensor can be located in, on or under the work surface 701, and can be co-located with a unit cell 100. In the preferred implementation, a levitated known load is kept at a fixed distance above the sensor or equivalently at a fixed distance from the work surface 701. In this implementation, the vertical displacement of the actuated magnets 102 is adjusted to keep the known load at the target height. Heavier loads require that the actuated magnets are closer to the levitated load to provide more force.
(139)
(140) Thus, referring to
(141) In example configurations, simulations can be performed to quantify this effect. In the simulations a set of actuations are optimized to support a load of 110N at 0.25 centimeter (cm) from a false floor 701. The magnets can be uniformly lowered in the simulation while keeping the configuration space unit fixed.
(142) Referring to
(143) A levitated object without dynamic forces to maintain stability will rapidly gravitate towards a non-levitated state. Stability of a levitated object can be viewed as ball resting on the top of a very steep hill, such that if the ball moves in any direction, it rapidly loses stability. The further the ball moves from the top of the hill, the more energy it takes to stop the ball and move it back to the top of the hill. In the same way, the longer the response time before adjusting forces are applied to a correct a configuration space unit's position, the more energy must be consumed to maintain levitation.
(144) Using this same analogy, to reduce the required levitation forces, or the speed and frequency of the required force adjustments, the system can reduce the slope of the hill, create speed bumps, or counter balancing forces. In an example system, some techniques to achieve analogous reductions in the speed of instability include any one or more of the following, by way of example.
Miscellaneous Considerations Applicable to All Disclosures Herein
(145) In an example configuration, an array of actuated magnets and/or electromagnet coils used as a work surface such as a floor may have some of the actuated permanent magnets attached to an actuator that can actuate (move) much more rapidly than other actuators in the floor system. These fast moving actuated magnets may have their heights adjusted at higher rates than other actuators in the system.
(146) Furthermore, some actuators may be mounted with permanent magnets that are higher strength than other magnets. Incorporating a proportion (such as th or th) of the actuators with fast moving actuators that are updated at a higher frequency, which may also have higher strength magnets, can alleviate or eliminate the need for faster responding electromagnet coils.
(147) In another configuration, the actuated permanent array may be placed along narrow paths, while electromagnets may be placed on the perimeters of the path. In this system, the actuated permanent magnets provide the levitation forces (Z forces), while the electromagnets on the edges of the path provide the high frequency lateral force adjustments (X and Y) needed to maintain levitation and keep the levitated configuration space unit on the desired path, e.g., over the bed of actuated permanent magnets and between the electromagnets along the perimeter.
(148) Example Component Configurations
(149) Referring to
(150) In the example of this configuration shown in
(151) In another example implementation, the floor comprises electromagnet coils, actuated permanent magnets, or both. The configuration space unit comprises a superconducting surface at the bottom of the configuration space unit, which provides stable levitation when repulsive forces are applied by the magnets within the floor. The repulsive and/or attractive forces applied by the magnets within the floor transport the configuration space unit across a false floor. A cryogenic cooling system can be used to maintain the superconducting surface also resides atop the configuration space unit, along with the electrical power system to power the cooling system.
(152) In yet another implementation, a cryogenic fluid and superconducting surface are separated from the cryogenic cooling system. In this manner, the configuration space unit incorporates a superconducting module that includes the cryogenic fluid and superconducting surface, but the configuration space unit does not contain the cryogenic cooling system nor the electrical power system. When the temperature of the superconducting module nears the point where superconductivity would be lost, the superconducting module connects to a stationary cryogenic cooling system to recharge. The configuration space unit can be permanently connected to the superconducting module, or the superconducting module can be swapable, so that the superconducting module needing recharging can be replaced by a fully charged superconducting module.
(153) The methods described within this patent application describing dynamically adjusting the magnetic forces applied to permanent magnets embedded within configuration space units through mechanical actuations of permanent magnets can be accomplished in a number of ways. While
(154) Referring to
(155) Furthermore, an additional means of adjusting the magnetic fields of permanent magnets acting on configuration space units to achieve stable levitation and motion is by using motors 1501 whereby the motor's rotating axis is mounted parallel to the horizontal plane representing the work surface.
(156) Referring to
(157) Referring to
(158) Referring to
(159) An additional approach for adjusting the magnetic fields of permanent magnets is by keeping the arrangement of permanent magnets fixed, and adding a separate arrangement of magnetically permeable material (i.e. any material with magnetic permeability that is not equal to 1) which can be dynamically reconfigured to alter the magnetic field of the bed of permanent magnets in the vicinity of a configuration space unit. The magnetically permeable material can be of any type such as iron, alloy steel, mu-metals or other diamagnetic or paramagnetic materials. Similar to the case of actuated permanent magnets, the magnetic field can be simulated for a given configuration of these permeable materials relative to fixed permanent magnets, and this configuration can be optimized such that the resulting magnetic field will exert a desired force on the levitated configuration space unit. The permeable materials can be attached to any type of mechanical motion system such as a linear actuator, motor, electroactive polymer etc. and this system of mechanically reconfigurable magnetically permeable materials can be used as a means of controlled magnetic levitation and/or movement.
(160) Referring to
(161)
(162) Referring generally to
(163) Referring to
(164) As shown in
(165) Alternatively, if rotating partial disc permanent magnets replace the stationary permanent magnets in the bed, then those permanent magnets can be used for stability and movement as well as levitation. Similarly, when unit cells of stationary permanent magnets with rotating magnetic permeable materials are substituted for the stationary permanent magnets in the bed, these unit cells can provide forces for levitation, stability and movement.
(166) Aspects herein can incorporate a dense array of permanent magnets, and electromagnets in an array on a surface, e.g., above permanent magnets.
(167) Referring to
(168) Three example configurations illustrated in
(169) Example Electromagnetic Coil and/or Magnet Configurations
(170) Referring to
(171)
(172)
(173)
(174)
(175)
(176)
(177)
(178)
(179) Referring to
(180) Referring to
(181) Referring to
MISCELLANEOUS
(182) With reference to the FIGURES generally, and the disclosure herein, aspects herein provide a system that can be made modular.
(183) For instance, in example implementations, the work surface, magnetic systems, controllers, support hardware, software, or combinations thereof can be modular, allowing dynamic scalability, adjustment, reconfiguration, etc., of the work surface itself, or of the included configurations therein (e.g., unit cells, electromagnets, permanent magnets, controllers, cooling systems, beds, tiles, platforms, etc.). Such can promote flexibility for repair, upgrade, reconfiguration, etc.
(184) For instance, various combinations of unit cells, work surfaces, etc., can be arranged in any order, grouping, density, etc. Arrays of unit cells and/or work surfaces can be formed into intermediate sections that can be combined in any order or combination. In this regard, work surfaces, e.g., work surface 701 can be made modular so that systems can be scalable, reconfigurable, adaptable, etc. This allows different sections to include different densities, strengths, sizes, etc. as the specific application dictates. This also allows systems to be configured as housed configurations that can be installed and assembled into existing locations, including over existing floors.
(185) As another example, a system can be provided as a modular configuration, e.g., implemented as a sensing floor module (SFM), that includes actuated magnets therein (e.g., via unit cells). The system can also optionally include a false floor on top such that the modular configuration can be installed on an existing floor as tiles that are hooked, snapped, locked or otherwise joined to each other so that they all work together as one floor.
(186) That is, the features herein, can be integrated with any components of any disclosure incorporated by reference herein.
(187) As noted more fully herein, a controller 104 can be provided. Here, controllers can function to control a module, group of modules, serve as a supervisory controller over a set of sub controllers, etc. That is, a controller can be provided for a single unit cell 100 up to any combination of unit cells, whether configured the same or different, in the same module, or otherwise.
(188) Moreover, aspects herein include the ability to scale systems from multiple unit cells, beds, modules, tiles, or other configurations, down to a single unit cell. That is, a single unit cell 100, e.g., as illustrated in any combination of
(189) In some configurations, Halbach arrays can be integrated, for example, in a configuration space unit and/or as an actuated magnet in a unit cell configuration. For instance, a Halbach array can be provided in addition to, or in lieu of a permanent magnet to implement the magnet 602,
(190) In some example configurations, a movement system can spin Halbach array in unit cells within a corresponding work surface, creating eddy currents in the work surface.
(191) Moreover, some configurations can use the same motor to cause a Halbach array to spin, and to raise and lower the Halbach array. In this regard, a switching mechanism changes motion from vertical actuation to rotational spinning of arrays.
(192) Some configurations utilize rotating magnets to change magnetic fields. Rotating magnets can also be combined with movements, e.g., vertical actuations, linear or rotational movements, etc., so that magnetic fields can be removed from the surface of floor. As such, actuations can be linear (e.g., vertical, rotational, or both in combination).
(193) Some configurations can utilize actuated permanent magnets to both generate permanent magnetic forces, and to generate a changing magnetic field to induce currents and therefore magnetic forces within the coils.
(194) Some aspects herein spin permanent magnets in a unit cell to create magnetic forces in outer/upper coils to provide both a constant field and a fast changing field. Aspects herein can incorporate rectifying circuits to provide DC current flow, so that the movement system can control a direction and timing of current flows to generate controlled induced magnetic fields.
(195) In some configurations, a configuration avoids positioning floor magnets in unit cells on a same grid as that of configuration space unit magnets, which can be helpful to avoid dead zones.
(196) In some configurations, a system comprises electromagnetic coils within the floor, and wheeled configuration space units.
(197) The terminology used herein is for the purpose of describing particular implementations only and is not intended to be limiting of the invention. As used herein, the singular forms a, an and the are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms comprises and/or comprising, when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
(198) The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present disclosure has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. Aspects of the disclosure were chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various implementations with various modifications as are suited to the particular use contemplated.