Method and apparatus for power transfer to an independent moving cart during travel along a track

Patent metadata

Field	Value
Publication number	US-11309737-B2
Application number	US-202016794520-A
Country	US
Kind code	B2
Filing date	Feb 19, 2020
Priority date	Sep 28, 2017
Publication date	Apr 19, 2022
Grant date	Apr 19, 2022

Abstract

A system and method for providing power to independent movers traveling along a track in a motion control system without requiring a fixed connection between the mover and a power source external to the mover. In one embodiment, a sliding transformer transfers power between the track and each mover. In another embodiment, an optical transmitter transfers power between the track and an optical receiver mounted on each mover. In yet another embodiment, a generator includes a drive wheel engaging the track as each mover travels along the track. A power converter on the mover receives the power generated on and/or transmitted 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.

First claim

We claim:

1. An apparatus for providing power to a mover in an independent moving cart control system, the apparatus comprising:
at least one mover, wherein the at least one mover includes at least one drive magnet mounted to the at least one mover;
a track having a length and defining a path along which the at least one mover travels:
a plurality of drive coils positioned along the length of the track, wherein the plurality of drive coils are controlled to generate an electromagnetic field to interact with the at least one drive magnet mounted on the at least one mover to control operation of the at least one mover;
at least one electrical device, wherein the at least one electrical device is mounted to the at least one mover;
a primary winding associated with the track, wherein the primary winding is configured to receive power from a power supply;
a secondary winding associated with the at least one mover that is positioned proximate the primary winding as the at least one mover travels along the track, wherein an air gap separates the secondary winding from the primary winding, and power from the power supply is inductively transferred from the primary winding to the secondary winding across the air gap; and
a power converter associated with the at least one mover that is operative to receive power from the secondary winding and to supply power to the at least one electrical device mounted on the mover.

2. The apparatus of claim 1 wherein the track includes a plurality of track segments.

3. The apparatus of claim 2 wherein the primary winding includes a plurality of windings and at least one of the plurality of windings for the primary winding is mounted to each of the plurality of track segments.

4. The apparatus of claim 2 wherein:
the primary winding includes a plurality of windings,
a first portion of the plurality of track segments includes at least one of the plurality of windings for the primary winding mounted to each of the plurality of track segments in the first portion, and
a second portion of the plurality of track segments has none of the plurality of windings mounted on the plurality of track segments in the second portion.

5. The apparatus of claim 4 further comprising an electrical energy storage device mounted on the at least one mover, wherein:
at least a portion of the power received from the secondary winding is stored in the electrical energy storage device when the at least one mover is located on the first portion of the plurality of track segments, and
the portion of power stored in the electrical energy storage device when the at least one mover is located on the first portion of the plurality of track segments is supplied to the at least one electrical device mounted on the at least one mover when the at least one mover is located on the second portion of the plurality of track segments.

6. The apparatus of claim 1 further comprising a supply-side power converter, wherein the supply-side power converter is configured to receive power from the power supply and to provide power to the primary winding.

7. The apparatus of claim 6 wherein the supply-side power converter is configured to provide an alternating current power to the primary winding, wherein a frequency of the alternating current power is at least 100 Hz.

8. A linear motor system comprising:
a track having a length and defining a path;
a mover configured to move along the path, wherein the mover includes at least one drive magnet mounted to the mover;
a plurality of drive coils positioned along the length of the track, wherein the plurality of drive coils are controlled to generate an electromagnetic field to interact with the at least one drive magnet mounted on the mover to control operation of the mover;
a primary winding associated with the track that receives power from a power supply;
a secondary winding associated with the mover that is positioned proximate the primary winding to define an air gap between the primary winding and the secondary winding;
an electrical device associated with the mover; and
a power converter connected between the electrical device and the secondary winding, wherein power from the power supply is inductively coupled from the primary winding to the secondary winding and the power converter supplies power from the secondary winding to the electrical device.

9. The apparatus of claim 8 further comprising a supply-side power converter, wherein the supply-side power converter is configured to receive power from the power supply and to provide power to the primary winding.

10. The apparatus of claim 9 wherein the supply-side power converter is configured to provide an alternating current power to the primary winding, wherein a frequency of the alternating current power is at least 100 Hz.

11. The apparatus of claim 9 wherein the track includes a plurality of track segments.

12. The apparatus of claim 11 wherein the primary winding includes a plurality of windings and at least one of the plurality of windings for the primary winding is mounted to each of the plurality of track segments.

13. The apparatus of claim 11 wherein:
the primary winding includes a plurality of windings,
a first portion of the plurality of track segments includes at least one of the plurality of windings for the primary winding mounted to each of the plurality of track segments in the first portion, and
a second portion of the track segments has none of the plurality of windings mounted on the plurality of track segments in the second portion.

14. The apparatus of claim 13 further comprising an electrical energy storage device mounted on the mover, wherein:
at least a portion of the power received from the secondary winding is stored in the electrical energy storage device when the mover is located on the first portion of the plurality of track segments, and
the portion of power stored in the electrical energy storage device when the mover is located on the first portion of the plurality of track segments is supplied to the at least one electrical device mounted on the mover when the mover is located on the second portion of the plurality of track segments.

15. A method of powering an electrical device associated with a mover in a linear motor system, comprising:
controlling operation of the mover by generating an electromagnetic field with a plurality of drive coils positioned along a track of the linear motor system, wherein the electromagnetic field interacts with at least one drive magnet mounted to the mover;
supplying power to a primary winding for the track in the linear motor system;
receiving inductively coupled power with a secondary winding associated with the mover, wherein the secondary winding is positioned proximate the primary winding as the mover travels along the track; and
coupling power received by the secondary winding to the electrical device through a power converter mounted on the mover.

16. The method of claim 15 wherein the step of supplying power to the primary winding for the track further comprises the steps of:
supplying power to an input of a supply-side power converter; and
generating power at an output of the supply-side power converter, wherein the power generated at the output of the supply-side power converter is supplied to the primary winding.

17. The method of claim 16 wherein the supply-side power converter is configured to provide an alternating current power to the primary winding, wherein a frequency of the alternating current power is at least 100 Hz.

18. The method of cla

Assignees

• Rockwell Automation Tech Inc

Inventors

• Floresta John
• Bruder Peter
• Sun Xikai
• Smit Peter M
• Haya Oliver C
• Cooper Mark R
• Yao Nanwei

Classifications

• H02J7/865

  Battery or charger load switching, e.g. concurrent charging and load supply (H02J7/50 takes precedence) · CPC title

• Y02T10/64

  Electric machine technologies in electromobility · CPC title

• B60L5/005

  without mechanical contact between the collector and the power supply line · CPC title

• H02J50/30

  using light, e.g. lasers · CPC title

• H02J50/10 Primary

  using inductive coupling · CPC title