System and method for contactless monitoring of performance in an independent cart system

Patent metadata

Field	Value
Publication number	US-11767174-B2
Application number	US-202117355714-A
Country	US
Kind code	B2
Filing date	Jun 23, 2021
Priority date	Jun 23, 2021
Publication date	Sep 26, 2023
Grant date	Sep 26, 2023

Abstract

A contactless monitoring system detects operating performance of movers in an independent cart system. A contactless sensor is provided on an actuator to automatically track a mover as it travels along the track. The sensor includes a transmitter configured to transmit a signal and a receiver configured to receive the signal after it is reflected off the mover. The actuator may be configured to mover the sensor in a single axis or in multiple axes of motion. As a mover travels along the track, the sensor transmits a signal towards the mover and detects the signal after it has been reflected off the mover. A controller may synchronize motion of the actuator with motion of the mover, such that the sensor may continually transmit the signal off the mover for at least a portion of the travel by the mover along the track.

First claim

We claim:

1. An apparatus for monitoring performance in an independent cart system, wherein the independent cart system includes a track and at least one mover, the apparatus comprising:
a sensing device mounted remote from the track and remote from each of the at least one movers of the independent cart system, the sensing device configured to:
transmit a signal toward the at least one mover as the at least one mover travels along the track of the independent cart system,
receive the signal reflected from the at least one mover, and
generate a feedback signal corresponding to the received signal;

an actuator operatively connected to the sensing device to move the sensing device in at least one axis of motion; and
a controller operative to control operation of the actuator in the at least one axis of motion such that the actuator moves the sensing device in coordination with the at least one mover as the at least one mover travels along the track.

2. The apparatus of claim 1 , wherein the controller is further configured to generate a motion profile for the at least one mover.

3. The apparatus of claim 1 , wherein either the sensing device or the controller is further configured to detect vibration of the at least one mover, speed of the at least one mover, or position of the at least one mover in response to the feedback signal.

4. The apparatus of claim 1 , wherein the sensing device is selected from one of an optical sensor, an acoustic sensor, a microwave sensor, a radio frequency sensor, and a thermal sensor.

5. The apparatus of claim 1 , wherein the actuator is mounted at a fixed position and is configured to pivot such that the at least one axis of motion is parallel to the track.

6. The apparatus of claim 1 , further comprising a mobile platform on which the actuator is mounted, wherein the controller is configured to move the mobile platform in tandem with the at least one mover.

7. The apparatus of claim 1 wherein the controller is configured to:
control the actuator to remain in one position, and
receive the feedback signal corresponding to the signal reflected off a plurality of movers.

8. The apparatus of claim 1 , wherein:
the at least one mover includes a first mover and a second mover, and
the sensing device is further configured to selectively transmit the signal toward either the first mover or the second mover as the first mover and the second mover travel along the track of the independent cart system.

9. The apparatus of claim 8 wherein the independent cart system includes a first track along which the first mover travels and a second track along which the second mover travels.

10. The apparatus of claim 8 , wherein the sensing device is mounted remote from the independent cart system.

11. A method for monitoring performance in an independent cart system, wherein the independent cart system includes a track and at least one mover, the method comprising the steps of:
receiving a signal at a sensing device mounted remote from the track and remote from each of the at least one movers of the independent cart system, wherein the signal corresponds to the at least one mover as the at least one mover travels along the track of the independent cart system;
generating a feedback signal at the sensing device corresponding to the received signal; and
controlling an actuator operatively connected to a sensing device, wherein the actuator is configured to move the sensing device in at least one axis of motion and wherein the actuator moves the sensing device in coordination with the at least one mover as the at least one mover travels along the track.

12. The method of claim 11 further comprising an initial step of transmitting the signal from the sensing device toward the at least one mover as the at least one mover travels along the track of the independent cart system and wherein the signal received at the sensing device is reflected from the at least one mover.

13. The method of claim 11 , further comprising the step of generating a motion profile for the at least one mover with a controller, wherein the controller is also configured to control the actuator.

14. The method of claim 11 , wherein the sensing device is selected from one of an optical sensor, an acoustic sensor, a microwave sensor, a radio frequency sensor, and a thermal sensor.

15. The method of claim 11 , wherein the actuator is mounted at a fixed position and is configured to pivot such that the at least one axis of motion is parallel to the track.

16. The method of claim 11 , wherein the actuator is a mobile platform, the method further comprising the step of controlling motion of the mobile platform in tandem with the at least one mover.

17. The method of claim 11 , wherein the actuator is controlled to remain in one position, and wherein the signal received at the sensing device corresponds to a plurality of movers passing the sensing device.

18. The method of claim 11 , wherein:
the at least one mover includes a first mover and a second mover, and
the signal received at the sensing device selectively corresponds to either the first mover or the second mover as the first mover and the second mover travel along the track of the independent cart system.

19. An apparatus for monitoring performance in an independent cart system, wherein the independent cart system includes a track, a first mover, and a second mover, the apparatus comprising:
a sensing device configured to:
selectively transmit a signal toward either the first mover or the second mover as the first mover and the second mover travel along the track of the independent cart system,
receive the signal reflected from either the first mover or the second mover, and
generate a feedback signal corresponding to the received signal;

an actuator operatively connected to the sensing device to move the sensing device in at least one axis of motion; and
a controller operative to control operation of the actuator in the at least one axis of motion such that the actuator moves the sensing device in coordination with either the first mover and the second mover, according to which of the first mover and the second mover the sensing device is selectively transmitting the signal toward, as the first mover and the second mover travel along the track.

Assignees

• Rockwell Automation Tech Inc

Inventors

• Das Jadav
• Schmidt Robert H
• Huang Yuhong

Classifications

• B65G43/00 Primary

  Control devices, e.g. for safety, warning or fault-correcting · CPC title

• B65G17/32

  Individual load-carriers · CPC title

• B65G2203/041

  Camera · CPC title

• B65G2203/044

  Optical · CPC title

• B65G2203/045

  Thermic · CPC title