Magnetic XY sorting conveyor

Patent metadata

Field	Value
Publication number	US-11958694-B2
Application number	US-202217693294-A
Country	US
Kind code	B2
Filing date	Mar 11, 2022
Priority date	Mar 11, 2022
Publication date	Apr 16, 2024
Grant date	Apr 16, 2024

Abstract

Exemplary embodiments provide a sorting system using the principles of linear motors to move a magnetized mat in multiple directions. The sorting system uses a series of stator coils in particular patterns to direct the magnetized mat along predefined looping pathways such that the magnetized mat can move articles in a desired direction. Embodiments include the use of multiple magnetized mats to improve package sorting rates. The magnetized mat is comprised of a plurality of magnetized and non-magnetized tiles which are connected using flexible tabs that form a living hinge. The living hinge flexes and allows the mat to travel along the predefined looping pathways. The sorting system may be used as a node in a larger grid sorting system and may be connected to conveyors, chutes, or other means for moving articles.

First claim

The invention claimed is:

1. A sorter comprising: a first XY-stator, a first tile assembly, and a controller,
wherein said first XY-stator comprises a first set of X-stator coils, a first set of Y-stator coils, and a first plurality of Hall sensors;
wherein said first set of X-stator coils is flush with said first set of Y-stator coils;
wherein said first XY-stator is operatively connected to said controller;
wherein said first tile assembly comprises a first plurality of tiles;
wherein said first plurality of tiles includes a first plurality of magnetic tiles and a first plurality of non-magnetic tiles; and
wherein said controller is configured to receive signals from said first plurality of Hall sensors and is configured to selectively apply currents to said first set of X-stator coils and to said first set of Y-stator coils in order to direct motion of said first tile assembly.

2. The sorter of claim 1 , wherein said first plurality of tiles are connected by a plurality of means for flexibly connecting.

3. The sorter of claim 1 , wherein each of said first plurality of tiles is connected to at least one other tile of said first plurality of tiles by one or more flexible connectors, wherein said one or more flexible connectors comprise at least one tab on a first one of said first plurality of tiles and at least one receptacle on a second one of said first plurality of tiles, and wherein said at least one receptacle is configured to receive said at least one tab.

4. The sorter of claim 3 , wherein said at least one receptacle comprises at least one groove and said at least one tab comprises at least one lip, and said receptacle and said tab are configured to allow said at least one lip to slide into said at least one groove when said tab is fully inserted into said receptacle.

5. The sorter of claim 3 , wherein said tab comprises an end and a middle section and said middle section is more flexible than a body of each of said first plurality of tiles.

6. The sorter of claim 3 , wherein said tab comprises an end and a middle section and said middle section is approximately 0.015 inches thick.

7. The sorter of claim 1 , wherein each of said first plurality of magnetic tiles is only connected to one or more of said first plurality of non-magnetic tiles.

8. The sorter of claim 1 , wherein each of said first plurality of magnetic tiles contain one or more polymagnets arranged in a Halbach array.

9. The sorter of claim 1 further comprising a second XY-stator and a plurality of curved sets of stator coils,
wherein an edge of said first XY-stator is adjacent to a top edge of each of said plurality of curved sets of stator coils and an edge of said second XY-stator is adjacent to a bottom edge of each of said plurality of curved sets of stator coils;
wherein said second XY-stator comprises a second set of X-stator coils, a second set of Y-stator coils, and a second plurality of Hall sensors;
wherein said second set of X-stator coils is flush with said second set of Y-stator coils;
wherein said second XY-stator is operatively connected to said controller;
wherein each of said plurality of curved sets of stator coils comprises an additional set of Hall sensors and is operatively connected to said controller; and
wherein said controller is configured to receive signals from said second plurality of Hall sensors and each said additional set of Hall sensors and is configured to selectively apply currents to said second set of X-stator coils, to said second set of Y-stator coils, and to each additional set of stator coils in order to direct motion of said first tile assembly.

10. The sorter of claim 9 , wherein said sorter is configured to apply currents in a sequence to said first XY-stator, to said second XY-stator, and to said plurality of curved sets of stator coils to move said first tile assembly from a location above said first XY-stator, along any of said plurality of curved sets of stator coils, to a location below said second XY-stator, and from a location below said second XY-stator, along any of said plurality of curved sets of stator coils, to said location above said first XY-stator.

11. The sorter of claim 9 further comprising a frame and a plurality of return chutes connected to said frame, wherein said first tile assembly passes through an interior portion of one of said plurality of return chutes, and wherein each of said plurality of return chutes limits a distance of said first tile assembly from each corresponding one of said plurality of curved sets of stator coils while said first tile assembly passes through said interior portion.

12. The sorter of claim 9 , wherein said first and second XY-stators and a first two of said plurality of curved sets of stator coils form a first loop and said first and second XY-stators and a second two of said plurality of curved sets of stator coils form a second loop,
wherein said sorter is configured to allow motion of said first tile assembly along said first loop from a first point on said first loop to any other point on said first loop and to allow motion of said first tile assembly from along said second loop from a first point on said second loop to any other point on said second loop.

13. The sorter of claim 9 , wherein said sorter further comprises a second tile assembly,
wherein said second tile assembly comprises a second plurality of tiles;
wherein said second plurality of tiles includes a second plurality of magnetic tiles and a second plurality of non-magnetic tiles; and
wherein said controller is configured to simultaneously control a respective position of both said second tile assembly and said first tile assembly.

14. The sorter of claim 13 , wherein said first and second XY-stators and a first two of said plurality of curved sets of stator coils form a first loop and said first and second XY-stators and a second two of said plurality of curved sets of stator coils form a second loop,
wherein said sorter is configured to allow motion of said first tile assembly and said second tile assembly along said first loop from a first point on said first loop to any other point on said first loop and to allow motion of said first tile assembly and said second tile assembly along said second loop from a first point on said second loop to any other point on said second loop.

15. The sorter of claim 14 , wherein said controller is configured to direct movement of said first tile assembly along said first loop simultaneously with movement of said second tile assembly along said second loop.

16. The sorter of claim 15 , wherein said first plurality of tiles are connected by a first plurality of means for flexibly connecting and said second plurality of tiles are connected by a second plurality of said means for flexibly connecting.

17. A sorter comprising: a first XY-stator, a second XY-stator, a plurality of curved sets of stator coils, a plurality of tile assemblies, and a controller;
wherein said first XY-stator comprises a first set of X-stator coils, a first set of Y-stator coils, and a first plurality of Hall sensors; and said first set of X-stator coils is flush with said first set of Y-stator coils;
wherein said second XY-stator comprises a second set of X-stator coils, a second set of Y-stator coils, and a second plurality of Hall sensors; and said second set of X-stator coils is flush with said second set of Y-stator coils;
wherein said first XY-stator is operatively connected to said controller;
wherein said second XY-stator is operatively connected to said controller;
wherein each of said plurality o

Assignees

• Laitram Llc

Inventors

• Ragan Bryant G
• Fourney Matthew L

Classifications

• B65G2203/042

  Sensors · CPC title

• B07C5/36

  Sorting apparatus characterised by the means used for distribution {(sorting according to destination B07C3/003, B07C3/02)} · CPC title

• B65G47/53

  between conveyors which cross one another · CPC title

• B65G23/18 Primary

  Suction or magnetic elements · CPC title

• B65G15/30

  Belts or like endless load-carriers (co-operating with rails or the like B65G21/22; {co-operating} with rollers B65G39/20) · CPC title