Magnetically floating carrier system

Abstract: A magnetically floating carrier system has a carriage body which is adapted to be floated by the attraction force of floating magnets acting upon the bottom surfaces of rails and driven by a linear motor. The rails are mounted on frames laid longitudinally along a track and having one side thereof supported. The carriage body is provided with a support member extending upwards at the other side of the frame to a point above the top surfaces of the frames. A pallet for supporting a load is mounted on the top end of the support member so as to be disposed over the frames. The carriage carries four magnets provided at front and rear parts thereof and are adapted to attract the pair of rails. The magnets are mounted at both ends of two beams mounted on front and rear parts of the carriage body for see-saw motions and steering motions.

Description: This invention relates to a magnetically floating carrier system according to the preamble part of claim 1. Such a carrier system is known from EP-A-0 141 334. This carrier system has the disadvantage that it is quite complicated to mount and remove the carriage from the railways, since the guide-rails and the main-rails obstruct a sideway movement. In a conventional magnetically floating carrier system, a carriage body is driven by a linear motor while keeping the body afloat with the attraction force of floating magnets acting on the bottom of the rails, the load is suspended with a pair of arms provided at the bottom of the carriage body and adapted to be closed by spring force or the like. In this type of carrier system, when the attraction by the floating magnets stops, guide rollers mounted on the carriage body are adapted to be supported on guide rails laid on the ground to prevent the carriage body from falling. The structure of the prior art system is disclosed in detail e.g. in Japanese Patent Unexamined Publication 1-126113. In the above-described conventional method, if the arms are not hooked securely, or if shock is applied to the carriage body e.g. at emergency stop, the arms might be unhooked, allowing the load to drop. Also, at a branching point of the track, the guide rails had to be cut off partially to allow the passage of floating magnets or a secondary conductor plate (reaction plate) of a linear motor which is mounted on the carriage body. This might cause the carriage itself to drop. Thus, the prior art system had much room for improvement in connection with safe transportation. Also, there were the following problems. 1) It is necessary to provide movable arms on the carriage and a mechanism for opening and closing the arms on the ground. Thus, the mechanism for transferring loads tends to be complicated. 2) Because the position and size of the arms are fixed, the size and shape of the article that can be loaded are limited. 3) Movable parts provided on the arms and the carriage, such as a magnet suspension device, or contact portions between guide rollers and rails are sources of dust. Since the load is located under these dust sources, it is difficult to provide a perfect protection against dust. A first object of the present invention is to solve these problems. In order to transfer a carriage onto another parallel track, to pass the carriage running ahead, or to move it from the main track into a charging station for charging, it has to be moved sideways. In the conventional systems, since the guide rails and the main rails obstruct such sideway movements, the carriage has to be moved sideways together with these rails by means of a traverser. This will not only complicate the structure but increase the dust generating areas. A second object of the present invention is to prevent these problems as well. Further, the floating magnets are mounted on beams capable of see-saw and steering motions for stabilizing floating control and for running on the curved rail. This arrangement causes rolling of the carriage body. The load might incline with such rolling motions. A third object of the present invention is to prevent the load from being affected by the rolling of the carriage body and thus to achieve stable transportation. These objects are solved by a magnetically floating carrier system according to the characterizing features of the main claim. Furthermore, the stators of the linear motor may be mounted in the frame with their front side down and protruding from the bottom surfaces of the frames, with a secondary conductor plate mounted on the carriage body below the rails so as to extend horizontally and to be disposed opposite to the stators. Furthermore, a balancer may be provided between the support member and the pallet, the balancer being adapted to turn the pallet sideways by gravity to a point where the load is balanced in a transverse direction. The balancer may comprise bearings supported on the support member and arranged symmetrically with respect to the center of the carriage body, and a rocking frame supporting the pallet and having an arcuate bottom surface supported on the bearings or may comprise frames mounted on front and rear parts of the pallets, the frames being pivotally coupled by pivot shafts to the top end of the support member over the center of the track. According to this invention, a load is placed stably on the pallet located over the frames (i.e. the load is supported from below). This arrangement provides the following advantages. 1) The load never falls. 2) Since the mechanism for transferring loads is used only for loading and unloading, its structure can be simplified. 3) The size and the shape of the load are not limited. 4) Since the portions where dust is produced are located under the load, the load is prevented from being polluted by dust. Also, in the arrangement according to the present invention, the support member can pass a branch portion of the track simply by providing a small gap between the main track and the branch railways. While the floating magnets are not activated, the pallet descends and rests on the frames at any point of the track, keeping the carriage body suspended therefrom. Thus, the load is prevented from falling. Further, since the carriage is mounted transversely in a cantilever manner so as to straddle the track, it can be removed from the track simply by shifting it sideways. But for such sideways shift, the secondary conductors of the linear motor have to be located under and in parallel to the rails. Further, by providing the carriage with the balancer, the pallet can be kept horizontal by the natural balancing function of the balancer even if the carriage body rolls. Thus, the load can be held stably. The magnetically floating carrier system according to this invention has a pallet supported in a cantilever manner and disposed over the frame of the track which is supported in a cantilever manner at the opposite side. A load is placed on the pallet. This arrangement can prevent the fall of the load and the carriage body and thus make it possible to transport loads safely with increased reliability. This arrangement also makes it possible to simplify the devices for loading and unloading. Further, the load can be protected against pollution by dust. The range of the load size can be widened. Further, by providing the secondary conductor plate of the linear motor under the rails to extend horizontally, only the carriage can be moved sideways. This makes it possible to simplify the mechanism for sideways movement and to reduce the number of portions where dust is produced. Further, the carriage provided with the balancer for the pallet can keep the pallet always in its horizontal position by turning it by gravity. Thus, even if it is impossible to prevent the carriage body from rolling by mounting the floating magnets on the beams capable of see-saw motions, the balance of load can be maintained. This greatly improves the stability in transportation. Other features and objects of the present invention will become apparent from the following description taken with reference to the accompanying drawings, in which: Fig. 1 is a front view of an embodiment of the carrier system according to the present invention; Fig. 2 is a perspective view of the same with the carriage removed from the track; Fig. 3 is a plan view of the carriage; Fig. 4 is a schematic plan view showing a branch point of the track; Fig. 5 is a schematic plan view of a side shift portion; Fig. 6 is a front view of one example of the balancer; Fig. 7 is a plan view of another example of the balancer; and Fig. 8 is a perspective view showing a modification of the balancer of Fig. 7. Numeral 1 in Fig. 1 designates frames which are laid continuously on a track so as to extend in a longitudinal direction of the track. Brackets 2 suspended from a ceiling or the like are coupled to one side of the frames 1 to support them in a cantilever manner. A shock absorbing material 3 is interposed as necessary between the frame 1 and the bracket 2. A pair of rails 4 made of a ferromagnetic material are mounted on the bottom of the frame 1 at both sides thereof. They are attracted to floating magnets 12. Stators 5 of a linear motor for generating a driving force in forward and reverse directions are accommodated in a center recess of the frame 1 with its front side down at predetermined spacings along the track. The stators 5 have their bottom portions protruding from cutouts formed in the bottom of the frame so that their protruding bottom surfaces are substantially at the same level as the bottom surfaces of the rails 4. The frames 1 may not be box-shaped ones as illustrated. But the box-shaped frames are advantageous in that they can be assembled easily and that cables for power supply and control can be passed through cavities thereof. As shown in Figs. 2 and 3, a carriage 10 carries four pairs of floating magnets 12 on its body 11, each pair at one of the four corners. Two each pairs are mounted on each of two beams 13 provided at front and rear of the body 11 of the carriage 10. The beams 13 are mounted to make a see-saw motion about a central horizontal axis and a steering motion (horizontal pivoting motion) about a central vertical axis. Gap sensors 14 are mounted on both ends of each beam 13 at front or rear of the magnets 12 so as to be located opposite to the bottom faces of the respective rails 4. A secondary conductor plate 15 of the linear motor is fixed to the body 11 so as to extend parallel thereto at substantially the same level as the pole surface of the magnets 12. The conductor plate 15 is preferably of a sufficient length in driving and stopping the carriage 10. For this purpose, in the embodiment, it extends across the beams 13 between the magnets 12 and terminates at the front and rear ends of the body 11. Support members 16 have one end thereof secured to the body 11 and the other end extending upwards along the other side of the frame 1 so that their ends are located higher than the top surface of the frame 1. A pallet 17 is secured to the top end of the support members 16 in a cantilever manner. The center of the pallet 17 with respect to the direction of width is located right over the center of the body 11 of the carriage to keep the balance of the load. The support member 16 is in the form of two pillars but may be one made by bending a plate-shaped member. The pallet 17 should preferably be provided along the edge thereof with stoppers 17a to prevent a load W from falling off. Shock absorbing devices 18 are provided at front and rear ends of the body 11 of the carriage 10 to lessen the shock when a carriage bumps against another carriage from behind. Though these elements are preferable, they may be omitted because the risk of car-to-car collisions is not very high. A cover 6 as shown by chain line in Fig. 1 may be provided to cover the bottom part of the carriage 10 facing the track. It serves to prevent dust on the track from scattering. Rollers 19 may be mounted on the bottom of the pallet 17 so that they will land on the frame 1 when they descend a distance G from the elevated position (Fig. 1). With this arrangement, even if the carriage body should move by inertia after it has stopped from floating, there will be no friction between the pallet 17 and the frame 1, which is a major cause of the production of dust. If the cover 6 is provided, the rollers 19 may be mounted on the car body 11 so that they bear on the cover 6. Irrespective of whether the rollers 19 are supported on the frame 1 or on the cover 6, the gap G or the amount of descent of the car body when the attraction force stops should not exceed the range within which the car body can be floated up again by the attraction force of the floating magnets 12. When it is necessary to stop the carriage immediately at a point where there is no stator, the floating magnets 12 have to be attracted to the rails 4. During such emergency braking, if the pole faces of the magnets 12 contact the bottom surfaces of the rails 4, friction will occur. Thus, rollers 20 should be adapted to abut bottom guide surfaces before the magnets 12 contact the rails 4 to prevent the carriage body from moving further up and thus to prevent the production of dust. In the embodiment, in order to reduce the number of component parts, the bottom surfaces of the rails 4 also serve as the guide surfaces against which the rollers 20 are adapted to abut. The carrier system according to this invention can prevent the load from falling or being polluted because it is mounted on the pallet 17. Also, loading and unloading are easy. When the attraction by the magnets stops, the pallet 17 lands on the frame, holding the carriage 10 suspended in the air. Thus, the carriage body 11 will not fall even if no guide rails or guide rollers are provided. Fig. 4 shows a branch portion of the track by way of example. The only requirement for such a branch portion is the provision of a gap ℓ large enough to allow the passage of the support member 16 between the main track 7 and the branch track 7a. Thus, the carriage body will never fall at such branch portions unlike the conventional systems in which the guide rails had to be cut off partially at the branch points. Since the frame 1 and the pallet 17 are supported in a cantilever manner from opposite sides, there will be no restriction whatsoever in moving the carriage 10 to the righthand side in Fig. 1. Thus, as shown in Fig. 5, by providing a side track 7b, only the carriage 10 can be moved sideways from the main track 7 onto the side track 7b. To move the carriage sideways, a stator for driving it sideways may be provided at side of the stator 5 to drive it with the linear motor. Otherwise, the carriage may be pulled with a retractable arm or cylinder. In order to prevent the carriage 10 from falling after it has moved onto the side track 7b, the pallet 17 may be supported on rails 8 and 4a (according to the positions of the gap sensors, the rails 8 may have to be provided not inside but outside the rails 4a). Otherwise, if the cover 6 is provided, the carriage body 11 may be supported on the cover 6. In the figure, the rails 4a are fixed on the ground, with the rails 8 supported at one side thereof on the rails 4a. The pallet 17 is placed on the top of the rails 8. In another arrangement, the branch track 7a or the side track 7b may be moved to eliminate the gap ℓ between the main track 7 and the branch track 7a or side track 7b and thus to stabilize the transition movements. Next, we shall describe a carriage provided with a balancer for the pallet 17. If, as described above, the floating magnets are mounted on the beams capable of see-saw motions for stabilizing floating control, the carriage body 11 might roll. If the pallet turns automatically in a direction opposite to the direction of the rolling motion by the same angle as the rolling angle, the pallet will not get inclined. Figs. 6-8 show specific examples of a balancer having such an automatic balancing function. A balancer 21 shown in Fig. 6 comprises a horizontal frame 23 mounted on the top end of the support member 16, and bearings 24 mounted on the frame 23 so as to be symmetrical with respect to the center of the carriage body. A rocking frame 25 carrying the pallet 17 has an arcuate bottom surface 25a, which is supported on the bearings 24. If the carriage body 11 rolls and inclines, the rocking frame 25 will automatically turn sideways by gravity to the point where the load is balanced in the transverse direction, thus keeping the pallet 17 always in its horizontal position. Fig. 7 shows another type of balancer 22 in which the support member 16 comprises a pair of front and rear struts shown in Fig. 2. Front and rear suspension frames 26 have their top ends coupled to the top ends of the struts by means of pivot shafts 27, which are provided with seals 30 to prevent the production of dust. The seals 30 include seals covering the friction portions of the shafts 27 and ones for reducing the production of dust itself by reducing the frictional resistance of the shafts. With this arrangement, the portions where dust is produced can be reduced compared with the balancer 21 of Fig. 6. A balancer 22' shown in Fig. 8 is in the form of a suspension frame 28 comprising transversely movable horizontal links 28a and vertical links 28b hung on both ends of the horizontal links 28a. The frame 28 is supported on the support member 16 by means of shafts 27 at the center of the carriage body. The links 28 are coupled together through coupling means 29 having seals 30 for preventing the production of dust. With this balancer 22', since the pallet 17 can always move horizontally, the influence of the rolling of the load can be reduced compared with the balancers 21 and 22. Also, compared with the balancer 21, the number of portions where dust is produced can be reduced. Further, in the structure of either Fig. 7 or Fig. 8, when the carriage body is rolling, the pallet 17 is turned in such a way that the gravity acts downwards.

Claims: A magnetically floating carrier system wherein a carriage body (11) is floated by the attraction force of floating mangets (12) acting upon the bottom surfaces of rails (4) and driven by a linear motor, wherein said rails (4) are mounted on a frame (1) laid longitudinally along a track and having one side thereof supported, wherein said carriage body (11) is provided with a support member (16) extending upwards at the other side of said frame (1), and wherein a pallet (17) for supporting a load (W) is mounted on the top end of said support member (16) so as to be disposed over said frame (1), characterized in that the assembly comprising said carriage body (11) and said pallet (17) is supported so as to be slidable in a transverse direction away from said frame (1), and that said carriage (10) carries four magnets (12) provided at front and rear parts thereof and are adapted to attract a pair of rails (4), said magnets (12) being mounted at both ends of two beams (13) mounted on front and rear parts of said carriage body for see-saw and steering motions. A magnetically floating carrier system as claimed in claim 1, wherein stators (5) of said linear motor are mounted in said frame (1) with their front side down and protruding from the bottom surface of said frame (1), and wherein a secondary conductor plate (15) is mounted on the carriage body (11) below said rails (4) so as to extend horizontally and be disposed opposite to said stators (5). A carriage for the magnetically floating carrier system as claimed in claim 1 or 2 , further comprising a balancer (21) provided between said support member (16) and said pallet (17) and adapted to turn said pallet (17) sideways by gravity to a point where the load (W) is balanced in a transverse direction. A carriage as claimed in claim 3 , wherein said balancer (21) comprises bearings (24) supported on said support member (16) and arranged symmetrically with respect to the center of said carriage body (11), and a rocking frame (25) supporting said pallet (17) and having an arcuate bottom surface supported on said bearings (24). A carriage as claimed in claim 3, wherein said balancer (22) comprises frames (26) mounted on front and rear parts of said pallet, pivot shafts (27) pivotably coupling said frames (26) to the top end of said support member (16) over the center of said carriage body (11), and dust preventive seals (30) for rotating portions. A carriage as claimed in claim 5, wherein said frames (28) comprise a combination of links (28a) and wherein said dust preventive seals (30) are provided on coupling portions between said links (28a).

Inventors: HAYASHI TSUNEYUKI C O SONY COR, MATSUOKA HIROAKI C O SONY CORP, MINAKATA TOSHIO C O OSAKA WORK, SHIMADA TOSHIRO C O OSAKA WORK, HAYASHI, TSUNEYUKI, C/O SONY CORPORATION, MATSUOKA, HIROAKI, C/O SONY CORPORATION, MINAKATA, TOSHIO, C/O OSAKA WORKS, SHIMADA, TOSHIRO, C/O OSAKA WORKS
Applicants: SONY CORP, SUMITOMO ELECTRIC INDUSTRIES, SONY CORPORATION, SUMITOMO ELECTRIC INDUSTRIES, LTD.
Application year: 1991
Main classification: B65G54
IPC codes: B60L13, B61B13, B65G54