Patent Publication Number: US-2022219744-A1

Title: Controlled architecture for transport systems

Description:
CROSS-REFERENCE TO PRIOR APPLICATION 
     This patent application relates to and claims benefit to U.S. Provisional Patent Application Ser. No. 61/488,012, filed May 19, 2011. 
    
    
     TECHNICAL FIELD 
     The present invention is directed to control architecture and, more particularly, to control architecture for use with transport systems for moving articles from one location to another location. 
     BACKGROUND OF THE INVENTION 
     Conventional transport systems used in industry for moving articles from one location to another typically comprise rotary dive systems having mechanical components such as gears, shafts, keys, sprockets, chains and belts, rollers, and the like for moving an axis or transport element (such as a conveyor belt) that transports articles along a predetermined path or track. The rotary drives are controlled using a computer control system that operates control software to permit an operator to enter into the control system various command parameters that are used to create a motion profile for the transport element being utilized by the particular transport system. 
     Transport systems, such as controlled motion systems utilizing linear drives, are used in a wide variety of processes (e.g. packaging, assembly automation, processes involving use of machine tools, etc.) and provide the advantage over conventional rotary drive systems of increasing both the speed and the flexibility of the process. In particular, linear motors operate as magnetic drives creating a changing magnetic field to directly transport the axis or transport element along a defined track, thereby eliminating various conventional axes, such as gear heads, shafts, keys, sprockets, chains and belts, used with traditional rotary drive systems. The reduction of mechanical complexity over rotary drive systems provides both reduced cost and increased speed capability by virtue of reduced inertia, compliance, damping, friction and wear. Further, controlled motion systems utilizing linear drives also provide greater flexibility than conventional rotary drive systems by allowing one or more individual axes or transport elements to be independently controlled while transporting articles along an entire track. 
     Unlike conventional rotary drive systems that have a single drive for energizing an axis or transport element for moving articles along a track, linear motion systems typically comprise interconnected track sections wherein one or more drives are electrically coupled to a plurality of transport elements and have individually controlled coils that cooperate with one or more control units to energize or de-energize the coils to create magnetic fields effective for providing controlled motion of each transport element traveling along the track. Such systems also employ a plurality of linear encoder readers spaced at fixed positions along the track and sensors mounted on each transport element that cooperate with the linear encoder readers to provide signals to a control unit for use in determining the position of each transport element along the track. 
     Typically, control architecture utilized for conventional linear motion transport systems include an input device, such as a keypad, whereby an operator enters command parameters (such as the particular track identification, the speed that a transport element or axis travels along the track, stop and start locations, and time parameters for the transport element) into a control unit, such as a convention computer system, to create a motion profile. The control unit functions to operate software specifically designed for controlling the operation of the particular linear transport system being used. Unfortunately, the use of such specifically designed software for controlling a particular linear motion transport system often requires the operator to learn new software protocols for each new designed software package. Thus, for example, an operator using a plurality of different transport systems must learn to operate a number of different software packages. 
     Conventional control systems are typically designed for transport systems where transport elements do not move from one drive section to another dive section, such as when transport items are traveling along different tracks or move from one track to another track. Accordingly, a need exists for control architecture that can control transport elements moving from one drive to another drive, such as linear motion systems when a transport element moves from traveling along one track to traveling along another track or when it is desirable to control transport elements traveling along different tracks using a single control system. 
     Another problem often encountered with the use of specifically designed control software is that it is often desirable to have a transport system of one manufacturer coupled to the same control system being used by a transport system of another manufacturer. Accordingly, such a combined system eliminates the need for an operator to use two different control software packages thereby decreasing the cost and complexity of the transport systems. Further, the use of transport systems from different manufacturers often requires the operator to use more than one control system (or software package) or learn the operation of different software packages thereby increasing the training time for the operator and decreases the efficiency of the overall operation. In addition, the difficulty of integrating two different transport systems having two different control systems significantly increases the complexity and cost of the overall operation. 
     Accordingly, it is desirable to have a control architecture effective for controlling a transport system that has similar programmatic features as used in conventional single drive systems, such as rotary drive systems. It is also desirable to have control architecture effective for controlling a transport system that allows an operator to use traditional software for controlling conventional single drive transport systems; that can be used to control a transport system having more than one drive system; that can be used with linear drive systems whereby transport elements operate on different tracks; that allows additional independent drive systems to be easily incorporated into the transport system; allows a single control system to operate more than one transport system or a transport system having more than one track; and allows an operate to use traditional control software for a transport system having a single transport element for controlling a transport system having more than one transport element. 
     SUMMARY OF THE INVENTION 
     The subject invention is control architecture that can be used to control a multi drive transport system or a transport system having more than one transport element using control system software for controlling a single drive transport system or a transport system having a single transport element. A preferred embodiment of the invention the control architecture operates a transport system, such as a linear drive system or a combination of linear drive systems and rotary drive systems. Preferably, the control architecture comprises a computer system having a controller for operating control system software for receiving input commands and protocols creating a motion profile for directing a transport element along a track, and a gateway for receiving the motion profile from the control system software and for operating gateway drive software that operates select an appropriate drive system for moving the transport element along the track in accordance with the motion profile. 
     A preferred embodiment of the invention the control architecture functions to control at least one transport system having one or more drive systems each drive system having more than one transport element for movement along one or more tracks and comprises a computer system having control system software and a controller for operating the control system software for controlling a transport system having a single drive system, the control system software operates to receive input commands and protocols for each transport system and creates a motion profile for each transport element; a gateway for receiving said motion profile from the control system software for each transport element and having gateway drive software that operates to select the appropriate drive system for controlling the movement of each transport element along the one or more tracks in accordance with the motion profile. 
     In another preferred embodiment of the invention the control architecture the one or more drive systems comprise a rotary drive system, a linear drive system, or a combination thereof. 
     In another preferred embodiment of the invention the control architecture further comprises a positioning system that cooperates with the gateway drive software to track the location of each transport element and ensure that each transport element is directed in accordance with the motion profile. 
     In another preferred embodiment of the invention the control architecture further comprises a positioning system that cooperates with the gateway drive software to track the location of each transport element and ensure that one transport element does not interfere with another transport element. 
     In a preferred embodiment of the invention the control architecture for controlling at least one transport system having one or more drive systems, each drive system having more than one transport element for movement along one or more tracks and comprises a computer for operating control system software functioning as a single drive application software for controlling one or more independent single drive systems, each single drive system having a single transport element thereon, wherein the control system software operates to create a motion profile for each single transport element; and a gateway having gateway drive software that operates to identify the drive system for each single transport element and energize and de-energize the one or more drive systems such that the more than one transport element each move along the one or more tracks in accordance with the motion profile. 
     In a preferred embodiment of the invention the control architecture for controlling a transport system having at least one drive system for moving more than one transport element along a track, the control architecture effective for performing the method comprising the steps of using a computer system for operating a control system software that functions to receive information from an operator and create a motion profile for each transport element, wherein the motion profile for each transport element is for a single drive system for moving a single transport element; communicating the motion profile for each transport element to a gateway, the gateway operates gateway drive software that functions to operate the drive system for moving each transport element along the track in accordance with the motion profile for each transport element. 
     In a preferred embodiment of the invention the transport system comprises more than one track, each track having at least one transport element traveling thereon. 
     In another preferred embodiment of the invention the transport system comprises at least one track having more than one transport element traveling thereon. 
     In a preferred embodiment of the invention the drive system includes activation elements comprising individual electric coils positioned along the track for creating changing magnetic fields to directly move an axis or transport element along one or more of the tracks in accordance with the motion profile. 
     In a preferred embodiment the operating control system software is that typically used for a single drive system. 
     In a preferred embodiment of the invention the control architecture operates to control one or more transport systems. 
     In a preferred embodiment of the invention the transport system comprises more than one linear drive systems. 
     In a preferred embodiment of the invention the transport system comprises at least one linear drive system and at least one non-linear drive system. 
     In a preferred embodiment of the invention the transport system comprises a linear drive system, a non-linear drive system or a combination thereof. 
     In another preferred embodiment of the invention the gateway operates to monitor the position of each transport element as it travels along one or more tracks. 
     In another preferred embodiment of the invention the gateway operates to select the drive system for each transport element and operates to energize and de-energize the drive system to move each transport element in accordance with its motion profile. 
     Other advantages, objects, and embodiments of the invention will be apparent from the following description, the accompanying drawings and the appended claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       To provide a more complete understanding of the present invention and further features and advantages thereof, reference is now made to the following description taken in conjunction with the accompanying drawings, in which: 
         FIG. 1  is a schematic representation of a preferred embodiment of a transport system of the subject application whereby the transport system comprises a linear magnetic drive system comprising a track and more than one transport elements effective for moving articles along a track; 
         FIG. 2  is a schematic representation of the transport system of  FIG. 1  showing a track segment having activation elements comprising a plurality of electrical coils effective for creating electromagnetic fields; 
         FIG. 3  is a schematic representation of a transport element of the transport system of  FIG. 1  showing reactive elements positioned thereon for cooperating with the activation elements for moving the transport element along the track; 
         FIG. 4  is a schematic representation of a preferred embodiment of the control architecture of the subject invention for controlling a transport system having transport elements effective for moving articles from one location to another location and showing a computer system for use by an operator for inputting information to create a motion profile for each transport element and a gateway coupled to the computer system for operating the transport system in accordance with the motion profile; 
         FIG. 5  is a flowchart depicting a method of operation of a preferred embodiment of the control architecture of the subject invention; 
         FIG. 6  is a schematic representation of another preferred embodiment of the invention showing the transport system comprising more than one linear magnetic drive system; and 
         FIG. 7  is a schematic representation of another preferred embodiment of the invention showing the transport system comprising a combination of at least one linear magnetic drive system and at least one rotary drive system. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention relates to control architecture for transport systems for receiving articles at one location and transporting the articles to another location. In describing the preferred embodiments of the invention illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents that operate in a similar manner to accomplish a similar purpose. 
     Referring to  FIGS. 1, 2 and 3 , a schematic representation of typical transport system  100  for moving articles from one location to another location having a preferred embodiment of the control architecture of the subject invention  102  is shown ( FIG. 4 ). In a preferred embodiment of the invention the transport system  100  is a linear magnetic drive system preferably includes a track  104  formed from interconnected track sections  106  having a drive system  108  comprising activation elements  110 , such as a plurality of electromagnet coils  112 , that operate by creating electromagnetic fields ( FIG. 2 ). Coupled to the track  104  is one or more axis or transport elements  114  mounted to permit each transport element  114  to travel along the track  104  ( FIG. 3 ). Each transport element  114  is movable independent of each other and includes reaction elements  116  preferably comprising one or more magnets  118 , such as rare-earth permanent magnets, which cooperate with the activation elements  110  positioned along the track  104  to produce relative movement there between when the activation elements  110  are energized and/or de-energized. In a preferred embodiment, as shown in  FIG. 4 , the control architecture  102  includes a gateway  120  that is electrically coupled to the drive system  108  to operate and control the motion of each transport element  114 . Each transport element  114  further includes a control sensor  122  ( FIG. 3 ) that provides a signal for use by the gateway  120  for operating the drive system  108  by energizing and/or de-energizing the activation elements  110  positioned along the track  104  thereby producing controlled movement of each transport element  114 . 
     In a preferred embodiment the control architecture  102  includes a computer system  124  or other similar system effective for implementing and operating control system software  126  that performs to permit an operator  0  to input commands and any desired protocols (such as the particular track identification, the speed that a transport element or axis travels along the track, and stop and start locations and length of time for the transport element) into the control architecture  102  to create a motion profile  128  for a transport element  114 . The computer system  124  preferably includes a controller  130  having a processor and a memory  132  for operating the system software  126 . It should be understood that the processor and memory  132  can comprise various computing hardware such as central processing units (CPU&#39;s), graphics processing units (GPU&#39;s), digital signal processors (DSP&#39;s), microprocessors and/or other such data processing devices. The computer system  124  further comprises other devices, such as a suitable input device, like a keypad, touch screen, or any other suitable input device  134  that can accept information from an operator  0 . The processor and memory  132  can include any of the usual devices used for the storage of data, such as computer hard drives, floppy discs, binary codes, optical bits, mechanical scribes, magnetic tapes, compact discs, digital audio tapes, analog tapes, vinyl discs, and any device or devices capable of storing data. It should be understood that the computer system  124  can include any combination of the above components, or any number of different components, peripherals, and other devices. Preferably, the computer system  124  operates under the control of an operating system, such as the WINDOWS operating system developed by Microsoft Corporation or the MACINTOSH operating system developed by Apple Computer Corporation. It should be understood, however, that other operating systems could be utilized to implement the control system software of the computer system of the present invention. 
     Referring to  FIG. 4 , gateway  120  of the control architecture  102  operates tor receive the motion profile  128  from the control system software  126  of the computer system  124 . As shown, the gateway  120  operates the drive system  108  by energizing or de-energizing the activation elements  110 , such as individual electromagnetic coils  112 , positioned along the track  104  create a moving magnetic field to directly move one or more of the axes or transport elements  114  along the track  104  in accordance with the motion profile  128 . 
     Preferably, gateway  120  includes a controller  136  and a processor and a memory  138  that operates the gateway drive software  140 . It should be understood that the processor and memory  138  can comprise various computing hardware such as central processing units (CPU&#39;s), graphics processing units (GPU&#39;s), digital signal processors (DSP&#39;s), microprocessors and/or other such data processing devices. The processor and memory  138  can include any of the usual devices used for the storage of data, such as computer hard drives, floppy discs, binary codes, optical bits, mechanical scribes, magnetic tapes, compact discs, digital audio tapes, analog tapes, vinyl discs, and any device or devices capable of storing data. Preferably, the processor and memory operates under the control of an operating system, such as the WINDOWS operating system developed by Microsoft Corporation or the MACINTOSH operating system developed by Apple Computer Corporation. It should be understood, however, that other operating systems could be utilized to implement gateway drive software of the present invention. 
     In a preferred embodiment, the computer system  124  is electrically coupled to the gateway  120  to permit communication there between. Referring to  FIG. 4 , an operator enters into the computer system  124 , using the conventional input device  134 , the various instructions and protocols needed to create a motion profile  128  for each transport element  114  for the particular transport system being utilized. Such instructions and protocols can include information such as the particular transport system and the particular axis or transport element(s). In a preferred embodiment of the invention, the control system software  126  is traditional software selected by the operator for controlling a transport system  100  having a particular drive system  108 , such as a linear drive system comprising a single track and a single transport element operating thereon or a conventional rotary axis system having a single transport element. The computer system  124  being in electrical communication with the gateway  120  operates to transfer the motion profile  128  created by the control system software  126  using the instructions and protocols inputted by the operator using the input device  132  of the computer system  124 . The gateway drive software  140  utilizing the motion profiles  128  operates to identify the particular transport system  100 , the particular drive system  108  and the axis or transport element  114  and identifies and activates the identified drive system  108  (such as a particular linear magnetic drive system by energizing and de-energizing the activation elements) to direct and move one or more of the transfer elements along a track in accordance with their motion profile  128 . 
     In a preferred embodiment the transport system  100  includes a positioning system  144  for determining and monitoring the position of each transport element  114  traveling along the track  104 . In a preferred embodiment, the positioning system  144  is of the type typically used for a linear motion system (as shown) and includes “incremental absolute” position sensors or encoders  146  and counter  148  that operates by sensing and counting incremental pulses (or digitize sine/cosine signals to create these pulses) to count up or down after a transport element  114  travels past a reference point. It should be understood that the positioning system  144  can be used as part of a linear motion system having a single axis or transport element or as part of a linear motion system having multiple axis or transport elements and operates to track the position of each such transport system as it moves along the track. The positioning system  144  is electrically coupled to the gateway  120  and provides a position signal  150  for each transport element  114 . It should also be understood however that other positioning systems that may be used for sensing the position of transport elements  114  moving along a linear motion system can also be utilized for such systems. The gateway  120  operates to use the position signal  150  for each transport element to  114 , such as through a conventional feedback control loop, to ensure that the transport elements  114  are operating (traveling along the track or path) in accordance with the motion profile  128  as well as to ensuring the one transport element does not interfere with the movement of another transport element. For an example, the gateway cooperates with the positioning system to calculate time and position of each transport element in association with their motion profiles and operates to adjust the motion profiles to ensure that the transport elements traveling along a track do not make contact with other transport elements or otherwise restrict movement of another transport element. 
     In a preferred embodiment of the invention the transport system  100  is a linear drive system comprising a track  104 , more than one axis or transport elements  114 , and a drive system  108  having one or more activation elements  110  positioned along the track  104 , and one or more encoders  146  positioned along the track  104 . Each transport element  114  is movably attached for traveling along the track  104 . Referring to  FIG. 5 , in operation, the control architecture operates such that the system software receives information, including instructions and/or protocols, from an operator (step  200 ) and creates a motion profile for directing the operation of each transport element (step  202 ). It should be understood that the control system software is traditional software for use in conventional single drive transport systems, such as conventional rotary drive transport systems, having a single transport element. In a preferred embodiment the control system software is conventional control system software for controlling more than one rotary drive system each having a single transport element. An operator using the control system software inputs control parameters and other information for creating a motion profile for each transport element operating on each transport system. Once the instructions and/or protocols are entered into the computer system by the operator, the system software operates to create and direct a motion profile to the processor and memory of the gateway (step  204 ). The gateway drive software is configured to receive and utilize the motion profile and determines the particular transport system and/or drive system (step  206 ) and operates the gateway to energize and de-energize the identified drive system to move each transport element in accordance with its motion profile (Step  208 ). It should now be understood that unlike conventional control systems for single drive transport systems, such as conventional rotary drive systems, in which the transport system has a single transport element controlled by a single drive, the control architecture of the subject invention allows an operator to control one or more transport systems each having one or more transport elements operating thereon. 
     In a preferred embodiment of the invention the drive system includes a positioning system that operates to provide a signal to the gateway which functions as a feedback control loop for use by the gateway drive software for ensuring that each transport element is operating in accordance with its motion profile (step  210 ). It should also now be understood that the positioning system further permits the gateway drive software to monitor the location of each transport element traveling along each transport system and operates to ensure that the transport elements do not contact another transport element or otherwise interfere with the movement of another transport element. 
     For another illustrative example of a preferred embodiment of the method of the subject invention, the identified drive system is a conventional linear motion drive system. The gateway control software operates to energize and de-energize the activation elements along the track that cooperate with the reaction elements on the individual transport elements to move the each transport element along the track in accordance with the motion profile for the particular transport element. The positioning system cooperates with the control sensor on each of the transport elements to provide a signal to the gateway effective for monitoring the location of each transport element and ensure that the transport elements are directed in accordance with the motion profile without interfering with another transport element. 
     It should now be apparent to one skilled in the art that the control architecture of the subject invention operates to allow a motion profile to be created using conventional control system software for a transport system having a single transport element and using a conventional single drive (such as a rotary drive system) to create motion profiles for transport systems having more than one drive and/or more than one transport element. In operation, the gateway of the subject invention operates to receive the motion profile for each transport element, determines the drive system for driving each transport element, and controls the drive system in accordance with the motion profile for each transport element. Accordingly, it should now be apparent to one skilled in the art that the control architecture of the subject invention operates such that it appears to the operator that each transport element is operating on its own independent drive system thereby allowing the operator to create motion profiles for multiple drive and/or multiple independently controlled transport elements by input information using conventional system software for controlling a single drive, signal transport element systems. 
     In another preferred embodiment of the invention the transport system comprises a transport system  100  having a drive system  108 , such as a linear drive system, having more than one track  104  and activation elements  110  positioned along each track  104 , and one or more encoders  146  also positioned along each track  104 . One or more transport elements  114  are movably attached for traveling along each track  104 . Referring to  FIG. 7 , in operation, the control architecture operates such that the control system software receives information, including instructions and/or protocols for directing the operation of each transport element from an operator (step  200 ) and creates a motion profile for each transport element (step  203 ). It should be understood that the control system software is traditional software for use in conventional single drive transport systems, such as conventional rotary drive transport systems or a single linear dive system, having a single transport element. Accordingly, the operator inputs instructions and/or protocols into the control system software as if each transport element was operating on a separate single drive transport system having a single transport element. Once the instructions and/or protocols are entered into the computer system by the operator, the control system software operates to communicate the motion profiles to the gateway (step  204 ). The gateway drive software is configured to receive and utilize the motion profiles and operates to select the particular transport elements (step  206 ) and energize and de-energize the activation elements positioned along the track that cooperates with the reaction elements on the individual selected transport elements to move each transport element along the track (step  208 ). The positioning system for each linear motion drive system cooperates with the control sensor on each transport element to provide signals to the gateway to track the location of each transport element and ensure that the transport elements are directed in accordance with their motion profile (step  210 ). It should now be understood that the control architecture of the subject invention operates such that the gateway can direct an individual or a plurality of independent or dependent transport systems based on the motion profile. 
     It should now be apparent to one skilled in the art that the control architecture of the subject invention can be used in conjunction or as part of a transport system comprising one or more linear drive systems and one or more rotary drive systems, or any combination thereof. Further, the control architecture of the subject invention can comprise two separate components, such as a separate computer system for operating the control system software and a separate gateway for operating the gateway drive software or can comprise a single component operating both the control system software and the gateway drive software such that a single processor or multiple processors operating both the control system software and the gateway drive software. It should also now be apparent to one skilled in the art that the control architecture of the subject invention can incorporate traditional software typically used for inputting and controlling conventional single drive systems, such as a conventional rotary drive system, to allow an operator to input information and/or instructions. Accordingly, an operator using traditional control software for a signal drive system can input control protocols and instructions for creating a motion profiles for a drive system having a plurality of transport elements. In another preferred embodiment of the invention the operator enters specific drive (or drive system) identification and information directed to that specific drive. The operator can continue adding information for each specific drive identified to be within a specific transport system until all the information has been entered. The system software then operates to create a motion profile and transmits the motion profile to the gateway. The gateway then operates to identify the particular drive system and directs the transport element(s) identified for each specific drive in accordance with the motion profile. It should now be apparent that the computer software operates as if there is one transport element for each drive system while the gateway permits multiple transport elements to operate on one or more drive systems. 
     It should now be apparent to one skilled in the art that the control architecture of the subject invention operates to allow a motion profile to be created for a transport system having more than one drive and/or more than one track and/or more than one axis or transport element using conventional software for creating a motion profile for a transport system comprising a single rotary drive system, or a multiple rotary drive system, or a linear drive system having a single track and one or more axis or transport elements moving along the track, or a linear drive system having more than one track with one or more axis or transport elements moving along each track. 
     It should now be apparent to one skilled in the art that the control architecture of the subject invention is effective for controlling a transport system that has similar programmatic features as used in conventional single drive systems having a single transport element. It should also now be apparent that the control architecture of the subject invention is effective for controlling a transport system that allows an operator to use traditional software for controlling conventional single drive, single transport element systems; can be used to control a transport system having more than one drive system; can be used with linear drive systems whereby transport elements operate on different tracks; that allows additional independent drive systems to be easily incorporated into the transport system; allows a single control system to operate more than one transport system or a transport system having more than one track; and allows an operate to use traditional control software to control one or more transport elements. Accordingly, in a preferred embodiment the control architecture of the subject invention operates such that linear drive systems (having one or more transport elements moving thereon) are virtualized to look and controlled such that the perceived view of the operator is such that it appears to be one or more rotary drive systems (one system for each transport element). 
     While the method and apparatus described constitute preferred embodiments of the invention, it is to be understood that the invention is not limited to the precise method and apparatus, and that changes may be made therein without departing from the scope of the invention which is defined in the appended claims.