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EP-4737363-A1 - LINEAR MOTOR CONVEYOR SYSTEM HAVING MULTIPLE SAFETY ZONES

EP4737363A1EP 4737363 A1EP4737363 A1EP 4737363A1EP-4737363-A1

Abstract

A linear motor conveyor system comprises a plurality of track sections (1-7) each comprising a plurality of coils (202) of a linear motor, the plurality of track sections being arranged to provide a conveyor path along which a plurality of shuttles move. The track sections are divided in a plurality of physical safety zones (204a-204c) each comprising a subset of coils of the linear motor and capable of independently de-energizing the subset of coils of the respective physical safety zone. A plurality of physical safety zones (204b, 204c) may be grouped in a virtual safety zone (206). A controller is configured to de-energize the subset of coils of the respective physical safety zones of a virtual safety zone when receiving a halt signal associated with the virtual safety zone to stop motion of shuttles within the virtual safety zone.

Inventors

  • DOLGOVYKH, Anton
  • AUGUSTIN, FLORIAN
  • KLEINIKKINK, ALBERT

Assignees

  • ATS Corporation

Dates

Publication Date
20260506
Application Date
20251031

Claims (15)

  1. A method for operating a linear motor conveyor system comprising a plurality of track sections and a plurality of physical safety zones, the method comprising: defining a plurality of virtual safety zones each comprising at least one physical safety zone of a plurality of physical safety zones each comprising a subset of a plurality of coils of a linear motor of a track section of a plurality of track sections that are capable of independently de-energizing the subset of coils of the respective physical safety zone; receiving a halt signal associated with a virtual safety zone of the plurality of virtual safety zones; and disabling the one or more physical safety zones of the virtual safety zone associated with the received halt signal to stop motion of shuttles within the virtual safety zone and de-energize the subset of coils of the one or more physical safety zones of the virtual safety zone.
  2. The method of claim 1, further comprising: stopping shuttles travelling on the conveyor system from entering a disabled physical safety zone.
  3. The method of claim 1 or 2, further comprising: enabling the disabled virtual safety zone; recovering shuttles in the enabled virtual safety zone to recovery positions; and resuming normal operation of the enabled virtual safety zone.
  4. The method of any one of claims 1 to 3, further comprising: controlling motion of shuttles in enabled virtual safety zones while one or more of the virtual safety zones are disabled.
  5. The method of claim 4, wherein at least one of virtual safety zones comprises a synchronous virtual safety zone associated with a synchronous machine.
  6. The method of claim 5, wherein the synchronous virtual safety zone comprises a synchronous portion of the track over shuttles move synchronously.
  7. The method of claim 6, wherein shuttles in the synchronous portion of the synchronous virtual move synchronously relative to one or more of: other shuttles in the synchronous portion; and an external synchronization device.
  8. The method of claim 7, wherein the synchronous virtual safety zone further comprises an asynchronous portion of the track over shuttles move asynchronously arranged on either end of the synchronous portion of the track.
  9. The method of any one of claims 1 to 8, wherein the halt signal is received when work is to be performed on equipment of a virtual safety zone.
  10. The method any one of claims 1 to 9, wherein the halt signal is provided when one or more of: a safety guarding is opened; an emergency stop is activated; a person is detected within a defined area; and a software interface.
  11. The method any one of claims 1 to 10, wherein at least two of plurality of virtual safety zones overlap with each other.
  12. A linear motor conveyor system comprising: plurality of track sections each comprising a plurality of coils of a linear motor, the plurality of track sections arranged to provide a conveyor path along which a plurality of shuttles move; a plurality of physical safety zones each comprising a subset of coils of the linear motor and capable of independently de-energizing the subset of coils of the respective physical safety zone; and a controller configured to perform a method according to any one of claims 1 to 11.
  13. The linear motor conveyor of claim 12, wherein one or more of: at least one of the physical safety zones comprises all of the coils of one of the track sections; at least one of the physical safety zones comprises a subset of the coils of one of the track sections; at least one of the physical safety zones comprises between 1 and 50 coils of one of the track sections; and at least one of the physical safety zones comprises between 10 and 30 coils of one of the track sections.
  14. The linear motor conveyor of any one of claims 12 or 13, wherein one or more of the physical safety zones is provided by safe torque-off (STO) functionality and wherein optionally the STO functionality disables power to coil driving circuity or shorts coils to decelerate shuttles.
  15. A non-transitory computer-readable medium storing instructions, which when executed by a controller performs a method according to any one of claims 1 to 11.

Description

TECHNICAL FIELD The current application relates to linear motor conveyor systems, and in particular to providing multiple safety zones within the linear motor conveyor. BACKGROUND Linear motor conveyor systems are used in manufacturing, assembly and automation processes. A linear motor conveyor uses a linear motor to independently control the movement of one or more shuttles along a track. The shuttles can carry raw material, parts, components, tooling etc. through one or more processes. Linear motor conveyor systems can have multiple sections at which different stations operate. The machines operating at the different sections may operate at relatively high speed and as such prevent a hazard to individuals. The different stations or sections are often enclosed within guarding or other protections in order to maintain a safe distance between the moving components, such as the shuttles on the conveyor or other equipment, and individuals. During commissioning and integration, or during operation, it may be necessary or desirable to have an individual work on or in proximity to one or more of the sections. When an individual is working on a section or is in close proximity to any components that present a potential hazard, the conveyor system is placed in a state that is safe to carry out the necessary work. This can include, for example, stopping the motion of any components and enabling a safety mechanism that prevents unintended movement of the components. While such safety mechanisms allow work on the conveyor or other components to be performed safely, it can require the stopping of the entire conveyor system to work on one section. For example, the conveyor system, or the different processing sections, may operate in a synchronous manner in which the movement of components is synchronized, either to each other or to a common external component such as a master synchronization component. Stopping one synchronous section can require stopping all of the synchronous sections. Stopping the entire conveyor system, whether during commissioning and integration, or during normal operations can be undesirable as it leads to a longer commissioning and integration process or lowers throughput during operation. An additional, alternative and or improved safety system allowing for safely working on the conveyor system is desirable. BRIEF DESCRIPTION OF THE DRAWINGS Further features and advantages of the present disclosure will become apparent from the following detailed description, taken in combination with the appended drawings, in which: FIG. 1 depicts an illustrative linear motor conveyor system;FIGs. 2A - 2C depicts details of a safety system of the linear motor conveyor system;FIG. 3A - 3C depicts operation of a virtual safety zone of a linear motor conveyor system;FIG. 4A - 4D depicts recovery of the virtual safety zone and the resumption of normal operation of the linear motor conveyor system;FIG. 5 depicts a method of operating a virtual safety zone;FIG. 6 depicts a further method of operating a virtual safety zone;FIG. 7 depicts a linear motor conveyor system with multiple synchronous stations;FIG. 8A depicts a linear motor conveyor system with multiple synchronous safety zones;FIGs. 8B and 8C depict an extended synchronous safety zone;FIGs. 9A - 9D depicts a recovery process with multiple synchronous safety zones;FIGs 10A, 10B depicts a portion of a recovery process for multiple synchronous safety zones;FIGs 10C, 10D depicts a portion of a recovery process for multiple synchronous safety zones; andFIG. 11 depicts a global recovery process for recovering a conveyor system with multiple synchronous safety zones. DETAILED DESCRIPTION In accordance with the present disclosure there is provided a linear motor conveyor system comprising: plurality of track sections each comprising a plurality of coils of a linear motor, the plurality of track sections arranged to provide a conveyor path along which a plurality of shuttles move; a plurality of physical safety zones each comprising a subset of coils of the linear motor and capable of independently de-energizing the subset of coils of the respective physical safety zone; and a controller configured to: define a plurality of virtual safety zones each comprising at least a portion one or more physical safety zones; receive a halt signal associated with a virtual safety zone of the plurality of virtual safety zones; and disabling the one or more physical safety zones of the virtual safety zone associated with the received halt signal to stop motion of shuttles within the virtual safety zone and de-energize the subset of coils of the one or more physical safety zones of the virtual safety zone. In a further embodiment of the linear motor conveyor, one or more of: at least one of the physical safety zones comprises all of the coils of one of the track sections; at least one of the physical safety zones comprises a subset of the coils of one of the track sections; at leas