Shuttle height monitoring systems for shuttles powered by linear synchronous motors

1 . A system comprising:

a track having a central axis, the track comprising a first rail segment on a first side of the central axis and a second rail segment on a second side of the central axis;

a first shuttle configured to transport one or more items from a first location to a second location using the track, the first shuttle comprising a first permanent magnet and a first conveyor assembly having a central axis that is transverse to the central axis of the track, wherein the first shuttle is configured to support the one or more items on the first conveyor assembly;

a second shuttle configured to move along the track, the second shuttle comprising a second permanent magnet;

a set of electromagnets disposed along the central axis of the track, wherein the set of electromagnets interact with the first and second permanent magnets to propel the first shuttle and the second shuttle, respectively;

a first laser sensor disposed adjacent to the track;

a first photoelectric sensor disposed adjacent to the track;

a second photoelectric sensor disposed adjacent to the first photoelectric sensor; and

a controller configured to:

determine, using the second photoelectric sensor, that the first shuttle is adjacent to the first laser sensor;

cause the first laser sensor to determine a first distance between the first permanent magnet and the first laser sensor; and

determine a first wear status of the first shuttle based at least in part on the first distance.

2 . The system of claim 1 , wherein the controller is further configured to:

determine that the first shuttle is due for maintenance based at least in part on the first wear status; and

cause the first shuttle to be automatically routed to a maintenance station.

3 . The system of claim 2 , wherein the controller is further configured to:

determine, using the first photoelectric sensor, that the second shuttle is adjacent to the first laser sensor;

cause the first laser sensor to determine a second distance between the second permanent magnet and the first laser sensor;

determine a second wear status of the second shuttle based at least in part on the second distance;

cause presentation of the first wear status and the second wear status at a display, wherein the first wear status is presented with a visual indicator indicating the first shuttle is due for maintenance.

4 . The system of claim 1 , wherein the first photoelectric sensor is oriented in a vertical position and the second photoelectric sensor is oriented in a horizontal position.

5 . A system for monitoring shuttle wear of a first shuttle and a second shuttle, the system comprising:

a track comprising a first rail segment that forms a first side of the track, and a second rail segment that forms a second side of the track;

a first sensor disposed adjacent to the track;

a second sensor disposed adjacent to the track;

a third sensor disposed adjacent to the second sensor; and

a controller configured to:

determine, using the third sensor, that the first shuttle is adjacent to the first sensor;

determine, using the first sensor, a first distance between a first lower portion of the first shuttle and the first sensor;

determine, using the second sensor, that the second shuttle is adjacent to the first sensor; and

determine, using the first sensor, a second distance between a second lower portion of the second shuttle and the first sensor.

6 . The system of claim 5 , wherein the second sensor and the third sensor are photoelectric sensors; and

wherein the second sensor is disposed in an upwards-facing orientation, and the third sensor is disposed in a sideways-facing orientation.

7 . The system of claim 5 , wherein the controller is further configured to:

cause the first distance to be stored in association with a first shuttle identifier of the first shuttle; and

cause the second distance to be stored in association with a second shuttle identifier of the second shuttle.

8 . The system of claim 7 , wherein the first distance is determined at a first time interval, and wherein the controller is further configured to:

determine, using the third sensor at a second time interval, that the first shuttle is adjacent to the first sensor;

determine, using the first sensor, a third distance between the first lower portion of the first shuttle and the first sensor;

determine that the third distance is less than the first distance; and

cause the third distance to be stored in association with the first shuttle identifier, wherein the third distance overwrites the first distance.

9 . The system of claim 8 , wherein the controller is further configured to:

determine that the third distance is less than a threshold value;

determine that the first shuttle is due for maintenance based at least in part on the third value; and

generate a notification that the first shuttle is due for maintenance.

10 . The system of claim 9 , wherein the controller is further configured to:

cause presentation of the second distance and the third distance at a display.

11 . The system of claim 10 , wherein the third distance is presented with a visual indicator indicating the first shuttle is due for maintenance.

12 . The system of claim 5 , wherein the track is a closed-loop track.

13 . The system of claim 12 , wherein the controller is further configured to:

determine that the first shuttle is a first shuttle and the second shuttle is a last shuttle in a sequence of shuttles moving along the track; and

cause an increment counter to be reset to 1, wherein an increment counter value of 1 indicates a subsequent distance value is associated with the first shuttle.

14 . The system of claim 5 , wherein the first sensor is a laser sensor that is disposed underneath the track, and wherein the second sensor and the third sensor are disposed along the first side or the second side of the track.

15 . The system of claim 5 , wherein the first shuttle comprises a conveyor and a permanent magnet that forms the first lower portion; and

wherein the track comprises an electromagnet disposed along the track, wherein the first shuttle is propelled via interaction between the electromagnet and the permanent magnet.

16 . A system comprising:

a track comprising a first rail segment and a second rail segment, wherein the first rail segment forms a first side of the track, and the second rail segment forms a second side of the track;

a first shuttle configured to move along the track;

a second shuttle configured to move along the track;

a first sensor disposed adjacent to the track;

a second sensor disposed adjacent to the track;

a third sensor disposed adjacent to the second sensor; and

a controller configured to:

determine, using the third sensor, that the first shuttle is adjacent to the first sensor;

determine, using the first sensor, a first distance between a first lower portion of the first shuttle and the first sensor;

determine, using the second sensor, that the second shuttle is adjacent to the first sensor; and

determine, using the first sensor, a second distance between a second lower portion of the second shuttle and the first sensor.

17 . The system of claim 16 , wherein the second sensor and the third sensor are photoelectric sensors; and

wherein the second sensor is disposed in an upwards-facing orientation, and the third sensor is disposed in a sideways-facing orientation.

18 . The system of claim 16 , wherein the controller is further configured to:

cause the first distance to be stored in association with a first shuttle identifier of the first shuttle; and

cause the second distance to be stored in association with a second shuttle identifier of the second shuttle.

19 . The system of claim 18 , wherein the first distance is determined at a first time interval, and wherein the controller is further configured to:

determine, using the third sensor at a second time interval, that the first shuttle is adjacent to the first sensor;

determine, using the first sensor, a third distance between the first lower portion of the first shuttle and the first sensor;

determine that the third distance is less than the first distance; and

cause the third distance to be stored in association with the first shuttle identifier, wherein the third distance overwrites the first distance.

20 . The system of claim 19 , wherein the controller is further configured to:

determine that the third distance is less than a threshold value;

determine that the first shuttle is due for maintenance based at least in part on the third value; and

cause the first shuttle to be automatically routed to a maintenance station.