Electromagnet switch for shuttles on a track
Systems and methods are disclosed for a track system for transporting a shuttle with a payload from one location to another location in a fulfillment center. A track system may include linear synchronous motors (LSMs) to propel the shuttle along a desired path of the track system. The track system may include multiple track paths, magnet assemblies, and electromagnets for diverting shuttles to alternative paths. To cause a shuttle to move from one track path to another track path, an electromagnet and a magnet assembly may be positioned at an intersection between the paths. When the electromagnet is energized the magnetic field of the electromagnet may attract the shuttle to a desired path (e.g., curved path) and the magnet assembly may cause to shuttle travel along the desired path.
1 . A system comprising:
a set of rails that form a track having a central axis, the set of rails 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, wherein the track comprises a linear path and a curved path that intersects the linear path;
a shuttle configured to transport items from a first location to a second location using the set of rails, the shuttle comprising:
a first ferrous block; and
a set of wheels;
a set of linear synchronous motors (LSMs) disposed along the central axis;
a wall structure extending along the curved path;
a magnet assembly forming a side of the curved path, the magnet assembly comprising a set of focused magnets arranged in series along an exterior of the wall structure and coupled to the wall structure, each focused magnet of the set of focused magnets having a housing, a set of magnets arranged in series and alternating in polarity, and a backing structure positioned behind the set of magnets such that the set of magnets is between the backing structure and the wall structure, the set of magnets and the backing structure disposed in the housing, wherein the backing structure comprises a set of plates and each backing structure is secured to a respective housing via a respective set of magnets, and wherein each housing and each backing structure is curved and configured to conform to the wall structure; and
an electromagnet disposed along a side of the curved path adjacent to the set of focused magnets and preceding the set of focused magnets along a direction of travel of the shuttle, the electromagnet configured to be selectively energized;
wherein the first ferrous block of the shuttle is attracted to the electromagnet and the set of focused magnets when the electromagnet is energized, causing the shuttle to divert from the linear path and enter the curved path when the electromagnet is energized.
2 . The system of claim 1 , wherein the shuttle comprises a second ferrous block and the set of LSMs is configured to propel the second ferrous block to cause the shuttle to advance along the central axis in the direction of travel.
3 . The system of claim 1 , wherein the wall structure is metallic and is configured guide the set of wheels of the shuttle as the shuttle traverses the curved path.
4 . A system comprising:
a set of rails that form a track, the set of rails comprising a first rail segment on a first side and a second rail segment on a second side, the track comprising a linear path and a curved path that intersects the linear path, the set of rails configured to guide a shuttle with a payload;
a wall structure that is curved;
a magnet assembly comprising a set of focused magnets arranged in series along an exterior of the wall structure and coupled to the wall structure, each focused magnet of the set of focused magnets having a housing, a set of magnets arranged in series alternating in polarity, and a backing structure positioned such that the set of magnets is between the backing structure and the wall structure, the set of magnets and the backing structure disposed in the housing, wherein the backing structure comprises a set of plates and each backing structure is secured to a respective housing via a respective set of magnets, and wherein each housing and each backing structure is curved and configured to conform to the wall structure; and
an electromagnet disposed along a side of the curved path adjacent to the magnet assembly and preceding the set of focused magnets along a direction of travel of the shuttle, the electromagnet configured to be selectively energized;
wherein a ferrous portion of the shuttle is attracted to the electromagnet and the set of focused magnets when the electromagnet is energized, causing the shuttle to enter the curved path.
5 . The system of claim 4 , further comprising a set of linear synchronous motors (LSMs) disposed along a central axis of the set of rails and configured to cause the shuttle to advance along the set of rails.
6 . The system of claim 5 , further comprising the shuttle configured to transport the payload from a first location to a second location using the set of rails, the shuttle comprising an onboard first ferrous portion configured to interface with the electromagnet and the set of focused magnets, an onboard second ferrous portion configured to interface with the set of LSMs, and a set of wheels configured to interface with the wall structure.
7 . The system of claim 4 , wherein for each focused magnet of the set of focused magnets, a respective set of magnets, a respective backing member, and a respective housing are coupled via a first threaded engagement and the respective housing and the wall structure are coupled via a second threaded engagement.
8 . The system of claim 4 , wherein one or more of the wall structure and backing member is stainless steel.
9 . The system of claim 4 , wherein each housing of the magnetic assembly is made from glass reinforced nylon and comprises a first set of through holes configured to receive a first set of bolts to couple the housing to the wall structure and a second set of through holes configured to receive a second set of bolts to couple the housing to a respective set of magnets and a respective backing member.
10 . A method comprising:
causing a shuttle having a payload and comprising a ferrous portion to advance along a set of rails that form a track, the set of rails comprising a first rail segment on a first side and a second rail segment on a second side, the track comprising a linear path and a curved path that intersects the linear path at an intersection;
determining to divert the shuttle from the linear path to the curved path at a switching area of the track positioned at the intersection, the curved path comprising a wall structure that is curved forming a side of the curved path, a magnet assembly comprising a set of focused magnets arranged in series along an exterior of the wall structure and coupled to the wall structure, and an electromagnet adjacent to the magnet assembly and preceding the magnet assembly along a direction of travel of the shuttle; and
causing the electromagnet to energize to divert the shuttle from the linear path to the curved path by attracting the ferrous portion in the shuttle,
wherein each focused magnet of the set of focused magnets has a housing, a set of magnets arranged in series alternating in polarity, and a backing structure positioned such that the set of magnets is between the backing structure and the wall structure, wherein the backing structure comprises a set of plates and each backing structure is secured to a respective housing via a respective set of magnets, and wherein each housing and each backing structure is curved and configured to conform to the wall structure.
11 . The method of claim 10 , wherein a set of linear synchronous motors (LSMs) is disposed along a central axis of the set of rails and adapted to propel a second ferrous portion of the shuttle.
12 . The method of claim 11 , further comprising, before causing the electromagnet to energize to divert the shuttle from the linear path to the curved, selectively causing the set of LSMs to energize to cause the shuttle advance along the linear path.
13 . The method of claim 10 , further comprising determining a destination corresponding to the payload and determining to divert the shuttle from the linear path to the curved path based on the destination.
14 . The method of claim 10 , wherein for each focused magnet of the set of focused magnets, a respective set of magnets, respective backing member, and respective housing are coupled via a first threaded engagement and the respective housing and the wall structure are coupled via a second threaded engagement.
15 . The method of claim 10 , wherein one or more of the wall structure and backing member is stainless steel.