System and method for determining real-time orientation on carts in an independent cart system

A system for real-time determination of orientation for a physical location on a mover in an independent cart system, the system comprising:

• a track having a plurality of track segments;
• a mover mounted on and configured to travel along the track in a two-dimensional coordinate system;
• a sensor mounted on the mover, wherein the sensor is configured to generate at least one feedback signal corresponding to a physical orientation of the mover in a coordinate system, wherein an origin of the coordinate system travels with the mover;
• a control circuit mounted on the mover, wherein the control circuit is configured to receive the at least one feedback signal and to generate a data packet including a value of the at least one feedback signal corresponding to the physical orientation of the mover;
• a transmitter mounted on the mover, wherein the transmitter is configured to receive the data packet from the control circuit and to transmit the data packet to a receiver located external from the mover;
• and
• a controller located remotely from the mover, wherein the controller is configured to:
• communicate with and to receive the data packet from the receiver,
• determine at least one rotational position of the mover as a function of the value of the at least one feedback signal in the data packet, wherein the rotational position of the mover includes rotation in a third dimension, the third dimension perpendicular to the two-dimensional coordinate system;
• and
• control operation of either the mover or an actuator, configured to interact with the mover, in real-time responsive to the at least one rotational position of the mover.