System and method for synchronizing motion of multiple vehicles in an independent cart system

A system for synchronizing motion of multiple movers in an independent cart system, the independent cart system including a track and a plurality of movers configured to travel along the track, wherein the track includes a plurality of track segments, the system comprising:

• a first mover for leading a chain of movers, wherein the first mover is selected from the plurality of movers in the independent cart system;
• at least one additional mover, wherein:
• the at least one additional mover is selected from the plurality of movers in the independent cart system, and
• the first mover and each of the at least one additional movers are included within the chain of movers;
• a first segment controller, wherein the first segment controller is located in a first track segment, selected from the plurality of track segments, and the first segment controller is configured to control operation of the first mover while the first mover is present on the first track segment;
• and
• at least one additional segment controller, wherein the at least one additional segment controller is located in an additional track segment, selected from the plurality of track segments, and the at least one additional segment controller is configured to control operation of the at least one additional mover while the at least one additional mover is present on the additional track segment, wherein:
• the first segment controller is configured to obtain a desired motion profile for the first mover,
• the first segment controller is configured to transmit the desired motion profile to the at least one additional segment controller,
• the at least one additional segment controller is configured to detect that the at least one additional mover is unable to follow the desired motion profile,
• the at least one additional segment controller is configured to determine a desired hold back for the at least one additional mover, wherein the hold back is a value to modify the desired motion profile to a modified motion profile such that the at least one additional mover is able to follow the modified motion profile,
• the at least one additional segment controller is configured to transmit the desired hold back to the first segment controller, and
• the first segment controller is configured to modify the desired motion profile for the first mover to the modified motion profile as a function of the desired hold back received from the at least one additional segment controller.