Variable motion system and method

A method for performing a manufacturing operation relative to at least a first path, comprising:

• mounting a plurality of first carriages for independent movement relative to a first path;
• providing each first carriage with a first reactive element;
• operatively associating a plurality of first active elements with the first reactive elements to produce relative movement between the first carriages and the first path, with each first active element being independently activated to control such relative movement;
• arranging a plurality of rows of switching sensors along said first path;
• operatively associating each row with a particular one of said first carriages;
• operatively associating each of said switching sensors with a particular one of said first active elements so as to enable activation of that particular first active element when the particular one of said first carriages operatively associated with the row of switching sensors that includes a particular switching sensor traverses into operative proximity of said switching sensor;
• associating a first tool with each first carriage for performing at least part of the manufacturing operation;
• and
• controlling the amount of activation of the first active elements to direct the first carriages along the first path where the manufacturing operation is at least partially conducted by the first tool.

A system for performing a manufacturing operation relative to first path and a second path comprising:

• a plurality of first active elements arranged along a first path;
• a plurality of second active elements arranged along a second path;
• at least one first carriage mounted for movement relative to the first path, each first carriage having a first tool and a first reactive element responsive to activation of the first active elements to produce relative movement between the first carriage and the first path;
• and
• at least one second carriage mounted for movement relative to the second path, each second carriage having a second tool and a second reactive element responsive to activation of the second active elements to produce relative movement between the second carriage and the second path;
• and
• at least one controller providing independent control of the amount of activation of each one of the first and second active elements in order to provide independent movement of each of the first and second carriages relative to the first and second paths, wherein the first and second tools cooperate to perform at least part of the manufacturing operation.

A system for performing a manufacturing operation comprising:

• a plurality of carriages including at least one primary carriage, and at least one secondary carriage, said primary and secondary carriages being mounted for independent movement relative to each other and relative to a path, each of said primary and secondary carriages having an associated reactive element;
• a plurality of active elements disposed along said path, said active elements being operative to establish fields when activated, said fields influencing said reactive elements and causing relative motion between the carriages and the path;
• a primary row of switching sensors arranged along said path;
• a secondary row of switching sensors arranged at different locations along said path relative to said primary row of switching sensors;
• at least one row of position sensors arranged along said path;
• a primary switching magnet affixed to each said primary carriage at a location corresponding to said primary row of switching sensors, each said switching sensor in said primary row being responsive to said primary switching magnet and operative to generate a primary switching signal for enabling activation of an associated one of said active elements when a primary carriage is in proximity to said switching sensor;
• a secondary switching magnet affixed to each said secondary carriage at a location corresponding to said secondary row of switching sensors, each said switching sensor in said secondary row being responsive to said secondary switching magnet and operative to generate a secondary switching signal for enabling activation of an associated one of said active elements when a secondary carriage is in proximity to said switching sensor;
• a position magnet affixed to each of said carriages at locations that correspond to said at least one row of position sensors, each said position sensor being responsive to at least one position magnet, and being operative to generate a position signal indicative of the position of one of the carriages along said path;
• and
• a controller responsive at least to said position signals, and being operative to provide a controlled amount of electrical energy to each enabled active element to effect a desired motion parameter for each of said primary and secondary carriages based on said position signals, said controller being operative to control the movement of said primary carriages independently relative to the movement of said secondary carriages.