Design and control of a magnetic levitation robotic platform for flexible manufacturing

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Recent developments in the field of linear-motor systems have led to renewed interest in precise and rapid material handling/positioning in manufacturing facilities. Most of such devices are yet limited to a single-axis (or one degree of freedom, 1-DOF) motion. This research proposal aims at the development of a revolutionary magnetic levitation floor platform (MLFP) for flexible manufacturing applications, aiming to eliminate conventional conveyer mechanism and maximize the factory space usage. The floor uses an array electromagnetic actuators which can levitate and move five robots simultaneously with 2-DOF for rapid work distribution in manufacturing facilities. Conventional manufacturing and production lines consist of several work stations (drilling, milling, lathes, etc.) and motorized multiple conveyers will be used to circulate a workpieces among those workstations to be machined or assembled. These fixed manufacturing/production lines should be totally rearranged if a different product is introduced into the line. Rearrangement of these fixed production lines are costly and time consuming. The development of a novel reconfigurable production line, in the form of the proposed MLFP, will have significant advantages. MagLev technology will allow physical contact, friction and noise to be minimized. Eliminating the need for traditional contact-based stiffness transfer mechanisms (timing belts, sprockets and gearboxes) will also provide for a significantly longer operational lifetime, with fewer maintenance issues. The proposed research will be carried out in the following steps: 1) Design the electromagnetic actuator to generate sufficient magnetic force for robots' magnetic levitation; 2) Develop a magnetic levitation platform using optimized energy/heat electromagnetic actuator; 3) Develop control system to realize the robot motions and evaluate the performance. There is a very significant global market for MLFP such as in cleanroom material transportation, electronic industry, and pharmaceutical industry. HQP including one PhD and one Master's students and two fourth-year students will be trained in a number of key areas, including mechatronics, systems design, prototyping, and manufacturing.