Design Guidelines
Transport System Design
MagneMover LITE User Manual 103
Rockwell Automation Publication MMI-UM002F-EN-P - October 2022
erance on the flatness of the guideway the larger the vehicle gap must be to make sure that the
magnet array never touches the top of the motor.
• A guideway using G3 pucks that is held to ±0.5 mm typically has a nominal vehicle
gap of about 1 mm, with a total gap range of 0.5 mm to 1.5 mm.
• A guideway using G4.2 and later pucks that is held to ±0.5 mm typically has a nominal
vehicle gap of about 1.5 mm, with a total gap range of 1.0 mm to 2.0 mm.
NOTE: The vehicle gap must be such that any deviations in the flatness of the vehicle sus-
pension surface do not allow the magnet array on the vehicle to touch down on either
the guide rails or the motors.
The recommendations for vehicle gap when using the G4 series magnet arrays that are shown
are for reference only. Smaller minimum vehicle gaps or larger maximum vehicle gaps is pos-
sible. However, exceeding the vehicle gap recommendations typically requires special design
considerations and can make it difficult for the position sensors in the motor to locate the
vehicles precisely. Contact your Motion Solutions Consultant or Technical Support (see Rock-
well Automation Support on page 486) for assistance.
• Minimum vehicle gap is 0.5 mm, 1.0 mm is the recommended minimum.
• Nominal vehicle gap is 1.5 mm for typical industrial applications.
• Maximum vehicle gap is 2.0 mm.
Vehicle Design
When designing custom vehicles for use with the MagneMover LITE, the following vehicle
design guidelines and considerations must be accounted for:
• Make the vehicles longer than the magnet array to help protect the array from impacts.
A minimum of 1 mm extra length at the front and back of the vehicle is recommended.
• The vehicle design determines the quantity and locations of suspension and lateral
guide wheels or other suspension and guidance features.
• The use of a low friction barrier, such as UHMW material, is recommended to help
prevent damage to either the magnet array or the motor if there is contact between the
magnet array and the motor. For the standard pucks and magnet arrays, this UHMW
material is already provided and must not be removed.
• Up to nine 62 mm vehicles (pucks) in motion per meter.
• Up to ten 62 mm vehicles (pucks) in a queue per meter standard, up to 12 vehicles in
queue per meter depending upon application.
• The payload, vehicle mass, and required acceleration must be within the limits of the
magnet array.
• Vehicles that carry payloads sensitive to magnetic fields must provide shielding or
separate the payload from the magnet array by 50…100 mm.
• When using curve motors or guideways with curves, make sure that the vehicle design
is able to negotiate the curves.
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