Method and system for managing modular conveyors

Abstract

The modular conveyor management method according to an embodiment of the present invention is executed by a computing device and includes the following steps: monitoring a conveyor system comprising multiple conveyor modules; determining, based on the monitoring results, whether a first conveyor module among the multiple conveyor modules needs to be replaced; determining the type of a second conveyor module to replace the first conveyor module; and notifying the user of at least one of whether the first conveyor module needs to be replaced or the determined type of the second conveyor module.

Description

[Technical Field]

[0001] This invention relates to a modular conveyor management method and system, and to a management technology for individually monitoring multiple conveyor modules and determining which modules need to be replaced and replacing them with suitable modules. [Previous Technology]

[0002] Conveyor systems are core equipment used in various industrial environments such as logistics centers, manufacturing processes, and production lines, providing the ability to transport large items efficiently and quickly. Conveyor systems mainly operate in an automated manner, which plays an important role in reducing reliance on human resources and improving the consistency and productivity of logistics operations.

[0003] Existing conveyor systems are installed in a fixed manner, transporting goods along a preset route. This system connects conveyor belts, rollers, chains, etc., at regular intervals to establish a fixed transport route. Each conveyor segment is connected by power and communication cables and equipped with sensors to control and detect the transport of goods in real time, tracking their location and detecting errors. The advantage of this structure is that it ensures stable and consistent transport of goods in large-scale logistics operations.

[0004] However, this fixed-design conveyor system has the following disadvantages and limitations.

[0005] First, there is a lack of flexibility. Existing fixed conveyor systems have fixed installation routes, making them unable to respond flexibly to changes in the working environment or logistics processes. For example, when the warehouse layout changes or a new movement route is required, a significant amount of time and money is needed to reinstall or rearrange the existing fixed conveyor lines. These fixed systems are particularly difficult to immediately reflect changing production needs or logistics requirements, thus reducing operational efficiency.

[0006] Secondly, maintenance is difficult. Stationary conveyor systems also present several maintenance challenges. For example, if a module malfunctions, the entire system typically needs to be shut down to repair or replace that module. This not only leads to operational disruptions and adversely affects productivity but also significantly increases maintenance time and costs. Furthermore, the fixed wiring structure and complex power and communication connections require dismantling and reinstalling wiring in case of problems, limiting the reduction of downtime.

[0007] However, scalability is limited. When changes in logistics operations or system expansion are needed after initial installation, the existing system cannot respond flexibly. If additional installations or expansions of the conveyor system are required, additional wiring and hardware installations are needed to ensure compatibility with the existing production line, which is inefficient in terms of time and cost. A major drawback of stationary systems is that they cannot be easily reconfigured or expanded as the volume of logistics processes increases or the working environment expands.

[0008] Due to the aforementioned drawbacks of existing conveyor systems, a new conveyor system is needed to address these issues. Specifically, a system is required that can flexibly adapt to changes in the logistics environment or system expansion, and that maximizes maintenance and operational efficiency. Furthermore, a new conveyor system with automated management capabilities is needed, enabling rapid module replacement and minimizing downtime in the event of system failure or performance degradation.

[0009] Existing Technical Documents

[0010] Patent Documents

[0011] Patent Document 0001: Korean Patent No. 10-2706195 (Publication Date: 2024.09.24) [Summary of the Invention]

[0012] In modern logistics and manufacturing environments, stationary conveyor systems have some limitations in terms of flexibility and maintenance. In particular, when logistics processes or production lines change, existing stationary systems require significant time and money to complete tasks such as route rerouting. Furthermore, if a part of the system fails, the entire production line will stop operating, which reduces operational efficiency and makes it difficult to minimize downtime during maintenance.

[0013] The problem this invention aims to solve is to provide a modular conveyor system capable of automatically managing multiple conveyor modules, instantly monitoring them, and quickly identifying and selecting the appropriate replacement module. This system minimizes downtime during maintenance based on module status information, enabling flexible operation, and allows for independent control and management of each module, maximizing the efficiency of logistics and the manufacturing environment.

[0014] Furthermore, in the system of the present invention, each module includes a unique power supply, CPU, communication, sensor, ID, etc., so data can be processed in real time and decisions can be made quickly based on the results.

[0015] According to an embodiment of the present invention, a modular conveyor management method may include the following steps: monitoring a conveyor system comprising multiple conveyor modules; determining, based on the monitoring results, whether a first conveyor module among the multiple conveyor modules needs to be replaced; determining the type of a second conveyor module to replace the first conveyor module; and notifying the user of at least one of whether the first conveyor module needs to be replaced or the determined type of the second conveyor module.

[0016] Each of the plurality of conveyor modules includes at least one of a power supply, a CPU, a communication line, a sensor, or a setting switch.

[0017] The setting switch may be a switch for setting at least one of the type or unique number of the conveyor module. The setting switch may be a DIP switch or a rotary switch. The DIP switch may be a binary-based switch, and the rotary switch may be a hexadecimal-based switch.

[0018] The types of the plurality of conveyor modules may include at least one of linear conveyor type, rotary conveyor type, merging conveyor type or branch conveyor type, wherein the rotary conveyor type may include a rotary conveyor type with multiple rotation angles.

[0019] The plurality of conveyor modules can be connected in parallel to form the conveyor system. Even if the power supply of a portion of the plurality of conveyor modules is cut off, the power supply of the other conveyor modules will not be cut off. Even if the communication of a portion of the plurality of conveyor modules is disconnected, the communication of the other conveyor modules will not be disconnected.

[0020] The first conveyor module needs to be replaced and the type of the second conveyor module can be determined based on information detected by sensors of multiple conveyor modules. The information detected by the sensors may include power supply, communication and other information related to items moving on each of the multiple conveyor modules.

[0021] A modular conveyor management system according to another embodiment of the present invention may include: one or more processors; and memory storing a computer program executed by the one or more processors, wherein when the computer program is executed, the one or more processors perform the following operations: monitoring a conveyor system including a plurality of conveyor modules; determining, based on the monitoring results, whether a first conveyor module among the plurality of conveyor modules needs to be replaced; determining the type of a second conveyor module to replace the first conveyor module; and notifying the user of at least one of whether the first conveyor module needs to be replaced or the determined type of the second conveyor module.

[0022] Each of the multiple conveyor modules may include at least one of a power supply, a CPU, a communication line, a sensor, or a setting switch.

[0023] The setting switch may be a switch for setting at least one of the type or unique number of the conveyor module. The setting switch may be a DIP switch or a rotary switch. The DIP switch may be a binary-based switch, and the rotary switch may be a hexadecimal-based switch.

[0024] The types of the plurality of conveyor modules may include at least one of linear conveyor type, rotary conveyor type, merging conveyor type or branch conveyor type, wherein the rotary conveyor type may include rotary conveyor type with multiple rotation angles.

[0025] The plurality of conveyor modules can be connected in parallel to form the conveyor system. Even if the power supply of a portion of the plurality of conveyor modules is cut off, the power supply of the other conveyor modules will not be cut off. Even if the communication of a portion of the plurality of conveyor modules is disconnected, the communication of the other conveyor modules will not be disconnected.

[0026] The first conveyor module needs to be replaced and the type of the second conveyor module can be determined based on information detected by sensors of multiple conveyor modules. The information detected by the sensors may include power supply, communication and other information related to items moving on each of the multiple conveyor modules.

[0027] According to another embodiment of the present invention, a computer program can be combined with a computing device to perform the following steps: monitoring a conveyor system including a plurality of conveyor modules; determining, based on the monitoring results, whether a first conveyor module among the plurality of conveyor modules needs to be replaced; determining the type of a second conveyor module to replace the first conveyor module; and notifying the user of at least one of whether the first conveyor module needs to be replaced or the determined type of the second conveyor module.

Implementation Method

[0039] Preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings. The advantages and features of the present invention, as well as methods of implementing them, will become apparent from the embodiments described in detail below in conjunction with the accompanying drawings. However, the technical concept of the present invention is not limited to the following embodiments and can be implemented in various different forms. The following embodiments are provided only to improve the technical concept of the present invention and to enable those skilled in the art to fully understand the scope of the present invention, which is defined only by the scope of the claims.

[0040] When affixing reference numerals to the constituent elements in each figure, the same constituent elements are assigned the same reference numerals as much as possible, even when shown in different figures. Furthermore, when describing various embodiments of the invention, detailed descriptions of related known structures or functions will be omitted if it is determined that such detailed descriptions may obscure the gist of the invention.

[0041] Unless otherwise defined, the terminology (including technical and scientific terms) used in the following embodiments may be used in the manner commonly understood by one of ordinary skill in the art to which this invention pertains. Furthermore, unless explicitly defined, terms defined in common dictionaries will not be ideally or over-interpreted. The terminology used in this invention is for illustrative purposes and is not intended to limit the scope of the invention. In this specification, singular expressions used in the following examples include plural concepts unless explicitly specified in the context.

[0042] Furthermore, terms such as first, second, A, B, (a), and (b) used in the following embodiments are only used to distinguish certain components from other components, and these terms are not intended to limit the nature or order of the components. When a component is described as "connected," "coupled," or "combined" to another component, the component may be directly connected or connected to that other component, but it may also be "connected," "coupled," or "combined" between each component.

[0043] As used in the specification, “comprises” and / or “comprising” means the presence of the mentioned components, steps, operations and / or elements, and does not exclude the presence or addition of one or more other components, steps, operations and / or elements.

[0044] FIG1 is a diagram showing a modular conveyor management system, a user terminal, and a network between the modular conveyor management system and the user terminal according to an embodiment of the present invention.

[0045] The modular conveyor management system 130 is a system that monitors multiple conveyor modules to monitor the status of each module in real time and determines whether a specific module needs to be replaced. Furthermore, it includes a function to determine the type of conveyor module to be replaced when necessary, and provides this determination result to the user to promote stable system operation. The modular conveyor management system 130 monitors the status of each conveyor module by communicating with the upper-level control system, and collects module-specific information such as power supply, CPU, communication modules, sensors, and ID in real time, playing an important role in automated maintenance and management tasks.

[0046] The user terminal 110 is connected to the modular conveyor management system 130 and receives information from the system regarding whether a specific conveyor module needs to be replaced and the type of conveyor module to be replaced. The user terminal 110 can be implemented in various forms, such as a smartphone, desktop computer, or tablet computer. Through the user terminal 110, the user can monitor the system status in real time and perform replacement work as appropriate. This allows the user to quickly replace modules without interrupting the logistics process and maximizes the flexibility and efficiency of system operation.

[0047] Network 120 can be implemented using various types of wired / wireless networks, such as Local Area Network (LAN), Wide Area Network (WAN), Mobile Radio Communication Network, Wireless Broadband Internet (Wibro), etc. Thus, user terminal 110 can communicate smoothly with modular conveyor management system 130 and exchange data in various ways depending on the network environment. Through this network connection, the system supports real-time data communication and quickly transmits the status of each conveyor module and whether replacement is needed.

[0048] The modular conveyor management system 130 improves the overall system operating efficiency, minimizes downtime that may occur during maintenance, and provides users with real-time information to perform optimal module replacement and management.

[0049] Figure 2 is an illustration showing a typical conveyor assembly used in logistics operations.

[0050] Reference numeral 210 indicates the conveyor body, designed to allow goods to move on the conveyor. This type of conveyor is used for the efficient transport of goods in large warehouses or manufacturing processes and operates automatically along a fixed route. Generally, the conveyor is installed continuously along the goods transport route, and power and communication systems must be installed for stable operation.

[0051] Reference numeral 220 indicates a communication and power cable. This cable is used to power the conveyor system and transmit various control signals, and is a crucial component of the system. However, in existing stationary conveyor systems, if the cable is physically damaged or broken, the operation of the entire conveyor line may cease. In particular, if the cable is damaged during maintenance work, it needs to be replaced immediately, which may lead to a system shutdown. Therefore, existing conveyor systems may be inefficient in terms of maintenance due to the fragility of these cables.

[0052] Reference numeral 230 indicates a cable duct, which is installed at the bottom of the conveyor and serves to physically protect the cables. Cable ducts protect power and communication cables, helping to protect them from external impacts or damage, but they are inconvenient to remove during maintenance. For example, when replacing a section of the conveyor belt or when a specific section of the conveyor is no longer in use, the cable duct needs to be removed and the cables disconnected. This process is very time-consuming and can be quite complex depending on the working environment.

[0053] Therefore, the existing conveyor system shown in Figure 2 has some limitations in terms of cable management and maintenance. In particular, the possibility of cable damage and the inconvenience of the maintenance process reduce the efficiency of the entire system, and these problems need to be improved by a new modular system.

[0054] Figure 3 is a diagram that briefly shows a module of a modular conveyor system according to an embodiment of the present invention.

[0055] Figure 3 shows how the modular conveyor system can be built and operated independently.

[0056] Reference numeral 310 indicates a power connection for supplying power to the module. The modular conveyor system is designed so that each module can receive power independently. This reduces interdependence between modules, ensuring that even if a particular module experiences a power failure, the operation of other modules will not be affected. This power separation structure increases system stability and allows for flexible responses during maintenance.

[0057] Reference numeral 320 indicates a communication line used for communication between modules. Each module communicates with the upper-level control system to monitor and control the module's status by exchanging data in real time. This allows modules to operate independently while maintaining connectivity with the entire system, and allows for rapid identification and replacement of faulty modules. The communication line can use various industrial communication protocols such as EtherCAT and RS485, allowing for flexible selection to meet system requirements.

[0058] Reference numeral 330 indicates a DIP switch used to set the unique ID of a module. In a modular conveyor system, each module must have a unique identification number so that the upper control system can identify and control each module. The DIP switch serves to set this unique number, and it can be easily set and reflected in the system when installing or replacing modules. The unique number set by the DIP switch is associated with the data of each module, playing an important role in preventing wiring mix-ups between modules throughout the system.

[0059] The module shown in Figure 3 consists of a power supply 310, a communication line 320, and a unique number setting switch 330. This configuration allows each module to operate independently while maintaining the consistency of the entire system. Furthermore, by providing independence and flexibility between modules, maintenance and system expansion are easy, and the interaction between modules can maximize the stability and performance of the system.

[0060] Therefore, the modular conveyor system according to an embodiment of the present invention solves the problems that may occur in existing fixed systems by setting independent power supply, communication and unique number for each module, and achieves more flexible and efficient operation in logistics and manufacturing environments.

[0061] Figure 4 is a drawing showing in detail a module of a modular conveyor system according to an embodiment of the present invention.

[0062] Figure 4 shows the components of each module and their interactions.

[0063] As illustrated in Figure 3, reference numerals 310 to 330 represent the power supply 310, the communication line 320, and the DIP switch 330 for setting a unique number, respectively. These components enable the module to operate independently and play an important role in integrating with the entire system to ensure smooth operation.

[0064] Reference numeral 410 indicates the CPU, which is the core control device of the module. The CPU processes data from each module and communicates with the upper-level control system to monitor and control the status of the modules. The CPU analyzes the status of the modules in real time based on the data input from the sensors. If a problem occurs, it is detected immediately and reported to the upper-level system. This improves the operating efficiency of the entire system and facilitates maintenance.

[0065] Reference numeral 420 indicates the sensor module, which is responsible for detecting various states of the module. The sensor module collects various data such as temperature, vibration, and power status in real time and transmits them to the CPU, playing an important role in predicting the possibility of module failure or detecting abnormal conditions. This maximizes the efficiency of maintenance work and minimizes system downtime.

[0066] Reference numeral 430 is the Driving Power Module, which is a device that provides the power required by the driving module. This module receives power from the main power supply 310 and transmits the power to the drive motor 440 of the conveyor. The driving power module helps the module operate smoothly by maintaining a stable power supply.

[0067] Reference numeral 440 is the driving module, which is the device that actually drives the conveyor belt. The driving module receives power from the drive power module 430 and rotates the conveyor belt to transport goods. Since each module can be driven independently, the system can operate more flexibly, and even if a problem occurs in a specific part, the other parts can still operate normally.

[0068] The modular conveyor system structure shown in Figure 4 allows for independent management of individual modules by combining power, communication, control, and sensor monitoring functions. This configuration maximizes ease of maintenance and ensures system flexibility and scalability, thereby significantly improving operational efficiency in logistics and manufacturing environments.

[0069] Figure 5 is a drawing showing the structure of multiple conveyor modules connected in series according to an embodiment of the present invention.

[0070] Figure 5 shows the structure in which each module operates independently and is integrated with the whole system. Figure 5 clearly demonstrates the scalability and flexibility of the modular conveyor system.

[0071] Reference numeral 510 is the first conveyor module (CONVEYOR #1), with a unique ID: 001000001. This ID is set in the form of a DIP switch as illustrated in Figure 6, with the first 3 digits indicating the module type and the last 6 digits indicating the unique number of each module. The first module is connected to the second module via power lines and communication lines.

[0072] Reference numeral 520 indicates the second conveyor module (CONVEYOR #2), ID: 001000002. The second module is a linear conveyor module of the same type as the first module, and is managed independently using the unique number 000002. This module is connected to the first module via power and communication cables, and the two modules can operate independently of each other.

[0073] Reference numeral 530 indicates the third conveyor module (CONVEYOR #3) and has ID: 002000003, signifying a curved module. This indicates that the modular conveyor system can connect modules of various shapes and sizes.

[0074] Reference numerals 511, 521, and 531 are schematic diagrams that briefly show the first, second, and third conveyor modules, respectively. This simplified diagram visually illustrates how each module is connected via power and communication lines.

[0075] In Figure 5, the power lines and communication lines are connected in parallel, so even if some components fail, the remaining modules can still operate normally. This parallel structure is an important design that can improve the reliability and stability of the system and has the advantage of allowing maintenance of individual modules without interrupting operation in logistics or manufacturing environments.

[0076] Therefore, the modular conveyor system shown in Figure 5 manages each module independently using an ID setting method, while providing flexibility when expanding or maintaining the system. The parallel connection of power and communication lines improves system stability and enables efficient operation in logistics and manufacturing environments.

[0077] Figure 6 is a diagram showing the configuration of a DIP switch according to an embodiment of the present invention.

[0078] Figure 6 illustrates the method for assigning a unique ID to each module of the modular conveyor system. The DIP switch is based on binary representation, and a unique binary value is set according to the ON / OFF state of the switch to determine the type and unique number of each module.

[0079] In the figure, reference numeral 610 indicates the part that sets the type of module, and reference numeral 620 indicates the part that sets the unique number of the module. Each switch can be set to 0 or 1, interpreted as 1 when in the ON state and 0 when in the OFF state.

[0080] The first area 610 of the DIP switch defines the module type. For example, 000 can represent a linear module and 001 can represent a curved module. This allows for the identification of various module types within the system. The second area 620 is used to set a unique identifier for the module. Each module must have a unique identifier within the system, and this number is set in binary. For example, 000001 can represent the first module, and 000010 can represent the second module.

[0081] In this way, the binary value set by the DIP switch is immediately reflected in the system, allowing each module to be managed by the upper-level control system. Users can change module settings through simple switch operations and easily set IDs when adding new modules or replacing existing modules.

[0082] The examples listed in this description are only some possibilities for DIP switch settings, but the invention is not limited thereto, and various module types or unique number systems can be used for settings. For example, the variety of module types can increase as the system expands, and the length of the unique number can also be extended or adjusted as needed. Therefore, the invention includes the possibility of flexible application to various situations.

[0083] FIG7 is a drawing showing the arrangement of a rotary switch according to an embodiment of the present invention.

[0084] Figure 7 illustrates how to set the type and unique number of each module in a modular conveyor system. This switch is used to set the module ID based on hexadecimal, which has a significant advantage over existing methods in that it can set more unique numbers and multiple module types.

[0085] Reference numeral 710 indicates the first area of ​​the rotary switch used to set the module type, corresponding to 610 in the DIP switch configuration of Figure 6. The rotary switch can select a hexadecimal value from 0 to F, which allows for more diverse settings for each module type. For example, 0 can represent a straight module, 1 can represent a curve module, 2 can represent a branching module, 3 can represent a merging module, etc. This expands the range of module types and enables various module configurations.

[0086] Reference numeral 720 is the second area of ​​the rotary switch used to set the unique number of the module, corresponding to 620 in Figure 6. This switch can also be set to a hexadecimal value from 0 to F, which assigns a unique identifier to each module. Compared to DIP switches using existing binary systems, the rotary switch can set more values ​​in a single digit, thus allowing for more unique numbers to be assigned. This is significant for improving management efficiency as the number of modules increases.

[0087] The rotary switch method provides the same functionality as the DIP switch method for setting module types and unique numbers, but the main difference is that more values ​​can be set at once. DIP switches use a binary-based ON / OFF representation, while rotary switches use a hexadecimal representation, allowing for a wider range of values ​​(0 to F). This allows for specifying more module types and unique numbers, simplifying management when the system expands or requires various modules.

[0088] Figure 8 is a diagram showing the types of various conveyor modules according to an embodiment of the present invention.

[0089] Figure 8 illustrates how the modular conveyor system can be flexibly configured to adapt to different logistics and production environments. Each module has different forms and functions, and can be used selectively according to specific circumstances.

[0090] Reference numeral 810 indicates a linear conveyor module with ID: 001. This module is the most commonly used type in logistics operations, responsible for transporting goods along a straight route. Linear conveyors are suitable for efficiently transporting goods at a constant speed in large warehouses or factories.

[0091] Reference numeral 820 is a merging conveyor module with ID: 002. Merging conveyors are used to combine two or more conveyor lines into one, and are particularly effective when the load on the conveyor is relatively small. The merging module can combine goods from multiple routes onto a single main route, simplifying the logistics process and improving work efficiency.

[0092] Reference numeral 830 is a branch conveyor module with ID: 003. Branch conveyors are used to split a route into two or more routes, and are particularly useful when the conveyor is loaded with a large amount of goods. In logistics operations, branch modules are very effective in separating specific items and transporting them to different routes. This allows for efficient logistics handling and prevents overloading.

[0093] Reference numeral 840 is a rotary conveyor (90-degree) module with ID: 004. This module is used to transport goods from a straight route to a curved route, mainly in situations where the logistics route is restricted or requires a change in the movement of goods. The 90-degree rotary conveyor improves space efficiency and maintains the flow of logistics operations by changing the route within a limited space.

[0094] Reference numeral 850 is a rotary conveyor (30 degrees) module with ID: 005. A 30-degree rotary conveyor can be used when you want to transport goods by slightly changing the route. This is very useful when fine-tuning the route is required or when a smooth transition in the logistics process is desired. For example, it can be effectively used on sections of a straight route where a slow change of direction is needed.

[0095] The merging module of 820 is used to effectively merge multiple routes into one when the number of items on the conveyor is less than a preset threshold. The branching module of 830 can be used to disperse items when overloaded, so as to achieve efficient handling and prevent overload. When it is necessary to change the position or route of items on the logistics line, the rotating modules of 840 and 850 can be used, so that flexible route design can be carried out in various working environments.

[0096] These modules can be combined to form modular conveyor systems suitable for various working environments. The form and function of each module help optimize workflows and improve logistics efficiency.

[0097] Figure 9 is a drawing showing the main components and interconnection structure of a modular conveyor system according to an embodiment of the present invention.

[0098] The components shown in Figure 9 operate independently and play an organic role in communication and control within the entire system.

[0099] 910 represents the power supply lines, connected in parallel. Parallel connection is a crucial element in increasing system stability and reliability. Because each module is powered independently, even if a problem occurs in the power supply lines of a specific section, the remaining modules can still operate normally. This increases system flexibility and allows maintenance personnel to replace or repair specific modules without shutting down the entire system.

[0100] 920 represents a communication line, which is also connected in parallel. The communication line exchanges data between modules and with the upper-level control system via industrial communication protocols such as EtherCAT and RS485. The parallel connection of the communication lines increases system reliability, so that even if the communication of a specific module is interrupted, it will not affect the communication of other modules. This allows the system to exchange data in real time and quickly detect and report the status of each module.

[0101] The processor shown in the figure serves as the control center of the module. The processor processes sensor data and I / O device input signals from each module in real time, thereby controlling the module's operation and reporting to the upper-level system. The processor can independently control each module and facilitate smooth interaction among all modules.

[0102] The communication module is responsible for data communication between the processor and external systems using protocols such as EtherCAT and RS485. Through the communication module, each module can exchange data with the upper-level control system, transmit status information in real time, and receive control commands from the upper-level control system.

[0103] The ID setting switch (DIP SWITCH) is a device that assigns a unique identification number to each module. This switch prevents confusion between modules and is an important element for distinguishing and managing modules. The ID can be set based on binary or hexadecimal, thus uniquely identifying each module.

[0104] An I / O module is an input / output device that connects to various external devices such as module sensors, motors, and emergency stop devices. Through an I / O module, data can be collected from sensors and drive devices such as motors can be controlled. For example, after processing data input from a sensor, the processor can send commands to drive or stop the motor via the I / O module. Furthermore, in the event of an emergency, the system can be immediately shut down using an emergency stop device.

[0105] Although these components operate independently, they can achieve efficient operation of the entire system through interconnected networks and communication systems. The parallel connection of power lines and communication lines improves system reliability and allows for flexible responses during maintenance or system expansion.

[0106] Figure 10 is a flowchart showing the process of a modular conveyor system management method according to an embodiment of the present invention.

[0107] Figure 10 illustrates the process of monitoring the status of conveyor modules, determining which modules need to be replaced, identifying the type of module to be replaced, and transmitting this information to the user in each step. Figure 10 systematically explains the automated management method of the modular conveyor system, with particular emphasis on the process of real-time detection of the status of each module and determination of which module to replace, in order to maximize the efficiency of the logistics process.

[0108] For S1010, in the conveyor system monitoring step, multiple modules included in the conveyor system are monitored in real time. Status information of each module is collected by sensors and communication modules, and the processor processes this information to analyze the module's status. Sensors provide real-time information on the power supply status, communication status, and item detection for each module. During this process, the system continuously confirms whether each module is operating normally or if any module is malfunctioning. This step allows for real-time understanding of the entire system's operating status and plays a crucial role in maintaining the reliability of the modular conveyor system.

[0109] Compared to S1020, in the step of determining whether the first conveyor module needs to be replaced, the system determines whether the first conveyor module needs to be replaced based on the data monitored by the system. In this step, the system can comprehensively analyze the sensor data and communication status of the module. If the module is not operating normally, is overloaded, or has an error, it is determined that it needs to be replaced.

[0110] In particular, the system can determine whether replacement is necessary based on the number of detected items. For example, if the number of detected item information in multiple modules exceeds a preset threshold, the system can detect the overload status of the corresponding module and determine that it needs to be replaced with a branch module that distributes the item flow. In this case, the system determines that the loading status of goods is too high, making it impossible to smoothly handle the logistics process, and replaces the module to alleviate the system's overload.

[0111] Conversely, if the detected item information is less than a preset threshold, the system can determine that it is more efficient to switch to a merging module that combines items scattered across multiple routes into one. In this case, since the number of goods is small, there is no need to process them through existing routes, and the system selects the merging module to integrate the logistics process and improve processing efficiency.

[0112] On the other hand, in the present invention, the threshold can be determined based on the maximum weight, maximum volume, etc. that the conveyor belt can handle.

[0113] Furthermore, even if a change in the logistics route is required, the system can determine whether a replacement is necessary. For example, when it is necessary to change the direction of product movement or switch the flow of goods to a different route due to changes in the working environment, the system identifies that the existing linear module needs to be replaced with a rotating module. At this time, the system can consider the changes in the logistics process and determine the appropriate rotation angle for the module.

[0114] Therefore, in step S1020, based on sensor data, various factors such as module malfunction, cargo quantity, and changes in logistics routes are considered to determine whether replacement is necessary. The system automatically detects problems, determines whether immediate replacement is required, and formulates the optimal replacement plan to address situations such as overload, the need to integrate logistics processes, or route changes.

[0115] For S1030, the step of determining the type of the second module used to replace the first conveyor module is a process of determining the appropriate type of module to replace the first module that needs to be replaced. The system determines the type of the second module by analyzing the ID setting information and type setting information of each module and the data detected in real time. At this time, the system can select a suitable module according to the working environment.

[0116] For example, if sensors installed on multiple conveyor modules detect an excessive number of items, the system can select a branching module. Branching modules divide the logistics process into two or more routes, preventing overloading and efficiently handling goods. Conversely, if the number of items is small, the system can select a merging module to combine goods from multiple routes into one. When there are fewer items, merging modules improve processing efficiency by combining items from multiple routes into one.

[0117] Additionally, if it is necessary to change the movement route of the items, the system can select a rotating module. A 90-degree or 30-degree rotating module can be useful when changing the direction of the logistics route or transporting goods along a curved route. In this way, the system determines the optimal module type based on the working environment, the condition of the items, and the requirements of the logistics process. This step plays a crucial role in enabling the system to flexibly select modules and maximize work efficiency.

[0118] For S1040, the system notifies the user whether the first conveyor module needs to be replaced and the type of the second module. This notification is transmitted via the user terminal or the upper-level system, allowing the user to quickly perform the replacement. This step provides not only information on whether a module needs to be replaced, but also information on the specific type of the second module to be replaced (e.g., linear, branching, rotary, etc.). The user can take necessary actions based on the provided information and perform the appropriate replacement operation according to the system's recommendations.

[0119] This step also allows for real-time tracking of the progress of the replacement work, which can improve the efficiency of system maintenance. In addition, users can quickly respond to changes in the logistics process based on the information provided by the system, and selectively replace other modules as needed.

[0120] Therefore, the flowchart shown in Figure 10 systematically explains a series of processes, including real-time monitoring of each module of the modular conveyor system, determining whether to replace them, identifying the appropriate replacement module, and quickly notifying the user. This can improve system maintenance efficiency and provide a rapid response to workflow issues.

[0121] FIG11 is a block diagram showing the hardware configuration of a computing device for modular conveyor management according to an embodiment of the present invention.

[0122] Referring to FIG11, the computing device 5000 may include one or more processors 5010, a bus 5060, a communication interface 5020, memory 5040 for loading a computer program executed by the processor 5010, and auxiliary memory 5030 for storing the computer program 5050. However, FIG11 only shows components relevant to embodiments of the present invention. Therefore, those skilled in the art should understand that other general components may be included in addition to those shown in FIG11. That is, the computing device 5000 may include various components in addition to those shown in FIG11. Furthermore, in some cases, the computing device 5000 may be configured to omit some components shown in FIG11. The components of the computing device 5000 will be described below.

[0123] The processor 5010 can control the overall operation of the various components of the computing device 5000. The processor 5010 may include at least one of a CPU (Central Processing Unit), MPU (Micro Processor Unit), MCU (Micro Controller Unit), GPU (Graphic Processing Unit), NPU (Neural Processing Unit), or any processor known in the art. Furthermore, the processor 5010 can execute operations of at least one application or program for performing operations / methods according to various embodiments of the present invention. The computing device 5000 may include one or more processors.

[0124] Furthermore, memory 5040 can store various data, commands, and / or information. Memory 5040 can load computer program 5050 from auxiliary memory 5030 to perform operations / methods according to various embodiments of the present invention. Memory 5040 can be implemented as volatile memory such as RAM, but the scope of the present invention is not limited thereto.

[0125] Furthermore, bus 5060 can provide communication functions between components of computing device 5000. Bus 5060 can be implemented as various types of buses, such as address bus, data bus, and control bus.

[0126] Furthermore, the communication interface 5020 can support wired / wireless Internet communication of the computing device 5000. In addition, the communication interface 5020 can support various communication methods other than Internet communication. Therefore, the communication interface 5020 may include communication modules known in the art.

[0127] Furthermore, the auxiliary memory 5030 can non-temporarily store one or more computer programs 5050. The auxiliary memory 5030 may include non-volatile memory such as ROM (Read Only Memory), EPROM (Erasable Programmable ROM), EEPROM (Electrically Erasable Programmable ROM), flash memory, hard disk, removable magnetic disk, or any type of computer-readable recording medium known in the art.

[0128] Furthermore, the computer program 5050 may include one or more instructions that, when loaded into the memory 5040, cause the processor 5010 to perform operations / methods according to various embodiments of the present invention. That is, the processor 5010 may perform operations / methods according to various embodiments of the present invention by executing one or more instructions.

[0129] For example, computer program 5050 may include multiple instructions to perform the following operations: monitoring a conveyor system including multiple conveyor modules; determining, based on the monitoring results, whether a first conveyor module among the multiple conveyor modules needs to be replaced; determining the type of a second conveyor module to replace the first conveyor module; and notifying the user of at least one of whether the first conveyor module needs to be replaced or the determined type of the second conveyor module.

[0130] According to an embodiment of the present invention, the management method of the modular conveyor system can effectively solve various problems that may occur in existing fixed conveyor systems. Existing fixed systems lack flexibility, are difficult to respond immediately to changes in the logistics environment, and have many limitations in terms of maintenance and scalability. In addition, once a failure occurs, the entire system will inevitably stop, which may seriously affect operational efficiency.

[0131] To address this problem, the present invention introduces a modular conveyor system that provides a solution for instantly monitoring the status of each module, quickly determining which modules need to be replaced, and then identifying and managing the type of modules to be replaced. This overcomes the limitations of existing systems and maximizes maintenance and management efficiency.

[0132] Specifically, the modular conveyor system of the present invention can be expected to achieve the following effects:

[0133] a) In terms of flexibility and scalability, systems with a modular design can quickly respond to changes in the logistics environment or operational requirements. For example, as logistics processes change, new routes can be easily set up or additional modules can be installed, thereby improving operational efficiency. Unlike fixed systems, modular structures offer flexibility and can easily adapt to changes in warehouses or production lines.

[0134] b) In terms of maintenance, the status of each module can be detected in real time, and faulty modules can be quickly replaced, allowing maintenance to be performed without interrupting the entire system. In particular, the parallel structure of communication and power lines ensures that even if some lines break, the remaining modules can still operate normally, thereby minimizing downtime. This helps improve system reliability and maximize operational efficiency.

[0135] C) In terms of cost efficiency, by accurately determining when module replacement is needed, unnecessary module replacements can be prevented and costs reduced. Existing fixed systems have high overall maintenance costs, but this invention can effectively manage costs by replacing only the necessary modules when necessary. This has the effect of reducing operating costs and long-term maintenance costs.

[0136] In this way, the modular conveyor system management method of the present invention can solve the problems of existing systems and achieve more efficient and flexible logistics management. The system can flexibly respond to changes in the logistics process and optimize maintenance work through real-time monitoring, which plays an important role in reducing costs and improving system uptime.

[0137] Various embodiments of the present invention and the effects according to the embodiments have been described above with reference to Figures 1 to 11. The effects of the technical concept of the present invention are not limited to the above-described effects, and those skilled in the art will clearly understand other effects not mentioned from the following description.

[0138] Furthermore, although the above embodiments illustrate the combination of multiple components into one or more operations, the technical concept of the present invention is not necessarily limited to these embodiments. That is, within the scope of the technical concept of the present invention, all components can be selectively combined in one or more combinations to operate.

[0139] Although multiple operations are shown in a specific order in the accompanying drawings, it should not be understood that the multiple operations must be performed in the specific order shown or sequentially, or that all of the shown operations must be performed to obtain the desired result. In some cases, multitasking and parallel processing may be more advantageous. Moreover, the separation of the various components in the above embodiments should not be construed as requiring such separation; the described program components and systems can generally be integrated together as a single software product, or packaged into multiple software products.

[0140] Although various embodiments of the invention have been described with reference to the accompanying drawings, those skilled in the art will understand that the technical concept of the invention can be implemented in different specific forms without altering the technical concept or essential characteristics of the invention. Therefore, the above embodiments should be understood as illustrative in all respects and not restrictive. The scope of protection of the invention should be interpreted by the appended claims, and all technical concepts within the equivalent scope should be interpreted as being included within the scope of the technical concept defined in this invention. [Simplified Explanation of the Diagram]

[0028] Figure 1 is a diagram showing a modular conveyor management system, user terminal and network according to an embodiment of the present invention.

[0029] Figure 2 is an attached diagram showing the components of the conveyor.

[0030] Figure 3 is a diagram that briefly shows a module of a modular conveyor system according to an embodiment of the present invention.

[0031] Figure 4 is a drawing showing in detail a module of a modular conveyor system according to an embodiment of the present invention.

[0032] Figure 5 is a drawing showing the structure of multiple conveyor modules connected in series according to an embodiment of the present invention.

[0033] Figure 6 is a drawing showing the configuration of a DIP switch according to an embodiment of the present invention.

[0034] FIG7 is a drawing showing the arrangement of a rotary switch according to an embodiment of the present invention.

[0035] Figure 8 is a diagram showing the types of various conveyor modules according to an embodiment of the present invention.

[0036] Figure 9 is a drawing showing the main components and interconnection structure of a modular conveyor system according to an embodiment of the present invention.

[0037] Figure 10 is a flowchart showing the process of a modular conveyor system management method according to an embodiment of the present invention.

[0038] FIG11 is a block diagram showing the hardware configuration of a computing device for inventory health management according to an embodiment of the present invention.

Claims

1. A modular conveyor management method, executed by a computing device, comprising the following steps: monitoring a conveyor system including multiple conveyor modules to obtain monitoring results; determining, based on the monitoring results, whether a first conveyor module among the multiple conveyor modules needs to be replaced; determining the type of a second conveyor module to replace the first conveyor module; and notifying a user of at least one of whether the first conveyor module needs to be replaced or the determined type of the second conveyor module, wherein... The multiple conveyor modules are connected in parallel to form the conveyor system. Even if the power supply of some of the multiple conveyor modules is cut off, the power supply of the other conveyor modules will not be cut off. Even if the communication of some of the multiple conveyor modules is disconnected, the communication of the other conveyor modules will not be disconnected. The step of determining the type of the second conveyor module includes determining that the type of the second conveyor module is a branch conveyor type when the number of items moving on the multiple conveyor modules exceeds a preset threshold, and determining that the type of the second conveyor module is a merging conveyor type when the number of items is less than the preset threshold.

2. As in request item 1, the modular conveyor management method, wherein, Each of the multiple conveyor modules includes at least one of a power supply, a CPU, a communication line or a setting switch, and a sensor.

3. As in request item 2, the modular conveyor management method, wherein, The setting switch is used to set at least one of the type or unique number of the conveyor module. The setting switch is a DIP switch or a rotary switch. The DIP switch is a binary-based switch, and the rotary switch is a hexadecimal-based switch.

4. As in Request 1, the modular conveyor management method, wherein, The types of the multiple conveyor modules include at least one of linear conveyor type, rotary conveyor type, merging conveyor type or branch conveyor type, and the rotary conveyor type includes rotary conveyor type with multiple rotation angles.

5. The modular conveyor management method as described in request item 1, wherein, The step of determining the type of the second conveyor module further includes determining that the type of the second conveyor module is a rotary conveyor type when the movement path of the items moving on the plurality of conveyor modules needs to be changed.

6. The modular conveyor management method as described in request item 2, wherein, Based on the information detected by the sensors of each of the plurality of conveyor modules, it is determined whether the first conveyor module needs to be replaced and the type of the second conveyor module. The information detected by the sensors includes power supply, communication and other information related to the items moving on each of the plurality of conveyor modules.

7. A modular conveyor management system, wherein, include: One or more processors; and memory storing a computer program executed by the one or more processors, wherein when the computer program is executed, the one or more processors perform the following operations: monitoring a conveyor system comprising multiple conveyor modules to obtain monitoring results; determining, based on the monitoring results, whether a first conveyor module among the multiple conveyor modules needs to be replaced; determining the type of a second conveyor module to replace the first conveyor module; and notifying the user of at least one of whether the first conveyor module needs to be replaced or the determined type of the second conveyor module. The multiple conveyor modules are connected in parallel to form the conveyor system. Even if the power supply to some of the multiple conveyor modules is cut off, the power supply to the other conveyor modules will not be cut off. Even if the communication of some of the multiple conveyor modules is disconnected, the communication of the other conveyor modules will not be disconnected. The operation of determining the type of the second conveyor module includes determining the type of the second conveyor module as a branch conveyor type when the number of items moving on the multiple conveyor modules exceeds a preset threshold, and determining the type of the second conveyor module as a merging conveyor type when the number of items is less than the preset threshold.

8. As in request item 7, a modular conveyor management system, wherein, Each of the multiple conveyor modules includes at least one of a power supply, a CPU, a communication line or a setting switch, and a sensor.

9. As in request item 8, a modular conveyor management system, wherein, The setting switch is used to set at least one of the type or unique number of the conveyor module. The setting switch is a DIP switch or a rotary switch. The DIP switch is a binary-based switch, and the rotary switch is a hexadecimal-based switch.

10. The modular conveyor management system as described in request item 7, wherein, The types of the multiple conveyor modules include at least one of linear conveyor type, rotary conveyor type, merging conveyor type or branch conveyor type, and the rotary conveyor type includes rotary conveyor type with multiple rotation angles.

11. As in request item 7, a modular conveyor management system, wherein, The operation of determining the type of the second conveyor module further includes determining that the type of the second conveyor module is a rotary conveyor type when the movement path of the items moving on the plurality of conveyor modules needs to be changed.

12. As in request item 8, a modular conveyor management system, wherein, Based on the information detected by the sensors of each of the plurality of conveyor modules, it is determined whether the first conveyor module needs to be replaced and the type of the second conveyor module. The information detected by the sensors includes power supply, communication and other information related to the items moving on each of the plurality of conveyor modules.

13. A computer program, in conjunction with a computing device, performs the following steps: monitoring a conveyor system comprising multiple conveyor modules to obtain monitoring results; determining, based on the monitoring results, whether a first conveyor module among the multiple conveyor modules needs to be replaced; determining the type of a second conveyor module to replace the first conveyor module; and notifying a user of at least one of whether the first conveyor module needs to be replaced or the determined type of the second conveyor module, wherein... The multiple conveyor modules are connected in parallel to form the conveyor system. Even if the power supply of some of the multiple conveyor modules is cut off, the power supply of the other conveyor modules will not be cut off. Even if the communication of some of the multiple conveyor modules is disconnected, the communication of the other conveyor modules will not be disconnected. The step of determining the type of the second conveyor module includes determining that the type of the second conveyor module is a branch conveyor type when the number of items moving on the multiple conveyor modules exceeds a preset threshold, and determining that the type of the second conveyor module is a merging conveyor type when the number of items is less than the preset threshold.

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