Method of setting a conveyor arrangement into operation

Abstract

Method of setting a conveyor arrangement (1) into operation, the conveyor arrangement (1) comprising, - a plurality of conveyor zones (2), each conveyor zone (2) is adapted to convey an object (9) from an inlet (I) of said conveyor zone (2) to an outlet (O) of said conveyor zone (2), - a plurality of zone controllers (11) adapted to control the operation of said conveyor zones (2); the method comprising the following steps: - providing a plan (1P) of a planned conveyor arrangement (1); - assembling the conveyor arrangement (1) according to said plan (1P) at an installation site.

Description

[0001] Method of setting a conveyor arrangement into operation

[0002] Description

[0003] The invention refers to method of setting a conveyor arrangement into operation.

[0004] WO 2024 / 149872 A1 discloses a method for planning a conveyor arrangement comprising the following steps: using an IT planning tool by a user; by using the IT planning tool, arranging representations of a plurality of conveyor zones in a manner, so that an inlet of an downstream conveyor zone is linked to an outlet of an upstream conveyor zone; within the IT planning tool defining a plurality of destinations; performing an automated analysis of the arranged representations; based on the performed automated analysis, automatically generating a destination look up table, in particular a plurality of individual destination look up tables, indicating a list of zones and / or destinations, which are located downstream of each of the outlets of the respective junction zones.

[0005] EP 3292 056 B1, also published as US 2021 / 0323772 A1 discloses a method for setting up a control unit in a conveying arrangement, wherein a zone controller controls one or more conveying zones. Each conveying zone comprises a conveying drive for conveying an object through the conveying zone. The zone controller performs a self-configuration. The zone controller thereby receives a signal from each motor connection socket or sensor connection socket and determines from the comparison of the signal with a comparison value whether a conveying drive or a sensor is connected to a motor connection socket or sensor connection socket.

[0006] US 2018 / 0162652 A1 discloses an integrated control system for conveyor systems that combines design, simulation, and operational control within a unified software environment. The system includes a design component for creating conveyor layouts, a test component with a PLC emulator for simulating system behavior, and a SCADA component for real-time monitoring and control. A key feature is the use of standardized PLC logic that interprets configuration data downloaded from the design tool, allowing flexible deployment across different conveyor configurations without rewriting PLC code. The system enables simulation and emulation of conveyor logic before physical installation, allowing users to test operational scenarios and identify logical issues early.

[0007] US 2022 / 0112036 A1 discloses a method for manufacturing a conveyance device that centers around the use of simulation prior to physical assembly. A key innovation is the virtual operation confirmation step, in which the behavior of the conveyance system is simulated using a software-based environment before any hardware is built or installed. This simulation is based on control logic and operational parameters assigned to virtual representations of the system’s zone controllers and conveyance units. The simulation allows to visualize the motion of conveyed objects, test control logic, and adjust parameters such as speed, timing, and routing behavior. Importantly, this process occurs before the actual conveyance units are assembled, enabling early detection and correction of functional mismatches or unrealistic assumptions. Once the simulated behavior aligns with the desired operation, the system is assembled and the finalized parameters are transferred to the physical controllers.

[0008] It is the object of the present invention to provide an easy way of installing a conveyor arrangement having a plurality of conveyor zones.

[0009] The invention comprises a method according to the main claim; embodiments are subject of the subclaims and the description.

[0010] The term “commissioning tool” refers in particular to a systematic and integrated support tool that supports in ensuring specific systems or equipment functionalities according to their intended functionality and the owner’s operational needs. It involves thorough tests, inspections, and documentation to verify that all components work efficiently together.

[0011] It is used for newly-built arrangements or those still in the design and construction phases. It ensures, that all components of the conveyor arrangement operate as intended and helps identify any defects early on.

[0012] This invention proposes a method for efficiently setting a modular conveyor arrangement into operation. In particular it simplifies the commissioning process by using a digital plan created in particular with an IT planning tool and verifies, in particular with a commissioning tool the physical assembly. Each conveyor zone is controlled by a local zone controller, which can be preconfigured and preassembled into modules. During installation or afterwards, the actual configuration of the assembled arrangement is compared with the planned configuration, automatically detecting any mismatches in wiring or controller placement.

[0013] One particular aspect is the ability of each zone controller to identify its neighboring controllers in particular via a bus connection. This allows the system to detect structural faults such as incorrect wiring or misplacement of modules. The commissioning tool visualizes these deviations, enabling technicians to quickly identify and correct errors. This approach significantly reduces setup time, increases reliability, and supports scalable, modular conveyor systems. The inventive method involves setting a conveyor arrangement into operation. The arrangement includes multiple conveyor zones. Each conveyor zone is adapted to convey an object from an inlet to an outlet. The arrangement also includes multiple zone controllers adapted to control the operation of the conveyor zones. The method includes providing a plan of a planned conveyor arrangement and assembling the conveyor arrangement according to this plan at an installation site. This forms the foundation of the invention by ensuring that the arrangement is built and operated based on a structured and predefined plan.

[0014] In an embodiment, the method includes providing a commissioning tool and connecting the commissioning tool to a plurality of the zone controllers at the installation site via a data connection, in particular a data bus. The commissioning tool has data access to the plan. This enables the system to verify the physical assembly against the digital plan, allowing for automated validation and error detection.

[0015] In an embodiment, the method includes obtaining assembly information from the connected zone controllers. The method further includes evaluating the obtained assembly information with the plan and generating deviation information. In particular, the deviation information comprises a determined difference between the obtained assembly information and a planned assembly information within the plan. This allows the system to automatically detect discrepancies between the planned and actual assembly, which is essential for ensuring correct installation.

[0016] In the context of the present invention, assembly information refers to data that describes how the components of a conveyor arrangement, such as conveyor zones and zone controllers, are physically and logically connected. This information is essential for verifying whether the system has been assembled correctly according to the intended design. There are two key types of assembly information:

[0017] Planned Assembly Information: This is the information generated during the planning phase of the conveyor arrangement. It is created using an IT planning tool and forms part of the digital plan of the system. The planned assembly information includes at least one or more of: the intended spatial layout of conveyor zones, the allocation of zone controllers to specific zones, the expected neighboring relationships between controllers and zones, the planned sequence of connections in the daisy-chain bus network: This information represents the target configuration that the physical assembly should match.

[0018] Obtained Assembly Information: This is the information collected from the actual, physically assembled conveyor arrangement. It is gathered in particular by the commissioning tool through communication with the installed zone controllers. The obtained assembly information includes at least one or more of: the real-time identification of neighboring controllers, the actual connections established via the bus system, the current configuration and identity of each controller: This data reflects the real-world state of the system after installation.

[0019] In an embodiment, the method includes obtaining assembled neighboring information describing a neighboring relation between assembled components within the assembled conveyor arrangement. The method further includes comparing the assembled neighboring information with planned neighboring information describing a planned neighboring relation between the components within the planned conveyor arrangement. The method includes generating deviation information indicating a deviation between the assembled neighboring information and the planned neighboring information.

[0020] In the context of the present invention, neighboring information refers to data that describes the logical or physical adjacency between components of the conveyor arrangement, particularly between zone controllers and between conveyor zones. This information is helpful for verifying whether the system has been assembled correctly and whether the communication and control structure matches the intended design. This helps identify structural faults such as incorrect wiring or misplacement of modules by comparing actual physical connections with the intended design.

[0021] In an embodiment, the method includes providing the deviation information as a user output. This ensures that any detected errors are clearly communicated to the user, making it easier to locate and correct faults during commissioning.

[0022] In an embodiment, the method includes a neighboring check step, in which each zone controller determines an identity of its neighboring zone controllers. In particular, the result of the neighboring check step comprises assembled neighboring information. This supports decentralized verification, where each controller contributes to the validation process, improving scalability and robustness.

[0023] In an embodiment, the plan comprises position data of each conveyor zone, in particular an absolute position or a spatial relation data between the conveyor zones. This enables spatial validation of the conveyor layout, ensuring that each zone is placed correctly according to the plan.

[0024] In an embodiment, the plan comprises position data of each zone controller, in particular an absolute position or a spatial relation to an individual conveyor zone. This helps verify that each controller is not only connected correctly but also physically located as intended. In an embodiment, the plan is generated by an IT planning tool. In particular, the IT planning tool is separate from the commissioning tool. This separation allows for a modular system architecture, where planning and commissioning can be handled independently and flexibly.

[0025] In an embodiment, the method includes providing the zone controller with an individual initial configuration. In particular, the initial configuration is based on the plan. The initial configuration is provided on the zone controller before assembling the conveyor arrangement on the installation site. This enables pre-configuration of controllers, reducing setup time and ensuring readiness for operation upon installation.

[0026] In an embodiment, the method includes preassembling at least two conveyor zones to a common conveyor zone preassembly at a preassembly site. The conveyor zone preassembly comprises a zone controller adapted to control at least one of the conveyor zones within the zone preassembly. This supports modular construction, allowing for efficient and error-reduced assembly through the use of preassembled units. By providing the preassembled zone with a zone controller, a faulty assembly of the conveyor zone preassembly at the installation site can be detected by means of the zone controller. In other words: The zone controller attached to the conveyor zone preassembly is the “intelligence” attached to the preassembly, which supports in finding faulty assemblies.

[0027] In an embodiment, the method includes transporting the conveyor zone preassembly from the preassembly site to the installation site. The method further includes connecting a plurality of preassemblies to obtain the conveyor arrangement at the installation site. This facilitates efficient deployment of the system, translating the modular design into practical benefits during installation.

[0028] In an embodiment, after assembling the conveyor arrangement, the method includes providing the zone controller with an individual full configuration by means of the commissioning tool. Allocating the full configuration to an individual zone controller is done by means of the initial configuration. This enables a two-step configuration process, where each controller receives the correct operational data while maintaining flexibility during installation.

[0029] A particular advantage of the invention lies in its ability to detect incorrect placement of a conveyor zone preassembly. Since each conveyor zone preassembly comprises at least one zone controller, the neighboring check, described in detail above, can be used to verify whether the preassembly is installed at its intended position. If the zone controller of a conveyor zone preassembly is connected to unexpected neighboring controllers, it can be identified as a deviation from the planned configuration. This allows structural errors, such as swapped or misplaced preassemblies, to be detected automatically and efficiently and repaired fast, thereby reducing commissioning time and avoiding operational faults caused by incorrect assembly.

[0030] An example embodiment of the invention is described in more detail with the help of the figures; herein show fig. 1 a conveyor zone in perspective view having a first embodiment light barrier; fig. 2 a basic conveyor arrangement; fig. 3 schematic representations of different conveyor zones; fig. 4 an IT planning tool showing a layout of a planned conveyor arrangement, showing a plurality of conveyor zones; fig. 5 the IT planning tool of figure 4 showing zone controller intended to control said zones within said planned conveyor arrangement; fig. 6 a) a table showing neighboring information of the planned conveyor arrangement of figure 4, b) a destination look up table valid for zone 2i of the planned conveyor arrangement of figure 4, c) a control ID table showing identification of the zone controllers of figure 5 and neighboring information of said zone controller according to a plan of the planned conveyor arrangement, d) a control ID table showing identification of the zone controllers of figure 5 and neighboring information of said zone controller according to a determined situation of the assembled conveyor arrangement, e) control zone allocation table showing the allocation of a zone controller to a conveyor zone, which is controlled by said zone controller; fig. 7 a process of uploading an initial configuration to a plurality of unconfigured zone controller; fig. 8 two assembled preassemblies of the planned conveyor arrangement according to figure 4; fig. 9 - 11 a commissioning tool for setting the assembled conveyor arrangement into operation in different situation during installation. Figure 1 shows an exemplary conveyor zone 2, comprising several conveyor rollers 3 which are driven together. For this purpose, one of the conveyor rollers 3 is designed as a motor- driven conveyor roller 3M, in particular motorized roller 3M. The motor-driven conveyor roller 3M is driven in particular by a three-phase motor arranged in the motorized conveyor roller 3M. Via one or more drive connectors 4, e.g. a drive belt, the conveyor rollers 3 of a conveyor zone 2 are drive-connected to each other and are jointly driven by the motor-driven conveyor roller 3M. An object 9 is linearly conveyed from an inlet I to an outlet O along a conveying direction d.

[0031] By means of a presence sensor 5, the presence of a conveyed object 9 arranged within the conveyor zone 2 can be determined. The presence sensor 5 thereby generates a sensor signal S5, which is connected via a signal line (not shown) to a local zone controller 11 presented further below. In the present embodiment the presence sensor 5 is a light barrier.

[0032] The conveyor rollers 3 and the presence sensor 5 are attached to a common support frame 6. The conveyor rollers 3 of several conveyor zones 2 can be attached to a common support frame 6.

[0033] The motor-driven conveyor rollers 3M are each controlled by at least one or a plurality of local zone controllers 11. A single zone controller 11 can control the motor-driven conveyor rollers 3M of several conveyor zones 2. A plurality of local zone controllers 11 are arranged in a conveyor arrangement 1 (figure 2), which communicate with each other via a bus connection 13.

[0034] Figure 2 shows a basic conveyor arrangement 1 , where conveyor zones 2a... e as described previously are used. A plurality of zone controllers 11 control the operation of the conveyor zones 2. A central controller 14 (e.g. programmable logic control) may be provided to control the overall operation of the conveyor arrangement 1.

[0035] Scanners (not shown) may be arranged along the conveyor zones 2 and provide identification data relating to objects 9 passing the scanner in the conveyor zones 2. These identification data are sent via bus connection 13 to the PLC 14. The PLC 14 has access to an object data base (not shown), which provides destination data based on the identification of the objects 9. Based on the acquired data the PLC 14 provides operation instructions to a local zone controller 11 , how to handle the object 9, i.e. to which of the outlets O said object 9 is to be conveyed. For the proper operation it is not required that each conveyor zone is equipped with an own scanner for identifying the object located in each conveyor zone. As a consequence, some conveyor zones, usually one of the most upstream zones, are provided merely with a sensor for detecting merely the presence of an object 9, without identifying the object 9. As described in European patent application 22 180 381.0, instead of a PLC or similar local zone controllers 11 may connected to a common higher-level object data broker (as the central controller), in particular via the bus connection 13, with which the local zone controllers are also connected to one another. The data broker provides destination data related to the identified objects 9 and the zone controllers 11 are adapted to control operation of the zones based on the provided destination data. For the purpose of the present invention the provision of a PLC is not required.

[0036] In particular the local zone controllers 11 control the motor-driven conveyor rollers 3M in such a way that the successively approaching conveyed objects 9 do not collide with each other. The control takes place in such a way that essentially only one conveyed object 9 is present per conveyor zone 2. However, slight overlaps may occur. For example, an upstream conveyed object 9b located on an upstream conveyor zone 2c may already enter a downstream conveyor zone 2d even though the downstream conveyed object 9a has not yet left this downstream conveyor zone 2d completely. Among other things, the sensor signals S5 of the presence sensors 5 serve as input variables here, although it is ensured that the two conveyed objects 9 do not touch and thus do not damage each other.

[0037] In the following course of the invention, reference is made to conveyor zones, using a schematic representation of said conveyor zones 2 as shown in figure 3. Here figure 3a represents schematically a conveyor zone 2 of figure 1 , which has one first inlet 11 and one first outlet 01. No more inlets and outlets are provided. The conveyor zone 2 can also be curved or from other shape.

[0038] Figure 3b shows the representation of another conveyor zone 2 having an extended scope of operation. Here in addition to the conveyor zone 2 of figure 3a the conveyor zone 2 has an additional, second outlet 02. The object 9 can be conveyed selectively from said first inlet 11 to one of said first and second outlets 01, 02. Optionally, the conveyor zone 2 has an additional, third outlet 03. In this option, the object 9 can be conveyed selectively from said first inlet 11 to one of said first, second and third outlets 01 , 02, 03.

[0039] As an example, said conveyor zone 2 of figure 3b can be formed by a conveyor zone 2 as shown in figure 1, which additionally is provided with a transfer device as described with reference to figure 5 of EP 3222 564 B1 (in this document and figure the transfer device is marked with the reference sign “20”).

[0040] Figure 3c shows the representation of a conveyor zone 2 having an extended scope of operation. Here in addition to the conveyor zone 2 of figure 3a, the conveyor zone 2 has an additional second inlet 12. Objects 9 can be conveyed from one of said first and second inlets 11 , I2 to said first outlet 01.

[0041] The transfer device as described with reference to figure 3b may also be suitable to provide said additional second inlet I2.

[0042] Figure 3d shows the representation of a conveyor zone 2 having an extended scope of operation. Here in addition to the conveyor zone 2 of figure 1 the conveyor zone has an additional second inlet I2 and an additional second outlet 02 and is an example as a combination of the embodiments of figures 3b and 3c.

[0043] The conveyor zones 2 each are controlled by a local zone controller 11 as shown in figure 1 or 2, in particular wherein one local zone controller 11 may be adapted to control the operation of more than one conveyor zone 2.

[0044] Reference is made to figure 4. Here position data 15P of a plan 1P of a conveyor arrangement 1 are shown in a graphical manner during planning the conveyor arrangement within a IT planning tool 20, which is described in more detail in International patent application WO 2024 / 149872 A1. The planned conveyor arrangement 1 comprises a plurality of conveyor zones 2 as shown in figure 3 in their absolute position and / or spatial relation to other conveyor zones within the conveyor arrangement. For better individualization, the conveyor zones are provided with indices 2a0 - 2a7, 2e - 2q, 2r0 - 2r9, 2s0 - 2s9.

[0045] The conveyor arrangement 1 comprises at least one feed-in station F1 , F2, where objects 9 can be put into the conveyor arrangement 1. The feed-in station F1, F2 may be attached to an outlet of an upstream conveyor arrangement (not shown). Close to the feed-in stations an identification scanner 7 is provided detecting an identification tag 97 (see figure 1) of objects 9 to be conveyed during normal operation. The identification scanner 7 may be a barcode I QR- Code reader or an RFID reader, depending on the identification tag 97 attached to an object.

[0046] The conveyor arrangement 1 comprises a plurality of destinations D1 - D16, to which an object 9 can selectively be conveyed.

[0047] Most conveyor zones 2 are of the type shown in figure 3a, merely having one inlet and one outlet, e.g. zones 2a0 - 2a7, 2e - 2h, 2j - 2m, 2o - 2q.

[0048] Some conveyor zones 2 are junction zones of the type shown in figure 3b, having at least two different outlets, e.g. zones 2i, 2n, 2r1-2r3, 2r6- 2r8, 2s2 - 2s3, 2s6 - 2s8. The conveyor zones 2 are controlled by a plurality of local zone controllers 11. When planning the conveyor arrangement with said IT planning tool 20, said individual zone controllers are planned as well. Accordingly, the plan 1 P of figure 5 comprises, as an example, nine zone controller 11a...j. As soon as finished also the configuration of the zone controllers can be finalized.

[0049] Each of the zone controllers 11 are adapted to control at least one of the conveyor zones 2, in particular up to four conveyor zones per zone controller. Here the zone controller 11 are located in proximity of the zones, controlled by the respective controller. In particular each zone controller is attached to a frame 6 (see figure 1) of a conveyor zone. A zone controller controlling a junction zone, is also referred to as a junction controller.

[0050] The zone controller are connected to each other in a daisy-chain manner by said bus connection 13 (see https: / / en.wikipedia.org / wiki / Daisy_chain_(electrical_engineering)). That means in particular, that a first zone controller 11a and a second controller 11b are connected to each other via a bus cable 13C, which is plugged into a socket of the first zone controller 11a and into a socket of the second zone controller 11 b; the second zone controller 11b and a third controller 11c are connected to each other via another bus cable 13C, which is plugged into a socket of the second zone controller 11b and into a socket of the third zone controller 11c; etc. the first zone controller may be connected in the same manner with the central controller 14 (see also figure 3).

[0051] The main task of a local zone controller 11 is to arrange conveying operation of the related conveyor zone, thereby initiating starting or stopping the drive motors of the zones depending on the sensor signals S5 of the presence sensors 5. In case that the zone is a junction zone, it is another task to initiate, that the object is taking the correct outlet of the plurality of outlets 01, 02, 03.

[0052] As an example and according to the disclosure of WO 2024 / 149872 A1 and WO 2023 / 247237 A1 it is described that the relation between the neighboring zones is known, i.e. which zone is upstream and downstream of a particular zone and which downstream zone can be reached via which of several outlets.

[0053] As an example the table of figure 6a shows in a zone table 16P the neighboring information as planned of the conveyor zones 2 in the planned conveyor arrangement 1 of figure 4. Each conveyor zone 2 is listed in a data set in the columns “Zone ID”. For each listed zone the “upstream zones” and the “downstream zones” are indicated in the respective columns. In case that the listed conveyor zone is a junction zone, the data set comprises information, via which of the plurality of outlets 01 , 02, 03 (see figure 3) the downstream conveyor zones can be reached. A conveyor zone, which is not a junction zone, has merely one outlet, in particular first outlet 01.

[0054] From the information of the zone table16P it is possible to determine a destination look up table, an exemplary destination look up table 17P according to the planned arrangement is shown in figure 6b. Such a destination look up table 17P shows for a plurality of destinations D1 ... D8 within the conveyor arrangement, which outlet of a plurality of outlets 01, 02, 03 (see figure 3) within a certain conveyor zone 2 leads to which destinations.

[0055] Figure 6b shows the destination look up table 17P related to an individual zone 2i (zone definitions see figure 6a and 4). Here the destination look up table 17P shows, that an outlet 02 (“path left”) leads to destinations D1-D4, an outlet 03 (“path right”) leads to destinations D5-D8, and an outlet 01 (“path straight”) is a default path for all remaining destinations. The information contained in the destination look up table 17P corresponds to the paths possible for reaching a destination according to the position data 15P and the zone table 16P in the planned conveyor arrangement 1P of figure 4.

[0056] A similar individual destination look up tables are provided for each other of the junction zones, but is not shown here in the figures.

[0057] Such a individual destination look up table 17P may be part of a configuration C of a zone controller (see later in figure 7). Accordingly, as soon as said destination look up is transferred to the correct zone controller 11 , said zone controller 11 is set into a condition to decide on its own, along which outlet a certain object has to travel, provided, that the destination of said certain object is known. The advantage is, that the local zone controller 11 can take over significant parts of the overall controlling within the conveyor arrangement without the need to ask the central controller for the right way for each object in a time critical manner (for more details of the decentral control of junction zones see WO 2024 / 149872 A1 and WO 2023 / 247237 A1).

[0058] Figure 6c shows a control ID table 18P as planned, the information of which can be generated during the above planning by the IT planning tool. In main the control ID table 18P of figure 6c comprises the following information:

[0059] The first and second columns allocate an identification (here the IP address) to each of the zone controllers, which are part of the planned conveyor zone according to figure 5. With this information each zone controller of the conveyor arrangement is individualized. The second and third columns provide a neighboring information to the controller identified in the second column. In sum neighboring information between the plurality of zone controllers with each other are provided by the control ID table 18P. It shows, as planned, the direct connections between the zone controllers via a bus cable 13C (see figures 2 and 5), connected into a first connecting socket 11S1 or a second socket 11S2. This information defines the neighboring information of the typical daisy-chain connection. Accordingly, each row in the planned ID table 18P of figure 6c constitutes a planned neighboring information NP.

[0060] Figure 6e shows a control zone allocation table 19P as planned, the information of which can be generated during the above planning by the IT planning tool. The control zone allocation table 1P defines, which conveyor zone is intended to be controlled by which zone controller. This allocation can be done as shown in figure 4 of International patent application PCT / EP2025 / 053405.

[0061] In some embodiments, the bus cable 13C is not planned within the IT planning tool as shown in figure 5. Without having planned the bus cable 13C, the neighboring information contained in the third and fourth column of control ID table 18P is not explicitly available from the IT planning tool. In this case, the neighboring information can be retrieved implicitly from other information already available in the plan 1P. As stated with reference to figure 6e and according to the plan 1 P, the zone controller 11f controls the zones 2k and 2I, where zone 2k is the upstream zone (see arrow P1 in figure 6e). From zone table 16P and / or from position data 15P it is known, that zone 2j is the upstream zone of zone 2k (see arrows P2 in figures 4 and 6a). According to the control zone allocation table 19P, the zone controller 11e controls the zones 2j (see arrow P3 in figure 6e). Accordingly, it is known from the plan 1 P, that controller 11e controls zone 2j which is upstream of the zone 2k, which is controlled by controller 11f. Accordingly, the zone controllers 11e and 11f are considered as neighboring zone controllers which are connected directly in the later installation process by a bus cable 13C, even if this information was not provided explicitly by the plan 1P. In any case, from the plan 1P it becomes clear, which zones are directly attached to each other. Accordingly, each row in the assembled ID table 18A of figure 6e constitutes an assembled neighboring information NA.

[0062] The zone table 16P of figure 6a, the destination look up table 17P of figure 6b, the control ID table 18P of figure 6c and the control zone allocation table 19P are all part of the plan 1P of the conveyor arrangement, and in the present embodiment generated with the help of and / or by the IT planning tool 20.

[0063] According to the above, the plan, in particular as shown by the provided tables, comprises neighboring information of different kinds of devices, e.g. such as controls and / or devices controlled by controls. This is particular advantageous if preassembled modules are used during assembly. As an example, conveyor zones such as shown in figure 1 or a group of such zones may be preassembled in a factory, where the preassembled zone may comprise the zone controller 11, the frame 6 , the rollers 3,3M, the sensor 5 and a preassembled wiring PW (see figure 8) connecting said components.

[0064] The above illustrate the planning of the conveyor arrangement with the help of said IT planning tool 20. Subsequently, the installation aspects of the installation of the conveyor arrangement in the real world are described.

[0065] When preparing the installation a plurality of unconfigured zone controllers 11nn (“no name”) are provided (see figure 7, left side). These unconfigured zone controllers 11nn comprise in main the same hardware and may be provided with an operating system. In principle, each of said plurality of unconfigured zone controllers 11nn can be used as any of the zone controllers 11 a - 11 i as planned in figure 5.

[0066] In an individualizing step, each of said unconfigured zone controllers 11nn is loaded with an initial configuration C11a, C11b...C11i (see figure 7, middle), which is individual for each zone controller and is depending on the position within the assembly and the tasks to be performed by the zone which is controlled by said individual zone controller. From that point in time it is defined, that

[0067] - the zone controller loaded with a first initial configuration C11a will constitute the first zone controller 11a;

[0068] - the zone controller loaded with a second initial configuration C11b will constitute the second zone controller 11b,

[0069] - the zone controller loaded with a nineth initial configuration C11 i will constitute the nineth zone controller 11i each as planned according of figure 5 and controlling the zones as defined in control zone allocation table 19P of figure 6e.

[0070] There are different possibilities of the content of the initial configuration. In a first embodiment, the initial configuration is a full configuration, comprising, all relevant values, which are required to set the zone controller into the condition to control the related zones properly. As an example the above configuration may comprise a full configuration which is subject of claim 1 within EP 3 286615 B1. In another embodiment the initial configuration may comprise the destination look up table 17 of figure 6b related to the respective zone controller. In a another embodiment, the initial configuration may comprise merely a brief configuration data which sets the zone controller into a condition to receive the correct full individual configuration at a later point in time. Here merely a control ID, such as the IP address shown in the control ID table 18 of figure 6c may be subject of said initial configuration. By having the IP address, the zone controller is in a condition to retrieve its full configuration database located in the central control or within the commissioning tool as described later.

[0071] Accordingly, a set of first to nine zone controllers 11a-11 i are individualized. This step is conducted before the conveyor arrangement is assembled at the final site at the customer.

[0072] In a another step, the components of a conveyor zones are preassembled at the factory, into conveyor zones preassembly 2Pa, 2Pf (see figure 8). Here several zones 2a0,2a1,2a2;

[0073] 2i,2k,2l from the planned arrangement of figure 4 are assembled to a common frame 6. Each of these preassemblies 2Pa, 2Pf form a transportable unit, which is transported later from the preassembly factory to the installation site. Already during preassembly, a preassembled wiring PW within the preassembly 2Pa...2pf is prepared; in particular all motorized rollers 3M and all presence sensors 5 are connected via preassembled wiring PWto the related zone and / or junction controller 11. Also some of the bus cables 13C may preassembled, but not connected to a neighboring zone controller, because said neighboring zone controller may part of a separate preassembly. Since zone 2k is a junction zone, said zone 2k is preassembled with a transfer device 2T. Said transfer device 2T is connected via said preassembly wiring PWwith the junction controller 11f.

[0074] Also, but of minor relevance here, the preassemblies may comprise a power supply device and respective power supply lines (see International patent application PCT / EP2025 / 067076).

[0075] In a next step all the preassemblies PWare transported to the installation site and assembled there to the complete conveyor arrangement 1 as planned in figures 4 and 5.

[0076] For putting the assembled conveyor arrangement into operation, a commissioning tool 30 is used, as shown in figures 9 to 11. The commissioning tool 30 is an IT application running on a personal computer. The commissioning tool has access to a database 31 , on which the plan 1P of the planned conveyor arrangement 1P is stored; the database 31 can be stored locally with the commissioning tool 30, alternatively the database 30 is located outside of commissioning tool and the commissioning tool has access to the database via a remote connection.

[0077] The plan 1 P thereby comprises comprehensive information about the spatial structure including neighboring information and details of the planned conveyor arrangement. In particular the plan 1P comprises one or kore of the following:

[0078] - spatial position data 15P of each conveyor zone, in particular from which a spatial, neighboring information between the conveyor zones can be retrieved;

[0079] - a list of zone controller (control ID table 18P, see figure 6c) along with a information, which conveyor zones is controlled by an individual zone controller (control zone allocation table 19P, see figure 6e);

[0080] - neighboring information, such as comprised in the control ID table 18 (see figure 6c);

[0081] - technical details of the hardware, e.g. number and types of the motorized rollers, zone length and width,... ;

[0082] - the destination look up tables 17P (see figure 6b).

[0083] The commissioning tool shows graphically a simplified representation of the conveyor arrangement 1 P as planned in figure 4. The commissioning tool 30 has communication access via a bus connection 13 to the assembled conveyor arrangement 1, in particular to the assembled zone controller 11 within the assembled conveyor arrangement 1.

[0084] Thereby the commissioning tool 30 is in communicative connection via the bus connection to zone controllers 11 , in particular all zone controllers 11, within the assembled conveyor assembly.

[0085] As stated above the zone controllers 11 are connected with each other in a daisy-chain manner. Accordingly, each zone controller 11 has a at lest one, in most cases two neighboring zone controllers 11. The target assembly situation - as planned - is shown in the commissioning tool 30 as in figure 9. This target assembly situation can be retrieved from the IT planning tool 20 of figure 4 and 5 and is stored in the plan 1P.

[0086] The commissioning tool 30 thereby checks the actual assembly situation, to determine neighboring information of assembled devices in the assembled conveyor arrangement 1 , as an example:

[0087] In a neighboring check step, each zone controller (lets call it the requesting zone controller) requests via the bus connection the neighboring controller 11 to provide its IP address (as an example of an identification of the controller) to the requesting zone controller. This step is performed by all zone controllers. As a result, each zone controller knows the IP address of the neighboring zone controller in the assembled state and can provide this neighboring information as obtained from the assembly to the commissioning tool 30. The commissioning tool 30 collects said obtained neighboring information provided by all zone controllers.

[0088] The result of neighboring check step can be summarized in a dataset shown in control ID table 18A (as obtained from the assembled conveyor zones) of figure 6d according to the assembly. The structure of the control ID table 18A (as obtained from the assembled conveyor zones) is similar to that of control ID table 18A ( as planned) of figure 6c. both tables comprising identical data as well as deviating data DV, wherein the deviating data DV reflect a situation in the assembled state, which is different to the planned state. The control ID table 18A of figure 6d is an example of an obtained assembly information 1A including obtained neighboring information. As an example the zone controller 11f has determined via checking the IP addresses of its neighboring controllers, that

[0089] - zone controller 11f is actually connected in the daisy-chain with the zone controller 11a and 11c (instead and according to the plan, the zone controller 11f has to be connected in the daisy-chain with the zone controller 11e and 11g);

[0090] - zone controller 11b is actually connected in the daisy-chain with the zone controller 11e and 11h (instead and according to the plan, the zone controller 11b has to be connected in the daisy-chain with the zone controller 11a and 11c).

[0091] The differences between control ID table 18A (as obtained from the assembled conveyor zones) of figure 6dand the control ID table 18P (as planned) of figure 6c which constitute deviations I deviating data DV, may be presented to the user in the tabular form and underlined as in figure 6d.

[0092] The commissioning tool 30 may also show the resulting connections including an indication of the deviations DV in the daisy-chain arrangement in figure 10.

[0093] The commissioning tool 30 visualizes the obtained situation by the daisy-chain, which now comprises “jumps” across the arrangement: The visualization of the jumps is an exemplary embodiment of a user output. The jumps indicate deviations DV between the actual assembled arrangement and the planned arrangement. Here the commissioning tool 30 works according to the assumption, that the zone controller are all located on the right position, but merely the wiring was done improperly.

[0094] These jumps are easily detectable indications of errors in the actual assembled assembly vs. the planned assembly. Here the installation technician can detect in an easy way, that something is not connected in a correct way and can efficiently detect the area, where rework is required.

[0095] Another embodiment is shown in figure 11. Here the same information is used as in the embodiment of figure 10 for detecting an error in the assembled conveyor assembly. Also in this situation, the zone controller 11f and 11b are assembled in the wrong position. Here the illustrated location of the zone controller 11f within the commissioning tool 30 corresponds to the detected position along the determined daisy chain. So here the deviations DV are illustrated in a user output by marking the zone controller 11b, 11f which positioned in a wrong position of the daisy chain. List of reference signs

[0096] 1 conveyor arrangement

[0097] 1 P Plan of a planned conveyor arrangement

[0098] 1A assembly information

[0099] 2 conveyor zone

[0100] 2Pa...2pf conveyor zone preassembly

[0101] 2T transfer device in conveyor zone

[0102] 3 conveyor roller

[0103] 3M motor-driven conveyor roller

[0104] 4 drive connector

[0105] 5 presence sensor

[0106] 6 support frame

[0107] 7 identification scanner (e.g. barcode reader)

[0108] 9 object to be conveyed

[0109] 11 zone controller

[0110] 13 bus connection

[0111] 13C bus cable

[0112] 14 central controller

[0113] 11 local zone controller

[0114] 11a..i configured zone controller

[0115] 11 nn unconfigured zone controller

[0116] C11a..i controller configuration

[0117] 13 bus connection

[0118] 14 PLC

[0119] 15P position data (as planned)

[0120] 16P zone table (as planned)

[0121] 17P destination look up table (as planned)

[0122] 18P control ID table (as planned)

[0123] 18A control ID table (as obtained from assembled conveyor zones)

[0124] 19P control zone allocation table (as planned)

[0125] 20 IT planning tool

[0126] NP neighboring information (as planned)

[0127] NA neighboring information (as obtained from assembled conveyor zones)

[0128] 30 IT commissioning tool

[0129] 31 database of commissioning tool

[0130] 97 identification tag C conveyor

[0131] D destination

[0132] DV deviation I deviating data

[0133] F feed-in station

[0134] I inlet

[0135] J junction

[0136] O outlet d conveying direction

[0137] S5 sensor signal (of presence sensor)

[0138] 11S1, 11S2 connecting sockets at zone controller for connecting the bus cable

[0139] C configuration of controller

[0140] PW preassembled wiring

Claims

Claims1. Method of setting a conveyor arrangement (1) into operation, the conveyor arrangement (1) comprising,- a plurality of conveyor zones (2), each conveyor zone (2) is adapted to convey an object (9) from an inlet (I) of said conveyor zone (2) to an outlet (O) of said conveyor zone (2),- a plurality of zone controllers (11) adapted to control the operation of said conveyor zones (2); the method comprising the following steps:- providing a plan (1 P) of a planned conveyor arrangement (1);- assembling the conveyor arrangement (1) according to said plan (1P) at an installation site.

2. Method according to the preceding claim, characterized by the following step:- providing a commissioning tool (30) and connecting the commissioning tool (30) to a plurality of said zone controllers (11) at the installation site via a data connection, in particular a data bus (13), wherein the commissioning tool (30) has data access to the plan (1P).

3. Method according to any of the preceding claims, characterized by the following steps:- obtaining assembly information (18A) from said connected zone controllers (11);- evaluating the obtained assembly information (18A) with the plan (1 P) and generating a deviation information (DV); in particular wherein the deviation information (DV) comprising a determined difference between the obtained assembly information (18A) and a planed assembly information (18P) within the plan (1P).

4. Method according to any of the preceding claims, characterized by the following steps:- obtaining assembled neighboring information (NA) describing a neighboring relation between assembled components within the assembled conveyor arrangement (1);- comparing the assembled neighboring information (NA) with planned neighboring information (NP) describing a planned neighboring relation between said components within the planned conveyor arrangement (1);generating a deviation information (DV) indicating a deviation between the assembled neighboring information (NA) and the planned neighboring information (NP).

5. Method according to any of claims 3 or 4, characterized by the step:- providing said deviation information (DV) as a user output.

6. Method according to the any of the preceding claims, characterized by a neighboring check step, in which each zone controller (11) determines an identity of its neighboring zone controllers, in particular wherein the result of the neighboring check step comprises a assembled neighboring information (NA).

7. Method according to any of the preceding claims, characterized in that the plan (1P) comprises position data of each conveyor zone, in particular an absolute position or a spatial relation data between the conveyor zones (2).

8. Method according to any of the preceding claims, characterized in that the plan (1P) comprises position data of each zone controller, in particular an absolute position or a spatial relation to an individual conveyor zone.

9. Method according to any of the preceding claims and claim 2, characterized in that said plan (1P) is generated by an IT planning tool (20), in particular said IT planning tool (20) is separate to said commissioning tool (30).

10. Method according to any of the preceding claims, characterized by the step of providing the zone controller (2a) with an individual initial configuration (C11a), in particular wherein the initial configuration (C11a) is based on the plan (1 P), wherein the initial configuration (C11a) is provided on the zone controller (2a) before assembling the conveyor arrangement (1) on the installation site.

11. Method according to any of the preceding claims, characterized by the step ofpreassembling at least two conveyor zones (2a, 2b; 2k, 2I) to a common conveyor zone preassembly (2Pa; 2Pf) at a preassembly site; wherein the conveyor zone preassembly (2Pa; 2Pf) comprises a zone controller adapted to control at least one of said conveyor zones within said zone preassembly (2Pa; 2Pf).

12. Method according to the preceding claim, characterized by the step of- transporting the conveyor zone preassembly (2Pa, 2Pf) from the preassembly site to the installation site;- connecting a plurality of preassemblies to obtain the conveyor arrangement (1) at the installation site.

13. Method according to any of the preceding claims, characterized by the step of after assembling the conveyor arrangement, providing the zone controller (2a) with a individual full configuration by means of said commissioning tool (30), wherein allocating the full configuration to an individual zone controller is done by means of the initial configuration (C11a).

14. Method according to any of the preceding claims, characterized by the step of:- detecting a false positioning of a conveyor zone preassembly (2Pa, 2Pf) within the assembled conveyor arrangement (1) by comparing obtained assembly information (NA) with planned assembly information (NP).

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