Method of controlling the operation of a conveyor arrangement

Abstract

Method of controlling the operation of a conveyor arrangement (1), the conveyor arrangement (1) is adapted to convey an object (9) in a downstream conveying direction (d), 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), - at least one zone controller (11), adapted to control the operation of at least one own conveyor zone (2), wherein the speed (vk, vl) of an object (9k, 9l) is controlled based on a gap value (q, q1, qt), wherein the gap value (q, q1, qt) refers to an actual distance and / or target distance between two objects (9k, 9l) subsequently conveyed within the conveyor arrangement (1), in particular between a leading object (9k) and a trailing object (9l).

Description

[0001] Method of controlling the operation of a conveyor arrangement

[0002] Description

[0003] The invention refers to a method of controlling the operation of a conveyor arrangement.

[0004] An intralogistic conveyor arrangement is shown in unpublished European patent application EP23151253.4. Such conveyor arrangements are optimized for postal parcels etc., wherein the objects are held at a distance to each other. Accordingly the objects are held separated in individual conveyor zones, where merely one parcel is located within one conveyor zone. The objects are driven at a standard speed, where the speed ensures accurate braking of an upstream object before hitting a stopped object downstream. The objects are conveyed at one single predefined speed level.

[0005] Unpublished European patent application EP23217020.9 shows another conveyor arrangement, where a trailing object is stopped and consequently blocking a conveyor zone. To increase the throughput efficiency, a speed of a trailing object located several zones upstream of the blocked zone is reduced. This is to avoid, that the trailing object is required to stop as well. The objects are always held at a distance which is defined by a zone length of the conveyor zones.

[0006] US 2016 / 0200522 A1 discloses a zone-based conveyor system in which each zone includes a sensor and a controller. The distance between two conveyed objects is determined eventbased by measuring the time difference between their respective detections at the same presence sensor. This time gap, combined with the known conveyor speed, is used to estimate the object-to-object distance. If the calculated gap falls within a predefined range, the trailing object is accelerated to reduce the distance; otherwise, normal speed is maintained.

[0007] US 2004 / 0065526 A1 discloses a conveyor induct system comprising a control point determination module and a gap control system. The gap control system centrally coordinates the adjustment of article spacing by receiving presence signals from horizontal photo-detector arrays, which are used to detect leading and trailing edges of articles and calculate gaps. These calculated gaps are compared to a desired gap value, and a feedback controller issues commands to a variable speed motor controller to adjust the conveyor speed accordingly. All gap correction decisions are made centrally, without distributed or zone-based control logic.

[0008] Another system using a central coordination of gaps is disclosed in US 2015 / 0336748 A1.

[0009] It is the object of the invention to improve the operation of a conventional conveyor arrangement.

[0010] - 1 -

[0011] 20250922 24041 PWO text.docx This object is solved by a method, a zone controller and a conveyor arrangement according to the main claims; embodiments are subject of the subclaims and the description.

[0012] For making the description easier to read, the following definitions are used to describe certain components and devices:

[0013] The term “own” describes the relation between a conveyor zone and a zone controller. An “own” conveyor zone is controlled by an individual zone controller. So each zone controller controls the operation of the own conveyor zones. In contrast thereto, a “foreign” conveyor zone is controlled by another zone controller, e.g. by a neighboring zone controller.

[0014] An own object in relation to a zone controller is an object which is located on an own conveyor zone. In more complex words: The own object is located on a conveyor zone, which is controlled by the related zone controller. In contrast thereto, a “foreign” object is located on a foreign conveyor zone.

[0015] In particular each of the zone controllers are adapted to control a limited number of conveyor zones, in particular the limited number is max. 10 or 8 or 4 or 2.

[0016] In particular the method controls the movement of objects on a conveyor arrangement. The arrangement includes multiple conveyor zones, each capable of moving an object from one end to the other. The speed of the objects is managed by zone controllers based on the distance between them. This ensures smooth and efficient operation of the conveyor system, preventing collisions and optimizing flow.

[0017] In particular the method allows that two objects are located in the same conveyor zone and temporarily located in different zones. The speed of the objects is adjusted to prevent them from touching each other. If the gap between the objects needs to be changed, their speeds are adjusted accordingly when they are in different zones. This flexibility enhances the arrangement’s ability to handle varying object sizes and speeds, improving overall efficiency.

[0018] In particular the method also covers situations where two objects are fully within one zone. The controller ensures that the objects do not touch each other, even if they are located in or conveyed into the same conveyor zones. This provides an additional layer of safety in combination with driving the objects very close to each other. The precision in handling objects is increased, whereas the risk of damage is low.

[0019] - 2 -

[0020] 20250922 24041 PWO text.docx In particular the method controls the speed of the objects to either change the gap between them to a target value or maintain a minimum gap. This precise control over object spacing helps in maintaining a consistent flow and prevents standstill and / or object jams.

[0021] In particular the conveyor system is managed by multiple controllers, each responsible for one or more conveyor zones. Distributed control allows for more scalable and robust system management, reducing the risk of a single point of failure. Also the installation effort and programming a central control (PLC) is reduced, since standard procedures of controlling the gap are managed by a routine control algorithms provided by the decentral zone controllers.

[0022] In particular each controller can adjust the speed of an object in its zone based on the position and speed of another object in a different zone controlled by another zone controller. This inter-controller communication enhances coordination and synchronization across the entire conveyor system and supports the decentral approach.

[0023] In particular the zone controller is adapted to control at least one conveyor zone. It includes communication sections to interact with other controllers and field devices like motors and sensors. It also has sections for setting speeds and tracking objects. This comprehensive functionality within each controller ensures efficient and autonomous operation of each zone.

[0024] In particular the zone controller can set the speed of a conveyor zone based on stored data about the objects in its zone. Utilizing historical and real-time data allows for more accurate and adaptive speed control, improving system responsiveness.

[0025] In particular the zone controller can also use data about objects in other zones to adjust the speed of its own zone (foreign data of foreign object). This holistic approach of data usage ensures that the entire system operates in a coordinated and optimized manner.

[0026] In particular data about objects in one zone can be shared with controllers managing other zones to help in speed adjustment. Enhanced data sharing improves the overall efficiency and coordination of the conveyor system.

[0027] In particular the data used for calculating the speed include the position and length of the objects, and optionally, a target gap value. Detailed object data allow for precise control and adjustment of speeds, ensuring smooth operation.

[0028] In particular the controller adjusts the speed based on the actual and target gaps between leading and trailing objects. This targeted speed adjustment helps in maintaining optimal spacing and flow of objects.

[0029] - 3 -

[0030] 20250922 24041 PWO text.docx In particular the zone controller can differentiate between objects in its own zone (own object) and those objects in other zones (foreign objects), adjusting speeds accordingly. This differentiation ensures that each controller can make informed decisions based on the specific context of its zone.

[0031] In particular the zone controller can create a speed difference between zones to adjust the gap between objects when these objects are in different zones. This capability allows for dynamic and flexible gap management, improving the system’s adaptability to changing conditions.

[0032] In particular the conveyor arrangement includes multiple zones and zone controllers, each controller controlling one or more conveyor zones, and is adapted to perform the described method. The modular design of the arrangement allows for easy scalability and maintenance, ensuring easy installation and programming effort.

[0033] IN an embodiment, the position of a conveyed object within a conveyor zone is determined by a zone controller using sensor signals and conveying data. In particular, a presence sensor, such as a light barrier, detects the entry and exit of an object into its sensing range. The entry time corresponds to the position of the leading edge of the object, while the exit time corresponds to the trailing edge. The length of the object is calculated from the time difference and the known conveying speed.

[0034] Subsequently, the position of the object can be updated at any time based on the rotational speed of the conveyor rollers and the elapsed time since the last sensor event. The zone controller stores this position data in an object tracking section, which includes an identification of the object, the conveyor zone it is located in, and a fine-grained position value within that zone.

[0035] This position data is used in combination with object length and target gap values to calculate actual gaps between objects and to control conveying speeds accordingly. The system supports both internal data (from own sensors and drives) and external data (from neighboring zone controllers), enabling precise and decentralized control of object spacing and flow.

[0036] A non-limiting example of the invention is described with respect to the figures; herein show fig. 1 an exemplary conveyor zone used within the invention; fig. 2 schematic diagrams showing a) the speed over time, and b) the speed-over-distance of a slow moving object;

[0037] - 4 -

[0038] 20250922 24041 PWO text.docx fig. 3 schematic diagrams showing a) the speed over time; and b) the speed-over-distance of a fast moving object; fig. 4 a conventional conveyor arrangement during operation in different situations along with a speed-over-distance diagram; fig. 5 an inventive conveyor arrangement during operation in different situations along with a speed-over-distance diagram; fig. 6 a schematic representation of a zone controller of the inventive conveyor arrangement in more detail; fig. 7 a schematic representation of an object tracking section of the zone controller of figure 6; fig. 8 another inventive conveyor arrangement during operation in different situations along with a speed-over-distance-diagram.

[0039] 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 motorized roller 3M. The motorized roller 3M is driven in particular by a three-phase motor arranged in the motorized roller 3M. Via one or more 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 motorized roller 3M. An object 9 is linearly conveyed from an inlet I to an outlet O.

[0040] In the embodiment shown here the conveyor rollers 3 establish a conveyor surface on which the object 9 is supported. In an another embodiment, a conveyor belt may be provided, on top of which the object 9 is supported.

[0041] By means of a presence sensor 5, the presence of a conveyed object 9 arranged on the conveyor zone 2 can be determined. The presence sensor 5 does not have to cover the entire conveyor zone 2; it is sufficient if the presence of a conveyed object 9 within a partial area of the conveyor zone 2 is detected by the presence sensor 5. The presence sensor 5 thereby generates a sensor signal S5, which is connected via a signal line (not shown) to a zone controller 11 presented further below. Presence detection can also be performed without an explicit sensor and can be derived from other raw data. For example, there are already approaches to derive the presence of a conveyed material on the conveyor zone 2 from other data, e.g. from the course of the current intensity in a conveyor zone 2.

[0042] - 5 -

[0043] 20250922 24041 PWO text.docx The conveyor rollers 3 and the presence sensor 5 are attached to a common support frame 8. The conveyor rollers 3 of several conveyor zones 2 can be attached to a common support frame 8.

[0044] The motorized rollers 3M or, for other embodiments, any other drive driving the conveyor zones 2 are each controlled by at least one or a plurality of zone controllers 11. A single zone controller 11 can control the motorized rollers 3M of several conveyor zones 2. Several such zone controllers 11 are arranged in a conveyor arrangement 1 (shown later) which communicate with each other via a bus connection 13. The zone controller 11 may be incorporated into one of the conveyor rollers 3 .

[0045] Figure 2 shows schematically the dynamics of a conveyed object 9. Hereby the object 9 is traveling at a first conveying speed v1. In case the zone controller 11 decides to stop the conveyed object 9 at a stop issuing time to, after a particular reaction time, reduction of speed starts and after traveling along a first stopping distance dx1 the object 9 comes to a standstill at first stop position x1.

[0046] Figure 3 shows nearly the same diagram as figure 2, where the object 9 is traveling in a high speed mode at a second conveying speed v2, which is about as fast as the double of the first conveying speed v1. It is needless to mention that a second stopping distance dx2 is increased tremendously compared to the first stopping distance of figure 2, so that the object comes to a standstill at second stop position x2 far behind the first stop position x1.

[0047] Figure 4 shows the result of an object accumulation in a conventional conveyor arrangement 1 as described in figure 7 of prior European patent application EP23217020.9. There are several conveyor zones 2a-f arranged along a conveying direction, where objects 9 are traveling from a first upstream conveyor zone 2a to a sixth downstream conveyor zone 2f. Each conveyor zone if controlled by a zone controller 11a-f, where one controller 11 may control more than one conveyor zone 2.

[0048] Figure 4 shows the operation of a conventional conveyor arrangement 1. The zone controllers 11 control the motorized rollers in such a way that the successively approaching conveyed goods 9 do not collide with each other, which is usually called “Zero pressure accumulation”. The control is performed conventionally in a manner that in main only one conveyed object 9 is present per conveyor zone 2. However, slight overlaps may occur. For example, an upstream conveyed object may already enter a downstream conveyor zone 2 from an upstream conveyor zone 2 even though a downstream conveyed object has not yet completely left said downstream conveyor zone 2. Among other things, the sensor signals S5 of the presence sensors 5 serve as input variables, although it is ensured that the two conveyed objects do not

[0049] - 6 -

[0050] 20250922 24041 PWO text.docx touch and thus do not damage each other. Each conveyor zone 2 has a zone length L2 in the conveying direction, which may be of the same length, or some of the conveyor zones 2 may be of smaller or larger zone length L2.

[0051] The operation of each conveyor zone 2 is controlled by a dedicated zone controller 11a, 11b, where one zone controller 11 controls the operation of one conveyor zone 2 or of a plurality of conveyor zones 2 (as shown in example of figure 4), as an example two, three or four zones.

[0052] In the example shown in figure 4, the sixth conveyor zone 2f is occupied by an occupying object 9f.

[0053] Two objects 9, a leading object 9k and a trailing object 9I are conveyed in an upstream second conveyor zone 2b at the first speed v1 (figure 4a). Since the third conveyor zone 2c is not occupied by an object the object 9 is further conveyed towards the third conveyor zone 2c. the situation shown in figure 4a, the fifth conveyor zone 2e is the conveyor zone 2 in front of (meaning directly before) the occupied sixth conveyor zone 2f. The fifth conveyor zone 2e is also called the first empty zone. When the presence of said conveyed object 9k within the first empty zone 2e is detected (e.g. by presence sensor 5e), stopping of said object 9k is initiated (figure 4b).

[0054] The same applies to the trailing object 9I, which will be stopped in the second empty zone 2d. Any further trailing object 9m,n,o will be stopped in an individual further zone 2c, b, a upstream of the respective preceding objects 9l,m,n. So according to the situation in figure 4d, all six conveyor zones 2a...2f are occupied with exact one object 9f, 9k..9o.

[0055] Figure 4e shows a course of speed of the respective objects 9 over the distance x. Here the course is depicted in a simplified manner indicating the speed v is immediately reduced. In reality the deceleration process would be in the form similar that what is shown in figures 2 and 3.

[0056] Occupied means hereby, that said occupying object 9f located within the conveyor zone 2f is in a non-moving condition. The fifth conveyor zone 2e is the conveyor zone in front of the occupied zone 2f, consequently the fifth conveyor zone 2e is the first empty zone. In general, the empty zones are numbered in the upstream direction starting from the occupied zone. Accordingly, here the

[0057] - fifth conveyor zone 2e is the first empty zone,

[0058] - fourth conveyor zone 2d is the second empty zone,

[0059] - third conveyor zone 2c is the third empty zone,

[0060] - etc..

[0061] - 7 -

[0062] 20250922 24041 PWO text.docx Figure 5 shows an inventive embodiment of a conveyor arrangement 1. In main, the same tasks as in figure 4 are performed, where an occupied conveyor zone 2f is occupied by an occupying object 9f, and a leading object 9k and a trailing object 9I are conveyed upstream of and in the direction to said occupied zone 2f. The individual figures 5a .. 5g show in exemplary situations the individual positions of the leading object 9k and the trailing object 9I.

[0063] Figure 5h shows the course of the speed vk of the leading object 9k (the “leading speed vk”, shown in a solid line) and the speed vl of the trailing object 9I (“the trailing speed vl” shown in a dotted line where the trailing speed vl is different to the leading speed vk) in relation to their position x (important: the speed is not shown in relation to time). In addition the figure 5 shows the course of the gap q between the leading object 9k and the trailing object 9I in relation to the position x of the leading object 9k.

[0064] Starting from figure 5a, the leading object 9k is conveyed at a speed vk and the trailing object 9I is conveyed with a speed vl, both speeds are on the level of a second speed v2, which is a comparatively high speed. There is a initial gap qO between the leading object 9k and the trailing object 9I and the leading object 9k and the trailing object 9I are arranged at a distance so that these objects are located on different conveyor zones 2b, 2a.

[0065] In figure 5b, it is requested by an external parameter change, to change the gap q between the objects 9k and 9I to a new target gap qt. Both objects 9k, 9I are located in different conveyor zones 2a, 2b, so that the objects 9 now can be driven at different speeds to reduce the gap q. Accordingly, the leading speed vk and the trailing speed vl are set to a level, so that the leading speed vk is smaller than the trailing speed vl.

[0066] As an example, the leading speed vk is amended to a first speed level v1, which is lower than the trailing speed vl (see situation B2 in figure 5b and 5h). The trailing speed vl is maintained (see situation B1 in figure 5b and 5h). General interpretation of terms: the term “set a speed” includes both changing and maintaining a speed level.

[0067] In the following (see figure 5c), the gap q between both objects 9k, I decreases (see C in figure 5h), since the two objects 9 are located on different conveyor zones 2b, 2c driven at said different speeds.

[0068] Due to the ongoing reduction of the gap q, subsequently (see figure 5d) the trailing object 9I enters the zone 2c, on which the leading object 9k is still located (the zone in which two objects are located are referred to as the “common zone”). The speed of said common zone 2c is set to the second level v2, so that the leading speed vk is increased to the second speed level v2 (see situation D in figure 5d and 5h) and the trailing speed vl is maintained at the

[0069] - 8 -

[0070] 20250922 24041 PWO text.docx second speed level v2. For a certain period the gap q remains constant at a level of q1, which is smaller than the initial gap qO but larger than the target gap qt.

[0071] Subsequently (see figure 5e) the leading object 9k leaves the common zone 2c and enters the downstream zone 2d (see situation E in figure 5e and h), whereby the trailing object 9I is still located on the (formerly common) conveyor zone 2c (see situation E in figure 5e and h). Now the objects 9k, 9I are located on different conveyor zones 2c, 2d. This situation can be used again to set a speed difference between the leading speed vk and the trailing speed vl in a manner, that the leading speed vk is lower than the trailing speed vl.

[0072] As an example, the leading speed vk is reduced to the first speed level v1 and the trailing speed vl is maintained at the second speed level v2 (see situation E in figure 5e and 5h).

[0073] Subsequently (see figure 5f) the gap q adopts the level of the target gap qt. Accordingly the leading speed vk and the trailing speed vl, which are located on different conveyor zones 2 are set to a same speed level to maintain the gap q at the level of the target gap qt.

[0074] In the aforementioned steps it is important, that a speed difference is generated to amend the gap q. In the aforementioned example, the leading speed vk was amended to achieve said required speed difference; alternative or in combination thereof the trailing speed vl can be amended. The shown principles can be used as well in an embodiment, where the gap q is to be increased, i.e. where the target gap qt is larger than the initial gap qO.

[0075] A particular aspect of the invention is, that in particular the plurality of zone controllers 11 are used to control the above steps of gap adjustment instead of a central PLC controller.

[0076] Therefore, reference is made to figure 6, exemplarily showing the second zone controller 11b of the plurality of zone controllers 11a..c of the conveyor arrangement of figure 5 . The zone controller 11b has a first communication section 118 for communication with other zone controllers 11a, 11c over the bus connection 13 (see figure 1). As an example a bus cable can be plugged into one of first connecting sockets 118S. Alternatively, a wireless communication between the various other zone controllers 11a ,c may be performed via suitable communication section 118 adapted for wireless communication.

[0077] The zone controller 11b has a second communication section 119 for communication with field devices such as presence sensors 5 (see figure 1) and motorized rollers 3M (see figure 1). A connecting cable connecting the field devices 5, 3M with the zone controller 11 can be plugged in to one of a plurality of second connecting sockets 119S. The data communication between the second communication section 119 and the field devices can be performed in various ways, e.g. in a bus communication, in a digital 1 :1 communication and / or an

[0078] - 9 -

[0079] 20250922 24041 PWO text.docx analogous 1:1 communication. The second communication section 119 may have several communication devices, e.g. a digital communication devices for bus communication with a motorized roller and an analogue communication device for communication with a light barrier.

[0080] The zone controller 11b has a speed setting section 111. The speed setting section 111 is adapted to calculate a drive speed v of a motorized roller 3M. The calculated speed v is communicated via the second communication section 119 to a motor controller 3C located within the motorized roller 3M (see figure 1).

[0081] The sections are connected to each other via an internal bus 110.

[0082] In another embodiment (not shown in the figures), the zone controller 11 itself may comprise a motor controller including a current inverter. Here the communication section 119 may transfer the calculated speed v to the internal current inverter. The current converter outputs e.g. a three phase, drive current via second connecting sockets 119S to a drive motor within a motorized roller 3M connected to the second connecting sockets 119S.

[0083] The zone controller 11b comprises an object tracking section 112. Within the object tracking section 112 several sets of object data 113 related to the status of conveyed objects 9 are stored and administrated.

[0084] The following description of the operation is based on the situation depicted in figure 5c in view of second zone controller 11b. The same applies also for the remaining zone controllers 11 in other situations.

[0085] The zone controller 11b stores within its object tracking section 112 a set of object data 113k, which is related to the object 9k. Said object 9k is located on the third conveyor zone 2c which is controlled by said second zone controller 11b. Consequently, the third conveyor zone 2c is an own conveyor zone 2 in relation to the zone controller 11b and the object 9k is an own object in relation to the zone controller 11b. Accordingly, in the present situation of figure 5c the second zone controller 11b stores within its object tracking section 112 a set of object data 113k relating to the leading, own object 9k.

[0086] The set of object data 113k comprises an identification “ID” of the related object 9k and a position data “pos” of said related object 9. The position data may be a combination of the identification of the conveyor zone 2, in which the object 9 is located along with an additional position specification, which specifies the position of the object 9 within the conveyor zone 2 in more detail. As an example and according to figure 5c, the position value “2c + 300” expresses, that the object 9k is located in the third conveyor zone 2c at 300mm behind the entry point of this specific conveyor zone 2c.

[0087] - 10 -

[0088] 20250922 24041 PWO text.docx In addition a gap value “gap” is allocated to each object 9. When referring to the example of figure 5, the target gap qt defines the distance, at which an upstream and / or downstream object 9 is to be located upstream of the related object 9. There may be different values for the upstream I downstream distance. In the present example the “gap” value refers to the distance upstream of the object 9.

[0089] In another embodiment the “gap” value may be a single (global) value relevant for all objects 9 within the present conveyor zone 2 or within a group of conveyor zones 2. In particular relevant is the pure existence of a target “gap” value and that the zone controller 11 , in particular the speed setting section 111 , has access to said “gap” value.

[0090] Data referring to a data set 113, in particular position data of an object 9 can be determined with the help of the signal of the presence sensor 5 e.g. a light barrier. Any time when an object 9 gets into the range of the light barrier at an entry time, a leading edge of the object 9 is at the position in conveying direction of the light barrier. The position of the light barrier within the conveyor zone 2 is a constant value and known. When the object 9 continues to travel, the position of the leading edge can be calculated with the help of the rotational speed of the conveyor roller 3 and the time elapsed since the entry time. When the object 9 gets out of range of the light barrier at an exit time, a trailing edge of the object 9 passes the light barrier. From the time difference along with the conveying speed a length LI, Lk of the objects 9k, 9I in the conveying direction can be calculated. The calculated length of the object is added to the set of object data 113 of the related object within the object tracking section 112.

[0091] Now, a differentiation is made between internal data DJnt of a zone controller 11 and external data D_ext of a zone controller 11.

[0092] Internal data DJnt are in particular data, which are generated by or obtained by a respective zone controller 11 based on the operation of the zone controller 11 itself or by the field devices controlled or connected to the zone controller 11 via the second communication section 119. In particular the internal data DJnt comprise the set of object data of an object 9 located on a conveyor zone 2 within the controlling responsibility of the zone controller 11 as well as operating data such as the speed value v(2c), v(2d) or a sensor signal S5 of a connected field device.

[0093] External data D_ext are provided to e. g. a zone controller 11b from a neighboring zone controller 11a, 11c or by a central PLC. External data D_ext are in particular data, which cannot be obtained out of the operation of the own zone controller 11 and the field devices connected to the own zone controller 11. In particular the external data D_ext comprise at least some of the internal data DJnt of a foreign zone controller 11a, 11c controlling other

[0094] - 11 -

[0095] 20250922 24041 PWO text.docx conveyor zones 2a, b, 2e,f than the own zone controller 11b (see figures 5 and 6). The external data D_ext comprise object data 1131, 113f of a foreign object 9I, 9f which is located on a conveyor zone 2c, 2f, controlled by a foreign zone controller 11a, 11c. The external data may also comprise sensor signals S5 allocated to other conveyor zones 2, which are controlled by a foreign zone controller 11.

[0096] According to figure 7, the object tracking section 112 has an object calculating section 114. The object calculating section 114 uses internal and external data DJnt, D_ext for calculating the above values of the set of object data 113 and keep the data sets up to date during operation. In particular the speed values v(2x) of own and foreign conveyor zones 2 can be used to calculate the actual position of own and foreign objects 9.

[0097] According to the above description and introduced values, a zone controller 11 is aware of any own object 9 located within its controlling responsibility as well as its position x and length Lx and the gap qt, at which this object has be located at a distance to another object. Same applies for foreign objects 9, which are located on foreign conveyor zones 2 outside of its controlling responsibility. As a consequence, the speed setting section 111 is enabled to calculate an actual gap between different conveyed objects and compare this actual gap with a target value qt. Accordingly the speed v of an object 9 can be set in a manner so as to control a the gap between two objects 9.

[0098] Figure 8 shows another procedure within the inventive arrangement.

[0099] In figure 8a, both objects, the leading object 9k and the trailing object 9I are traveling with a same speed vk, vl of a high speed level v2 (see situation A in figure 8a). The objects 9k, 9I are arranged to each other at an initial gap qO. A minimum target gap qt is allocated to the trailing object 9I and in particular associated to the respective set of object data 113 (see figure 7). Since this target values represent merely a minimum target, the zone controllers 11 do not initiate any speed difference to amend the actual gap in direction to the target gap qt, as long as the actual gap qO is not smaller than the minimum target gap qt.

[0100] Suddenly, the speed vk of the leading object 9k is reduced to a lower speed level v1 (see situation B2 in figure 8b). Possible reasons for this speed reduction are various but at the moment not of relevance. As an example a jam situation in front of the leading object 9k (not shown) may force the leading object itself to reduce its speed. Please note, that the leading object 9k here may be a trailing object in relation to another object more downstream of the leading object 9k (also the trailing object 9I may be a leading object in relation to another object located more upstream of said object 9I).

[0101] - 12 -

[0102] 20250922 24041 PWO text.docx Since the actual gap qO is still larger than the minimum target gap qt, the speed vl of the trailing object 91 remains at the high speed level v2 (see situation B1 in figure 8b).

[0103] In situation C of figure 8c, the trailing object 9I reaches the conveyor zone 2c, on which the leading object 9k is located. Since both objects are located on the same conveyor zone 2c, the trailing object 9I adopts the same speed vk = v1 of the leading object 9k.

[0104] In situation D of figure 8d, the leading object 9k reaches the next zone 2d, so that trailing object 9I (still located on conveyor zone 2c) is not located anymore on a same conveyor zone 2 with the leading object 9k. Since the actual gap q1 is still larger than the minimum target gap qt, the trailing object 9I is accelerated to the second speed v2.

[0105] In situation E of figure 8e the actual gap is equal to the target gap qt. Accordingly the zone controller 11b controlling the conveyor zone 2c, where the trailing object 9I is located, reduces the (maximum) speed of the leading object 9k to the first speed level v1 1 the speed vk of the leading object 9k, so that the target gap qt is maintained (this is a simplified illustration; in a real situation, the controller 11 has started to reduce the speed already before the actual gap is equal to the minimum target gap qt).

[0106] As long as the speed of the leading object 9k stays on the low speed level v1 , the trailing object 9I cannot be conveyed at a higher speed (see figure 8f), so both objects are conveyed at the same low level speed v1.

[0107] In situation G2 of figure 8g, the leading object 9k can be accelerated again to a higher speed v2. Immediately, the actual gap slightly increases over the level of minimum target gap qt. The zone controller 11c controlling the operation of the trailing object 9I recognizes the increase of the actual gap and accelerates the trailing object to the second speed v2 (situation G1 of figure 8g). This would also be the case even if the zones 2, where the trailing object 9I and the leading object 9k are located are controlled by different zone controllers 11.

[0108] - 13 -

[0109] 20250922 24041 PWO text.docx List of reference signs

[0110] 1 conveyor arrangement 2a...f conveyor zone 3 conveyor roller 3C motor controller 3M motorized roller 4 connector 5 Presence sensor 8 support frame 9 object 9k leading object 9I trailing object 9f occupying object 11a...f zone controller 13 bus connection 110 internal bus 111 speed setting section 112 object tracking section 113 object data 114 object calculating section 118 first communication section 118S first connecting socket 119 second communication section 119S second connecting socket x conveying position q, qi gap between leading and trailing object q0 initial gap qt target gap v conveying speed vk leading speed (speed of leading object) vl trailing speed (speed of trailing object) d conveying direction I inlet of conveyor zone O outlet of conveyor zone L2 length of conveyor zone Lf, Lk, LI length of individual object S5 sensor signal

[0111] - 14 -

[0112] 20250922 24041 PWO text.docx

Claims

Claims1. Method of controlling the operation of a conveyor arrangement (1), the conveyor arrangement (1) is adapted to convey an object (9) in a downstream conveying direction (d), 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),- at least one zone controller (11), adapted to control the operation of at least one own conveyor zone (2), characterized in that the speed (vk, vl) of an object (9k, 9I) is controlled based on a gap value (q, q1, qt), wherein the gap value (q, q1, qt) refers to an actual distance and / or target distance between two objects (9k, 9I) subsequently conveyed within the conveyor arrangement (1), in particular between a leading object (9k) and a trailing object (9I).

2. Method according to the preceding claim, characterized in that the method allows, that said two objects (9k, 9I) are temporarily located within one conveyor zone (2) and temporarily located on different conveyor zones (2), wherein the speed (vk, vl) of said objects (9k, 9I) is controlled in a manner so as to prevent that said objects (9k, 9I) contact each other, and that for amending an actual gap (q 1 ) between said objects (9k, 9I) the conveying speeds (vk, vl) of said objects (9k, 9I) are amended in a targeted manner by creating a speed difference between said objects (9k, 9I) when said objects (9k, 9I) are located temporarily on different conveyor zones (2).

3. Method according to any of the preceding claims, characterized in that the method allows, that said two objects (9k, 9I) are temporarily located fully within one common conveyor zone (2), wherein the at least one zone controller (11) controls the speed (vk, vl) of said objects (9k, 9I) in a manner so as to prevent that said objects (9k, 9I) contact each other even if said objects (9k, 9I) are located in or conveyed into the same conveyor zones (2).- 15 -20250922 24041 PWO text.docx4. Method according to any of the preceding claims, characterized in the method controls the speed (vk, vl) of said objects (9k, 9I) in a manner- so as to change an actual gap (q1) between said objects (9k, 9I) to a target gap (qt); and / or- to maintain a minimum target gap (qt) between said objects (9k, 9I).

5. Method according to any of the preceding claims, characterized in that the conveyor arrangement (1) is controlled by a plurality of zone controllers (11), each zone controller (11) controls the operation of one or a plurality of conveyor zones (2).

6. Method according to the preceding claim, characterized in that for adapting the gap between two objects at least one of said zone controllers (11b) controls a speed (vk) of an own object (9k) which is located on an own conveyor zone (2c, 2d) which is controlled by said zone controller (11b); and wherein said zone controller (11b) controls the speed (vk) of said own object (9k) by the position and / or speed of a foreign object (9I) located on a foreign conveyor zone (2b) controlled by another zone controller (11a).

7. Method according to any of the preceding claims, characterized in that an actual position of an object is determined by combining presence sensor signals with conveyor speed data over time.- 16 -20250922 24041 PWO text.docx8. Zone controller (11b) adapted to control the operation of at least one own conveyor zone (2) in a conveyor arrangement (1), in particular the conveyor arrangement (1), adapted to convey an object (9) in a downstream conveying direction (d), where 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),- at least one zone controller (11), each adapted to control the operation of at least one or a plurality of own conveyor zones (2); the zone controller (11b) comprising:- a first communication section (118) adapted to communicate with at least one foreign zone controller (11a, 11c) controlling at least one foreign conveyor zone (2a, 2b, 2e, 2f) of the conveyor arrangement (1);- a second communication section (119) adapted to communicate with at least one field device (3M, 5), the field device comprises at least a drive motor (3M) of the own conveyor zone (2c, 2d);- a speed setting section (111) adapted to set a conveying speed of an own conveyor zone (2c, 2d);- an object tracking section (112), the object tracking section (112) is adapted to store object datasets (113) containing status data of an own object (9k, 9f) conveyed on an own conveyor zone (2c, 2d).

9. Zone controller (11 b) according to the preceding claim, characterized in that the zone controller (11b), in particular the speed setting section (111) of said zone controller (11b), is adapted to control a conveying speed of an own conveyor zone (2c, 2d) based on stored object data (113k) of an own object (9k); in particular that in addition the zone controller (11b), in particular the speed setting section (111) section of said zone controller (11b), is adapted to control said conveying speed (v) of said own conveyor zone (2c) also based on object data (1131) of a foreign object (91), in particular received from an other zone controller (11a).- 17 -20250922 24041 PWO text.docx10. Zone controller (11 b) according to any of claims 8 to 9, characterized in that object data (113) of a foreign object (9I) located on a foreign conveyor zone (2a, 2b, 2e, 2f) is provided to the zone controller (11b) from a foreign zone controller (11a) via the first communication section (118).

11. Zone controller (11) according to any of claims 8 to 10, characterized in that the object data (113k, 1131) used for calculating the conveying speed (vk, vl), in particular the object data (113) of said own object (9k) and / or said foreign object (9I), which are the basis for the speed calculation, comprise:- a conveying position (pos) of said object (9),- a length (L) of said object (9).- optional a target gap value (qt) allocated to said object (9)12. Zone controller (11) according to any of claims 8 to 11 , characterized in that the zone controller (11b) is adapted to control the conveying speed based on a gap value (q, q1, qt) indicating an actual and / or target gap between a leading object (9k) and a trailing object (9I), in particular that at least temporarily- one of the leading object (9k) and the trailing object (9I) is a foreign object, and- the other one of the trailing object (9I) and leading object (9k) is an own object.

13. Zone controller (11b) according to any of claims 8 to 12, characterized in that the zone controller is adapted to determine an actual position of an object by combining presence sensor signals with conveyor speed data over time.

14. Zone controller (11b) according to any of claims 8 to 13, characterized in that the zone controller (11), in particular the speed setting section (111) of the zone controller (11b), is adapted to differentiate whether a trailing object (9I) and a leading object (9k) are located both on a same conveyor zone (2) or on different conveyor zones (2), and the zone controller (11b) is adapted for amending the gap (q) between said objects (9) in a manner, that for the time, that said trailing object (9I) and said leading object (9k) are located on different conveyor zones (2), the zone controller- 18 -20250922 24041 PWO text.docx(11) is adapted to generate in a targeted manner a speed difference between the conveying speeds (v) of the conveyor zone (2) on which the trailing object (9I) and the leading object (9k) are located.

15. Conveyor arrangement (1), adapted to convey an object (9) in a downstream conveying direction (d), where the conveyor arrangement (1) comprises:- 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 of zone controllers (11) according to any of claims 8 to 14, each adapted to control the operation of at least one or a plurality of own conveyor zones (2); in particular the conveyor arrangement (1) is adapted to perform a method according to any of claim 1 to 7.- 19 -20250922 24041 PWO text.docx

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