Adaptive Conveyor Zoning Using Image-Based Material Detection
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Solution Overview
Problem
Conveyor systems face challenges in efficiently adapting zones to accommodate varying sizes and types of conveyed materials, leading to potential delays and inefficiencies in material processing.
Innovation Solution
A conveyor system that includes a conveying device, an image capture device, an evaluation device, and a control device, which captures image information of the conveyor line, evaluates the material being conveyed, and dynamically adjusts the size, number, and speed of the zones to optimize material flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the conveyor line is divided into multiple zones with fixed size and speed, then the system structure is simple and easy to control, but the system cannot efficiently adapt to varying sizes and types of conveyed materials
Solution Approach 1:
The patent applies dynamics by making the zone configuration movable and adjustable rather than fixed. The control device dynamically modifies zone boundaries, sizes, and speeds based on real-time detection of conveyed material characteristics. This allows the conveyor system to adapt its structure to different material types and sizes, resolving the contradiction between adaptability and complexity.
Solution Approach 2:
The patent changes physical parameters of the conveyor zones (size, speed, number) based on detected material properties. The control device adjusts these parameters dynamically to optimize conveying efficiency for different materials, thereby improving adaptability while maintaining manageable system complexity through automated parameter adjustment.
2Productivity
If the zones are manually configured for different materials, then the system can handle various material types, but the adaptation process is time-consuming and causes delays
Solution Approach 1:
The patent implements preliminary action by having the image capture device detect and the evaluation device analyze material characteristics before the material reaches the conveying zones. The control device then pre-configures the appropriate zone settings based on this advance information, eliminating delays that would occur if configuration had to wait for material arrival.
Solution Approach 2:
The patent uses feedback by creating a closed-loop system where the image capture and evaluation devices continuously monitor conveyed materials, and the control device adjusts zone configurations in real-time based on this feedback. This automated feedback mechanism enables rapid adaptation without manual intervention, improving productivity while minimizing adaptation time.
3Adaptability or versatility
If a single uniform zone configuration is used throughout the conveyor line, then the system is easy to operate and maintain, but it cannot optimize processing for different material types
Solution Approach 1:
The patent applies segmentation by dividing the conveyor line into multiple independent zones that can be individually configured. Each zone can have different size, speed, and activation status based on material requirements. This segmentation enables adaptability while maintaining operational simplicity through automated control of individual zones rather than managing a complex monolithic system.
Solution Approach 2:
The patent implements universality by creating a control system that can manage multiple zone configurations using a single unified control device. This multi-functional control apparatus can adapt to various material types while presenting a simple, consistent interface for operation, thereby achieving both adaptability and ease of operation.
Data Source
AI summary
The invention relates to a conveyor system (100) for transporting a conveyed material (11-16), comprising a conveying device (20) that is designed to transport the conveyed material (11-16) along a conveyor line (30), the conveyor line (30) being divided into multiple zones (31-36).