Autonomous Conveyor Carriers with On-Board Power
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Solution Overview
Problem
Conventional conveyor systems require extensive electrical and pneumatic infrastructure, are limited by fixed paths, and lack autonomous operation, making them inefficient and inflexible for industrial applications.
Innovation Solution
A conveyor system featuring a passive, non-electrified rail with self-contained, autonomously driven carriers equipped with microprocessors, wireless communication, and on-board power sources, allowing for programmable control of travel parameters and operation in various configurations, including curved paths and load orientation adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional conveyor systems use continuous moving chains or rotating friction drives, then power transmission is achieved, but extensive electrical and pneumatic infrastructure is required
Solution Approach 1:
Each carrier is equipped with its own power supply (battery) and drive mechanism, allowing it to propel itself along the rail without requiring external power transmission infrastructure. The carrier serves its own power and propulsion needs independently
Solution Approach 2:
The power supply and drive mechanism are extracted from the central conveyor infrastructure and placed individually on each carrier. This eliminates the need for continuous moving chains, rotating friction drives, and associated electrical/pneumatic infrastructure that would otherwise be required to transmit power centrally
2Strength
If conveyor systems use fixed infrastructure rails, then structural support is provided, but the paths are predetermined and inflexible
Solution Approach 1:
While the rail structure remains fixed and passive, the carriers are made dynamically controllable through onboard microprocessors and drive mechanisms. Each carrier can independently adjust its speed, acceleration, and stopping points, enabling flexible routing and operational adaptability without modifying the physical rail infrastructure
Solution Approach 2:
The conveyor system is segmented into independent, autonomously controlled carriers rather than a centralized controlled system. Each carrier operates independently with its own control system, allowing individual carriers to take different paths or schedules while sharing the common fixed rail infrastructure
3Device complexity
If conveyor systems lack autonomous operation, then system control is simplified, but operational efficiency and flexibility are reduced
Solution Approach 1:
Each carrier is equipped with a self-contained control system including microprocessor, memory for preprogrammed instructions, and wireless communication capability. The carrier autonomously executes its travel parameters and can be remotely reprogrammed without requiring complex centralized control infrastructure
Solution Approach 2:
Traditional mechanical control systems with physical connections and centralized control are replaced with electronic and wireless communication systems. Carriers receive control instructions wirelessly and execute them autonomously, eliminating the need for complex mechanical control linkages
Data Source
AI summary
A conveyor system including a fixed, non-powered rail defining a conveyor path, and a plurality of automated conveyor carriers supported on the rail. Each carrier includes an on-board motor, at least one wheel forming an interface with the rail, and an on-board power source selectively powering the on-board motor to drive the ACC along the rail. Each of the plurality of carriers operates to power the on-board motor from the on-board power source under the direction of instructions programmed to a local controller.