Autonomous Conveyor System With Tag-Based Switch Control
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Solution Overview
Problem
Conveyor systems for manufacturing are challenging to install, modify, and maintain due to the need for extensive programming and rebalancing, especially when changes occur, leading to increased labor costs and potential drift over time.
Innovation Solution
A conveyor system with machine-readable and writable tags on work piece carriers, autonomous switch control devices, and interconnected endless conveyors that allow for autonomous operation without central control, enabling easier installation, modification, and maintenance by determining next operation addresses and controlling flow based on tag data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional conveyor systems are used with centralized control software, then the system can handle complex manufacturing operations, but the system becomes difficult and costly to install, modify, and maintain due to extensive programming requirements
Solution Approach 1:
The centralized control software is segmented into autonomous control units distributed across individual conveyor sections and operation stations. Each control unit independently manages its local conveyor section, eliminating the need for complex centralized programming while maintaining full manufacturing operation capability through coordinated autonomous decisions.
2Adaptability or versatility
If traditional conveyor systems are modified by adding or removing operating stations, then the system can adapt to changing manufacturing needs, but significant labor and reprogramming are required to rebalance the system
Solution Approach 1:
The autonomous control units enable the conveyor system to self-adjust and self-balance when operating stations are added or removed. Each control unit independently monitors workpiece flow and automatically adjusts conveyor speeds and routing decisions, eliminating the need for manual rebalancing and reprogramming during system modifications.
3Productivity
If traditional conveyor systems operate over time, then production continues, but wear and stoppages cause the system to drift, requiring periodic rebalancing and reprogramming
Solution Approach 1:
Autonomous control units continuously monitor workpiece flow, conveyor speed, and system status in real-time, using feedback loops to automatically compensate for drift caused by wear and stoppages. This self-correcting mechanism maintains system reliability and stability over time without requiring periodic manual intervention or reprogramming.
4Manufacturing precision
If extensive programming is used to control each sensor and actuator, then the system can precisely control workpiece flow, but the system becomes costly and time-consuming to install and maintain
Solution Approach 1:
The complex mechanical control system based on centralized software programming is replaced with an autonomous control system where individual control units make real-time decisions based on local sensor input and pre-programmed rules. This substitution maintains precise workpiece flow control while dramatically reducing installation and maintenance time by eliminating the need for extensive centralized software configuration.
Data Source
AI summary
Disclosed herein is a conveyor system comprising a plurality of work piece carriers, each presenting a machine readable and writable tag and being adapted for supporting at least one work piece during transportation. The system further comprises distribution highway conveyors each in the form of an endless conveyor adapted for transporting and circulating the work piece carriers, flow balancing conveyors and operation unit conveyors. Control of the system is achieved by autonomous switch control devices arranged at each intersection between conveyors to control the flow of the work piece carriers at the respective intersection.