Battery Tray Speed Control for Shock-Prone Conveyor Sections
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Solution Overview
Problem
Existing transport devices for batteries are prone to shocks during movement, which can damage the batteries, and existing systems fail to effectively adjust the speed of the tray to mitigate these shocks, especially in unpredictable environments.
Innovation Solution
A transport device with a shock sensor, reader, and controller that divides the movement path into areas, using RFID tags to identify shock levels, and adjusts the tray's speed based on sensed shock data to minimize damage by reducing speed in high-shock areas and increasing speed in low-shock areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the tray moves at a constant speed, then the productivity is improved, but the batteries are damaged by shocks in high-shock areas
Solution Approach 1:
The transport device dynamically adjusts the tray's speed based on real-time shock sensor data and pre-stored shock level information for different path areas. The controller continuously monitors shock levels and modifies the transport speed accordingly, transitioning from constant speed to variable speed operation to minimize battery damage while maintaining overall productivity.
Solution Approach 2:
The system implements a feedback mechanism where shock sensors continuously monitor the actual shock levels experienced by the tray during transport. This real-time feedback is fed back to the controller, which compares it with stored threshold values and adjusts the transport speed accordingly. This closed-loop control ensures that the tray speed is optimized based on actual conditions rather than operating at a fixed constant speed.
2Object-affected harmful factors
If the tray speed is reduced in high-shock areas, then the battery damage is minimized, but the transport time increases
Solution Approach 1:
The transport path is divided into multiple areas with different shock characteristics, and the tray speed is locally optimized for each area. In high-shock areas, the speed is reduced to protect batteries, while in low-shock areas, the speed is maintained or increased to compensate for the time lost. This localized speed adjustment strategy minimizes overall transport time while protecting batteries in critical areas.
Solution Approach 2:
The system performs preliminary actions by pre-storing shock level information for different path areas in advance. Before the tray enters a high-shock area, the controller has already received and processed the shock level data, allowing it to proactively adjust the speed before the tray encounters the harmful shock conditions. This advance preparation prevents battery damage without causing unexpected delays.
3Productivity
If the tray speed is increased in low-shock areas, then the productivity is improved, but the shock sensor and control system complexity increases
Solution Approach 1:
The transport device serves itself by using onboard shock sensors to automatically detect and measure shock levels during operation. The controller autonomously processes the sensor data, compares it with stored threshold values, and adjusts the tray speed without external intervention. This self-service capability reduces the need for complex external monitoring and control infrastructure while maintaining high productivity through automated speed optimization.
Solution Approach 2:
The system replaces complex mechanical speed control mechanisms with electronic sensing and control. Instead of using mechanical devices to physically detect and respond to shock conditions, the patent uses electronic shock sensors and a digital controller that processes electrical signals. This substitution of mechanical systems with electronic ones reduces overall system complexity while enabling more precise and responsive speed adjustment for improved productivity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system minimizes battery damage by dynamically adjusting the tray's speed in response to shock levels, enhancing transport efficiency and reducing defective batteries.
Implementation Method 1
a shock sensor that is disposed at the tray, and senses an amount of shock transferred to the tray
Implementation Method 2
one or more recognized members that are installed along a path of the tray, a reader that is disposed at the tray, and recognizes the one or more recognized members
Data Source
AI summary
Disclosed are a transport device for moving batteries and a control method thereof. The transport device for conveying batteries according to the present disclosure comprises a tray which carries batteries while moving along a conveyor belt, a shock sensor that is disposed at the tray, and senses an amount of shock transferred to the tray, a recognized member that is installed along a path of the tray, a reader that is disposed at the tray, and recognizes the recognized member, and a controller that receives values measured by the shock sensor and the reader and stores the values in a server, and in a section in which a predetermined value or greater of shock is transferred to the tray, decreases a speed of movement of the tray.