Conveyor Bundle Positioning Simulation for Layer Pattern Formation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Automating the process of placing bundles in a desired pattern on a load former is challenging due to the need for precise rotation and positioning of bundles, which is time-consuming and requires new calculations each time the size or shape of the bundles changes.
Innovation Solution
A method and system that uses a conveyor system to automatically determine the required shifts and rotations of bundles based on their initial position, creating a control data set to replicate the desired pattern on a physical conveyor system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a robotic arm or human operator manually arranges bundles on a load former, then the desired pattern can be achieved, but the process is time-consuming and difficult to automate
Solution Approach 1:
The system performs preliminary calculations to determine the exact rotation and positioning angles for each bundle before the conveyor operation begins. The computer model pre-computes the control data set that will guide the conveyor sections to position bundles correctly, eliminating the need for real-time manual or robotic adjustment during the actual bundling process.
Solution Approach 2:
The patent replaces manual or robotic mechanical positioning with an automated conveyor system controlled by computer-generated instructions. The conveyor sections, guided by pre-calculated control data, automatically position bundles in the desired pattern without human intervention or complex robotic manipulation.
2Manufacturing precision
If manual calculations are performed to determine bundle rotation and positioning, then the desired pattern can be formed, but the process requires new calculations each time bundle size or shape changes
Solution Approach 1:
The system automatically adjusts positioning parameters based on input data about bundle dimensions and desired pattern specifications. When bundle size or shape changes, the computer model re-calculates the control data set using updated parameters, maintaining precision without requiring manual intervention or complex procedural changes.
Solution Approach 2:
The patent uses a computer model that creates a virtual representation of the bundle arrangement process. This digital model copies the physical constraints and geometry of bundles and conveyor sections, allowing automated calculation of positioning instructions without manual geometric computations.
3Adaptability or versatility
If different layers of bundles have different patterns, then customization is achieved, but new calculations are required for each layer configuration change
Solution Approach 1:
The system dynamically generates control data for different layer patterns by accepting input specifications for each layer's desired configuration. The computer model automatically adapts calculations based on the specific pattern requirements for each layer, enabling versatile customization without manual recalculation or reconfiguration of the physical system.
Data Source
AI summary
A method includes defining a configuration of physical bundles on a physical support surface, providing a bundle computer model of at least one of the physical bundles and providing a conveyor computer model of a physical conveyor. The physical conveyor is a conveyor configured to carry the physical bundles from an upstream end of the physical conveyor to a downstream end and to deposit the physical bundles on the physical support surface. The physical conveyor includes a controller and at least one adjustment section configured to adjust a position and/or orientation of the physical bundles. Also using a processor running the conveyor computer model to automatically determine from the conveyor computer model and the bundle computer model a control data set including instructions for causing the controller to operate the physical conveyor to produce the configuration of the given number of the physical bundles on the physical support surface.