Conveyor Carrier Locking for Precise High-Acceleration Positioning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing conveyor systems face challenges with high acceleration and deceleration forces leading to slippage, synchronization issues causing load peaks, and the need for precise positioning of components in industrial production, especially in automotive series production, which are costly and prone to vibration-induced inaccuracies.
Innovation Solution
A conveyor system with a station-assigned carrier principle using a linear conveyor and a locking unit that positively connects and decouples the component carrier, allowing for precise positioning and transfer between segments without synchronization, and incorporates energy storage to manage acceleration and deceleration phases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If friction-based chain/belt or roller conveyors are used for horizontal conveying, then the design is simple and robust with cost-effective solution, but the conveyors reach their limits at high acceleration or deceleration rates causing slippage
Solution Approach 1:
The patent replaces the friction-based mechanical connection (chain/belt/roller) with a magnetic field-based connection using permanent magnets. The magnetic attraction force between the magnets on the conveyor and the magnetically attractable material on the component carrier provides a reliable connection that is not dependent on friction, enabling high acceleration and deceleration without slippage.
2Productivity
If multiple components are transported simultaneously with high acceleration, then productivity is improved, but the power supply network is subjected to excessive load due to high inrush currents during start-up
Solution Approach 1:
The control system activates the drives of multiple conveyor segments in a staggered, periodic manner rather than simultaneously. This sequencing of start-up actions distributes the inrush current demand over time, preventing excessive peak loads on the power supply network while still enabling simultaneous transport of multiple components through coordinated operation.
3Reliability
If synchronization of rotational speeds is implemented at conveyor joints to prevent slippage, then positioning reliability is improved, but cycle time of the entire system is negatively impacted
Solution Approach 1:
The magnetic connection eliminates the need for mechanical synchronization of conveyor segments. Since the magnetic force acts independently on each component carrier regardless of the relative speeds of adjacent conveyors, the system can operate segments at different speeds without causing slippage, thereby reducing cycle time while maintaining positioning reliability.
4Measurement precision
If external position measuring systems are used for precise positioning, then positioning accuracy is improved, but the systems are expensive and prone to vibration-induced inaccuracies
Solution Approach 1:
The system uses the magnetic connection mechanism itself to provide positioning information. The position of the component carrier is detected by sensing the magnetic field characteristics of the permanent magnets that are already part of the conveyor system, eliminating the need for separate external measuring systems. This self-service approach reduces cost and vibration susceptibility.
5Adaptability or versatility
If component carriers are decoupled from the conveyor during processing, then processing operations can be performed, but the component carriers must be regularly repositioned and additional staking devices are required
Solution Approach 1:
The conveyor system is divided into separate functional segments: transport segments with magnetic drives and stationary processing segments. Component carriers are automatically transferred between these segments by the magnetic connection mechanism, which can selectively engage and disengage. This segmentation allows processing operations to occur on stationary carriers while eliminating the need for additional staking devices, as the magnetic connection provides inherent positioning stability.
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
Ensures reliable, cost-effective, and flexible positioning of components with high acceleration and deceleration rates, reducing maintenance and energy load peaks, while maintaining precise positioning accuracy and reducing external position measuring system costs.
Implementation Method 1
the drive movement of the component carrier segment by segment is implemented using several permanently excited synchronous linear motors arranged in a row
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a conveyor system for an industrial production plant, comprising a conveyor line provided with a stationary, linear conveyor (27), in particular with at least one toothed belt or chain extending in the conveying direction, wherein a component carrier (21) is movable along the conveyor line by means of the conveyor (27). The component carrier (21) can be positively connected to the conveyor (27) and decoupled from the conveyor (27), wherein a stationary locking unit (23) is provided on the conveyor line, and wherein the locking unit (23) is configured to decouple the component carrier from the conveyor (27) and to secure the component carrier (21) in a fixed position in a work train.Using this conveyor system, the component carrier containing the component to be machined can be secured precisely at the correct location within a processing station, independent of slippage and vibrations of the conveyor. The conveyor can be reused for other transport tasks during processing, and high acceleration and deceleration rates can be achieved with low wear. Furthermore, the locking unit allows the component carrier to be transferred to another segment of the conveyor line without the component carrier being temporarily unguided.