Conveyor Article Release Timing Control

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Solution Overview

Problem

Conventional material handling systems face challenges in optimizing the release time of articles from upstream conveyors to downstream conveyors, particularly in wedge merge mode, leading to inefficiencies and productivity losses due to pre-calibrated release times and manual recalibration requirements when switching between merge modes.

Innovation Solution

A controller system that records and predicts the dimensions of articles using historical logs, dynamically computes release times based on cumulative lengths and operating speeds, and creates empty spaces on upstream conveyors to accommodate upcoming articles, allowing for real-time optimization of article release without pre-defined release times.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If pre-calibrated release times are used for article release, then the system operation is simplified, but productivity is reduced due to idle wait times and inability to adapt to varying article dimensions

Engineering Contradiction:

Improvearticle release efficiencyVSAvoididle wait time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The system transitions from static pre-calibrated release times to dynamic release time computation. The controller continuously monitors article dimensions, conveyor speeds, and queue lengths, then dynamically adjusts release times in real-time to eliminate idle wait times and optimize productivity.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system implements feedback loops where sensors detect article dimensions and positions, the controller processes this information to compute optimal release times, and the conveyors execute the adjusted release schedule. This closed-loop control enables continuous optimization of article release based on actual system conditions.

Inventive Principle:

Principle #23Feedback

2Reliability

If manual recalibration is performed when switching between merge modes, then the system maintains operational control, but time is lost and operational complexity increases

Engineering Contradiction:

Improvemerge operation controlVSAvoidmode switching operation

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The system performs self-calibration by automatically detecting article dimensions and computing appropriate release parameters when switching between wedge merge and zipper merge modes. The controller adapts to different merge modes without requiring manual intervention, maintaining reliability while simplifying operation.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system dynamically changes operational parameters (release times, conveyor speeds) based on the selected merge mode and real-time conditions. When switching between wedge merge and zipper merge, the controller automatically adjusts these parameters to optimize performance for each mode without manual recalibration.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If articles are released without creating empty spaces, then the conveyor operates continuously, but collisions occur between articles from different upstream conveyors

Engineering Contradiction:

Improveconveyor utilizationVSAvoidarticle collision

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The system performs preliminary actions by creating empty spaces on downstream conveyors before releasing articles from upstream conveyors. The controller predicts upcoming article dimensions and pre-positiones empty spaces to ensure safe merging, preventing collisions while maintaining high conveyor utilization.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Empty spaces act as intermediaries between articles from different upstream conveyors. By introducing these buffer zones, the system enables safe merging of articles without direct contact, eliminating collisions while preserving continuous conveyor operation and productivity.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Device complexity

If fixed release times are used, then the control system is simpler, but the system cannot adapt to random article dimensions and speeds

Engineering Contradiction:

Improvecontrol system complexityVSAvoidarticle dimension adaptation

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The control system transitions from fixed, static release times to dynamic, adaptive release time computation. The controller continuously adjusts release parameters based on real-time measurements of article dimensions, conveyor speeds, and system state, enabling adaptation to varying article characteristics while maintaining manageable complexity through systematic control algorithms.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS10577191B2Conveyor article management system

Publication Date: 2020.03.03 INTELLIGRATED HEADQUARTERS LLC

AI summary

Various embodiments described herein relate to a method of predicting article dimensions and controlling release timing of upcoming articles from upstream conveyors and dynamically computing release times for the upstream conveyors. The method includes predicting a dimension of an upcoming article and creating empty spaces on an upstream conveyor between one or more upstream articles from among a set of upstream articles by controlling an operating speed of a set of drive motors of the upstream conveyor based on the predicted dimension for the upcoming article. Further, the release times of the set of upstream articles is dynamically computed based on a cumulative length of the set of upstream articles and an operating speed of the upstream conveyor.