Sensor-Guided Conveyor Chain Control for Precise Workpiece Transport
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Solution Overview
Problem
Transport systems in machining devices face issues with reduced precision, reliability, and service life due to mechanical and thermal stress, leading to premature wear and increased maintenance needs, which can result in economic damage and reduced machining quality.
Innovation Solution
A transport system equipped with sensors to detect condition variables such as preload force, instantaneous load, and dynamic behavior, combined with actuators to actively adjust and influence these variables, minimizing vibrations and noise, and enabling predictive maintenance to extend service life and improve machining accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If circulating transport means are used to continuously transport workpieces through machining regions, then productivity is improved, but manufacturing precision deteriorates due to reduced conveying precision from mechanical and thermal stress
Solution Approach 1:
The transport system transitions from a static configuration to a dynamic one by introducing actuators that can actively adjust the position and preload of transport chain sections in real-time, allowing the system to adapt to mechanical and thermal stress changes while maintaining conveying precision
Solution Approach 2:
Sensors are integrated into the transport system to continuously monitor condition variables such as preload force, instantaneous load, and dynamic behavior. This feedback enables real-time detection of precision deviations caused by wear or stress, allowing for immediate corrective action through the actuators to maintain manufacturing precision
2Productivity
If transport systems operate for extended periods without maintenance, then productivity is improved, but reliability deteriorates due to premature wear and breakdown
Solution Approach 1:
The system performs preliminary detection of wear and condition changes through sensors before they lead to breakdown. By monitoring condition variables continuously, the system can identify early signs of wear and trigger maintenance actions or adjustments before reliability is compromised
Solution Approach 2:
The transport system monitors its own condition through integrated sensors and can automatically adjust its operation or trigger maintenance alerts based on detected wear and performance degradation, enabling self-diagnosis and self-adjustment to maintain reliability
3Reliability
If frequent maintenance is performed to maintain reliability, then reliability is improved, but productivity deteriorates due to reduced device availability
Solution Approach 1:
Continuous monitoring of condition variables provides real-time feedback on the actual wear and performance state of the transport system. This enables maintenance to be performed only when necessary, based on actual condition rather than fixed schedules, thereby maintaining reliability while minimizing interruptions to productivity
Solution Approach 2:
The system can adjust operational parameters such as preload force and transport speed based on detected wear and condition changes. By changing these parameters dynamically, the system can compensate for wear effects and maintain reliability without requiring frequent maintenance shutdowns
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 achieves precise conveying operations, high reliability, long service life, and reduced maintenance requirements, enhancing machining quality and device availability by continuously monitoring and adjusting parameters in real-time.
Implementation Method 1
at least one sensor for detecting at least one condition variable, in particular the preload force and/or instantaneous load on the at least one circulating transport means and/or the dynamic behavior of at least one section of the transport system
Implementation Method 2
at least one actuator for influencing at least one condition variable of the transport system... Vibration and noise emissions can be minimized by virtue of the optimized preload forces of the chain
Data Source
AI summary
A transport system (1) for transporting workpieces (2) which preferably consist at least in sections of wood, wood-based materials, plastic or the like, comprising at least one circulating transport means (15); a guide arrangement (4) for guiding the at least one circulating transport means (15); at least one sensor (10, 11, 12) for detecting at least one condition variable, in particular the preload force and/or instantaneous load on the at least one circulating transport means (15) and/or the dynamic behavior of at least one section (6, 8) of the transport system (1); and at least one actuator (13, 20) for influencing at least one condition variable of the transport system (1).