Conveyor Roller Control Switching for Fast Digital Diagnostics

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Solution Overview

Problem

Conveyor systems with analog-controlled motorized rollers face challenges in maintenance and downtime due to the complexity of matching control signals and the need for extensive cabling, making it difficult to quickly replace or reconfigure rollers during failures, leading to prolonged downtime and financial losses.

Innovation Solution

A conveyor apparatus with a drive control module that receives analog control signals and switches to a digital communication state upon receiving a switchover command, allowing for the transmission and reception of digital diagnostic and configuration data, which includes characteristics and operating data of the conveyor apparatus, thereby facilitating quicker maintenance and replacement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If analog control signals are used for controlling conveyor rollers, then the system can operate in zero-pressure accumulation mode with individual task actuation, but the maintenance and reconfiguration process becomes time-consuming due to the complexity of matching control signals

Engineering Contradiction:

Improveindividual task actuationVSAvoidmaintenance time

Core Design Contradiction:

Adaptability or versatilityVSEase of repair

Solution Approach 1:

The patent changes the signal type parameter from analog to digital for diagnostic data transmission. The drive control module can operate in analog mode for control or switch to digital mode for data exchange, changing the communication parameter based on the task at hand. This allows quick reading of diagnostic data without analog signal matching during maintenance.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The existing analog control connection interface is made multi-functional by enabling it to handle both analog control signals and digital diagnostic data. The same physical connection serves dual purposes: analog operation during normal conveyance and digital communication during diagnostics, eliminating the need for separate cabling.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Measurement precision

If analog control signals are used for conveyor apparatus, then the system can be controlled precisely, but extensive cabling and complex signal matching are required for data transmission, increasing device complexity

Engineering Contradiction:

Improvecontrol precisionVSAvoidcabling complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The control connection interface is designed to be universal, handling both analog control signals for precise operation and digital diagnostic data transmission. The same physical connection serves multiple functions, eliminating the need for separate analog and digital cabling systems.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The drive control module dynamically switches between analog operating mode and digital communication mode based on the task. During normal operation, it processes analog control signals with high precision. During diagnostics, it switches to digital mode for data exchange, adapting its functionality in real-time.

Inventive Principle:

Principle #15Dynamics

3Reliability

If analog control signals are used for conveyor rollers, then the system can operate reliably, but the replacement and reconfiguration of rollers during failures leads to prolonged downtime and financial losses

Engineering Contradiction:

Improveoperational reliabilityVSAvoiddowntime

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system performs preliminary actions by storing diagnostic data (operating hours, cycle counts, error logs) in the drive control module during normal operation. When a failure occurs, this pre-collected data is immediately available for reading via digital communication, enabling rapid diagnosis and replacement without time-consuming analog signal matching.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces the mechanical/analog process of signal matching with electronic digital data transmission. Instead of manually matching analog control signals during maintenance, the system uses digital communication over the existing connection interface to quickly read diagnostic data and configure replacement rollers.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS11795001B2Analog-controlled transport device with data read-out

Publication Date: 2023.10.24 INTERROLL HLDG

AI summary

A conveyor apparatus includes a drive unit, a connection interface which transmits analog signals, and a drive control module which is coupled to the drive unit and to the connection interface via signal technology. The drive control module receives analog control signals via the connection interface in an operating state and controls the drive unit as a function of the analog control signals, outputs digital diagnostic signals via the connection interface in a digital communication state, and switches from the operating state to the digital communication state upon receipt of a switchover command. The switchover command is made up of a predetermined analog control signal or a predetermined sequence of analog control signals.