Range-Sensing Conveyor Control for Parcel Density Balancing

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Solution Overview

Problem

Conventional conveyor systems face inefficiencies due to imbalances and variability in parcel flow, leading to reduced throughput and increased equipment investment, as they struggle to maintain optimal gap spacing and density for effective sorting and processing.

Innovation Solution

A range sensing parcel flow management system that uses photo eyes and sensors to determine parcel flow density 1D, 2D, or 3D volumetrically on conveyors, adjusting conveyor speed ratios to maximize density and volume on receiving conveyors, thereby optimizing conveyor surface utilization and throughput.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional conveyor systems maintain minimum gap spacing for effective sorting, then sorting effectiveness is improved, but throughput decreases

Engineering Contradiction:

Improvesorting effectivenessVSAvoidthroughput

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system dynamically adjusts conveyor speed based on real-time parcel density measurements. The controller continuously monitors occupancy and modulates conveyor speed to maintain optimal density, transforming the static conveyor operation into a dynamic adaptive system that balances sorting effectiveness and throughput

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system implements a closed-loop feedback mechanism where density sensors measure parcel occupancy, the controller compares measured density against target density, and adjusts conveyor speed accordingly. This feedback loop enables continuous optimization of both sorting effectiveness and throughput

Inventive Principle:

Principle #23Feedback

2Productivity

If feed conveyors move maximum parcels on given conveyor area, then efficiency at induction is improved, but imbalance and variability occur at merge areas

Engineering Contradiction:

Improveinduction efficiencyVSAvoidflow balance

Core Design Contradiction:

ProductivityVSStability of the object's composition

Solution Approach 1:

The system uses real-time density measurements from sensors at merge areas to provide feedback to the controller, which then adjusts feed conveyor speeds to correct imbalances and maintain stable flow composition

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The controller dynamically changes operational parameters (conveyor speeds) based on measured density and flow conditions, adjusting feed rates and timing to maintain balanced flow composition despite variability in parcel arrival

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If conventional systems use package counting and speed control, then basic flow management is achieved, but density control on given conveyor area is not optimized

Engineering Contradiction:

Improveflow managementVSAvoiddensity control

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The system replaces conventional mechanical counting methods with optical or electromagnetic sensors that directly measure parcel density. This substitution enables continuous real-time density measurement and control, achieving precise density management on given conveyor areas

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The controller dynamically adjusts conveyor speed parameters based on real-time density measurements, optimizing the density of packages on given conveyor areas through continuous parameter modulation rather than fixed speed operation

Inventive Principle:

Principle #35Parameter changes

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 enhances conveyor performance by increasing the density and volume of parcels on receiving conveyors, achieving up to 75% efficiency compared to 60% in conventional systems, while minimizing the number of conveyors required, thus improving overall throughput and reducing equipment needs.

Implementation Method 1

A range sensing parcel flow management system uses photo eyes and sensors to determine parcel flow density

Methodology Applied

Scientific EffectPhotoelectric Effect: Photoelectric Effect

Data Source

PatentUS11459188B2Range sensing conveyor package management system for measuring and controlling density of parcels on a conveyor

Publication Date: 2022.10.04 FIVES INTRALOGISTICS CORP

AI summary

The present invention relates to the field of using different sensing and detection methods to determine parcel flow density 1D lineal, 2D area or 3D volumetrically on a selected section of a feed conveyor and receiving conveyor and adjusting conveyor speed ratios proportioned according to ratio of desired density to current density to increase the density or volume of parcels in a selected area of the receiving conveyor.