Conveyor Flow Density Control for Parcel Spacing and Throughput
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Solution Overview
Problem
Conventional conveyor systems face inefficiencies due to imbalances in parcel flow density, leading to reduced throughput and equipment inefficiencies, as they struggle to maintain optimal gaps between parcels for sorting while maximizing conveyor capacity.
Innovation Solution
A range sensing apparatus measures parcel flow density 1D, 2D, or 3D volumetrically and adjusts conveyor speed ratios to achieve desired density on receiving conveyors, using sensors and a programmable logic controller to optimize parcel spacing and prevent jams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conveyor speed is increased to maximize throughput, then productivity improves, but parcel flow density becomes unbalanced causing gaps and reducing sorting efficiency
Solution Approach 1:
The system dynamically adjusts conveyor speeds based on real-time parcel density detection. The feed conveyor and receiving conveyor operate at variable speeds that are continuously optimized to maintain target density levels, allowing the system to adapt to changing parcel flows while maximizing throughput and maintaining sorting efficiency.
Solution Approach 2:
The system uses density detection devices to monitor parcel flow density and provides feedback to the control system. This feedback loop enables automatic adjustment of conveyor speeds to maintain optimal density levels, resolving the contradiction between high throughput and sorting efficiency by continuously balancing parcel spacing.
2Productivity
If feed conveyor speed is increased to maximize area utilization, then productivity improves, but parcel density on receiving conveyor becomes unbalanced causing jams
Solution Approach 1:
The system changes the speed parameter of the feed conveyor based on detected parcel density. When density is too high, the feed conveyor speed is reduced; when density is too low, speed is increased. This dynamic parameter adjustment maximizes area utilization while preventing jams and maintaining flow balance.
Solution Approach 2:
The system performs preliminary density detection upstream of the merge area and adjusts feed conveyor speed in advance to prevent density imbalances. By detecting and responding to density conditions before parcels reach the receiving conveyor, the system prevents jams and maintains optimal flow balance.
3Device complexity
If conventional counting methods are used to control conveyor speed, then device complexity is reduced, but measurement precision of parcel density is insufficient
Solution Approach 1:
The system replaces conventional mechanical parcel counting methods with optical or electromagnetic density detection devices. These non-contact sensing methods provide precise measurement of parcel density and spacing without adding significant mechanical complexity to the control system, enabling accurate real-time monitoring of flow density.
Data Source
AI summary
Method and apparatus for sensing and detecting parcel flow density on a selected section of a feed conveyor and receiving conveyor and for adjusting conveyor speed to control parcel flow density. The conveyors include a range sensing field of measurement at selected locations. A range sensing device has a virtual encoder and a signal generating and detecting means extending across the surface of the conveyors. Computer means calculates a percentage of desired occupancy of the receiving conveyor and percentage of actual occupancy of the receiving conveyor. A programmable logic controller controls conveyor speed and start-stop movement of the feed conveyor and receiving conveyor based upon signals received from the range sensing detection device to optimally space packages on the feed conveyor or receiving conveyor.