Conveyor Flow Device Control With Decentralized Local Controllers
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Solution Overview
Problem
Conveyor systems for automated production face challenges in setup, maintenance, and cost due to the need for extensive programming and rebalancing, particularly when changing manufacturing configurations or dealing with wear and stoppages, which require significant labor and reprogramming.
Innovation Solution
A conveyor system with local controllers that can autonomously process sensor data, generate command data, and communicate with central controllers, reducing the load on central controllers and allowing for real-time decision-making, thereby facilitating easier design, assembly, and maintenance, and potentially reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a central controller is used to control all functions in the conveyor system, then centralized control and coordination are achieved, but the amount of wiring and programming required increases substantially
Solution Approach 1:
The control system is segmented into a central controller and multiple local controllers. Each local controller is assigned to specific flow devices (stop devices, switch devices, merge devices) and handles local control functions independently. This segmentation reduces the wiring burden on the central controller and distributes the programming complexity across multiple simpler local controllers that communicate with the central controller through standardized data interfaces.
2Ease of operation
If extensive programming is used to handle each sensor and actuator in the central controller, then complete system control is achieved, but the cost and time for setup and maintenance increases
Solution Approach 1:
Local controllers are equipped with autonomous capabilities to handle specific control functions without requiring constant central controller intervention. For example, local controllers can process sensor data from their associated flow devices and execute control commands locally, reducing the programming burden on the central controller and enabling faster setup and maintenance operations.
3Stability of the object's composition
If the conveyor system is centrally controlled with all functions managed by the central controller, then system coordination is improved, but the cost for designing and configuring the system increases
Solution Approach 1:
The control architecture is divided into hierarchical levels: a central controller for high-level coordination and local controllers for device-specific control. This segmentation allows the system to maintain coordination through standardized communication protocols while reducing design and configuration costs by distributing control logic to simpler, more specialized local controllers that can be independently configured and replaced.
4Loss of information
If all control functions are centralized, then system-wide monitoring is achieved, but the robustness of the system decreases due to the single point of failure
Solution Approach 1:
The control system is segmented into independent local controllers that can operate autonomously even when disconnected from the central controller. Each local controller maintains local monitoring and control capabilities, ensuring that failures in the central controller do not completely halt system operations. The central controller continues to provide system-wide monitoring through standardized data interfaces, achieving both robustness and comprehensive monitoring.
Data Source
AI summary
The present document discloses a conveyor system comprising a plurality of workpiece carriers, each adapted for supporting at least one workpiece during transportation, a conveyor, adapted for transporting the workpiece carriers, at least one flow device for controlling a movement of one of the workpiece carriers relative to the conveyor, the flow device comprising a local controller, at least one workpiece carrier sensor and at least one actuator, and a central controller, which is in data communication with the flow device, and having a memory containing a flow plan comprising data describing an intended flow of workpieces in the conveyor system.