Conveyor Flow Devices With Local Control for Flexible Workpiece Routing
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Solution Overview
Problem
Conveyor systems for automated production face challenges in cost-effective design, installation, and maintenance due to the need for extensive programming and rebalancing, especially when changes occur, leading to increased labor and potential system drift over time.
Innovation Solution
A conveyor system with local controllers that convert sensor data into standardized formats, reducing the load on central controllers, allowing for decentralized decision-making and autonomous operations, such as stopping workpiece carriers, and enabling dynamic flow plans that can be altered without shutting down the system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a central controller handles all sensor data and actuator control, then centralized control is achieved, but wiring requirements and programming complexity increase substantially
Solution Approach 1:
The control system is segmented into multiple independent flow devices, each with its own local controller. Each flow device operates autonomously to manage workpiece flow in its specific section, eliminating the need for a single centralized controller to handle all operations. This segmentation reduces wiring requirements and programming complexity while maintaining automated control throughout the system.
Solution Approach 2:
Each flow device is equipped with a local controller that autonomously manages its own operations without requiring constant intervention from a central controller. The local controllers independently process sensor data and control actuators within their respective zones, enabling self-service operation that reduces overall system complexity.
2Extent of automation
If extensive programming is used to handle each sensor and actuator, then complete system control is achieved, but installation and maintenance labor costs increase
Solution Approach 1:
The control system is divided into multiple independent flow devices with local controllers, where each unit handles its own sensors and actuators. This modular approach reduces programming complexity compared to a fully centralized system, as each local controller only needs to manage its specific section rather than the entire system, thereby reducing installation and maintenance labor.
Solution Approach 2:
The local controllers are designed with universal functionality to handle multiple tasks including sensor data acquisition, workpiece tracking, and actuator control within each flow device. This multi-functionality reduces the need for specialized programming for each component, simplifying both installation and maintenance operations.
3Stability of the object's composition
If the system is centrally controlled with all functions managed by a central controller, then unified coordination is achieved, but the system requires substantial wiring and programming effort
Solution Approach 1:
The unified coordination function is distributed across multiple local controllers rather than concentrated in a single central controller. Each local controller maintains coordination within its section while independently operating, achieving unified system coordination through decentralized management. This segmentation significantly reduces wiring requirements and programming effort compared to a fully centralized architecture.
Solution Approach 2:
Local controllers act as intermediaries between sensors/actuators and the central system, processing and managing control functions at the local level. This intermediary approach maintains system-wide coordination while reducing the burden on any single controller and minimizing wiring complexity.
Data Source
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AI summary
The present document discloses a conveyor system comprising a plurality of workpiece carriers (WPC), each adapted for supporting at least one workpiece (WP) during transportation, a conveyor (10, 10a, 10b, 10c, 10d), adapted for transporting the workpiece carriers (WPC), at least one flow device (3, 4, 5, 6) for controlling a movement of one of the workpiece carriers (WPC) relative to the conveyor (10, 10a, 10b, 10c, 10d), the flow device (3, 4, 5, 6) comprising a local controller (30, 40), at least one workpiece carrier sensor and at least one actuator, and a central controller (100), 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. The document also discloses a method of operating a conveyor system, stop devices and switch device for use in such a conveyor system.