Container Conveyor Friction Sensing for Adaptive Cleaning
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Solution Overview
Problem
Existing conveyor belt lubrication systems fail to react to external factors influencing friction coefficient, leading to undesirable deviations and inefficiencies in container conveyance.
Innovation Solution
A sensor device detects contamination and friction characteristics of the conveyor element, triggering cleaning or lubrication adjustments to maintain optimal friction, using a cleaning device to rinse and foam-clean the conveyor element, and a lubricating device to apply lubricant metered based on sensor feedback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If preset cyclical metering intervals are used for lubricating conveyors, then the lubrication process is simple and automated, but the system cannot react to external factors influencing friction coefficient, leading to undesirable deviations
Solution Approach 1:
The patent implements a feedback mechanism where a sensor device continuously monitors the friction characteristic value of the conveyor element and provides real-time information to the control unit. The control unit adjusts the lubrication process based on this feedback, transitioning from preset cyclical intervals to a demand-driven system that responds to actual friction conditions, thereby resolving the contradiction between operational simplicity and control accuracy.
Solution Approach 2:
The lubrication system is transformed from a static preset interval system to a dynamic system that adapts to changing friction conditions. The control unit modifies lubrication timing and dosage based on real-time sensor data, allowing the system to respond dynamically to external factors such as contamination that affect the friction coefficient.
2Device complexity
If traditional belt lubrication plants are used, then the system is straightforward to implement, but it cannot detect contamination or adjust to maintain optimal friction, causing excessive lubrication
Solution Approach 1:
The sensor device provides continuous feedback on friction characteristic values and contamination levels to the control unit. This feedback enables the system to distinguish between when lubrication is needed and when it is not, preventing excessive lubricant application while maintaining optimal friction conditions, thus reducing lubricant loss.
Solution Approach 2:
The system performs self-diagnosis through the sensor device that continuously monitors friction conditions and contamination. The control unit automatically adjusts or terminates lubrication based on this self-monitoring, eliminating the need for manual intervention and optimizing lubricant usage without requiring complex external control systems.
3Reliability
If the conveyor element is cleaned frequently to remove contamination, then friction characteristics are maintained, but downtime and operational interruptions increase
Solution Approach 1:
The sensor device detects contamination and friction characteristic changes before they significantly impact conveyor performance. This early detection allows the control unit to schedule cleaning operations during appropriate downtime windows or adjust lubrication in advance, preventing severe contamination buildup that would require urgent interruptions.
Solution Approach 2:
Real-time monitoring of friction characteristic values and contamination levels provides feedback that enables proactive maintenance scheduling. The control unit can plan cleaning operations based on actual sensor data trends, optimizing the timing to minimize disruption to container conveyance while maintaining friction characteristics.
4Productivity
If the sensor device continuously monitors friction characteristics, then optimal lubrication timing is achieved, but the device complexity and sensor requirements increase
Solution Approach 1:
The sensor device provides continuous feedback on friction characteristics, enabling precise control of lubrication timing and dosage. This feedback mechanism, while adding some device complexity, significantly improves conveyor operational efficiency by ensuring optimal friction conditions are maintained throughout the conveying process.
Solution Approach 2:
The patent replaces complex mechanical lubrication control mechanisms with a sensor-based monitoring and control system. Instead of using complex mechanical timers or manual adjustment mechanisms, the system uses sensor devices to detect friction characteristics and electronically controls the lubrication process, simplifying the overall system architecture while improving efficiency.
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
Ensures sustainable operation by preventing excessive lubrication, saving resources and maintaining optimal friction, while allowing flexible and targeted cleaning and lubrication, reducing downtime and improving conveyor efficiency.
Implementation Method 1
a sensor device which is configured to detect at least one of a contamination of the circulating conveyor element, a contamination of the containers and a friction characteristic value (e.g., friction coefficient, static friction coefficient and/or sliding friction coefficient) of the circulating conveyor element
Implementation Method 2
using a cleaning device to rinse and foam-clean the conveyor element
Data Source
AI summary
The invention relates, inter alia, to an apparatus for conveying containers. The apparatus has a container conveyor with a circulating conveyor element and a sensor device which is configured to detect at least one of a contamination of the circulating conveyor element, a contamination of the containers and a friction characteristic value of the circulating conveyor element. The apparatus further comprises a user interface and/or a cleaning device for cleaning the circulating conveyor element. The apparatus further comprises a processing device which is configured to operate the user interface to output a request to clean the circulating conveyor element and/or to operate the cleaning device to clean the circulating conveyor element depending on a signal output of the sensor device.