Individually Actuated Conveyor Grouping Packages
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Solution Overview
Problem
Existing methods and devices for grouping packages into predefined groups often result in disruptions, damage to packages or containers, and high maintenance and operational costs due to accumulation pressure and the need for guide railings.
Innovation Solution
A method and device using a conveying system with individually controllable conveyors and a control algorithm that interpolates and detects the position and speed of packages, adjusts target speeds to maintain predefined spacing, and controls conveyor speeds to prevent accumulation pressure, thereby forming precise and reliable package groups without guide railings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If packages are accumulated to form predefined package groups using prior art methods, then package grouping is achieved, but accumulation pressure causes packages to be pushed into the grouping zone, disrupting allocation and causing damage
Solution Approach 1:
The patent applies dynamics by making the conveyor system movable and adjustable. Each conveyor unit can independently change its speed and position dynamically during operation. The control device continuously adjusts conveyor speeds to maintain optimal spacing between packages, allowing the system to adapt to varying package flows and prevent accumulation pressure while maintaining high productivity.
Solution Approach 2:
The patent changes operational parameters by continuously adjusting conveyor speeds and package spacing. The control device monitors package positions and modifies conveyor parameters in real-time to maintain predefined spacing intervals. This parameter adjustment prevents accumulation pressure buildup while ensuring packages are grouped efficiently according to predefined specifications.
2Ease of operation
If guide railings are used to prevent lateral break-out of accumulated packages, then package guidance is improved, but manually adjustable railings require considerable effort at format changes and automatically adjustable railings incur high maintenance effort and costs
Solution Approach 1:
The patent extracts and removes the guide railings from the system entirely. Instead of using physical railings to prevent lateral break-out, the invention relies on the controlled spacing and positioning of packages through the dynamic conveyor system. The packages are guided by their predetermined spacing and the controlled flow between conveyor units, eliminating the need for complex railing mechanisms and their associated adjustment and maintenance requirements.
Solution Approach 2:
The patent replaces the mechanical railing system with a control-based system. Instead of using physical mechanical structures (railings) to guide packages, the invention uses electronic control devices that monitor package positions and adjust conveyor speeds to maintain proper spacing. This substitution eliminates the mechanical complexity of railings while achieving the same guidance function through intelligent control.
3Ease of operation
If guide railings are used to prevent lateral break-out, then package guidance is improved, but contact between packages and railings leads to damage of packages or containers
Solution Approach 1:
The patent extracts and removes the guide railings from the system entirely. Instead of using physical railings to prevent lateral break-out, the invention relies on the controlled spacing and positioning of packages through the dynamic conveyor system. The packages are guided by their predetermined spacing and the controlled flow between conveyor units, eliminating the need for complex railing mechanisms and their associated adjustment and maintenance requirements.
Solution Approach 2:
The patent replaces the mechanical railing system with a control-based system. Instead of using physical mechanical structures (railings) to guide packages, the invention uses electronic control devices that monitor package positions and adjust conveyor speeds to maintain proper spacing. This substitution eliminates the mechanical complexity of railings while achieving the same guidance function through intelligent control.
4Reliability
If individually controllable conveyors are used with control algorithm, then precise package grouping without accumulation pressure is achieved, but device complexity and control system requirements increase
Solution Approach 1:
The patent segments the conveyor system into multiple independently controllable units. Each conveyor unit can be controlled separately, allowing precise management of package flow and spacing. This segmentation enables the system to handle packages in discrete segments, with each unit contributing to the overall grouping function. The modular structure, while increasing control complexity, provides the reliability needed for precise package grouping without accumulation pressure.
Solution Approach 2:
The patent implements feedback control by continuously monitoring package positions and using this information to adjust conveyor speeds. The control device receives data about package locations and feeds this information back to adjust the operation of individual conveyor units in real-time. This feedback mechanism ensures that packages are grouped reliably according to predefined specifications while maintaining optimal spacing and preventing accumulation pressure, justifying the increased control system complexity.
Data Source
AI summary
A method and device for grouping packages into specified package groups in an interference-free and fault-free manner with a conveyor having multiple individually actuatable conveyors arranged one behind the other with an inlet-side and a discharge-side end. The packages are supplied to the conveyor device at the inlet-side end one after the other, and a control algorithm is carried out to interpolate and/or detect the position and/or the speed of each individual package. A target speed is determined for each individual package based on the detected and/or interpolated position and/or speed of the package. A target speed is determined for the individual conveyors to achieve the target speed for each package to set a specified distance to the leading and/or following package at the discharge-side end. The speed of the individual conveyors is controlled to the respective determined target speed for the conveyor.