Conveyor Line Inspection for Geometric Deviation Detection

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Solution Overview

Problem

Conveyor apparatuses face issues with objects getting stuck or lost, leading to compromised operation and requiring frequent manual maintenance with safety concerns.

Innovation Solution

A conveyor apparatus with a maintenance device equipped with sensors and actuators that can move along the conveyor line, recording and analyzing conditions to identify and address issues, such as stuck objects or geometric deviations, reducing downtime and improving safety.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of repair

If manual maintenance and repair activities are performed on conveyor apparatus, then maintenance and repair can be carried out, but operational downtime increases and occupational safety risks arise

Engineering Contradiction:

Improvemaintenance and repair capabilityVSAvoidoperational downtime

Core Design Contradiction:

Ease of repairVSLoss of time

Solution Approach 1:

The conveyor apparatus performs self-diagnosis and self-monitoring through integrated sensors and control units that continuously track operational parameters, enabling the system to detect and report maintenance needs without external intervention, thereby eliminating downtime associated with manual inspection and scheduling maintenance only when actually needed

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual mechanical inspection and repair activities are replaced by automated sensor systems, electronic monitoring, and computer-controlled diagnostics that can detect issues remotely and guide maintenance personnel precisely, reducing the frequency and duration of manual intervention while improving safety

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If conveyor apparatus operates at higher speed, then productivity increases, but problems and failures may occur more frequently

Engineering Contradiction:

Improveconveying speedVSAvoidconveying reliability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system incorporates continuous feedback loops where sensors monitor operational parameters in real-time, and the control unit adjusts operating conditions dynamically to prevent failures before they occur, allowing the conveyor to operate at optimal speeds while maintaining reliability through proactive parameter management

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The monitoring system detects early signs of wear, misalignment, or potential failures before they escalate into actual problems, enabling preliminary corrective actions to be taken during normal operation or during planned maintenance windows rather than causing unexpected breakdowns at high speed

Inventive Principle:

Principle #10Preliminary action

3Reliability

If frequent manual maintenance is performed, then reliability is maintained, but occupational safety risks and operational disruption increase

Engineering Contradiction:

Improveconveying reliabilityVSAvoidoccupational safety risks

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

Hazardous manual inspection tasks in moving or hard-to-reach areas are replaced by robotic inspection units, remote sensors, and electronic monitoring systems that can detect issues without personnel needing to physically access dangerous zones, thereby maintaining reliability while eliminating occupational safety risks

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

Sensor systems and monitoring devices act as intermediaries between the conveyor apparatus and maintenance personnel, providing remote information about system status and enabling diagnostics without direct human contact with moving parts, thus maintaining reliability while protecting worker safety

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS20250361094A1Method for operating a conveyor apparatus, conveyor apparatus and use

Publication Date: 2025.11.27 DEUT POST AG

AI summary

A method for operating a conveyor apparatus for conveying objects is disclosed. The conveyor apparatus includes a circulating conveyor line with one or more movable conveyor devices for supporting the objects, and a maintenance device for recording the conveyor line, the method includes moving the maintenance device along the conveyor line, recording the conveyor line using the maintenance device for obtaining information relating to a top side and/or a bottom side of the conveyor line, and comparing the obtained information with previously known information about the conveyor line for localizing a geometric deviation in the conveyor line.