Conveyor Load Cell Weight Detection for Overload Prevention
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Solution Overview
Problem
Optical methods used for tracking items on conveyors are plagued by issues such as short lifespan, maintenance requirements, and inability to detect item weight, leading to overloading of conveyor zones, which causes mechanical issues and potential motor failure.
Innovation Solution
A computer-implemented method using load sensors to dynamically detect item weight on conveyor zones and generate weight condition indications, allowing for prediction-based actions to prevent overloading and reduce collisions between items.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If optical methods are used for tracking items on conveyors, then item detection capability is provided, but the system suffers from short lifespan, maintenance requirements, and inability to detect item weight
Solution Approach 1:
The patent replaces optical sensing systems with load cell-based mechanical sensing systems. Load cells directly measure the weight of items on conveyor zones through force detection, eliminating the need for optical sensors. This substitution resolves the contradiction by removing the maintenance-prone optical components while gaining the additional capability of weight detection, thereby improving reliability and extending system lifespan.
Solution Approach 2:
The patent changes the detection parameter from optical properties (reflectivity, color) to mechanical properties (weight, force). By using load cells to measure force exerted by items on conveyor zones, the system transitions from surface-level optical detection to substantial weight-based detection. This parameter change enables weight detection capability while eliminating optical sensor maintenance requirements.
2Measurement precision
If optical sensors are used for item tracking, then item presence detection is achieved, but overloading of conveyor zones cannot be detected
Solution Approach 1:
The patent replaces optical detection systems with mechanical load cell systems that directly measure weight. Load cells are positioned under conveyor zones to detect the force exerted by items, enabling precise weight measurement. This mechanical sensing approach directly addresses the harmful effect of overloading by providing accurate weight detection, allowing the system to identify and respond to overweight items before they cause damage.
Solution Approach 2:
The patent implements a feedback mechanism where load cells continuously monitor the weight of items on conveyor zones and provide real-time data to a processing system. When overweight items are detected, the system can automatically adjust conveyor operations, such as slowing down or stopping the conveyor zone, to prevent overloading. This feedback loop resolves the contradiction by enabling precise weight measurement while actively preventing the harmful effects of overloading.
3Device complexity
If no weight detection is implemented, then system simplicity is maintained, but mechanical issues and motor failure occur due to overloading
Solution Approach 1:
The patent introduces load cells as simple mechanical sensors that directly measure weight without complex electronics or processing. Load cells convert force into electrical signals through strain gauge technology, providing a straightforward detection mechanism. This simple mechanical sensing approach improves reliability by detecting overloading conditions that would otherwise cause mechanical issues and motor failure, while adding minimal complexity to the conveyor system.
Solution Approach 2:
The patent enables the conveyor system to self-monitor its own load conditions through integrated load cells. The load cells are embedded in the conveyor structure and automatically detect weight without requiring external intervention. This self-service capability improves reliability by allowing the system to identify and respond to overloading conditions autonomously, preventing mechanical damage while maintaining operational simplicity.
4Ease of operation
If optical methods are used for item tracking, then item detection is possible, but collisions between items occur due to lack of weight awareness
Solution Approach 1:
The patent implements a feedback system where load cells monitor item weight in real-time and communicate this information to the conveyor control system. When overweight items are detected, the system can adjust conveyor speed or positioning to prevent collisions with other items. This feedback mechanism improves ease of operation by enabling smooth, collision-free conveyor operation, while the underlying weight detection capability prevents the harmful effect of item collisions.
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
The method effectively identifies overweight items and prevents overloading, reducing mechanical issues and extending conveyor system efficiency and lifespan by eliminating the reliance on optical sensors.
Implementation Method 1
accessing a load condition data object, wherein the load condition data object is indicative of the force exerted on at least one conveyor zone
Data Source
AI summary
Method, apparatuses, and computer program products for dynamically detecting an item within a conveyor zone are disclosed herein. An example method may comprise: accessing a load condition data object, wherein the load condition data object is indicative of a force exerted on at least one conveyor zone, processing the load condition data object using a weight condition detection model to generate a weight condition indication associated with the at least one conveyor zone, and causing one or more prediction-based actions to be performed based at least in part on the weight condition indication.