Conveyor Load Tracking With Location-Based Record Reconstruction
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Solution Overview
Problem
Existing load tracking systems on conveyors face challenges in efficiently managing and scaling load record arrays due to the need to accommodate missing load information, leading to difficulties in tracking unexpected movements and requiring large record arrays with additional management.
Innovation Solution
A system that uses a controller to maintain data records and location records for conveyor loads, updating these records based on sensor events to accommodate unexpected movements by creating new records for unexpected loads and disassociating old records, allowing for efficient tracking without the need for large, scalable arrays.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the load record array is sized large to accommodate missing load information, then the system can track unexpected movements and maintain reconstruction capability, but the device complexity and management difficulty increase
Solution Approach 1:
The patent divides the conveyor into multiple discrete locations and implements tracking independently at each location. Each location maintains its own load record array and reconstruction capability, rather than using a single large global array. This segmentation allows each location to manage only the records relevant to its immediate area, reducing overall system complexity while maintaining comprehensive tracking coverage.
Solution Approach 2:
The system implements location-specific record management where each conveyor location has its own optimized record array sized for local needs. Rather than uniformly allocating records across the entire conveyor system, each location dynamically manages its own record pool based on local load patterns and reconstruction requirements, reducing total memory usage and simplifying management.
2Reliability
If the load record array is sized large to accommodate every possible load location, then all loads can be tracked, but the quantity of records increases and scaling becomes difficult
Solution Approach 1:
The patent segments the conveyor system into multiple locations, with each location maintaining its own load record array. This allows the total record storage to be distributed across locations rather than concentrated in one large array, reducing the memory footprint at any single point and enabling easier scaling by adding or removing location-specific records as needed.
Solution Approach 2:
The system transitions from a single-dimension global record array to a multi-dimensional structure where records are organized by location. This dimensional change allows the system to track loads across the entire conveyor while keeping local record arrays manageable in size, as each location only needs to store records for loads currently or recently present at that specific location.
3Productivity
If additional management is implemented to determine record availability and reconstruction status, then record reuse can be optimized, but the operational complexity increases
Solution Approach 1:
The patent implements automatic record management at each location where the system self-monitors load presence, automatically determines when records can be reused, and manages reconstruction status without external intervention. Each location independently tracks its own record availability and reallocates records as loads move through the conveyor, eliminating the need for centralized complex management while maintaining high reuse efficiency.
Solution Approach 2:
The system uses sensor feedback from each conveyor location to automatically update record status and determine availability for reuse. When sensors detect load presence or absence, the system automatically adjusts record allocation and reconstruction status based on this feedback, eliminating manual management complexity while optimizing record utilization through real-time information.
Data Source
AI summary
A conveyor load tracking method, including associating a designated load with a designated load data record associated with a designated load location record encompassing a first segment of the conveyor and designated load expected travel distances after associated conveyor travel. An unknown load is detected entering a second segment with a sensor outside of the designated load expected travel distances, and a new data record associated with the unknown load is created. The new data record is associated with a new location record encompassing the second segment and encompassing new expected load travel distances of the unknown load after associated conveyor travel. The sensor detects that the designated load is not present at the at a first expected travel distance, and in response the designated load data record is disassociated from the designated load location record, and paired with the new data record and its new location record.