Conveyor Mover Tracking With Magnetic Encoder and Integrated ID
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional conveyor tracking systems face challenges such as misalignment, excessive gaps, dirt interference, and battery-powered tag failures, leading to inaccurate position tracking and ID management of moving elements in linear motor conveyor systems.
Innovation Solution
The system employs a combination of magnetic sensors and a magnetic encoder strip, along with color sensors and a color gradient encoder strip, to accurately track the position and ID of moving elements. This setup includes a processor to process sensor readings, turn illumination LEDs on and off, and handle quasi-Gray code configurations for enhanced tracking precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional ID readers are used to track moving elements, then ID identification can be achieved, but the system requires additional hardware and physical space for mounting readers
Solution Approach 1:
The patent combines ID identification and position tracking functions into a single magnetic sensor system. The encoder strip integrates both ID encoding and position marking, allowing one sensor to perform both functions simultaneously, eliminating the need for separate ID readers and position sensors
Solution Approach 2:
The magnetic sensor serves multiple functions: it detects both the unique ID of the moving element and its precise position along the conveyor. The encoder strip is designed to provide both identification information and position reference, making the system multi-functional with minimal hardware
2Loss of information
If stationary readers are used for ID tracking, then ID can be read at specific points, but the ID is not available at all positions/times along the path
Solution Approach 1:
The magnetic sensor continuously tracks the moving element along the entire conveyor path, providing uninterrupted ID and position information. Unlike stationary readers that only capture data at specific points, the continuous tracking system maintains constant monitoring, ensuring ID availability at all positions and times
3Measurement precision
If conventional position feedback systems are used, then position control can be achieved, but additional hardware is required to track specific pallet or fixture numbers
Solution Approach 1:
The system merges position feedback and ID tracking into a single integrated solution. The encoder strip contains both position reference marks and unique ID encoding, while the magnetic sensor detects both types of information simultaneously, eliminating the need for separate position sensors and ID readers
4Measurement precision
If magnetic sensors with encoder strip are used, then accurate position and ID tracking is achieved, but the system requires precise alignment and may be affected by environmental factors
Solution Approach 1:
The system uses magnetic field detection which is inherently resistant to environmental factors like dirt, dust, and moisture that affect optical systems. The magnetic encoder strip and sensor combination converts potential environmental vulnerabilities into advantages by using non-contact magnetic sensing that operates reliably in harsh manufacturing environments without requiring physical access or being affected by contamination
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 system provides improved accuracy and reliability in tracking moving elements, enabling precise location and ID management, even in high-speed and high-acceleration environments, while reducing the need for additional hardware and minimizing errors due to environmental factors.
Implementation Method 1
a plurality of magnetic sensors; a magnetic encoder strip that is readable by the magnetic sensors
Data Source
AI summary
A system and method for tracking a location of a moving element on a conveyor system. The system including: magnetic sensors; a magnetic encoder strip that is readable by the magnetic sensors; and a processor for receiving and processing the sensor readings to determine a location of the moving element. The method including: sensing a current location of the moving element, wherein at least one of the magnetic sensors and magnetic encoder are associated with the moving element; and providing a current location to a conveyor system controller. The system may further include: color sensors; and a color gradient encoder strip that is readable by the color sensors, wherein the color gradient encoder strip and color sensors provide moving element location at start up and the magnetic sensors and magnetic encoder strip track moving element location during operation. In this case, the method is adjusted accordingly.