Accumulation Conveyor Speed Control for Partial Load Pressure
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In accumulation conveyor systems, partial loading of containers can lead to excessive pressure and potential damage, such as scratches or dents, despite overall load control maintaining conveyor speed.
Innovation Solution
Implement a partial load detection system using encoders to adjust conveyor speed based on localized load conditions, with threshold-based speed control units to manage partial and total loads independently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the accumulation conveyor continues to move based on overall load control, then productivity is maintained, but workpiece damage occurs due to excessive pressure in densely collected areas
Solution Approach 1:
The conveyor belt is divided into multiple detection zones (first detection zone and second detection zone) along the transport direction. Each zone independently monitors workpiece density and triggers speed adjustment when local thresholds are exceeded, preventing the need to stop the entire conveyor while protecting workpieces in dense areas
Solution Approach 2:
Different regions of the conveyor belt are monitored with different detection zones positioned at specific locations. The system applies local speed control based on workpiece density in each zone, allowing the conveyor to maintain overall operation while providing targeted protection where workpieces are densely collected
2Object-affected harmful factors
If the accumulation conveyor speed is reduced to prevent workpiece damage, then workpiece protection is improved, but productivity decreases
Solution Approach 1:
The detection zones continuously monitor workpiece density and periodically trigger speed adjustments only when local density thresholds are exceeded. The conveyor operates at normal speed during most periods, reducing to lower speed only periodically when needed to protect workpieces, thereby minimizing impact on overall productivity
Solution Approach 2:
The conveyor speed is dynamically adjusted based on real-time workpiece density detection in each zone. The speed control unit automatically increases or decreases speed according to the detected load conditions, allowing the system to optimize between protection and productivity based on actual operating conditions rather than using fixed speed limits
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
Prevents excessive pressure and damage to containers by adjusting conveyor speed according to partial load, ensuring stable and damage-free transport.
Implementation Method 1
a plurality of encoders which are provided for each of the accumulation conveyors and are configured to output a signal according to a transport distance of the at least one accumulation conveyor
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An accumulation conveyor system comprises: a plurality of accumulation conveyors (20) on which workpieces (W) are sequentially transported downstream; a partial load detection unit that detects a partial load that is the accumulation of workpieces (W) only in a detection area (A) that is part of an area that includes the downstream end in the transport direction in an area in which the workpiece (W) on one of the accumulation conveyors (20) is being transported; and a speed control unit that adjusts the speed of the accumulation conveyor (20) on the basis of the value of the partial load detected by the partial load detection unit. The speed control unit decreases the speed of the accumulation conveyor (20) in accordance with the increase in the load value.