Conveyor Carriage Position Correction Using Encoder and Rail Sensors
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Solution Overview
Problem
Existing control systems for conveyor means, such as hoisting gear and cranes, face challenges in accurately determining the position of carriages on rails due to slippage and adverse environmental conditions, leading to incorrect load positioning and potential collisions.
Innovation Solution
A method and control unit that incorporate a safety device with a sensor apparatus to detect position signals on the carriage and rail, allowing for the determination of a real carriage position, which is then used to correct an assumed position calculated by a rotary encoder, thereby improving positional accuracy and reducing slippage errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a rotary encoder is used to determine the position of the carriage, then the position can be determined indirectly through rotation signals, but the position accuracy deteriorates due to slippage and environmental conditions
Solution Approach 1:
The patent introduces a safety device as an intermediary component that includes a sensor apparatus for detecting actual carriage position and a safety apparatus for correcting the assumed position from the rotary encoder. This mediator resolves the contradiction by combining the ease of rotary encoder operation with the accuracy of direct position sensing, using the safety device to bridge the gap between indirect measurement and actual position.
2Adaptability or versatility
If a programmable logic controller is used for controlling the conveyor means, then the control functionality is improved, but the programming complexity and safety inspection requirements increase
Solution Approach 1:
The patent segments the control system into distinct functional modules: a programmable logic controller for control functionality and a separate safety device for position correction and safety monitoring. This segmentation allows the PLC to provide versatile control while the safety device handles position accuracy and safety inspections, reducing the overall programming complexity and inspection requirements for the control system.
3Productivity
If the assumed position from the rotary encoder is used directly, then the system operation is simplified, but harmful effects such as wrong positioning and collisions occur
Solution Approach 1:
The patent implements a feedback mechanism where the safety device continuously monitors the actual carriage position using the sensor apparatus and compares it with the assumed position from the rotary encoder. The safety apparatus then corrects the assumed position based on this feedback, eliminating wrong positioning and collisions while maintaining efficient system operation. The feedback loop ensures accuracy without sacrificing productivity.
Data Source
AI summary
A method and control unit for operating conveyor means, the conveyor means comprising a drive unit, a control unit, a carriage moved along a rail by the drive unit, the control unit being controlled by a control device, a rotary encoder connected to a shaft of the drive unit or of a measuring wheel of the carriage and registering a rotation of the shaft, a rotation angle signal and/or a rotational speed signal being transmitted to the control device by an encoder device to determine an assumed position of the carriage on the rail. At least one position signal is detected by a sensor apparatus disposed on the carriage and the rail, a real position of the carriage on the rail being determined using the position signal by a safety apparatus, the assumed position being corrected according to the real position by the safety device.