Conveyor Roller Controller With Wireless On-Site Configuration

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Solution Overview

Problem

Existing conveyor systems with multiple conveyor zones require cumbersome and labor-intensive installation, configuration, and maintenance of motor-driven conveyor-rollers due to the need for wired connections to a centralized control center, making on-site adjustments difficult for technicians.

Innovation Solution

Incorporation of a wireless configuration port in the conveyor-roller controller allowing for bidirectional communication with mobile devices for parameter setting and data exchange, enabling technicians to configure and monitor motor-roller settings directly on site without relying on a central control center.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If wired connections to centralized control center are used for controller configuration and monitoring, then system reliability and stable communication are improved, but installation complexity and maintenance time increase

Engineering Contradiction:

Improvecommunication stabilityVSAvoidwiring complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the mechanical wired connection system with a wireless communication system. The controller includes a wireless communication interface that enables bidirectional data exchange with mobile devices without requiring physical wiring between the controller and the central control center or technician devices, thus eliminating wiring complexity while maintaining communication stability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a wireless communication interface as an intermediary between the controller and external devices (mobile devices, central control center). This intermediary enables data exchange without direct physical connections, allowing technicians to configure and monitor controllers wirelessly while the system maintains reliable communication through standardized wireless protocols.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If wired configuration ports are used for parameter setting, then communication stability is improved, but on-site configuration ease deteriorates

Engineering Contradiction:

Improvecommunication stabilityVSAvoidon-site configuration ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent replaces wired configuration ports with wireless communication interfaces. Technicians can use mobile devices to configure and monitor controllers directly at the conveyor zone without needing to run wires or return to a central control room, significantly improving on-site configuration ease while maintaining communication reliability through error-correcting wireless protocols.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The controller enables technicians to perform configuration and monitoring operations independently at the device location using wireless communication. The controller can receive configuration parameters and send status information directly to mobile devices without requiring intervention from centralized control personnel, empowering on-site technicians to service the system autonomously.

Inventive Principle:

Principle #25Self-service

3Stability of the object's composition

If centralized control center mediation is used for all controller communications, then system coordination is improved, but maintenance time and technician mobility increase

Engineering Contradiction:

Improvesystem coordinationVSAvoidmaintenance time

Core Design Contradiction:

Stability of the object's compositionVSLoss of time

Solution Approach 1:

The patent segments the communication architecture by enabling direct wireless communication between individual controllers and technician mobile devices, while maintaining the option for centralized coordination. This segmentation allows technicians to work independently at each conveyor zone without needing to route all communications through the central control center, reducing maintenance time while preserving system coordination capabilities.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The controller stores configuration parameters and status information locally, allowing technicians to perform configuration and diagnostics operations directly at the device without needing to access the central control center. This preliminary preparation of data at the controller enables rapid on-site maintenance while the controller can still coordinate with the central system when needed.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS12600572B2Motor-driven conveyor-roller controller, system comprising such a controller and method for operating a motor roller

Publication Date: 2026.04.14 KYOWA EUROPE GMBH

AI summary

A motor-driven conveyor-roller controller for conveyor installations for conveying containers. The controller incudes a power inlet, a wired I/O port, and a wired motor roller port. The controller is configured to output motor roller control signals for a motor roller at the motor roller port. The controller is configured to receive motor roller status signals from the motor roller at the motor roller port and to receive motor roller control signals for the motor roller at the I/O port. The wired I/O port is configured to exchange control information with a central control center. The controller includes a wireless configuration port that is configured to wirelessly receive, from a mobile device, at least configuration signals for the motor roller and/or send status signals representing motor roller status information.