Conveyor Routing Module Gridlock Prevention

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Solution Overview

Problem

Material handling systems with intersecting conveyors often experience gridlock issues due to inefficient article release and transfer processes, leading to bottlenecks and reduced efficiency.

Innovation Solution

A processor-controlled routing module with four intersecting transfer conveyors that uses sensors and zone control modules to manage article flow, determining optimal release points and paths to avoid congestion by assessing availability and priority across the system.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If articles are continuously released onto intersecting conveyors to maximize throughput, then productivity increases, but gridlock and congestion occur reducing system reliability

Engineering Contradiction:

ImprovethroughputVSAvoidsystem stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The control system continuously monitors conveyor occupancy and article positions, using sensor feedback to dynamically adjust release decisions. When occupancy thresholds are approached, the system reduces release rates to prevent gridlock, thereby maintaining both high throughput and system stability through real-time adaptive control

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system dynamically adjusts article release rates based on real-time conveyor conditions rather than operating at fixed maximum capacity. This dynamic control allows the system to optimize throughput during clear periods while preventing congestion buildup, resolving the contradiction between maximizing productivity and maintaining reliability

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If multiple articles are held in queue for transfer to optimize routing decisions, then adaptability improves, but loss of time increases due to waiting

Engineering Contradiction:

Improverouting flexibilityVSAvoidarticle wait time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The system performs preliminary routing assessments and makes transfer decisions before articles fully arrive at the intersection. By pre-evaluating destination requirements and conveyor availability, the system minimizes queue waiting time while maintaining routing flexibility through advance planning

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The control system divides routing decisions into discrete, manageable segments for each article rather than batching multiple articles together. This segmentation allows individual articles to be routed efficiently based on their specific destinations, reducing unnecessary wait time while maintaining overall system adaptability

Inventive Principle:

Principle #1Segmentation

3Productivity

If conveyor speed is increased to improve productivity, then throughput increases, but measurement precision and control accuracy deteriorate

Engineering Contradiction:

Improveconveying speedVSAvoidarticle position detection

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The system replaces mechanical position detection methods with optical sensing technology that can accurately measure article positions at high conveyor speeds. This substitution maintains measurement precision even as conveying speed increases, allowing the system to achieve both high productivity and accurate control

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS9309058B2Transfer conveyor arrangement and control

Publication Date: 2016.04.12 INTELLIGRATED HEADQUARTERS LLC

AI summary

A routing module capable of conveying incoming articles from a plurality of infeed conveyor zones to a plurality of discharge conveyors is controlled efficiently to avoid gridlock. The control logic may consider upstream fullness and downstream fullness conditions. Articles may be conveyed to alternative destinations to avoid upstream articles from being delayed due to the lack of availability of the desired destination path for an article.