Conveyor Routing Configuration Using Station-Level Pallet Flow Analysis
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional systems face challenges in configuring conveyor systems with the required specificity and granularity, particularly in planning and managing pallet movement within manufacturing or automation systems, leading to inefficiencies and potential downtime.
Innovation Solution
A method and system for conveyor system configuration that includes performing pallet-flow analysis, generating target and move configurations, finalizing routing targets, and exit move configurations, utilizing a processor to determine operation points, calculate required move distances, and configure routing targets and pallet entry routings, ensuring efficient pallet movement and system optimization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual configuration methods are used for conveyor systems, then system setup can be completed, but the configuration process takes a substantial amount of time and requires significant manual effort
Solution Approach 1:
The system performs self-configuration by automatically analyzing station layouts, calculating pallet flow paths, and generating routing configurations without requiring manual intervention. The automated configuration engine processes station definitions and generates complete conveyor system configurations independently, eliminating the need for manual setup while maintaining comprehensive system control
Solution Approach 2:
The patent replaces manual mechanical configuration processes with automated computational methods. Instead of manually setting up conveyor parameters, operators define stations and the system automatically calculates optimal pallet routing, move configurations, and routing targets using algorithms that process station layouts and generate complete system configurations
2Reliability
If conventional systems are used for planning pallet movement, then basic conveyor operation can be maintained, but the systems have difficulty in planning and managing movement of pallets within a manufacturing or automation system
Solution Approach 1:
The system segments the conveyor system into discrete stations with defined entry and exit points. Each station is analyzed independently for pallet flow requirements, and routing configurations are generated for each station segment. This segmentation approach simplifies the overall complex pallet management by breaking it into manageable station-level configurations
Solution Approach 2:
The patent introduces an automated configuration engine as an intermediary between station definitions and conveyor operation. This engine processes station layouts, calculates pallet flow paths, and generates routing configurations, serving as a mediator that translates high-level station definitions into detailed movement management instructions without requiring direct manual intervention
3Productivity
If detailed configuration parameters are set for conveyor systems, then system performance can be optimized, but the number of parameters that need to be configured, monitored and adjusted increases
Solution Approach 1:
The system performs preliminary automated calculation of optimal configuration parameters during the configuration phase. Routing targets, move configurations, and pallet flow parameters are pre-calculated based on station layouts and performance requirements. This preliminary action eliminates the need for manual adjustment of numerous parameters during operation, as the system is pre-optimized for desired throughput
Solution Approach 2:
The automated configuration engine serves multiple functions simultaneously: it analyzes station layouts, calculates pallet flow paths, determines routing targets, generates move configurations, and validates system performance. This multi-functional approach consolidates what would otherwise require multiple separate configuration processes into a single automated system
Data Source
AI summary
A method for automatic target configuration in a conveyor system, the method including: perform a pallet-flow analysis for a station; generate target and move configurations for the station; determine if there are more stations and perform the pallet flow analysis and the generate target and move configurations until all stations are completed; finalize routing targets' configurations; and finalize exit move configurations. A system for automatic target configuration in a conveyor system, the system including: a processor; a processor readable memory storing computer instructions, which, when executed by the processor, cause the processor to: perform a pallet-flow analysis for a station; generate target and move configurations for the station; determine if there are more stations and perform the pallet flow analysis and the generate target and move configurations until all stations are completed; finalize routing targets' configurations; and finalize exit move configurations.