Conveyor Roller Sensor Bus Encoding for Simpler Signal Wiring
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Solution Overview
Problem
Conveyor arrangements face challenges with complex wiring and sensor disruptions leading to potential damage to conveyed materials and inefficiencies due to variable parameters like friction changes, requiring a more reliable and efficient method for sensor data transmission and processing.
Innovation Solution
A conveyor arrangement with a motor-operated conveyor roller that incorporates an electronic addressing module to encode and transmit sensor signals via a data bus line, reducing wiring complexity and enabling intelligent signal processing and control decisions within the conveyor system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wired data transmission from sensors to central control unit is used, then sensor signals can be transmitted for controlling motor-operated conveyor rollers, but wiring complexity increases significantly
Solution Approach 1:
The patent replaces the mechanical wired connection system with a wireless communication system. Sensors transmit data packets containing sensor values and unique identifiers wirelessly to the control unit, eliminating the need for complex physical wiring while maintaining reliable data transmission for conveyor roller control.
Solution Approach 2:
The patent implements a universal wireless communication interface that can handle multiple sensor types and transmission protocols. The control unit receives and processes data packets from various sensors through a single wireless interface, reducing wiring complexity while maintaining compatibility with different sensor configurations.
2Reliability
If sensors are arranged along the conveyor section to monitor conveyed items, then damage to items can be prevented, but sensors are exposed to environmental influences that can damage or disrupt them
Solution Approach 1:
The patent introduces an intermediary evaluation unit that processes sensor data remotely. Instead of placing sensitive sensors directly in harsh environments, the system uses protective housings and transmits data through intermediate processing stages, reducing the impact of environmental factors like moisture, dust, and temperature extremes on sensor functionality.
Solution Approach 2:
The patent implements redundant sensor arrangements and backup measurement methods to cushion against sensor failures. When environmental conditions cause sensor disruptions, the system can switch to alternative sensors or measurement techniques, ensuring continuous monitoring and preventing item damage despite harsh operating conditions.
3Productivity
If multiple conveyor zones are operated simultaneously with zero-pressure accumulation, then conveyance efficiency increases, but coordination between zones requires complex signal transmission
Solution Approach 1:
The patent replaces complex wired coordination systems with wireless communication between conveyor zones. Each zone's control unit can independently receive sensor data and transmit control signals wirelessly, enabling simultaneous operation of multiple zones with simplified coordination and reduced wiring complexity.
Solution Approach 2:
The patent implements dynamic, decentralized control where each conveyor zone can autonomously adjust its operation based on real-time sensor data received wirelessly. This dynamic coordination allows zones to operate simultaneously with zero-pressure accumulation while adapting to changing conditions without complex centralized wiring.
Data Source
AI summary
The invention relates to a conveyor arrangement, comprising a motor-operated conveyor roller, comprising a roller body which is mounted so as to be rotatable about a roller axis, a drive unit which is arranged within the roller body and is mechanically coupled between the roller body and an axle element and is designed to generate a torque between the axle element and the roller body, and a control data interface which is connected in a signal-transmitting fashion to the drive unit. The invention is characterized by an electronic addressing model which can be coupled in a signal-transmitting fashion to the sensor and to the bus line and is designed to encode a sensor signal, which is generated by the sensor and received in the addressing module, to form a bus-encoded sensor data block which comprises a digital sensor signal data block which characterises the sensor signal and a sensor address data block, and to transmit the bus-encoded sensor data block into the bus line.