Method and system for wireless communication in a conveyor system
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Solution Overview
Problem
Conveyor systems face challenges in providing reliable power to moving elements and accessories without the need for bulky batteries or complex cabling, and existing inductive power transfer systems suffer from inefficiencies and safety issues, while also requiring onboard energy storage and limited accessory capabilities due to bandwidth and reliability concerns in wireless communications.
Innovation Solution
The system employs interlaced power pick-up panels with inductive panels on the conveyor track to provide consistent power to moving elements, and a simplified wireless communication protocol that reduces bandwidth usage and enhances reliability, allowing for complex accessory control and operation during movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional inductive power transfer systems use a high frequency alternate current primary conductor extending along the entire motion path, then power can be provided to moving elements, but electromagnetic field radiation occurs along the entire motion path irrespective of the location of pick-up units, resulting in energy waste and potential safety issues
Solution Approach 1:
The primary conductor is divided into multiple discrete segments positioned at specific locations along the motion path rather than forming a continuous conductor. Each segment is activated only when a pick-up unit is in proximity, thereby confining electromagnetic field radiation to localized areas only when power transfer is actually needed, reducing energy waste and potential safety hazards.
2Ease of operation
If a single fixed frequency power supply is used to energize the primary conductor, then the system is simple to operate, but intelligent pick-up units are required to provide on/off control and/or variable power output, increasing device complexity
Solution Approach 1:
Instead of placing intelligence and control capabilities in the moving pick-up units, the control logic is inverted and placed in the stationary master controller. The master controller monitors the position of moving elements and activates specific primary conductor segments accordingly, eliminating the need for intelligent pick-up units while maintaining ease of operation with a single fixed frequency power supply.
3Adaptability or versatility
If conventional wireless communication protocols are used with accessories on moving elements, then communication capability is provided, but the reliability of communications and bandwidth available become insufficient for high speeds and accelerations of modern conveyor systems
Solution Approach 1:
A simplified communication protocol is implemented that changes key parameters including using predetermined frequencies for communication signals, reducing message complexity to essential information only, and implementing redundancy mechanisms. These parameter changes enable reliable wireless communication with accessories on moving elements even at high speeds and accelerations by reducing susceptibility to interference and minimizing data transmission requirements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables reliable and efficient power transfer to moving elements and accessories, eliminating the need for batteries and cabling, while ensuring consistent power and fast, precise control through efficient wireless communication, even at high speeds and accelerations.
Implementation Method 1
the track section includes a track power system including a plurality of inductive panels, wherein the one or more power pick-up panels extend into gaps between the plurality of inductive panels such that the one or more power pick-up panels and the plurality of inductive panels overlap in an interlaced fashion
Data Source
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AI summary
A method and system for wireless communication in a conveyor system. The method includes: formulating a command from a master controller to an accessory controller; translating the command into a simplified protocol; transmitting the simplified command via a wireless communications channel; receiving the simplified command at a wireless receiver; processing the simplified command by the accessory controller; formulating a response to the master controller from the accessory controller; transmitting the response via the wireless communications channel; and translating the response for handling by the master controller. The system includes: a downlink converter/transmitter configured to translate a command into a simplified protocol and send a simplified command via a wireless signal; an accessory receiver/transmitter configured to receive the wireless signal; and an accessory interface configured to communicate the simplified command to the accessory for execution.