Conveyor Zone Monitoring with Shared Distance Sensors
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Solution Overview
Problem
Conventional conveyor systems require a large number of sensors in each zone, leading to increased costs and complexity.
Innovation Solution
A conveyor apparatus with a conveyance path divided into zones, using distance measuring sensors disposed every predetermined number of zones and controlled by a unit that calculates object positions and sizes, reducing the need for sensors while efficiently conveying objects of varying sizes and orientations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor is provided in each zone, then the detection accuracy of conveyed objects is improved, but the number of sensors increases and costs increase
Solution Approach 1:
Multiple zones are monitored by a single distance measuring sensor. The sensor is positioned to measure distances to conveyed objects across multiple zones simultaneously, and the control unit calculates positions in each zone based on these measurements, eliminating the need for separate sensors in each zone
Solution Approach 2:
A single distance measuring sensor performs multiple functions by detecting objects in multiple zones. The control unit processes the sensor data to determine object positions, sizes, and orientations across different zones, making the sensor universal for monitoring the entire conveyance path
2Area of stationary object
If a sensor is provided in each zone, then the detection coverage is improved, but the device complexity and manufacturing costs increase
Solution Approach 1:
The system merges multiple detection functions into a single sensor unit. By strategically positioning the distance measuring sensor and using control unit calculations, the system achieves comprehensive coverage of multiple zones without installing multiple sensors, thereby reducing system complexity
Solution Approach 2:
The patent replaces a mechanical system of multiple physical sensors with a single sensor combined with computational processing. The control unit uses algorithms to calculate object positions and dimensions based on distance measurements, substituting physical sensor multiplication with mathematical computation
3Quantity of substance
If distance measuring sensors are disposed every predetermined number of zones, then the sensor count is reduced and costs are lowered, but the measurement coverage per sensor must be increased
Solution Approach 1:
The distance measuring sensor is positioned in three-dimensional space above or beside the conveyance path to maximize its measurement range. By optimizing the spatial position and measurement angle, a single sensor can effectively cover multiple zones that would otherwise require separate sensors
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
Reduces sensor count, lowers costs, and enables efficient conveyance of objects by minimizing spacing and accurately positioning them on the conveyor path.
Implementation Method 1
distance measuring sensors that measure, from upstream to downstream on the conveyance path, distances to the conveyed objects conveyed on the conveyance path
Implementation Method 2
distance measuring sensors are disposed every predetermined number of zones among the plurality of zones
Data Source
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AI summary
A conveyor apparatus includes: a conveyance path provided with a plurality of conveyance rollers that convey, along a conveyance direction of conveyed objects, the conveyed objects; and distance measuring sensors that measure, from upstream to downstream on the conveyance path, distances to the conveyed objects conveyed on the conveyance path, wherein the conveyance rollers are formed by drive rollers connected to motors controlled by a control unit and free rollers that freely rotate, the conveyance path is divided into a plurality of zones each including at least one of the drive rollers and a plurality of the free rollers, and the distance measuring sensors are disposed every predetermined number of zones among the plurality of zones.