Zone-Based Conveyor Routing Control via Centralized Information Transfer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional conveyors require a large number of information read-out devices and programmable logic computers (PLCs), making them complex to install and reconfigure, with many components contributing to the complexity of construction and operation.
Innovation Solution
A conveyor system divided into zones with an object identifying device, initial information transmitting unit, conveyance destination storage, information receiving and transmitting units, allowing conveyance destination information to be transferred between zones with the movement of objects, reducing the need for multiple information read-out devices and PLCs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If information read-out devices and PLCs are installed at each branching point, then the conveyor can accurately control object routing, but the device complexity and number of components increase significantly
Solution Approach 1:
The patent merges the information read-out device, information processing unit, and control functions into a single integrated control device located at the start position. This consolidation eliminates the need for multiple distributed PLCs and read-out devices at each branching point, while maintaining accurate routing control through centralized information processing and transmission along the conveying passage.
Solution Approach 2:
The patent introduces conveyance destination information as an intermediary that travels with the object along the conveying passage. This information acts as a mediator between the control device and branching points, enabling routing decisions without requiring complex control systems at each branching location. The information is transmitted from the start position to the final destination, simplifying the control architecture.
2Reliability
If multiple information read-out devices and PLCs are installed throughout the conveyor, then routing control is achieved, but the construction work and installation complexity increase
Solution Approach 1:
The patent combines multiple control functions (information reading, processing, and routing control) into a single control device at the start position. This merging reduces the number of components that need to be installed and configured during construction, while maintaining full routing control capability through centralized management and information transmission along the conveying passage.
Solution Approach 2:
The patent performs preliminary information processing at the start position before the object enters the conveying passage. The control device reads the object information, determines the routing path, and transmits the conveyance destination information to the final destination in advance. This preliminary action eliminates the need for complex real-time control systems at each branching point during installation and operation.
3Adaptability or versatility
If conventional conveyor control systems are used, then routing functionality is achieved, but the number of PLCs and components makes the system difficult to reconfigure
Solution Approach 1:
The patent merges all control functionality into a single reconfigurable control device at the start position. This centralized approach allows easy reconfiguration by simply changing the control logic or destination information in one location, rather than reconfiguring multiple distributed PLCs and read-out devices throughout the system. The conveyance destination information can be updated to adapt to different routing requirements.
Solution Approach 2:
The patent implements a dynamic information transmission system where the conveyance destination information is transmitted along the conveying passage and can be updated based on changing routing requirements. This dynamic approach allows the system to be reconfigured without physical changes to the hardware, simply by modifying the information processing and transmission logic in the control device.
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
An object is to provide a conveyor that enables the number of information read-out devices to be largely reduced and that can be easily constructed. An object identifying device (45) is installed in the first zone. The object identifying device (45) is a bar code reader. Information read by the bar code reader is transmitted to a host control device (46). The host control device (46) identifies an object from information described in a bar code, makes an inquiry about a conveyance destination of an object, transmits the address of the target place to a zone controller (10) of the second zone, and inputs the address to a conveyance destination storage unit of the zone controller (10) of the second zone. The conveyance destination information input to the conveyance destination storage unit is passed on to the downstream zone controller (10) with the conveyance of the object.