Conveyor Zone Control for Zero-Pressure High-Throughput Handling
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Solution Overview
Problem
Conveyor systems face inefficiencies in throughput and maintenance of zero-pressure accumulation due to varying object weights and dimensions, leading to unsynchronized acceleration and deceleration, which can cause damage and reduce optimal throughput.
Innovation Solution
A conveyor device with interconnected control units that transmit object-specific parameters between zones, allowing dynamic adjustment of conveyor parameters based on detected properties such as mass, length, and friction, ensuring synchronized movement and minimizing slip.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conveyor zones operate in block discharge mode with simultaneous start, then conveying operation becomes more constant, but conveyed objects with different weights cannot be accelerated and decelerated synchronously leading to additional load on conveyor drives
Solution Approach 1:
The patent applies dynamics by making the conveyor drive parameters adaptive rather than fixed. The control unit dynamically adjusts acceleration and deceleration profiles based on the detected weight of each conveyed object, allowing synchronized operation despite weight variations. This resolves the contradiction by making the system flexible enough to handle diverse objects while maintaining stable conveying operation.
Solution Approach 2:
The patent changes the parameters of the conveyor drive system based on the properties of conveyed objects. Sensors detect object weight and dimensions, and the control unit modifies conveying parameters (speed, acceleration, timing) accordingly. This allows the system to maintain synchronous operation for objects with different weights, reducing additional loads on drives while preserving operation stability.
2Productivity
If conveyor drives are controlled to accelerate and decelerate conveyed objects, then throughput rate increases, but unsynchronized movement causes pressure accumulation and damage to conveyed objects
Solution Approach 1:
The patent implements feedback control where sensors continuously monitor the position, speed, and weight of conveyed objects, and the control unit adjusts drive parameters in real-time based on this feedback. This ensures that acceleration and deceleration are synchronized across all conveyor zones, preventing pressure accumulation and object damage while maintaining high throughput rates.
Solution Approach 2:
The patent applies preliminary action by detecting and storing parameters of conveyed objects (weight, dimensions) in advance, before they reach subsequent conveyor zones. This allows downstream zones to pre-calculate and prepare appropriate acceleration and deceleration profiles, ensuring synchronized movement and preventing harmful pressure accumulation while maximizing throughput.
3Object-affected harmful factors
If safety distances are maintained between conveyed objects for zero pressure accumulation conveying, then object damage is prevented, but achievable throughput through the conveyor line is reduced
Solution Approach 1:
The patent makes the spacing between conveyed objects dynamic rather than fixed. By continuously monitoring object weight and conveying parameters, the system adjusts safety distances in real-time, maintaining the minimum required distance for zero pressure accumulation conveying while minimizing gaps to maximize throughput.
Solution Approach 2:
The patent changes the safety distance parameter based on the specific characteristics of each conveyed object and the conveying conditions. The control unit calculates optimal spacing that prevents pressure accumulation and object damage while allowing tighter packing than fixed safety distances, thereby increasing throughput without compromising object safety.
Data Source
AI summary
The invention relates to a conveyor device for conveying conveyed objects along a conveyor line, comprising a first conveyor zone, which constitutes a first segment of the conveyor line, and which comprises a first conveyor drive for generating a driving or conveying force braking force on a conveyed object located in the first conveyor zone, a first control unit which is connected to the first conveyor drive in terms of signaling and is designed to control the first conveyor drive with first conveyor parameters selected from: first conveying speed, first conveying acceleration or deceleration, first conveying duration. The invention is characterised in that the first control unit is adapted to transmit the first parameter of conveyed object to the third control unit via the second signal transmission path.