Curved-Track Conveyor Control With Sinusoidal Motion Profiles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional conveyor systems face challenges in handling moving elements on curvilinear or curved sections due to differing forces and changes in velocity and acceleration, particularly during transitions from straight to curved sections, which can lead to issues like jerk and wear on bearings/wheels, and require complex control systems or costly electromagnetic drives.
Innovation Solution
A conveyor system with a rotary driven star wheel and a controller that manages the speed of moving elements to achieve a sinusoidal velocity profile, ensuring smooth transitions between straight and curved track sections, using a rotary wheel with radial spokes for engagement and magnetic attraction for support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional linear motor systems are used in curved sections with smaller radius, then the conveyor system can be more compact, but the moving elements experience different forces and changes in velocity/acceleration causing jerk and wear on bearings/wheels
Solution Approach 1:
The controller applies preliminary deceleration before the moving element enters the curved section and preliminary acceleration after exit, creating smooth velocity transitions. This preliminary action prevents sudden changes in velocity and acceleration that cause jerk and bearing wear, while still allowing compact curved sections with smaller radii.
2Speed
If electromagnetic drives are used to control speed transitions, then smooth velocity profiles can be achieved, but the system becomes more complex and costly
Solution Approach 1:
The controller performs multiple functions using a single device: it controls the linear motor drive during straight sections, manages the rotary motor drive during curved sections, and coordinates transitions between different drive systems. This multi-functional approach achieves smooth velocity profiles without requiring separate complex control systems for each function.
3Ease of manufacture
If the track is formed in sections and attached together, then the conveyor system is easier to construct, but complex control is required to manage transitions between sections
Solution Approach 1:
The conveyor track is divided into modular sections that can be easily manufactured and assembled separately. The controller manages transitions between these segments by coordinating the drive systems at the joints, allowing simple modular construction while maintaining smooth operation through intelligent control of velocity and acceleration profiles.
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
The system provides smoother transitions and reduces wear on moving elements, allowing for smaller radius curved sections and higher throughput without the need for complex control systems or expensive materials, while being agnostic to different drive systems.
Implementation Method 1
using a rotary wheel with radial spokes for engagement and magnetic attraction for support
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A conveyor system and method for controlling the same. The conveyor system includes: at least one moving element; a track including: a straight track section with a first mechanism for moving the moving element; and a curved track section connected to the straight track section including a second mechanism for moving the moving element; and a controller configured to control a speed of the moving element as the moving element moves from the straight track section to the curved track section and vice versa such that a velocity profile of the moving element includes a sinusoidal portion to provide a transition from straight to rotary motion or from rotary to straight motion having a linear position profile. In the method, the controller controls at least one of the first mechanism and the second mechanism to move the moving element according to the velocity profile including the sinusoidal portion.