Distributed Conveyor Controller for PLC-Free Line Continuity
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Solution Overview
Problem
Conventional conveyor control systems rely on central PLCs, leading to high installation costs, complex processes, and system shutdowns due to errors or structural changes, with no efficient means to recognize I/O errors or automatically adjust operations without stopping the entire conveyor line.
Innovation Solution
A non-PLC-based conveyor controller system where embedded software enables communication between controllers for autonomous operation, allowing for automatic signal transmission and error logging, reducing the need for central control and enabling flexible system configuration and expansion without halting the entire conveyor system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a central PLC-based control system is used, then centralized control capability is achieved, but installation cost and complexity increase
Solution Approach 1:
The patent divides the centralized PLC control system into multiple independent distributed controllers, each managing a specific conveyor section. This segmentation eliminates the need for complex centralized PLC installation and I/O connections while maintaining control capability through local autonomous operation of each controller unit.
2Measurement precision
If separate installation of motor driver and optical sensor is used, then precise object detection is achieved, but material and installation costs increase
Solution Approach 1:
The patent combines the motor driver and optical sensor into an integrated controller unit. This merging reduces material costs by eliminating separate components and installation costs by reducing the number of separate installations required, while maintaining precise object detection capability through the integrated sensor system.
3Loss of information
If all I/O connections are connected to main PLC, then centralized monitoring is achieved, but wiring complexity and error checking time increase
Solution Approach 1:
The patent extracts the I/O connection requirements from the centralized PLC system and relocates them to local distributed controllers. Each controller independently manages its own I/O connections for motor drivers and sensors, eliminating complex wiring to a central PLC while maintaining monitoring capability through inter-controller communication.
4Ease of operation
If central PLC controls all conveyors, then unified control is achieved, but system shutdown occurs when PLC error occurs
Solution Approach 1:
The patent segments the control system into independent distributed controllers that can operate autonomously. When one controller encounters an error, only its local conveyor section is affected, while other sections continue operating normally through their independent controllers, thus maintaining system continuity while preserving unified control through coordinated operation.
5Adaptability or versatility
If PLC program needs to be changed for structural changes, then adaptability is achieved, but production stoppage occurs during reprogramming
Solution Approach 1:
The patent implements dynamic reconfigurability in distributed controllers, allowing individual controllers to be modified or replaced without affecting the entire system. Structural changes can be made to specific conveyor sections by reprogramming only the affected local controllers, while other sections continue operating, thus maintaining productivity during adaptations.
6Area of stationary object
If multiple controllers are installed for long conveyor, then control coverage is improved, but controller cost and I/O connections increase
Solution Approach 1:
The patent designs universal distributed controllers with standardized interfaces and integrated functions that can manage multiple I/O devices. Each controller is capable of controlling motor drivers, reading optical sensor signals, and communicating with neighboring controllers, reducing the total number of controllers needed while maintaining comprehensive control coverage for long conveyor systems.
Data Source
AI summary
Disclosed is a non-PLC-based conveyor controller that controls object transport on a conveyor through communication between controllers with embedded software includes a first controller-connector that performs transmission/reception of data and operation signals with a left non-PLC-based conveyor controller, a second controller-connector that performs transmission/reception of data and operation signals with a right non-PLC-based conveyor controller, an input section through which an object detection signal from a sensor for an object transported on the conveyor is input, an output section that outputs a motor driving signal for operating the conveyor, and a control section that when the object detection signal is input, transmits an entry prohibition signal to the right controller through the first controller-connector, transmits a progress signal to the right controller through the second controller-connector, and outputs the motor driving signal through the output section so that the object is transported to the conveyor controlled by the right controller.