Distributed Drive Carousel with Segmented Motor Control
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Solution Overview
Problem
Current carousel conveyor systems in airports are energy-intensive, have high mechanical costs, and require frequent downtime due to the use of single large drive units, which are not efficiently controlled and result in excessive energy consumption and reduced availability.
Innovation Solution
The implementation of a carousel conveyor system with multiple smaller friction drive units along the carousel path, each equipped with an electric motor and controlled by a programmable logic controller that adjusts motor operation based on load feedback, allowing for closed-loop control and efficient energy use by disengaging motors during low load conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a single large drive unit is used, then the carousel can be driven with sufficient power, but energy consumption increases and system availability decreases due to downtime for repairs
Solution Approach 1:
The single large drive unit is divided into multiple smaller distributed drive units positioned at different locations along the carousel path. Each drive unit independently drives a section of the conveyor chain, allowing the system to maintain sufficient total power while reducing individual unit size and energy consumption.
Solution Approach 2:
The distributed drive units are equipped with sensors and control systems that allow dynamic adjustment of power output based on actual load conditions. The controller monitors carousel load and selectively activates or adjusts the power of individual drive units, enabling the system to consume less energy during low-load conditions while maintaining sufficient power when needed.
2Power
If a single large drive unit is used, then the carousel can be driven with sufficient power, but system availability decreases due to downtime for repairs
Solution Approach 1:
The single large drive unit is divided into multiple smaller distributed drive units positioned at different locations along the carousel path. Each drive unit independently drives a section of the conveyor chain, allowing the system to maintain sufficient total power while reducing individual unit size and energy consumption.
Solution Approach 2:
The distributed drive configuration provides built-in redundancy where multiple drive units can compensate for failures in individual units. The controller is programmed to detect failures and redistribute load to remaining functional drives, cushioning against the impact of individual unit failures and maintaining system availability.
3Power
If multiple drive units are used with basic on/off controls, then additional power can be provided, but control complexity increases without intelligent load response
Solution Approach 1:
Sensors are installed to detect the actual load on the carousel at different positions. The controller receives feedback signals from these sensors and uses them to intelligently adjust the power output of individual distributed drive units, optimizing power distribution based on real-time load conditions rather than using simple on/off control.
Solution Approach 2:
The control system automatically monitors load conditions and adjusts drive unit operation without requiring manual intervention. The distributed drives self-regulate their power output based on local load detection and controller instructions, enabling intelligent load response while keeping the control system manageable.
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
This solution reduces mechanical costs, extends drive unit life, improves system availability, optimizes energy consumption, and minimizes downtime by dynamically adjusting power usage based on load demands, resulting in a more efficient and reliable conveyor system.
Implementation Method 1
A friction drive chain is disposed on the conveyor support frame for movement along the carousel path. The friction drive units each include a friction drive wheel positioned for driving contact with the drive chain.
Data Source
AI summary
A carousel according to the invention uses a number of smaller, less expensive drive units at different locations along the carousel path in place of a single larger drive unit of comparable capacity. Closed loop control according to the invention allows individual drives to be de-energized when the power requirements do not demand their usage. When not energized, the drives may be disengaged from the chain, such as by way of a linear actuator as described hereafter. Benefits of such a system include reduced mechanical costs, longer drive life, better redundancy/higher availability, correct drive power, lower energy use, closed loop system monitoring and reduced collateral damage.