Ethernet Line Tracking Encoder for Conveyor Positioning
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Solution Overview
Problem
Current line-tracking systems for robotic systems are expensive due to the use of multiplexers and specialized hardware, and are limited in scalability and accuracy as the conveyor line moves, requiring additional computers for data distribution.
Innovation Solution
A control system comprising a line tracking encoder, a master controller, and slave controllers connected via a direct communications network, which processes and transmits tracking data to accurately predict the conveyor position and control robot movements without the need for multiplexers or additional computers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiplexers and specialized wiring are used to distribute encoder data to robot controllers, then line-tracking functionality is achieved, but system cost increases and scalability is limited
Solution Approach 1:
The patent replaces the mechanical/electrical multiplexer system with a software-based Ethernet communication system. The encoder data is transmitted over standard Ethernet networks using TCP/IP protocols, eliminating the need for specialized multiplexer hardware and complex wiring while maintaining line-tracking accuracy.
Solution Approach 2:
The system uses standard Ethernet infrastructure that can serve multiple functions simultaneously - line-tracking data transmission, robot control communication, and system monitoring - replacing dedicated specialized wiring with a universal network protocol that handles multiple data streams efficiently.
2Reliability
If multiplexers are used to distribute encoder inputs to multiple robot controllers, then line-tracking is enabled, but the number of controllable robots is limited by multiplexer output capacity
Solution Approach 1:
The patent substitutes the hardware multiplexer with a software-based data distribution system over Ethernet. The master controller receives encoder data and distributes it to multiple slave controllers through network communication, allowing virtually unlimited scalability based on network capacity rather than hardware port limitations.
Solution Approach 2:
The system transitions from a one-to-one or limited one-to-many hardware connection model to a many-to-many network communication model. Multiple slave controllers can simultaneously receive and process encoder data through the Ethernet network, adding a dimensional aspect of concurrent data distribution that overcomes hardware port constraints.
3Measurement precision
If separate intervening computers with specialized Ethernet hardware are used for data distribution, then timing information can be maintained, but system cost increases and field failure risk increases
Solution Approach 1:
The patent extracts the timing synchronization functionality from separate intervening computers and integrates it directly into the master controller software. The master controller maintains timing information using software-based time stamping and synchronization protocols, eliminating the need for specialized external hardware while preserving timing accuracy.
Solution Approach 2:
The system merges the functions of the master controller, timing synchronization, and data distribution into a single integrated software platform. The master controller simultaneously manages encoder data reception, timing synchronization, and distribution to multiple slave controllers over Ethernet, reducing hardware complexity while maintaining precision.
Data Source
AI summary
A robot control system includes a line tracking encoder that measures a reference position of a conveyor line and transmits a tracking signal representing tracking data including the reference position of the conveyor line. A master controller is in communication with the encoder to receive the tracking signal, process the tracking data represented by the tracking signal, and generate a data packet in response to processing of the tracking data. A slave controller is in communication with the master controller and at least one robot for receiving the data packet and controlling the movement of the at least one robot in response to the data packet. A communications network directly interconnects the master controller and the slave controller and transmits the data packet from the master controller to the slave controller.