Motor-Driven Roller Configuration Using Motor-to-Roller Speed Ratio
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Solution Overview
Problem
Conveyor systems with motor-driven rollers face challenges in ensuring the correct configuration file is saved to each motor driven roller, especially in large installations, due to the need for different models with varying speed and torque ranges.
Innovation Solution
An apparatus comprising a processor and memory configured to transmit signals to the motor, receive rotational speed data, calculate ratios of motor to roller speed, and compare these ratios to predefined values to determine the appropriate configuration data for automatic configuration of motor driven rollers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual configuration methods are used for motor driven rollers, then configuration can be performed with simple equipment, but accuracy and reliability of configuration file assignment deteriorates in large installations
Solution Approach 1:
The motor driven roller automatically determines its own configuration by measuring its rotational speed and comparing it to predefined values. The system performs self-identification of its model type through the ratio calculation between motor speed and roller speed, eliminating the need for manual configuration and ensuring accurate file assignment.
Solution Approach 2:
The system uses feedback from speed sensors to continuously monitor motor and roller rotational speeds. This feedback enables automatic calculation of the speed ratio, which is then compared against predefined thresholds to identify the correct configuration file, ensuring accurate configuration assignment.
2Reliability
If automatic configuration is implemented, then configuration accuracy improves, but device complexity increases due to additional sensors and processing
Solution Approach 1:
The control board serves multiple functions: it controls motor operation, processes speed sensor signals, calculates rotational ratios, compares values against predefined thresholds, and automatically assigns configuration files. This multi-functionality reduces the need for separate dedicated components for each task.
Solution Approach 2:
The patent replaces manual mechanical configuration processes with electronic automation. The control board uses electronic signal processing and algorithmic comparison to determine configuration, substituting the need for manual intervention and physical configuration media handling.
3Measurement precision
If multiple predefined numeric values are used for ratio comparison, then configuration precision improves, but processing time increases
Solution Approach 1:
The system pre-calculates and stores multiple predefined numeric values representing different model types before operation begins. During configuration, the measured ratio is immediately compared against these pre-prepared values, eliminating the need for complex real-time calculations and enabling rapid model identification.
Data Source
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AI summary
Methods, apparatuses, and computer program products for automatic configuration of a motor driven roller (MDR) are provided. For example, a computer-implemented method may include transmitting a signal to a motor of an MDR to instruct the motor to rotate at a predetermined rotational speed; receiving a signal indicating an actual rotational speed of the motor; receiving a signal indicating an actual rotational speed of a roller being rotated by the motor; dividing the actual rotational speed of the motor by the actual rotational speed of the roller to obtain a ratio of motor speed to roller speed; comparing the ratio to predefined numeric values to determine if the ratio matches any of the predefined numeric values, each of the predefined numeric values being associated with predefined motor configuration data; and transmitting, to the MDR, the predefined motor configuration data corresponding to the predefined numeric value matching the ratio.