Modular Conveyor System With Standardized Grid Interfaces
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Solution Overview
Problem
Conventional conveyor systems are inflexible and require extensive preparation and setup, making it difficult to quickly assemble, disassemble, and reconfigure them, especially for overhead systems, which limits their portability and adaptability in dynamic environments like e-commerce warehouses.
Innovation Solution
A modular conveyor system with standardized modules that can be easily connected and disassembled, featuring a uniform grid structure for conveyor technology interfaces and support structures, allowing for rapid setup and reconfiguration without on-site wiring or extensive preparation, enabling immediate operation and scalability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional conveyor systems are permanently connected to the factory building, then structural stability is ensured, but portability and reconfigurability are lost
Solution Approach 1:
The conveyor system is divided into discrete modular segments that can be independently assembled and disassembled. Each module contains complete functional units (motors, conveyors, control systems) that maintain structural integrity while enabling reconfiguration. The standardized interfaces between modules allow stable connections to be formed repeatedly during assembly and disassembly cycles.
Solution Approach 2:
The system transitions from a fixed permanent installation to a dynamic reconfigurable structure. Modules can be moved between locations and reconnected to form different conveyor configurations. The connection mechanisms are designed to provide stable structural bonds when assembled, while allowing the overall system composition to change over time based on operational requirements.
2Adaptability or versatility
If modular conveyor systems are designed for portability, then adaptability is improved, but setup time and preparation requirements increase
Solution Approach 1:
Modules are pre-assembled with all necessary components (motors, conveyors, control systems, wiring) integrated and tested before delivery to the site. This preliminary preparation eliminates the need for on-site assembly of individual components and reduces setup time. Modules arrive ready-to-install with standardized connection interfaces that enable rapid deployment.
Solution Approach 2:
Multiple functional components are merged into integrated module units. Each module combines conveyor mechanisms, drive systems, control electronics, and structural elements into a single pre-assembled unit. This consolidation reduces the number of separate assembly operations required on-site and minimizes preparation time while maintaining portability.
3Reliability
If modules are connected and tested on-site, then system integration is achieved, but installation time and error potential increase
Solution Approach 1:
System integration testing is performed preliminarily at the manufacturer's facility before modules are shipped to the customer site. Each module undergoes functional testing and integration verification in advance, ensuring that components work together correctly. This preliminary integration reduces on-site testing requirements and minimizes installation time while maintaining high system reliability.
Solution Approach 2:
Modules are designed with self-identifying features and automated connection systems that reduce manual configuration and testing on-site. Standardized interfaces with built-in alignment and connection mechanisms enable modules to self-assemble and self-validate their integration, reducing the need for time-consuming manual testing and minimizing errors during installation.
4Area of stationary object
If overhead conveyor systems are installed on building ceilings, then space utilization is improved, but portability and quick deployment are compromised
Solution Approach 1:
The overhead conveyor system is segmented into modular units that can be independently installed and removed. Each module contains the necessary structural support and conveyor components to function autonomously when connected to adjacent modules. This segmentation enables quick deployment by allowing modules to be installed in sequence without requiring complete system installation, while still achieving effective space utilization when assembled.
Solution Approach 2:
The overhead conveyor system transitions from a fixed ceiling installation to a dynamic, reconfigurable structure. Modules can be quickly deployed and connected to overhead support structures using standardized mounting interfaces. The system maintains effective space utilization when assembled but can be rapidly disassembled and relocated, providing adaptability while achieving space efficiency during operation.
Data Source
Figure 1A~1B
Figure 1C~9B
Figure 2~3
AI summary
The invention relates to a portable conveying equipment system (10) having modularly constructed conveying equipment (14), particularly modularly constructed suspended conveying equipment (14), and having a plurality of transport modules (12), each formed from a plurality of previously installed and previously tested conveying equipment components (90). The modules (12) are arranged directly adjacently one alongside another and/or one above another in order to form the system (10) in a state where they are connected to one another. The conveying equipment (14) has: a plurality of conveyance routes (28), which jointly form a previously defined conveyance route course (24) in relation to the material flow, each of the conveyance routes having a separate machine frame (106); at least one drive unit (102); at least one control unit (76); and a transport means (104) that is movable by means of the at least one drive unit (102) along the conveyance route course (24) in order to transport load carriers (16), preferably suspended hangers (128), pockets (20) or trolleys, through the system (10). Each module (10) has: standardized exterior dimensions (H, B, L); a support structure (30), the dimensions (H, B, L) of which are adapted to the standardized exterior dimensions (H, B, L); and at least one of the conveyance routes (28), wherein the machine frame (106) of each of the conveyance routes (28) is permanently connected to the support structure (30), preferably along a uniform grid (86).