Modular Conveyor Communication Layout for Real-Time Control
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Solution Overview
Problem
Conventional modular conveyor systems face challenges with high communication latency, limited variability, and complex changes, making them unsuitable for large systems with many individual modules, and they struggle to efficiently manage small-scale conveyor modules.
Innovation Solution
A modular conveyor system with two logical communication levels, where one level is used for layout recognition and configuration, and the other for real-time operation, allowing decentralized control and reducing latency, enabling flexible and efficient management of both large and small conveyor systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single communication interface is used for both layout recognition and real-time control in modular conveyor systems, then device complexity is reduced, but communication latency increases and real-time performance deteriorates
Solution Approach 1:
The communication interface is segmented into two separate logical levels: a first communication level for layout recognition and configuration, and a second communication level for real-time operational control. This segmentation allows each level to be optimized independently, with the first level handling non-time-critical topology discovery and the second level ensuring deterministic real-time control signals, thereby eliminating the latency issues that would arise from using a single shared communication interface.
2Adaptability or versatility
If decentralized control is implemented in each conveyor module, then system adaptability and flexibility improve, but communication complexity and coordination overhead increase
Solution Approach 1:
The patent introduces a hierarchical dimension to the communication architecture, with the first communication level operating at the physical/topology dimension for automatic layout recognition, and the second communication level operating at the control dimension for real-time operational commands. This dimensional separation allows decentralized modules to maintain high adaptability while the hierarchical structure manages communication complexity by organizing interactions into distinct functional layers.
Solution Approach 2:
The first communication level performs preliminary actions by automatically recognizing and storing the system layout and topology before real-time control begins. This preliminary topological mapping enables the second communication level to efficiently coordinate decentralized modules without repeatedly discovering the physical arrangement, thereby reducing ongoing communication overhead while maintaining system flexibility.
3Manufacturing precision
If manual configuration and wiring of conveyor modules is performed, then manufacturing precision and system reliability improve, but installation time and labor costs increase
Solution Approach 1:
The conveyor modules perform self-service through automatic layout recognition using the first communication level. When modules are physically connected, they automatically exchange identification signals and build a topological map of the system without requiring manual configuration. This self-service capability maintains high configuration accuracy through automated detection while dramatically reducing installation time and labor requirements compared to manual wiring and configuration methods.
Solution Approach 2:
The patent replaces manual mechanical configuration processes with automated electronic communication-based layout recognition. Instead of physically wiring and manually configuring each module connection, the system uses the first communication level to electronically discover and map the physical topology, substituting labor-intensive mechanical configuration tasks with automated electronic detection and processing.
4Adaptability or versatility
If changes are made to the conveyor system layout or programming during operation, then system adaptability improves, but system stability and reliability may be compromised
Solution Approach 1:
The separation into two communication levels enables independent handling of reconfiguration and operational control. When layout changes occur, the first communication level automatically detects and adapts the topological mapping without affecting the second communication level's real-time control operations. This segmentation allows the system to adapt to changes while maintaining operational stability, as each level operates independently within its own functional domain.
Solution Approach 2:
The first communication level continuously monitors the physical layout and provides feedback about topological changes to the control system. This feedback mechanism enables the system to automatically detect and adapt to layout modifications while the second communication level maintains stable real-time control based on the updated topology, ensuring both adaptability and reliability during system changes.
Data Source
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AI summary
The invention relates to a modular conveyor system (10) comprising multiple individual conveyor modules (11), wherein an individual conveyor module (11) comprises at least one conveyor device (13), at least one power supply, at least one actuator for driving the conveyor device (13), an output unit for the control of the actuator and an integrated control unit (12), wherein the integrated control unit (12) has a computing unit for processing information and a communications unit (14), and wherein the communications unit (14) is designed to carry out the communication of the individual conveyor modules (11) with a central control system, on the one hand, and/or the communication of the individual conveyor modules (11) with one another, on the other hand, in such a way that the communication of the individual conveyor modules (11) with one another is implemented at two logical communication levels. The invention further relates to a method for controlling modular conveyor systems.