Modular Conveyor Controller Networking for Self-Configuration
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Solution Overview
Problem
Conventional conveyor systems lack advanced control capabilities, such as discerning article information and tracking differently sized articles, leading to issues like jams and collisions, and are difficult to maintain and reprogram, requiring laborious processes.
Innovation Solution
The implementation of modular conveyor controllers that can detect and configure themselves, communicate through networks, and automatically adjust operations based on connected controllers and sensor data, including photo-eye sensors and motorized rollers, to manage article movement and conveyor operations efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional controllers are used to monitor sensors, then basic article detection is achieved, but advanced control capabilities and article information discernment are lost
Solution Approach 1:
The controller receives feedback signals from sensors including photo-eyes and monitors their status to detect articles. The controller uses this feedback information to determine article presence, size, and position, enabling advanced control capabilities while maintaining basic detection functions.
Solution Approach 2:
The controller is designed to perform multiple functions: basic sensor monitoring, article detection, article size determination, and advanced control operations. This multi-functional design allows the same controller to handle both simple detection tasks and complex control scenarios without requiring separate specialized devices.
2Reliability
If conventional controllers track articles through sensor monitoring, then article presence is detected, but tracking of differently sized articles and prevention of collisions is unable
Solution Approach 1:
The controller continuously receives feedback from sensors positioned along the conveyor to track article movement. By analyzing the timing and pattern of sensor activations, the controller determines article size and position, enabling accurate tracking of differently sized articles and prediction of potential collisions before they occur.
Solution Approach 2:
The controller uses sensor feedback to predict potential collisions or jam situations before they occur. By determining article size and position in advance, the controller can take preliminary actions such as adjusting conveyor speed or activating warning signals to prevent collisions, thereby maintaining high productivity while ensuring reliable tracking.
3Ease of operation
If multiple conventional controllers are programmed individually, then basic conveyor operation is achieved, but programming time and labor are excessive
Solution Approach 1:
The patent combines the programming and configuration functions into a unified process. The controller automatically receives configuration information from replacement controllers and merges it with existing system parameters, eliminating the need for individual programming of each controller and significantly reducing setup time while maintaining operational simplicity.
Solution Approach 2:
The controller performs self-configuration by automatically receiving and processing configuration data from replacement controllers. This self-service capability eliminates the need for manual programming of each controller, allowing the system to reconfigure itself automatically and reducing both programming time and labor requirements.
4Reliability
If conventional controllers are replaced, then system redundancy is achieved, but reprogramming of replacement controllers is laborious
Solution Approach 1:
The replacement controller automatically receives configuration information from the previous controller or neighboring controllers and configures itself without manual intervention. This self-service replacement process maintains system reliability by ensuring the replacement controller is properly configured while dramatically simplifying the repair process and reducing labor requirements.
Solution Approach 2:
The replacement controller copies configuration data from the previous controller or neighboring controllers in the system. This copying mechanism ensures that the replacement controller inherits the correct operational parameters and settings, maintaining reliability while eliminating the need for manual reprogramming and making the replacement process straightforward.
Data Source
AI summary
A conveyor controller for being implemented into a conveyor system includes control circuitry and one or more network interfaces for coupling with other conveyor controllers. In one embodiment, the control circuitry configured for detecting whether another conveyor controller is connected and to determine which network interface is used in order to set the direction of the conveyor system. In another embodiment, the control circuitry is configured, to receive configuration data from a conveyor controller connected to a network interface, and to detect if another conveyor controller is and to transmit configuration message to another conveyor controller that includes additional configuration data associated with the conveyor controller. In still another embodiment, the control circuitry transmits configuration data to a replacement conveyor controller upon getting a request from the replacement conveyor controller that has been connected to a network interface.