Motor-Driven Roller Bus Control for Intralogistics
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Solution Overview
Problem
Motor-driven conveyor rollers in intralogistics face challenges with data transmission and reliability, particularly due to cable damage leading to system failures, which can result in significant time and financial losses when a single roller fails, disrupting the entire conveyor line.
Innovation Solution
The implementation of a bus line for data transmission within the motorized conveyor roller, allowing for real-time monitoring and control of actual and target states, including mechanical, thermal, and temporal operating data, along with configuration data, using protocols like CAN bus, enables efficient data transfer and enhances system reliability by providing real-time monitoring and predictive maintenance capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If individual data cables are used for data transmission, then data transmission capability is improved, but device complexity and susceptibility to damage increase
Solution Approach 1:
The patent combines multiple individual data cables into a single bus line that runs through the hollow axle element. This consolidation reduces the number of separate cables needed while maintaining data transmission capabilities, thereby reducing device complexity and the risk of cable damage.
Solution Approach 2:
The bus line is nested within the hollow axle element, utilizing the internal space of the axle for cable routing. This nesting approach protects the data transmission line and simplifies the overall structure by integrating the cable pathway into an existing structural component.
2Loss of information
If more cables are routed through the hollow axle element, then data transmission capability is improved, but the limited space becomes insufficient
Solution Approach 1:
Multiple data transmission functions are merged into a single bus line, allowing high-capacity data transmission through one cable rather than requiring multiple separate cables. This resolves the space limitation while maintaining transmission capability.
Solution Approach 2:
The bus line serves multiple functions: transmitting data bidirectionally, providing power, and enabling communication between the drive unit and external control systems. This multi-functionality eliminates the need for separate cables for each function.
3Ease of manufacture
If external wiring is used for power supply, then ease of installation is improved, but susceptibility to collision damage increases
Solution Approach 1:
The power supply wiring is nested within the hollow axle element, protecting it from external collision damage. The axle structure serves as a protective conduit, maintaining reliability while allowing relatively easy installation through the existing axle pathway.
Solution Approach 2:
The hollow axle element acts as an intermediary structure that houses and protects the power supply wiring. This mediator shields the vulnerable cables from mechanical damage while maintaining electrical connectivity.
4Ease of repair
If a single roller fails, then component replacement cost is reduced, but entire conveyor line operation is interrupted
Solution Approach 1:
The bus line enables real-time feedback transmission from the drive unit to external control systems, allowing monitoring of the roller's operational status. This early detection capability allows for proactive maintenance scheduling, preventing unexpected failures that would interrupt conveyor line operation.
Solution Approach 2:
Through continuous monitoring via the bus line, the system can detect early signs of drive unit failure and schedule maintenance before actual failure occurs. This preliminary action prevents unexpected breakdowns and maintains conveyor line continuity.
Data Source
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AI summary
The invention relates to a motor-driven conveyor roller comprising a conveyor roller tube rotatably mounted about an axle element, a drive unit arranged inside the conveyor roller tube, which is designed for torque generation and rotational movement between the axle element and the conveyor roller tube and is mechanically coupled to the axle element and the conveyor roller tube, a power line running from outside the conveyor roller tube to the drive unit, and a data line running from outside the conveyor roller tube to the drive unit, wherein the data line is designed as a bus line and is connected to the drive unit via a bus interface arranged in the conveyor roller tube.The motor-driven conveyor roller comprises an electronic control unit with a first control circuit, which is arranged inside the conveyor roller tube and is designed to perform one or more of the functions of the control unit, and a second control circuit, which is connected to the bus interface via the bus line, is arranged outside the conveyor roller tube and is designed to perform one or more of the functions of the control unit.