Overhead Conveyor Overfill Detection Using Dual RFID Sensors
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Solution Overview
Problem
Existing overhead conveyor systems face challenges in determining the fill level of accumulation conveyor sections, leading to potential overfilling and system blockages, which can result in inefficient space utilization and operational disruptions.
Innovation Solution
Implementing an overfill sensor system with two sensors spaced apart along the conveyor line, using identifiers such as RFID transponders to detect carriers and determine the fill status by measuring the time interval between sensor detections, allowing for early detection of overfilling before it occurs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the accumulating conveyor line is dimensioned generously to avoid overfilling, then the reliability of the conveyor system is improved, but the area utilization deteriorates
Solution Approach 1:
The system performs preliminary detection of carrier presence using sensors positioned along the conveyor line. By detecting carriers at multiple points before the accumulation zone, the system can predict potential overfilling conditions in advance and take preventive actions, such as controlling the inlet of new carriers or alerting operators, thereby avoiding overfilling without requiring excessive buffer space.
Solution Approach 2:
The system implements a feedback mechanism where sensors continuously monitor the positions of carriers on the conveyor line. This information is fed back to a control system that can adjust the carrier flow into the accumulation zone, dynamically preventing overfilling conditions while optimizing the use of available space.
2Area of stationary object
If the accumulating conveyor line is dimensioned compactly to improve area utilization, then the area utilization is improved, but the reliability deteriorates due to overfilling risks
Solution Approach 1:
By positioning sensors at strategic locations before the accumulation zone, the system detects carriers in advance and predicts when the accumulation line will reach its capacity. This allows the system to prepare preventive measures, such as stopping the inlet of new carriers, before overfilling occurs, enabling compact design without sacrificing reliability.
Solution Approach 2:
The sensor network provides continuous feedback on carrier positions and accumulation levels. This real-time information enables the control system to dynamically manage carrier flow, preventing overfilling in compact configurations by adjusting the inlet rate based on current accumulation status.
3Device complexity
If manual monitoring of fill level is used, then the device complexity is reduced, but the productivity deteriorates due to operational disruptions
Solution Approach 1:
The system implements self-service monitoring where sensors automatically detect carrier positions and the control system autonomously determines fill levels and prevents overfilling conditions. This eliminates the need for manual monitoring while maintaining high productivity through automated decision-making and carrier flow control.
Solution Approach 2:
The automated feedback system continuously monitors carrier positions and provides real-time information about accumulation levels. This enables the system to automatically respond to approaching capacity limits, preventing operational disruptions without requiring manual intervention, thereby maintaining high productivity with minimal added complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables effective monitoring of conveyor fill levels, preventing overfilling and system blockages, while optimizing space usage by allowing for more precise control of carrier flow and transfer to other conveyor sections.
Implementation Method 1
The identifier can be an optically readable identifier, for example a barcode or a QR code, or an electromagnetically readable identifier, such as an RFID transponder
Implementation Method 2
The identifier can be an optically readable identifier, for example a barcode or a QR code
Implementation Method 3
The carriers can, for example, be driven by a driver and/or driven by gravity along a gradient of the conveyor line
Data Source
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AI summary
The invention describes a conveying section (1) for an overhead conveyor (100), wherein the conveying section (1) has a plurality of carriers (2) which are suspended in a guide profile (3) of the conveying section (1) and driven by a driver (4) along the guide profile (3), characterized in that the carrier (2) has an identifier (5) and the conveying section (1) has an overfill sensor (6) with at least two sensors (7.1, 7.2) spaced apart in the longitudinal direction of the guide profile (3) for reading the identifier (5). A corresponding method is further described.