Radar Conveyor Gap Control for Consistent Load Density
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Solution Overview
Problem
Conveyor systems face challenges in accurately detecting objects and controlling load densities due to limitations of proximity sensors, leading to inefficiencies and delays.
Innovation Solution
A conveyor control system utilizing radar devices to determine object dimensions, distances, speeds, and gaps, generating a point cloud for precise load density management, and controlling conveyor parameters to maintain optimal gaps and densities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If proximity sensors are used to detect objects on conveyor lines, then the system can control conveyor operation based on object detection, but the detection accuracy is insufficient leading to incorrect load density determination
Solution Approach 1:
The patent replaces proximity sensors with radar devices that use electromagnetic waves to detect objects. The radar device transmits electromagnetic waves and receives reflections to determine object positions, distances, and dimensions, providing significantly more accurate detection data for load density calculation.
Solution Approach 2:
The patent introduces radar technology as an intermediary detection method between the conveyor system and objects. The radar device acts as a mediator that provides precise measurement data about object positions and dimensions, enabling accurate load density determination without direct contact or line-of-sight requirements.
2Measurement precision
If radar devices are used to accurately detect objects, then load density determination improves, but device complexity increases
Solution Approach 1:
The radar device performs multiple functions simultaneously: detecting object presence, measuring object dimensions, calculating distances between objects, and providing data for load density determination. This multi-functionality reduces the need for multiple separate sensors and measurement devices.
Solution Approach 2:
The patent combines detection, measurement, and control functions into an integrated radar-based system. The controller receives radar data and automatically processes it to determine load density and control conveyor operation, merging what would otherwise be separate systems into a unified solution.
3Reliability
If multiple sensors are deployed to improve detection coverage, then detection reliability improves, but system complexity and cost increase
Solution Approach 1:
The patent replaces multiple proximity sensors with a single radar device that provides superior detection capabilities. The radar's electromagnetic wave-based detection method offers all-around coverage and penetration capabilities that would require multiple optical or proximity sensors to achieve, thereby reducing system 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
Enhances conveyor efficiency by accurately detecting objects and maintaining consistent load densities, reducing delays and damage, and optimizing throughput.
Implementation Method 1
a radar device configured to send a first electromagnetic wave to a first object and a second electromagnetic wave to a second object on a first conveyor section, receive a reflection of the first electromagnetic wave from the first object and a reflection of the second electromagnetic field from the second object
Implementation Method 2
a radar device configured to send a first electromagnetic wave to a first object and a second electromagnetic wave to a second object
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3
AI summary
Methods, apparatuses and systems for a conveyor control system are disclosed herein. An example apparatus may comprise a radar device for sending and receiving electromagnetic waves to first and second objects on a first conveyor section. A first and second timing or frequency variations between the sent and received first and second electromagnetic waves are determined. The apparatus may comprise a controller configured to generate a point cloud using any of the first and second timing or frequency variations, determine any of first dimensions, a first distance, and a first speed of movement of the first object and second dimensions, a second distance, and a second speed of movement of the second object on the first conveyor section using the point cloud, determine a first gap between the first object and the second object, and control one or more first operating parameters of the first conveyor section using the first gap.