Sensor-Guided Spool Tension Control for Dynamic AGV Carriers
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Solution Overview
Problem
Existing spooling systems for multi-line chain carriers, especially those used in manufacturing and servicing applications, face challenges with spring-driven spool drums that can cause autonomous ground vehicles (AGVs) to skid or be hindered, as the required spring force can be prohibitively large, and manual or pre-programmed control is necessary for dynamic paths, which is not suitable for all manufacturing processes.
Innovation Solution
A spool tension coupling system that includes a sensor to detect changes in tension at the end of an elongate carrier, allowing for automatic control of the spooling apparatus to regulate tension, enabling flexible deployment and retraction of the carrier, thus allowing AGVs to move freely without strain or hazards, and eliminating the need for manual operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a spring-driven spool drum is used to retract the elongate carrier, then the carrier can be automatically retracted, but the spring force required becomes prohibitively large for larger carriers, causing the ground vehicle to skid or be prevented from moving
Solution Approach 1:
The patent replaces the spring-driven mechanical spool drum with a motorized spool drum controlled by a control system. The motorized system uses a sensor to detect tension changes in the elongate carrier and automatically adjusts spooling accordingly, eliminating the need for large spring forces while maintaining automatic retraction capability.
Solution Approach 2:
The patent employs a sensor that provides feedback on tension changes in the elongate carrier to the control system. This feedback mechanism allows the motorized spool drum to respond dynamically to tension variations, automatically regulating the amount of carrier extended without requiring excessive force, thus resolving the contradiction between automatic retraction and excessive spring force.
2Ease of operation
If manual or pre-programmed control is used for motorised spool drums, then the system can be controlled, but it is not suitable for manufacturing or servicing processes requiring AGVs to follow a dynamic path
Solution Approach 1:
The sensor-based feedback system continuously monitors tension in the elongate carrier and automatically adjusts spooling in real-time. This enables the system to adapt to dynamic path changes and varying operational conditions without manual intervention or pre-programming, while maintaining ease of operation through automatic control.
Solution Approach 2:
The control system performs self-service by automatically detecting tension changes and regulating spooling without requiring external manual control or pre-programmed paths. The system adapts dynamically to operational needs, enabling AGVs to follow dynamic paths while maintaining simplicity of operation.
3Ease of operation
If an excess amount of the elongate carrier is deployed across the floor, then the ground vehicle can move freely, but it causes a hazard such as the ground vehicle running over or snagging on the elongate carrier
Solution Approach 1:
The sensor continuously monitors tension in the elongate carrier and provides feedback to the control system. When the carrier becomes too loose or excess is deployed, the tension change is detected and the control system automatically adjusts spooling to retract the carrier, preventing hazards while maintaining vehicle mobility.
Solution Approach 2:
The motorized spool drum with automatic control replaces the passive spring-driven system. This active control system can dynamically adjust carrier deployment and retraction based on real-time tension feedback, preventing excess carrier deployment hazards while ensuring ground vehicle mobility is maintained.
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
The system ensures appropriate tension is maintained between the spooling apparatus and the AGV, preventing excess carrier deployment hazards and allowing AGVs to move dynamically without manual intervention, suitable for larger carriers that would otherwise require motorized control.
Implementation Method 1
The sensor of the spool tension coupling senses movement of the spring carriage with respect to the terminal due to forces acting on the spring carriage by the elongate carrier in order to determine the changes in tension at the end of the elongate carrier.
Data Source
Figure 1~2
Figure 3~4c
Figure 5
AI summary
A spool tension system (30, 35, 40, 50, 80, 85) is provided for a spooled multiline elongate carrier (45) connected between a ground vehicle (10) and a spooling apparatus, in order to connect the ground vehicle to services. A terminal (30) of the ground vehicle is coupled to one end of the elongate carrier via a sensing arrangement (80, 85) which is arranged to provide a signal indicating tension at the end (90) of the elongate carrier (45). The spooling apparatus is arranged to spool the elongate carrier (45) in response to the signal, such that the tension in the elongate carrier (45) is regulated during movement of the ground vehicle (10).