Spool Tension Coupling With Sensor Feedback for AGV Cable Retraction
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Solution Overview
Problem
Existing spooling systems for multi-line chain carriers, particularly in manufacturing and servicing environments, 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 applications.
Innovation Solution
A spool tension coupling system that includes a terminal with a sensor to detect changes in tension, allowing for automatic control of the spooling process, ensuring appropriate elongate carrier extension and preventing over-deployment, which includes a motorized drum and a controller to regulate tension based on tension signals from the sensor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a spring-driven spool drum is used to retract the carrier, then the carrier is automatically retracted, but the spring force becomes prohibitively large for larger carriers
Solution Approach 1:
The patent replaces the spring-driven mechanical retraction system with an electric motor-driven spool drum. The motor provides the necessary force to retract the carrier without requiring large spring forces, thereby eliminating the problem of prohibitively large spring forces while maintaining automatic retraction functionality.
Solution Approach 2:
The system uses a tension sensor to automatically detect when the carrier needs retraction and triggers the motor to operate accordingly. This self-service mechanism eliminates the need for manual intervention while avoiding the need for oversized springs, as the system responds dynamically to actual tension conditions.
2Ease of operation
If manual or pre-programmed control is used for motorised spool drums, then control is possible, but it is not suitable for dynamic paths
Solution Approach 1:
The patent incorporates a tension sensor that provides real-time feedback on the tension in the carrier. This feedback enables the control system to automatically adjust the spool drum's operation in response to changing conditions, allowing the system to adapt to dynamic paths without manual intervention or pre-programming.
Solution Approach 2:
The system transitions from static control methods (manual or pre-programmed) to dynamic control based on real-time tension sensor data. The motorized spool drum responds dynamically to changing tension conditions, enabling adaptation to dynamic paths while maintaining ease of operation through automatic control.
3Productivity
If the carrier is extended across the floor, then services are provided to the vehicle, but excess deployment creates safety hazards
Solution Approach 1:
The tension sensor provides continuous feedback on the carrier's tension state, enabling the control system to monitor and regulate the amount of carrier deployed. When the carrier becomes taut or exceeds appropriate extension, the system automatically retracts it, preventing safety hazards while maintaining service provision during normal operation.
Solution Approach 2:
The system proactively prevents excess carrier deployment by using the tension sensor to detect approaching hazardous conditions and triggering retraction before the hazard occurs. This preliminary anti-action ensures safety while allowing full productivity during normal service provision.
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
Enables AGVs to move freely without strain, prevents hazards from excess carrier deployment, and eliminates the need for manual spooling control, suitable for larger carriers providing multiple services like power, compressed air, and data, while protecting cables and hoses from tension forces.
Implementation Method 1
a sensor coupled to the terminal and arranged to provide a signal in response to changes in tension at the end of the elongate carrier
Data Source
AI summary
A spool tension system is disclosed for a spooled multi-line elongate carrier connected between a ground vehicle and a spooling apparatus, in order to connect the ground vehicle to services. A terminal of the ground vehicle is coupled to one end of the elongate carrier via a sensing arrangement which is arranged to provide a signal indicating tension at the end of the elongate carrier. The spooling apparatus is arranged to spool the elongate carrier in response to the signal, such that the tension in the elongate carrier is regulated during movement of the ground vehicle.