Tugger Train Hierarchical Control for Independent Element Movement
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Solution Overview
Problem
Existing tugger train systems face limitations in independent movement and control of tugger train elements due to rigid coupling, which restricts the flexibility and efficiency of loading and unloading operations, leading to increased effort and potential blockages during movement.
Innovation Solution
Implementing a hierarchical control system with a tugger train master control unit and slave control units connected via a signal-transmitting bus, allowing independent vertical movement and coordinated control of tugger train elements, enabling one-sided or simultaneous lowering and raising, and flexible operation through programmable logic controllers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If rigid coupling is used to connect tugger train elements, then structural stability is improved, but flexibility and ease of operation deteriorate
Solution Approach 1:
The control system is segmented into master and slave control units distributed across different tugger train elements. Each element can be controlled independently through this segmentation, allowing one-sided lowering or raising operations without requiring all elements to move simultaneously, thus improving operational flexibility while maintaining structural stability through the hierarchical control architecture.
Solution Approach 2:
The system transitions from static rigid coupling to dynamic controlled coupling. The hierarchical control system enables dynamic adjustment of each tugger train element's position independently, allowing the system to adapt its configuration during operation. This dynamic control permits elements to be lowered or raised individually based on operational needs, resolving the contradiction between stability and flexibility.
2Stability of the object's composition
If rigid coupling is used to connect tugger train elements, then structural stability is improved, but device complexity increases
Solution Approach 1:
The control system is divided into master and slave control units, where each unit manages a specific tugger train element. This segmentation reduces the complexity burden on any single controller and enables distributed intelligence. The master control unit coordinates overall system operations while slave units handle local operations, making the overall system more manageable and less complex despite the added control functionality.
Solution Approach 2:
Each tugger train element equipped with its own control unit can operate semi-autonomously. The slave control units can initiate and execute local operations such as lowering or raising specific elements without requiring constant intervention from the master control unit or manual operation. This self-service capability reduces the operational complexity and simplifies the control architecture by distributing decision-making authority.
3Stability of the object's composition
If all tugger train elements must move simultaneously, then structural stability is maintained, but productivity decreases
Solution Approach 1:
The simultaneous movement requirement is segmented and abolished through independent control of individual elements. Each tugger train element can be lowered or raised independently based on operational needs, allowing parallel operations across different elements. This segmentation enables multiple elements to be serviced simultaneously or at different times, significantly improving productivity while maintaining structural stability through controlled independent movement.
Solution Approach 2:
Instead of requiring all elements to move simultaneously (complete action), the system allows partial actions where only the necessary elements are moved at any given time. The hierarchical control system enables selective operation of individual elements or groups of elements, performing just enough action to complete the loading or unloading task without unnecessary movement of other elements, thereby improving efficiency and reducing idle time.
Data Source
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AI summary
The present invention relates to a tugger train (1a) comprising a first tugger train element (1aa) configured to accommodate at least one logistics element (2), and a second tugger train element (1ab) configured to accommodate at least one logistics element (2). The tugger train (1a) is characterized in that the first tugger train element (1aa) has a tugger train master control unit (50), and that the second tugger train element (1ab) has a tugger train slave control unit (51), wherein the tugger train master control unit (50) of the first tugger train element (1aa) is connected to the tugger train slave control unit (51) of the second tugger train element (1ab) via a tugger train bus (52) for signal transmission.