Virtual 3D Model for Conveyor Material Flow Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for controlling material flow in warehouses require significant outlay for image recognition, real-time processing, and decentralized control systems, leading to high costs and a need for specialized staff, especially in larger installations.
Innovation Solution
A virtualized three-dimensional model of the warehouse is created and controlled centrally, allowing image recognition to operate cyclically rather than in real-time, reducing the burden on image recognition and eliminating the need for traditional sensors and PLC systems, with IP cameras capturing images to adjust the model and generate control commands for actuators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If real-time image recognition and decentralized PLC control are used, then object position determination and material flow control are achieved, but system complexity and costs increase significantly
Solution Approach 1:
The patent creates a virtual copy of the conveyor system including objects, conveyance techniques, and actuators. This virtual model is updated cyclically from image data and used for control decisions, replacing the need for complex real-time image recognition and decentralized PLC systems while maintaining reliable object tracking and control
Solution Approach 2:
The virtual model serves as an intermediary between image capture and control actuation. Instead of directly processing images in real-time to control actuators, the system uses the virtual model to mediate this information flow, simplifying the control architecture while maintaining reliable object position determination
2Measurement precision
If real-time image recognition is implemented, then object identification and tracking are improved, but processing burden and costs increase
Solution Approach 1:
The system performs image recognition and virtual model updates cyclically rather than in continuous real-time. Images are captured at defined intervals and the virtual model is adjusted periodically, reducing the processing burden and energy consumption while maintaining sufficient measurement precision for control purposes
3Ease of operation
If decentralized PLC control with multiple sensors is used, then material flow control is achieved, but installation and maintenance costs increase
Solution Approach 1:
The patent merges multiple decentralized PLC control units and sensor systems into a single centralized control system that uses the virtual model. This consolidation simplifies installation by reducing the number of separate control units and cabling required, while maintaining ease of operation through the unified virtual model interface
Solution Approach 2:
By using a virtual copy of the conveyor system, the patent eliminates the need for complex decentralized PLC programming and extensive sensor cabling. The virtual model provides all necessary control information, simplifying both installation and maintenance while preserving material flow control functionality
4Extent of automation
If conventional sensor systems with cabling are used, then actuator control is achieved, but installation outlay and complexity increase
Solution Approach 1:
The patent replaces the mechanical sensor-cabling-PLC control system with an optical imaging system combined with a virtual model. IP cameras capture images that are processed to update the virtual model, which then controls actuators, eliminating the need for extensive physical cabling and decentralized PLC infrastructure while maintaining full actuator control capability
Data Source
AI summary
A method for controlling the material flow of goods to be conveyed in a conveyor system of a real warehouse by a virtual three-dimensional model, for which purpose the conveyor system of the real warehouse is virtualized in a central computer, for which purpose a virtual three-dimensional model of the real conveyor system having the dimensions of the individual conveyor components and the movement parameters thereof, including the actuator properties and the identity, shape and position of the goods to be conveyed, is stored, and the conveyor system of the real warehouse is centrally controlled from the virtual model, images of the goods to be conveyed in the real conveyor system are cyclically captured by sensors, and the virtual model is cyclically compared with the reality on the basis of the recorded images.