Virtual Conveyor Path Segmentation for Route and Spacing Control
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Solution Overview
Problem
Existing digital twin systems lack effective methods for controlling virtual conveyors in a virtual environment, particularly in segmenting conveyors into multiple paths based on joints and managing transportation routes of products.
Innovation Solution
A system and method for controlling conveyors in a virtual environment, which involves segmenting a virtualized conveyor into multiple paths based on joints and using a twin model module to control transportation routes of products, including safety distance management and direction changes using bar code scanning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conveyor is virtualized as a single unit in a digital twin system, then the system structure is simple, but the ability to control multiple transportation routes and manage product flow is limited
Solution Approach 1:
The virtual conveyor is segmented into multiple paths based on joint positions, allowing independent control of each path while maintaining the overall conveyor structure. This segmentation enables flexible route management for products without requiring complete structural redesign.
Solution Approach 2:
The conveyor system is transformed from a single linear path to a multi-dimensional path network by introducing joint-based segmentation. This allows products to be routed through different paths (straight or turning) based on destination requirements, adding a routing dimension to the control system.
2Reliability
If safety distance monitoring is implemented between products on the conveyor, then collision prevention is improved, but the control system complexity increases
Solution Approach 1:
The system continuously monitors the distance between adjacent products on the conveyor and provides feedback to the control logic. When the distance falls below the safety threshold, the system automatically adjusts product spacing or stops conveyance to prevent collisions, creating a closed-loop safety mechanism.
Solution Approach 2:
The safety distance is predetermined and set before product conveyance begins. The control system proactively maintains this distance by regulating product release timing and speed, preventing dangerous situations before they occur rather than reacting to imminent collisions.
3Measurement precision
If direction changing units with barcode scanning are added to joints, then product routing precision is improved, but the device complexity and cost increase
Solution Approach 1:
Products carry barcode identifiers that automatically identify their destination requirements. The direction changing units scan these barcodes and autonomously determine the appropriate routing path without human intervention, enabling self-service routing decisions at each joint.
Solution Approach 2:
Manual or mechanical routing decisions are replaced with optical barcode scanning and automated control logic. The system uses optical recognition (barcode reading) combined with digital control to determine routing paths, substituting complex mechanical switching mechanisms with simpler electronic control based on product identification.
Data Source
AI summary
A system for controlling a conveyor in a virtual environment includes a twin model module comprising control logic and configured to virtualize a control system for conveyors installed in a factory. The system also includes a digital factory module configured to virtualize the conveyors installed in the factory and create a virtual factory model controlled by the twin model module. A virtualized conveyor includes multiple paths formed by segmenting the conveyor based on joints. The twin model module is configured to control transportation routes of products based on the joints.