Wireless Conveyor Control for Closed-Loop Vehicle Reliability
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Solution Overview
Problem
Existing conveying systems in manufacturing cells face reliability issues due to interference with data and signal transmission, particularly in environments with contamination, necessitating the use of data and signal cables.
Innovation Solution
A control module with bidirectional wireless data and signal transmission using antennas, converters, and speed-related sensors to regulate vehicle movement in real time, eliminating the need for physical cables and preventing electrical resistance at contact points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If data and signal cables are used for transmission between control module and vehicle, then connection reliability is improved, but electrical resistance at contact points occurs due to contamination
Solution Approach 1:
The patent replaces the mechanical cable-based data and signal transmission system with a wireless transmission system using antennas. This substitution eliminates physical contact points that are susceptible to contamination and electrical resistance, thereby maintaining connection reliability without the harmful effects of cable-based systems in contaminated manufacturing environments.
2Object-affected harmful factors
If wireless transmission is implemented, then electrical resistance at contact points is eliminated, but data transmission interference may occur in manufacturing environment
Solution Approach 1:
The patent replaces the mechanical cable-based data and signal transmission system with a wireless transmission system using antennas. This substitution eliminates physical contact points that are susceptible to contamination and electrical resistance, thereby maintaining connection reliability without the harmful effects of cable-based systems in contaminated manufacturing environments.
3Reliability
If cables are laid along the vehicle in production hall, then data and signal transmission is established, but installation complexity and maintenance difficulty increase
Solution Approach 1:
The patent replaces the mechanical cable-based data and signal transmission system with a wireless transmission system using antennas. This substitution eliminates physical contact points that are susceptible to contamination and electrical resistance, thereby maintaining connection reliability without the harmful effects of cable-based systems in contaminated manufacturing environments.
4Manufacturing precision
If real-time closed loop control is implemented, then vehicle movement precision is improved, but system complexity increases
Solution Approach 1:
The patent implements a closed-loop control system where the control module receives feedback from the vehicle's actual position and sends corrected position commands to achieve precise movement. The control module calculates the difference between the actual position and target position, then transmits corrected position commands to guide the vehicle to the target location, ensuring accurate positioning through continuous feedback and adjustment.
Solution Approach 2:
The patent replaces the mechanical cable-based data and signal transmission system with a wireless transmission system using antennas. This substitution eliminates physical contact points that are susceptible to contamination and electrical resistance, thereby maintaining connection reliability without the harmful effects of cable-based systems in contaminated manufacturing environments.
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
Enhances the reliability and efficiency of conveying systems by enabling real-time control of vehicle movement and data transmission without the need for cables, reducing interference and maintaining consistent operation.
Implementation Method 1
at least one antenna (164) for bidirectional transmission of data and signals in a wireless manner between the vehicle (100; 130) and the control module (150)
Implementation Method 2
a speed-related sensor, and the drive unit (111) is configured to transmit the output signal of this speed-related sensor to the control module (150) in a protocol format
Data Source
Figure 1
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Figure 4
AI summary
The invention relates to a conveyor system of a production cell with a stationary control module and at least one rail- or track-bound self-propelled vehicle, as well as a production cell with a programmable logic controller (PLC) and a conveyor system. The control module has at least one antenna for bidirectional wireless transmission of data and signals between the vehicle and the control module. The vehicle has at least one antenna, which is assigned to a drive unit of the vehicle. The drive unit has a converter for converting a data set transmitted by the control module in a protocol format into digital control signals for a drive motor of the drive unit.Furthermore, the drive unit has a speed-related sensor, and the drive unit transmits the output signal of this speed-related sensor to the control module in a protocol format, so that the control module regulates the vehicle's driving profile in real time in a closed loop. The present invention increases the reliability of the conveyor system.