Wireless Mesh Conveyor Modules for Robust Communication
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Solution Overview
Problem
Legacy conveyor systems rely on costly and complex cabling for communication, leading to extended repair cycles when faults occur, and existing wireless solutions do not support a complete modular topology, being either too expensive or not robust against disruptions.
Innovation Solution
A modular conveyor system utilizing wireless mesh communication, where modules with low-power wireless mesh devices form an ad hoc network to route communications, enabling peer-to-peer communication and alternate paths when direct links are obstructed, and integrating with supervisory systems for association and configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If legacy cabled communication schemes are used, then communication reliability is maintained, but system complexity and cost increase significantly
Solution Approach 1:
The patent replaces the mechanical cabling system with a wireless communication system. Each conveyor module is equipped with a wireless transceiver that communicates with adjacent modules and the supervisory system wirelessly, eliminating the need for physical cables and cable management infrastructure while maintaining communication reliability through protocol-level error handling and retransmission mechanisms.
Solution Approach 2:
The patent divides the communication system into independent modular units, where each conveyor module has its own wireless transceiver. This segmentation allows each module to communicate independently with its neighbors and the supervisory system, eliminating the need for a centralized cabling infrastructure and reducing overall system complexity.
2Device complexity
If daisy-chain wired communication is used, then cabling complexity is reduced, but repair time increases when faults occur
Solution Approach 1:
By replacing the mechanical cabling system with wireless communication, the patent eliminates physical cable faults that require repair. The wireless transceivers communicate through radio frequency, eliminating connectors, cable joints, and physical infrastructure that are prone to failure and require manual intervention for repair.
Solution Approach 2:
The wireless communication system provides automatic fault detection and recovery through protocol-level error handling, retransmission mechanisms, and dynamic path selection. When a communication link fails, the system automatically routes messages through alternative paths without requiring manual intervention, enabling self-healing capabilities.
3Reliability
If access point infrastructure is used for wireless communication, then wireless communication is enabled, but system cost increases
Solution Approach 1:
The patent eliminates the need for centralized access point infrastructure by dividing the wireless communication function into distributed transceivers embedded in each conveyor module. Each module acts as an independent communication node, forming a mesh network that routes messages through multiple hops, eliminating the need for expensive access point hardware and infrastructure.
Solution Approach 2:
The wireless transceiver in each conveyor module serves multiple functions: it acts as both a communication endpoint for local module interaction and as a routing node for messages traversing the network. This multi-functionality eliminates the need for dedicated access point infrastructure, as each module contributes to the overall network functionality.
4Device complexity
If simple point-to-point wireless connections are used, then system cost is reduced, but robustness against communication disruptions decreases
Solution Approach 1:
The patent implements dynamic path selection in the wireless mesh network, where message routing adapts in real-time based on link availability. When a direct or intermediate communication path becomes unavailable due to obstruction or interference, the network dynamically selects alternative routes through other modules, maintaining communication robustness without requiring expensive redundant infrastructure.
Solution Approach 2:
The wireless mesh network incorporates feedback mechanisms where each transceiver monitors link quality and communicates availability status to neighboring nodes. This feedback enables the network to detect disruptions and dynamically reroute messages through alternative paths, maintaining robustness against communication disruptions while using cost-effective simple wireless transceivers.
Data Source
AI summary
A modular conveyor system is disclosed in which components of each conveyor module is designed for wireless mesh communication. The communications may be within a module or between modules. Certain of the components may be powered by battery, such that the components may be completely wireless. The network may be entirely self-configuring such that the modules may be assembled and the network established in a straightforward manner.