Conveyor diagnostic system having local positioning system

A conveyor diagnostic system for monitoring loading of a conveyor line assembly including at least one sensor component coupled to the conveyor line assembly. The sensor component is adapted for detecting loading of the conveyor line assembly and is further adapted for generating and transmitting a signal that is correlative of the loading of the conveyor line assembly. The conveyor diagnostic system also includes a ground station adapted to receive and process the signal that is correlative of the loading of the conveyor line assembly. Furthermore, the conveyor diagnostic system includes a local positioning system that is adapted for detecting the location of the sensor component in relation to a reference point. A method of using the conveyor diagnostic system is also disclosed.

FIELD OF THE INVENTION

The present invention relates generally to a conveyor diagnostic system and, more specifically, to a conveyor diagnostic system having a local positioning system.

BACKGROUND OF THE INVENTION

Most conveyor line assemblies include moving parts, such as chains, rollers, and the like that undergo a significant amount of loading during operation. These loads may vary over time or may be concentrated in certain areas of the conveyor line assembly. For instance, loads on the conveyor line assembly can increase over the operating life of the assembly. Likewise, load concentrations can develop due to structural misalignment, wear, or lack of proper lubrication of certain components of the conveyor line assembly. Such loading can cause the conveyor line assembly to malfunction or fail, which can lead to losses in productivity.

Conveyor diagnostic systems have been designed for measuring and monitoring these loads. Typical systems measure loading by using strain gauges that are coupled to chain links of the conveyor line assembly. The loads are monitored to thereby properly maintain and preferably avoid failure of the conveyor.

However, conventional conveyor diagnostic systems do not allow the user to directly identify where the measured loads occur on the conveyor line assembly. Thus, although the user is able to identify the degree of loading on the conveyor, the user will likely not be able to identify which specific components need maintenance or replacement to reduce the loading. Accordingly, there remains a need for a conveyor diagnostic system that can effectively detect loading of a conveyor line assembly and that can locate where certain loads occur.

SUMMARY OF THE INVENTION

The present invention overcomes the disadvantages of the related art in a conveyor diagnostic system for monitoring loading of a conveyor line assembly. The conveyor diagnostic system includes at least one sensor component coupled to the conveyor line assembly. The sensor component is adapted for detecting loading of the conveyor line assembly and is further adapted for generating and transmitting a signal that is correlative of the loading of the conveyor line assembly. The conveyor diagnostic system also includes a ground station adapted to receive and process the signal that is correlative of the loading of the conveyor line assembly. Furthermore, the conveyor diagnostic system includes a local positioning system that is adapted for detecting the location of the sensor component in relation to a reference point.

In another aspect, the present invention is a method of monitoring a conveyor line assembly that involves detecting loading of the conveyor line assembly using at least one sensor component coupled to the conveyor line assembly. The method also involves generating a signal that correlates to the loading of the conveyor line assembly. Furthermore, the method involves processing the signal that correlates to the loading of the conveyor line assembly. In addition, the method involves locating the at least one sensor component in relation to a reference point to thereby analyze an identified portion of the conveyor line assembly.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to the drawings and in particularFIG. 1, one embodiment of a portion of a conveyor line assembly10is generally illustrated. As shown, the conveyor line assembly10includes a conveyor chain12having at least one—and preferably a plurality—of chain links. For instance, in the embodiment shown, the conveyor chain12includes a plurality of dual links14and a plurality of single links16coupled in alternating manner by pins18. The conveyor line assembly10also includes a carrier assembly20for movably supporting the chain12. The carrier assembly20includes trolleys22having an upper portion24, an intermediate portion26, and a lower portion28. The upper portion24of each trolley22is pivotally coupled to a roller30, and the roller30is rotationally supported by a beam32. The intermediate portion26of each trolley22is coupled in any suitable manner to one of the single links16of the conveyor chain12. The lower portion28of each trolley22can be used to support an article for moving the article along an assembly line.

As shown inFIG. 1, the conveyor line assembly10also includes a conveyor diagnostic system34for monitoring loading of the conveyor line assembly10. The conveyor diagnostic system34includes at least one sensor component36shown in detail inFIG. 2. In the embodiment shown, the sensor component36is coupled to one of the single links16of the conveyor chain12and can detect loading of the corresponding single link16. However, those having ordinary skill in the art will appreciate that the sensor component36could be coupled anywhere along the conveyor chain12or to any other suitable component of the conveyor line assembly10without departing from the scope of the present invention. It should also be appreciated that the conveyor diagnostic system34could include a plurality of sensor components36, each coupled to individual links16, without departing from the scope of the invention.

As shown inFIG. 2, the sensor component36is disposed inside the single link16for detecting loading of that link16as it moves along the conveyor line assembly10. In one embodiment, the sensor component36is of a type disclosed in Applicant's U.S. Pat. No. 6,865,955, which is hereby incorporated by reference in its entirety. The sensor component36includes a plurality of sub-structures37a,37b,37c,37dmounted to the link16and includes a circuit having a plurality of strain gauges wired into a Wheatstone Bridge. The plurality of strain gauges generates a signal that correlates to the loading of the link16. More specifically, mechanical loading of the link16causes resistance changes in the strain gauges such that an electrical signal is generated.

Furthermore, in one embodiment, the sensor component36is adapted for detecting multiple loading types including tension, bending, and torsion loads in the link16. Also, the sensor component36can detect multi-axial loading in the link16. More specifically, as shown inFIG. 2, the link16defines three axes (labeled X, Y, and Z), and the sensor component36can detect axial loads along any of these axes, bending loads about any of these axes, and/or torsion loads about any of these axes.

For instance, in the embodiment shown inFIG. 2, the strain gauges of the sub-structure37aare oriented to primarily detect tension loading along the Z axis, the strain gauges of the substructure37bare oriented to primarily detect bending loads about the X axis, the strain gauges of the substructure37care oriented to primarily detect bending loads about the Y axis, and the strain gauges of the substructure37dare orientated primarily detect bending (torsional) loads about the Z axis. The strain gauges for each substructure37a,37b,37c,37dare oriented to be sensitive enough in the direction of the load component it is measuring and stiff enough in all other directions to minimize the influence on the overall stiffness of link16. In one embodiment, the sensor component36also compensates for temperature effects as well as cancellation of signals caused by extraneous loading such as the other loads measured by the other substructures37a,37b,37c,37d. Accordingly, the sensor component36can detect and measure the loading of the link16more precisely for improved analysis of the loading on the conveyor line assembly10as will be discussed in greater detail below. It should be appreciated that the link16can include any number of substructures37a,37b,37c,37dand that the substructures can be oriented to detect any type of load with respect to any axis depending on the application of the conveyor diagnostic system34.

The sensor component36is also adapted for transmitting the signal that correlates to the detected loading of the link16. For these purposes, the sensor component36is electrically connected to a transceiver38with a sensor antenna39that transmits and receives RF signals. The transceiver38transmits signals that correlate to the loading of the link16and also receives command signals that affect the operation of the sensor component36as will be discussed in greater detail below.

As shown inFIG. 1, the conveyor diagnostic system34further includes a ground station42that generally receives and processes the signals generated and transmitted by the sensor component36. In the embodiment shown, the ground station42includes a processor44, a controller46, and a database48. Generally speaking, the controller46generates control signals that control the operation of the conveyor diagnostic system34, the processor44processes data supplied by the sensor component36, and the database48provides information regarding the conveyor line assembly10to a user based on the processed data. The processor44, controller46, and database48can be electrically connected in any suitable manner. For instance, in one embodiment, the processor44, controller46, and database48are included in a computer.

The conveyor diagnostic system34also includes an intermediate communicator50. The intermediate communicator50receives the RF signals from the sensor component36and in turn transmits correlative signals to the ground station42. For these purposes, the intermediate communicator50includes appropriate circuitry and an intermediate antenna52. Likewise, the ground station42includes appropriate circuitry and a ground antenna54. RF signals transmitted from the sensor antenna39are received by the intermediate antenna52of the intermediate communicator50, which in turn transmits correlative RF signals to the ground station42via the intermediate antenna52. Those signals are received by the ground station42via the ground antenna54. As such, the sensor component36, the intermediate communicator50, and the ground station42can each be disposed remotely from each other and yet those components can still effectively communicate. This can be especially advantageous in situations where the link16, and thus the sensor component36, moves a relatively far distance away from the ground station42.

It should be appreciated, however, that the sensor component36could directly communicate with the ground station42without an intermediate communicator50without departing from the scope of the invention. It should also be appreciated that the sensor component36, the intermediate communicator50, and the ground station42could be directly wired together without departing from the scope of the present invention. Furthermore, it should be appreciated that the intercommunication between the sensor component36, the intermediate communicator50, and the ground station42could occur via any suitable signal transmission means other than RF transmission without departing from the scope of the invention.

The conveyor diagnostic system34also includes a local positioning system (LPS)58adapted for detecting the location of the sensor component36in relation to a reference point. In one embodiment, the LPS58includes a plurality of remote locating devices60that are disposed in spaced relationship to each other as shown inFIG. 1. The remote locating devices60can be disposed in any suitable location, such as in various spaced locations in a manufacturing plant. The LPS58is adapted to detect the distance between the sensor component36and the remote locating devices60to thereby locate the sensor component36. The remote locating devices60can be of any suitable type suitable for detecting the distance to the sensor component36. In one embodiment, the LPS58detects the distance between the sensor component36and a maximum of three separate remote locating devices60. These distances are represented by lines L1, L2, and L3inFIG. 1. The distances L1, L2, and L3are communicated to the processor44of the ground station42, which employs known triangulation methods to locate the sensor component36in one embodiment. The reference point used to locate the sensor component36can be anywhere that is suitable, and in one embodiment, the LPS58locates the sensor component36with enough precision to determine an area of the conveyor line assembly10where the sensor component36is located in relation to the rest of the conveyor line assembly10. Accordingly, the conveyor diagnostic system34can associate particular loads experienced by a particular link16with particular areas of the conveyor line assembly10. As such, the user can analyze and monitor the conveyor line assembly16with more precision, and the user can correct problematic areas of the conveyor line assembly10more efficiently.

The LPS58can include at least one existing sensor, such as the HX5 Series sensors from Hexamite, the PAL 650 from Multispectral Solutions, Inc., the HF, LPS, or LPS007 from SYP Tech. Corp., the UWB from UBI Sense, the RFID from Pin Point, or a combination of these and other technologies. It should also be appreciated that RF sensors and known triangulation methods could be utilized by the LPS58. Radar, magnetic, and/or optical sensors could also be used without departing from the scope of the invention. Also, especially in cases where the conveyor line assembly10is well established, a mathematical three-dimensional equation of the conveyor line assembly10can be generated which, together with one or more locus points (i.e., L1, L2, L3ofFIG. 1) detected by the LPS58, can be used to locate the sensor component36.

In operation, the conveyor chain12moves along the conveyor line assembly10. As the link16moves with the chain12, the sensor component36in the link16detects the load experienced by the link36and transmits an RF signal correlative of the loading to the intermediate communicator50. The intermediate communicator50in turn transmits a correlative RF signal to the ground station42, and the processor44processes data based on those signals using any suitable mathematical model. The database48is accessed and used to identify a condition of the conveyor line assembly10based on the signals received from the sensor component36. For instance, if a high degree of loading is detected as represented inFIG. 1, the database48is accessed to identify possible conditions that might cause such loads, such as insufficient lubrication, or the like. In one embodiment, the database48also includes associated courses of action that could be taken under such conditions. Using the previous example, the database48might indicate that lubrication is needed or that parts should be replaced in order to reduce the loads.

In one embodiment, the ground station42also includes a display56that communicates the status of the conveyor line assembly10and any appropriate course of action to the user. The status of the conveyor line assembly10can be displayed in any suitable manner, such as with graphs, prepared textual messages, and the like. In the embodiment shown, the conveyor diagnostic system34also includes an alarm system61that can alert a user as to potential problems in the conveyor line assembly10. The conveyor diagnostic system34also includes a reporting system62that generates electronic reports and/or hard copies of reports of the condition of the conveyor line assembly10.

In one embodiment, the processor44processes the data in real time such that users can monitor the condition of the conveyor line assembly10substantially as the loads occur. As such, problems with the conveyor line assembly10can be corrected more quickly, and problems can be predicted and avoided.

In one embodiment, the controller46also causes the ground station42to transmit control signals to the sensor component36. For instance, in one embodiment, the control signals cause the sensor component36to start detecting the load on the link16and other control signals cause the sensor component36to stop detecting the load. It should be appreciated that the control signals sent by the ground station42to the sensor component36could cause the sensor component36to operate in any predetermined fashion without departing from the scope of the invention.

The conveyor diagnostic system34could also be used to analyze conditions that caused a previous failure of the conveyor line assembly10. In addition, the conveyor diagnostic system34could be used in association with a plurality of similar conveyor line assemblies10to compare the conditions of each. For instance, if loading in a certain area of one of the conveyor line assemblies10is significantly greater than the corresponding area of another conveyor line assembly10, users will likely be aware of a potential problem. The conveyor diagnostic system34could be further used when a conveyor line assembly10is first used to determine baseline conditions, and then the system34can be used to compare those baseline conditions to the condition of the conveyor line assembly10as it is used. The conditions detected using the conveyor diagnostic system34can be used to monitor existing conveyor line assemblies10and/or for designing better conveyor line assemblies10in the future. For instance, data obtained by the conveyor diagnostic system34can be used to develop mathematical relationships between load conditions and the location of the sensor component36, the drive motor parameters, the articles moved by the conveyor chain, and the like for designing better conveyor line assemblies10.

Also, in one embodiment, the conveyor diagnostic system34is adapted to automatically operate the conveyor line assembly10based on the loads detected by the sensor component36. For instance, if the sensor component36detects loading at levels beyond a predetermined threshold, the controller46could be programmed to cause the conveyor chain12to stop moving to thereby avoid damage to the conveyor line assembly10.

In summary, the conveyor diagnostic system34allows for more precise monitoring of the conveyor line assembly10by providing important information about the load conditions of the conveyor line assembly10. The conveyor diagnostic system34also locates areas where particular loading occurs. As such, users can more easily determine problems associated with the conveyor line assembly10and avoid damage or failure of the conveyor line assembly10. In addition, users can more easily design and build conveyor line assemblies10that have improved operating characteristics.