Conveyor drive control system
First Claim
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1. A drive control system for a conveyor comprising:
- a conveyor device that is operable to move material via a flexible member along a single conveyor that is propelled by two or more motors in a load sharing drive control application;
a computer for processing data;
a dynamic mathematic model calculation program executed by said computer, said program being operable to continuously evaluate the torque requirements of the system and produce a signal responsive of actual torque demands;
a PLC operable to monitor and control all input and output devices associated with the conveyor;
a motor controller in communication with the PLC, said controller is operable to receive input data from the PLC and deliver torque and speed power outputs to a motor;
a motor operable to receive the torque and speed power outputs and provide power to a primary moving element of said system; and
a plurality of primary zones positioned about the conveyor, each said zone including a counting device near proximal ends of said zones for counting a number of segments of said flexible member.
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Abstract
A drive control system for conveyor utilizes a dynamic chain pull calculation program that is integrated with a PLC, which communicates to a plurality of controllers. The controllers in turn automatically adjust their associated drive motors so as to maximize efficiency at moving material on a conveyor system. Sensing devices provide continuous load parameters to a PLC that in turn, processes the data and adjusts the system'"'"'s operation based upon desired conditions.
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Citations
21 Claims
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1. A drive control system for a conveyor comprising:
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a conveyor device that is operable to move material via a flexible member along a single conveyor that is propelled by two or more motors in a load sharing drive control application; a computer for processing data; a dynamic mathematic model calculation program executed by said computer, said program being operable to continuously evaluate the torque requirements of the system and produce a signal responsive of actual torque demands; a PLC operable to monitor and control all input and output devices associated with the conveyor; a motor controller in communication with the PLC, said controller is operable to receive input data from the PLC and deliver torque and speed power outputs to a motor; a motor operable to receive the torque and speed power outputs and provide power to a primary moving element of said system; and a plurality of primary zones positioned about the conveyor, each said zone including a counting device near proximal ends of said zones for counting a number of segments of said flexible member. - View Dependent Claims (2, 3, 4, 5, 6, 8, 9, 10)
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7. A drive control system for a conveyor comprising:
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a conveyor device that is operable to move material; a computer for processing data; a dynamic chain pull calculation software program executed by said computer, said program being operable to continuously evaluate the torque requirements of the system and produce a signal responsive of actual torque demands; a PLC operable to monitor and control all input and output devices associated with the conveyor; a motor controller in communication with the PLC, said controller is operable to receive input data from the PLC and deliver torque and speed output to a motor; a motor operable to receive the torque and speed power outputs and provide power to a primary moving element of said system, and an encoder that is operable to produce a signal that, when compared to similar signals produced by other encoders within the system, can be indicative of a number of links within a predetermined zone of the conveyor.
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11. A drive control system for a conveyor comprising:
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one or more variable speed motors for driving a flexible member; a dynamic flexible member calculation program that continuously interprets torque requirements for each motor in the system, said program operable to process a real time signal and compare said signal to a preferred performance indicia; one or more sensors operable to create a signal indicative of a load position and weight and send data to a PLC; a PLC that converts the data from said sensors and transmits said real time signal to a computer processing the dynamic flexible member calculation program; a device for determining a value of lengths within a given segment of the flexible member; a computer operable to process the real time signal from the PLC using the dynamic flexible member calculation program and generates drive torque data for each motor; and a motor controller operable to control each variable speed motor so that proper torque is generated by each motor as needed. - View Dependent Claims (13, 14, 15)
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12. A drive control system for a conveyor comprising:
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at least one motor for driving a conveyor device; a dynamic chain pull calculation program that continuously interprets torque requirements for each motor in the system; one or more sensors operable to create a signal indicative of a load position and weight and send data to a PLC; a PLC that converts the data from said sensor and transmits a signal to a computer processing the dynamic chain pull calculation program; a computer operable to process the signal from the PLC using the dynamic chain pull calculation program and generates drive torque and speed power outputs for each motor; a motor controller operable to control each motor so that proper torque is generated by each motor as needed; and at least one encoder in communication with said PLC, said encoder is operable to measure a number of link segments that pass through each drive assembly over time as well as operating as a speed feedback reference device.
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16. A drive control system comprising:
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a computer for processing data; a dynamic calculation software program executed by said computer, said program being operable to continuously evaluate the torque requirements of the system and produce a signal responsive of actual torque demands; a PLC operable to monitor and control all input and output devices associated with a machine; a motor controller in communication with the PLC, said controller is operable to receive input data from the PLC and deliver torque and speed power outputs to a motor; a motor operable to receive the torque and speed power outputs and provide power to a primary moving element of the machine, said moving element is operable to impart motion to a flexible member that is driven by said motor; and a plurality of primary zones positioned about the machine, each said zone including a counting device near proximal ends of said zones, said counting device is operable to determine segments of the flexible moving member, said computer being operable to received load information and then with the aid of the dynamic calculation software program calculate a base line torque requirement for a motor in the drive control system. - View Dependent Claims (18, 19)
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17. A drive control system comprising:
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a computer for processing data; a dynamic chain pull calculation software program executed by said computer, said program being operable to continuously evaluate the torque requirements of the system and produce a signal responsive of actual torque demands; a PLC operable to monitor and control all input and output devices associated with a machine; a motor controller in communication with the PLC, said controller is operable to receive input data from the PLC and deliver torque and speed power outputs to a motor; a motor operable to receive the torque and speed power outputs and provide power to a primary moving element of the machine; a plurality of primary zones positioned about the machine, each said zone including a counting device near proximal ends of said zones, and secondary zones and a device for counting a number of chain links within each secondary zone.
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20. A method of operating a drive control system for a conveyor comprising:
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a. providing a conveyor device, motor and a control system; b. inputting predetermined load information and calculating a base line torque requirement for each motor in the system; c. sensing dynamic load conditions on the conveyor and creating signals; d. sending signals to a computer that operates a dynamic chain pull calculation program; e. processing said signals with said program in order to adjust torque requirements for each motor; and f. counting the number of links in a conveyor chain and adjusting one of said motors as determined by the program.
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21. A method of operating a drive control system for a conveyor having a series of motors in a load sharing application, the method comprising:
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a. providing a conveyor device, motor and a control system; b. inputting predetermined load information and calculating a base line torque requirement for each motor in the system; c. sensing dynamic load conditions on the conveyor and creating signals; d. sending signals to a PLC that operates a dynamic chain pull calculation program; e. processing said signals with said program in order to adjust torque requirements for each motor; and f. counting the number of links in a conveyor chain and adjusting all of said motors as determined by the program.
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Specification