Conveyor system and method of operating the same

1. A conveyor system including a cart that moves along a track, the system comprising:

a rail that supports the cart as it moves along the track;

a plurality of sensors operably connected to the rail, the plurality of sensors configured to measure vibrations of the rail as the cart moves along the track; and

a central controller that collects data from the plurality of sensors, including a processor configured to analyze the data to determine whether a frequency of the vibrations is within a predetermined range that corresponds to normal operation of the conveyor system;

wherein the conveyor system includes an inner rail and an outer rail, and the plurality of sensors includes a pair of sensors, with a first sensor operably connected to the inner rail at a location along the track and a second sensor operably connected to the outer rail at the same location along the track, such that the cart passes the pair of sensors at substantially the same time; and

wherein the processor compares the data collected from the first sensor to the data collected from the second sensor to identify if an anomaly exists at only one side of the cart.

2. The conveyor system of claim 1 , wherein, when the frequency of the vibrations is outside of the predetermined range, the central controller reports that the cart has experienced a mechanical fault.

3. The conveyor system of claim 1 , wherein, when the frequency of the vibrations is outside of the predetermined range, the central controller reports that the cart has experienced an impact.

4. The conveyor system of claim 1 , wherein the sensors of the plurality of sensors are spaced along the track at substantially equal intervals.

5. The conveyor system of claim 1 , wherein multiple carts move along the track, and wherein, when the frequency of the vibrations is outside of the predetermined range, at least one of the multiple carts is presumed to have experienced a mechanical fault, and the processor is configured to determine a location of the at least one of the multiple carts that experienced the mechanical fault.

6. A conveyor system including a cart that moves along a track, the system comprising:

a rail that supports the cart as it moves along the track;

a plurality of sensors operably connected to the rail, the plurality of sensors configured to measure vibrations of the rail as the cart moves along the track; and

a central controller that collects data from the plurality of sensors, including a processor configured to analyze the data to determine whether a frequency of the vibrations is within a predetermined range that corresponds to normal operation of the conveyor system;

wherein the cart includes one or more cart sensors and an on-board controller, wherein the on-board controller collects data from the one or more cart sensors to determine whether measurements taken of the cart as the cart moves along the track are within a predetermined range of values that corresponds to normal operation of the conveyor system.

7. The conveyor system of claim 6 , wherein the one or more cart sensors include at least one of:

an accelerometer which measures acceleration forces experienced by the cart as the cart moves along the track;

strain gauges positioned at a joint between the cart and an adjacent cart which measure thrust forces experienced at the joint as the cart moves along the track; and

a gyroscope which measures oscillations experienced by the cart as the cart moves along the track.

8. The conveyor system of claim 6 , wherein the central controller collects data from the one or more cart sensors on the cart to define the predetermined range of values that corresponds to normal operation of the conveyor system.

9. A method of operating a conveyor system that includes a rail, the method comprising the steps of:

providing a plurality of sensors on the rail that are configured to measure vibrations of the rail;

providing a test cart that includes one or more cart sensors configured to take measurements of the test cart;

moving the test cart along the rail while collecting data from the one or more cart sensors on the test cart and collecting data from the plurality of sensors on the rail;

analyzing the data from the plurality of sensors on the rail to define a predetermined range of frequencies of vibrations of the rail that correspond to the test cart moving along the rail under normal operation;

analyzing the data from the one or more cart sensors on the test cart to define a predetermined range of values that correspond to the test cart moving along the rail under normal operation;

providing an operational cart that includes one or more cart sensors configured to take measurements of the operational cart and moving the operational cart along the rail;

analyzing data from the plurality of sensors on the rail as the operational cart moves along the rail to determine whether the frequency of the vibrations of the rail is within the predetermined range of frequencies of vibrations of the rail; and

analyzing data from the one or more cart sensors on the operational cart as the operational cart moves along the rail to determine whether the measurements taken of the operational cart are within the predetermined range of values.

10. The method of claim 9 , wherein a central controller receives the data from the plurality of sensors on the rail to define the predetermined range of frequencies of vibrations of the rail and receives the data from the one or more cart sensors on the test cart to define the predetermined range of values.

11. The method of claim 10 , wherein the central controller determines whether the frequency of the vibrations of the rail is within the predetermined range of frequencies of vibrations of the rail; and

wherein an on-board controller on the operational cart receives the data from the one or more cart sensors on the operational cart as the operational cart moves along the rail to determine whether the measurements taken of the operational cart are within the predetermined range of values.

12. The method of claim 9 , further comprising a step of removing the test cart such that only the operational cart moves along the rail.

13. The method of claim 9 , wherein a plurality of operational carts are provided and simultaneously moved along the rail.

14. The method of claim 13 , wherein, when the frequency of the vibrations is outside of the predetermined range of frequencies of vibrations of the rail, at least one of the plurality of operational carts is presumed to have experienced a mechanical fault, and further comprising a step of determining a location of the at least one of the plurality of operational carts that experienced the mechanical fault.

15. The method of claim 9 , wherein the one or more cart sensors including at least one of:

an accelerometer which measures acceleration forces;

strain gauges positioned at a joint between the cart and an adjacent cart which measure thrust forces experienced at the joint; and

a gyroscope which measures oscillations experienced by the cart.