Conveyor controller with analytics system
A data analytics system has been developed for conveyor systems that helps to monitor items along conveyors as well as assist in monitoring the status or health of equipment of the conveyor. Tracking items in conveying systems within a facility can be difficult. Conveyed items can become jammed, lost, or even fall off the conveyor. Based on input from motors and sensors along the conveyor, the data analytics system is able to detect lost or jammed items. With input from the sensors, the data analytics system is also configured to detect equipment wear and damage. The data analytic system further aggregates data from the various conveyor systems to generate statistics as well as other information that can be used for modeling and simulating the conveyor system. The aggregate data can be used to generate measures such as travel efficiency analytics for reporting purposes.
1. A system, comprising:
a conveyor system including a conveyor;
a data analytics system configured to monitor conveyor status of the conveyor system;
wherein the conveyor system includes a conveyor controller that controls a conveyor zone; and
wherein the conveyor controller is configured to track an item in the conveyor zone without a sensor.
2. The system of claim 1 , wherein the conveyor controller includes a controller card.
3. The system of claim 1 , wherein the conveyor zone includes a conveyor motor that provides mechanical power for moving one or more items along the conveyor zone, and the conveyor controller is configured to measure an electrical property of the conveyor motor to determine the conveyor status.
4. The system of claim 3 , wherein the conveyor motor includes a motorized drive roller.
5. The system of claim 3 , wherein the electrical property includes current drawn by the conveyor motor.
6. The system of claim 3 , wherein the electrical property of the conveyor motor is indicative of item weight.
7. The system of claim 3 , wherein the electrical property of the conveyor motor is indicative of motor wear.
8. The system of claim 3 , wherein the electrical property of the conveyor motor is indicative of item jamming.
9. The system of claim 3 , wherein the conveyor controller is configured to measure an electrical property of the conveyor motor when idle to determine the conveyor status.
10. The system of claim 1 , wherein:
the conveyor controller includes a temperature sensor; and
the data analytics system is configured to generate a heat map based on temperature data from temperature sensor of the conveyor controller.
11. The system of claim 1 , wherein the conveyor controller includes an accelerometer configured to measure conveyor equipment vibrations in the conveyor zone.
12. The system of claim 1 , wherein:
the conveyor controller includes a clock; and
the clock is configured to measure item travel time in the conveyor zone.
13. The system of claim 12 , wherein the clock is configured to measure conveyor motor run time.
14. The system of claim 1 , wherein the conveyor zone includes a sensor operatively connected to the conveyor controller to monitor for presence of one or more items in the conveyor zone.
15. The system of claim 14 , wherein the sensor includes a photoeye.
16. The system of claim 14 , wherein the conveyor controller is configured to communicate with a downstream conveyor controller that controls a downstream conveyor zone.
17. The system of claim 16 , wherein the downstream conveyor controller is configured to determine a malfunction in the conveyor system upon detection of an undetected item in the downstream conveyor zone.
18. The system of claim 17 , wherein the malfunction includes misalignment of the sensor.
19. The system of claim 17 , wherein the malfunction includes item loss.
20. The system of claim 17 , wherein the malfunction includes item jamming.
21. The system of claim 17 , wherein the malfunction includes equipment malfunction.
22. The system of claim 1 , wherein the conveyor controller tracks the item based on an electrical property of a conveyor motor for the conveyor zone.
23. The system of claim 22 , wherein the conveyor controller is configured to assign an identifier for the item and transmit the identifier to a downstream conveyor controller.
24. The system of claim 1 , wherein:
the data analytics system is configured to generate an alert based on the conveyor status; and
the alert includes a message about one or more changes to the conveyor system.
25. The system of claim 1 , wherein:
the data analytics system is configured to generate information for a simulation of the conveyor system; and
the data analytics system is configured to provide a comparison between the simulation and actual implementation of the conveyor system.
26. The system of claim 1 , wherein the data analytics system is configured to provide package travel efficiency analytics.
27. A system, comprising:
a conveyor system including a conveyor;
a data analytics system configured to monitor conveyor status of the conveyor system;
wherein the conveyor system includes a conveyor controller that controls a conveyor zone;
wherein the conveyor zone includes a sensor operatively connected to the conveyor controller to monitor for presence of one or more items in the conveyor zone;
wherein the conveyor controller is configured to communicate with a downstream conveyor controller that controls a downstream conveyor zone; and
wherein the downstream conveyor controller is configured to determine a malfunction in the conveyor system upon detection of an undetected item in the downstream conveyor zone.
28. The system of claim 27 , wherein the malfunction includes misalignment of the sensor.
29. The system of claim 27 , wherein the malfunction includes item loss.
30. The system of claim 27 , wherein the malfunction includes item jamming.
31. The system of claim 27 , wherein the malfunction includes equipment malfunction.
32. A system, comprising:
a conveyor system including a conveyor;
a data analytics system configured to monitor conveyor status of the conveyor system; and
wherein the data analytics system is configured to provide package travel efficiency analytics.