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The conveyor system is essential in modern production and logistics, facilitating the efficient storage, sorting, handling, and distribution of materials. By automating transport processes, it enhances efficiency, accuracy, and safety while effectively reducing labor costs.
As the power source of the conveyor system, the motor's performance directly affects its efficiency and capability. Traditional drive systems, like three-phase asynchronous motors, lead to higher energy consumption with frequent load changes. Additionally, challenges with adaptability, reliability, and control precision may raise maintenance costs and complexity.
Problems and Risks of Traditional Conveyor Systems
Significant energy losses: Conveyor systems typically face varying loads and frequent start-stops, which leads to excessive motor power and high energy losses.
Potential safety risks: Traditional three-phase asynchronous motors operate at 380 V AC, posing potential safety risks to maintenance personnel.
Insufficient stability: Traditional conveyor systems often lack stability during acceleration and deceleration, increasing the risk of goods falling or tilting.
High positioning errors: In traditional conveyor systems, high speed and heavy loads cause minimal friction between items and rollers. As a result, overshooting occurs frequently due to the substantial inertia of the goods.
Time-consuming maintenance: Traditional centralized communication systems often involve extensive cabling, complex wiring, and numerous control cabinets, resulting in prolonged maintenance times.
To tackle the challenges of traditional conveyor systems, the BlueSword team has developed a distributed ultra-low voltage DC servo conveyor system. This system employs high overload and variable load servo technology, and incorporates the latest innovations in logistics robotics. The wide adoption of ultra-low voltage DC servo motors increases system flexibility under specific application scenarios.
By optimizing motor performance, we have significantly reduced energy consumption and effectively addressed the challenges of performance matching in high-load and variable environments. This has led to improved energy efficiency, enhanced overload response capability, and higher safety standards in the conveyor system.
Key Innovations to Address Communication and Power Challenges
distributed communication protocol with multiple CAN interfaces: During the innovation of communication circuit design, we have introduced a PN/CAN gateway with multiple CAN interfaces and our self-developed CAN repeaters. This technology not only greatly elevates network flexibility and reliability, but also simplifies the wiring between PLC and servo systems, effectively improving overall system stability and data transmission efficiency.
Flat cable serial communication and power supply solution: It overturns the traditional "star-shaped" wiring mode and innovatively adopts a "serial" distributed connection scheme. This design streamlines on-site wiring, optimizes space utilization, and boosts modular configuration efficiency. It also impressively enhances the convenience of installation, adjustment, and subsequent maintenance.
Significant Advances in Drive and Control Integration Technology
More adaptable controller structure: To meet diverse operational needs, we have innovated the controller card structure. By utilizing high-performance components (such as MOSFETs, MCUs, and DC-DC converter chips) along with our own controller card, we successfully created servo electric rollers. This achievement ensures full autonomous control from hardware to software, providing highly customizable conveying solutions.
Important breakthroughs in integrated system control: Through in-depth research on position loop regulation, we have greatly improved control precision and system stability in drive and control integration as well as servo motor synchronization. This offers robust support for precise material handling under variable conditions.
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Advantages of distributed Ultra-Low Voltage DC Servo Conveyor System
More energy efficient: The operational efficiency and power factor of servo motors are significantly superior to three-phase asynchronous motors, achieving over 51% energy savings. It helps companies reduce costs, increase efficiency, and meet carbon reduction goals.
Safer use of electricity: The servo conveyor system adopts 48V DC power supply, which can not only ensure the safety of relevant personnel in the operation process, but also reduce the requirements of equipment safety protection.
Smoother delivery: When the servo conveyor system handles pallet materials, the overall shaking amount of the goods is ≤ 5 mm, which minimizes the risk of loose stacking of goods. This enables film-free transportation, saving operational costs for companies.
More accurate positioning: The servo motor allows for precise control over acceleration and deceleration times. It ensures smooth start-stop operations and accurate positioning on the conveyor line.
Faster installation: The modular design effectively reduces project implementation time by approximately 40%. Using punctured flat cables and plastic expansion rivets, the installation time has been greatly reduced.
More convenient maintenance: The distributed communication control units offer fast real-time response and easy maintenance, allowing for quick replacement of multiple conveying equipment. With compact and lightweight design, the DC servo motors further enhance convenience in maintenance. Electric control cabinets are reduced by 90%, cutting implementation and maintenance time by 50%.
Compared to centralized AC asynchronous conveyor systems, the distributed ultra-low voltage DC servo conveyor system stands out in modern industrial automation and logistics due to its exceptional technical advantages. This technology not only improves operational efficiency but also reduces energy consumption and carbon emissions, providing companies with a competitive edge.
BlueSword's servo conveyor system has been successfully applied in 18 industries, such as communications, e-commerce & retail, chemical, electronics, pharmaceutical, and 3PL, and has achieved remarkable application effects. Its outstanding performance and broad application prospects are leading the logistics conveying field to new heights.
We hope more companies will draw inspiration from this innovative practice, and join us in promoting technological progress and market diversification in the logistics industry. Together, let's seize this opportunity to commit to achieving the goal of sustainable logistics.
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