System and method for conveyor system configuration, testing and diagnostics

A method for conveyor configuration and testing, the method comprising:

• receive input data relating to configuration of a conveyor system;
• determine configuration parameters related to the conveyor system based on the input data;
• configure the conveyor system based on the configuration parameters;
• provide for changes to the configuration parameters;
• display the configuration of the conveyor system;
• simulate operation of the conveyor system;
• monitor at least one operational parameter related to the conveyor system, wherein the at least one operational parameter is calculated based on the configuration parameters and a machine learning model based on operational data from actual conveyors, wherein the machine learning model comprises:
• at least one factor comprising current levels in the conveyor system;
• a physics model for determining simulated current;
• and
• a regression model for determining temperature based on the simulated current;
• determine if configuration parameters need to be adjusted based on the at least one operational parameter;
• if the configuration parameters need to be adjusted, return to receive input data, otherwise, continue the simulation until otherwise terminated.

A system for conveyor configuration and testing, the system comprising:

• a data acquisition module configured to receive input data relating to configuration of a conveyor system;
• a configuration module configured to prepare a digital two-dimensional model of a conveyor system;
• a simulation module configured to run a simulation of the configured conveyor system, monitor at least one operational parameter using a machine learning model during operation of the simulation of the conveyor system, wherein the machine learning module comprises:
• at least one factor comprising current levels in the conveyor system;
• a physics model for determining simulated current;
• and a regression model for determining temperature based on the simulated current, and determine if the configuration of the conveyor system needs to be adjusted based on the monitored at least one operational parameter;
• and
• a results module configured to, if the configuration needs to be adjusted, automatically make an adjustment and return control to the configuration module, otherwise, to return to the simulation module to continue the simulation until otherwise terminated.