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 a first operational parameter related to the conveyor system, wherein the first operational parameter is calculated based on the configuration parameters and a machine learning model based on operational data from actual conveyors, the machine learning model comprising:
• at least one factor comprising at least a second operational parameter that can be generally co-related to the monitored first operational parameter in the conveyor system;
• a physics model for predicting the simulated second operational parameter;
• and
• a regression model for determining a predicted first operational parameter based on the simulated second operational parameter;
• determine if configuration parameters need to be adjusted based on the predicted first 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 model of a conveyor system;
• a simulation module configured to run a simulation of the configured conveyor system, monitor at least one operational parameter during operation of the simulation of the conveyor system using a machine learning model, 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.