Adaptive Joint Connector for Conveyor Track Alignment
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Solution Overview
Problem
Conventional conveyor systems face challenges in maintaining alignment between track sections, leading to issues such as noise, wear, and vibration, especially in linear motor conveyor systems where high forces cause misalignment due to manufacturing tolerances.
Innovation Solution
An adaptive joint connector system that includes a first segment for attachment to one track section and a second segment that can adjust to non-alignment in multiple dimensions to maintain alignment, using moveable components and clamps to accommodate manufacturing tolerances, ensuring alignment within tight tolerances (e.g., 100 microns or less).
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If track sections are formed in sections to make construction easier, then ease of manufacture is improved, but alignment precision deteriorates due to manufacturing tolerances
Solution Approach 1:
The joint connector acts as an intermediary component between track sections, absorbing misalignment errors through its adaptive second segment that can move or adjust position to compensate for tolerance variations in attachment features
Solution Approach 2:
The second segment is designed with movable or adjustable characteristics that allow it to change its position or orientation to accommodate misalignment, transforming the rigid connection into a flexible one that adapts to manufacturing tolerances
2Productivity
If high forces are applied to move or stop the moving element quickly to increase production speeds, then productivity is improved, but alignment precision deteriorates due to increased misalignment
Solution Approach 1:
The joint connector incorporates dynamic or movable elements that can adjust in real-time to misalignment caused by high forces during operation, maintaining alignment precision even when productivity demands rapid acceleration and deceleration
3Manufacturing precision
If reduced tolerances are used in making track sections to improve alignment, then alignment precision is improved, but device complexity increases due to stricter manufacturing requirements
Solution Approach 1:
The joint connector serves as a mediator that compensates for larger manufacturing tolerances, allowing standarder parts to be used while still achieving precise alignment at the joint, thereby reducing overall manufacturing complexity
4Device complexity
If conventional rigid connectors are used to connect track sections, then device complexity is reduced, but alignment precision deteriorates and causes noise, wear, and vibration
Solution Approach 1:
The joint connector uses movable or adjustable components that can adapt to misalignment, reducing noise, wear, and vibration by allowing controlled movement rather than forcing rigid alignment, while maintaining relatively simple construction
Data Source
AI summary
A joint connector for track sections of a conveyor wherein the track sections comprise a feature that requires alignment, the joint connector including: a first segment for attachment to an attachment feature of a first track section of the conveyor; and a second segment for attachment to an attachment feature of a second track section of the conveyor, wherein the second segment is configured to be adaptive to non-alignment of the attachment features of the first and second track sections in order to maintain alignment of the feature after installation of the joint connector.