Adjustable Conveyor Flights for Uniform Parcel Gapping
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Solution Overview
Problem
Existing conveyor systems struggle to maintain consistent spacing of objects of varying sizes while ensuring efficient throughput, particularly in scenarios requiring uniform or variable gaps for downstream processing.
Innovation Solution
A dynamic gapping conveyor system with independently controlled flights, comprising a front flight for stopping and a rear flight for supporting parcels, uses a linear transport system to adjust spacing by rotating and lifting panels to create uniform gaps between parcels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If automated equipment is used to set parcels at a desired uniform gap, then uniform spacing is achieved, but device complexity and cost increase
Solution Approach 1:
The patent employs dynamic flights that can move between raised and lowered positions to adjust parcel spacing. The flights are actuated by a linear transport system that dynamically positions them based on real-time parcel detection, replacing static automated positioning equipment with a flexible, motion-based system that achieves uniform spacing through controlled movement rather than complex mechanical positioning.
Solution Approach 2:
The system uses sensors to detect parcel positions and automatically controls the flight actuation, enabling the conveyor to self-regulate spacing without external automated positioning equipment. The control system processes sensor data and autonomously actuates flights to maintain desired gaps, reducing the need for additional complex automated handling devices.
2Adaptability or versatility
If flights are made adjustable to accommodate parcels of different sizes, then adaptability improves, but device complexity increases
Solution Approach 1:
The flights are designed with adjustable positions along the conveyor belt, allowing them to be raised or lowered to accommodate parcels of varying sizes. The linear transport system enables dynamic repositioning of flights based on detected parcel dimensions, providing adaptability through motion rather than requiring multiple fixed-position flight configurations.
Solution Approach 2:
The same flight structure serves multiple functions: it acts as a stopping barrier, a spacing regulator, and a size-adaptation mechanism. By combining these functions into a single adjustable component actuated by the linear transport system, the patent avoids the complexity of separate mechanisms for each function while maintaining versatility across different parcel sizes.
3Productivity
If the conveyor maintains the smallest possible gap between parcels, then productivity increases, but the risk of harmful interactions between parcels increases
Solution Approach 1:
The system detects upcoming parcels in advance using sensors and pre-positions the flights to appropriate heights and locations before the parcels arrive. This preliminary action allows the conveyor to maintain optimal small gaps while being prepared to immediately raise flights if potential harmful interactions are predicted, balancing productivity with safety through proactive control.
Solution Approach 2:
The conveyor incorporates sensors that continuously monitor parcel positions, sizes, and spacing in real-time, feeding this information back to the control system. The control system uses this feedback to dynamically adjust flight positions, maintaining the smallest safe gaps between parcels while automatically increasing spacing when sensor data indicates potential harmful interactions, thus optimizing throughput with safety constraints.
Data Source
AI summary
A conveying system employs a plurality of sets of coordinating flights for controlling the spacing of objects conveyed by a conveyor. Each set of coordinating flights includes a front flight having a rotatable panel that can selectively move into a vertical position for stopping a parcel and a rear flight having a horizontal panel for supporting a parcel from below.