Adjustable Star Wheel Conveyor for Flexible Article Handling
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Solution Overview
Problem
Current rotary devices in automated handling lines are inflexible and costly, as they often require multiple star wheel plates and separate motors to accommodate articles of varying sizes and shapes, and lack adjustable height capabilities.
Innovation Solution
An adjustable star wheel system with a rotational adjustment mechanism that uses the existing main drive motor to adjust the angular displacement of rotatable elements, and an elevation adjustment mechanism to adjust the height of these elements, allowing for flexible handling of different article sizes and shapes without the need for multiple change parts or additional motors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple star wheel plates are used to accommodate different container sizes and shapes, then adaptability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The star wheel plate is designed with movable adjustment elements that can be repositioned along radial slots to change the pocket configuration. This dynamic adjustability allows a single plate to accommodate multiple container sizes and shapes, replacing the need for multiple fixed configuration plates and reducing device complexity
Solution Approach 2:
A single star wheel plate is designed to perform multiple functions by accommodating different container types through adjustable elements. The plate can be reconfigured to handle various container diameters, heights, and shapes, making one universal component replace multiple specialized plates
2Adaptability or versatility
If separate motors are used for height adjustment of rotary devices, then adaptability is improved, but device complexity and cost increase
Solution Approach 1:
The height adjustment function is merged with the existing main drive motor by incorporating a gear mechanism that converts the motor's rotational motion into vertical displacement of the star wheel plate. This eliminates the need for separate adjustment motors while maintaining adaptability
Solution Approach 2:
The main drive motor is designed to perform dual functions: driving the rotation of the star wheel and enabling height adjustment through an integrated gear mechanism. This multi-functionality reduces the total number of motors required in the system
3Adaptability or versatility
If star wheel plates are changed frequently to accommodate different containers, then adaptability is improved, but loss of time increases
Solution Approach 1:
The adjustment elements can be quickly repositioned along radial slots during operation or with minimal downtime, allowing rapid reconfiguration of the star wheel plate for different container types without requiring plate changes
Solution Approach 2:
Adjustment elements are pre-positioned in standardized locations along radial slots, allowing operators to quickly switch between pre-defined configurations for different container types, reducing adjustment time
4Adaptability or versatility
If powered height adjustment mechanisms are added to rotary devices, then adaptability is improved, but manufacturing cost increases
Solution Approach 1:
The height adjustment mechanism is combined with the existing main drive motor through a gear mechanism, eliminating the need for separate powered adjustment systems and reducing manufacturing costs while maintaining adaptability
Data Source
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AI summary
An adjustment mechanism (28) for adjusting the configuration of the pockets (60) of a star wheel conveyor (22) is disclosed. The adjustment mechanism (28) may be in the form of a support (82) and an adjustment element (80) movably connected to the support. The adjustment element (80) is movable to contact one or more of the rotatable elements (32) of a star wheel conveyor (22) in order to adjust the rotational position of the individual rotatable element(s) (32) to set the dimensions of pockets (60) for the articles (10) to be conveyed. The adjustment mechanism (28) can form part of a star wheel conveyor system (22) comprising a star wheel (22) and such mechanism(s).