Ball Conveyor Table With Gear Plate For Precision Positioning
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Solution Overview
Problem
Existing ball conveyor table systems are expensive, complex, and fail to meet high dynamic requirements for conveying and positioning sensitive articles like printed circuit boards, semiconductor substrates, and photovoltaic elements, and they are not suitable for clean room and antistatic environments.
Innovation Solution
A ball conveyor table system with a gear plate featuring angular recesses for point-like guidance of balls, driven by a single drive gear that meshes with multiple gear wheels, and an eccentric displacement mechanism for precise movement in the X and Y directions, ensuring delay-free and slip-free transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional driven ball systems are used, then articles can be conveyed, but the systems are expensive and complex with high maintenance requirements
Solution Approach 1:
The patent replaces complex electric motor-driven ball systems with a purely mechanical gear-based system. Multiple balls are arranged in a grid pattern and driven by a single drive gear that engages all balls simultaneously through direct mechanical contact, eliminating the need for individual motors and complex control systems for each ball.
Solution Approach 2:
A single drive gear serves multiple functions by simultaneously driving all balls in the array, replacing what would traditionally require multiple independent drive units. This universal drive mechanism reduces both component count and system complexity while maintaining the ability to convey articles across the entire ball table surface.
2Manufacturing precision
If traditional ball conveyor systems are used, then articles can be moved, but they fail to meet high dynamic requirements for precise positioning
Solution Approach 1:
The ball array is segmented into a grid pattern with balls positioned at regular intervals. This segmentation allows for precise control of individual ball positions while maintaining synchronized movement across the entire array, enabling both high positioning accuracy and efficient conveying of large articles.
Solution Approach 2:
The drive gear rotates in periodic cycles, engaging and driving all balls simultaneously in a rhythmic motion. This periodic action ensures consistent positioning accuracy while maintaining conveying speed, as the regular engagement pattern prevents slippage and maintains synchronization across all balls throughout the conveying process.
3Ease of repair
If traditional driven ball systems are used, then articles can be conveyed, but the systems are difficult and expensive to maintain
Solution Approach 1:
The patent extracts and eliminates the complex electrical motor components from each ball position, retaining only the essential mechanical elements (balls and gear). This extraction simplifies maintenance by removing expensive electrical components that require specialized service, leaving a simple mechanical system where balls can be easily replaced by removing them from their recesses.
Solution Approach 2:
The mechanical gear system is designed to be inherently maintainable through simple manual intervention. Balls that become worn or damaged can be easily removed from their recesses and replaced without requiring specialized tools or expertise, enabling operator-level maintenance and reducing dependency on complex repair systems.
4Object-affected harmful factors
If traditional ball conveyor systems are used, then articles can be moved, but they do not meet clean room and antistatic requirements
Solution Approach 1:
The patent specifies particular material parameters for the balls and gear components that are suitable for clean room environments. The balls are made from materials with appropriate surface properties that prevent particle generation and static accumulation, while the gear design incorporates features that minimize dust generation and facilitate easy cleaning, all without adding mechanical complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables quick, accurate, and cost-effective movement and positioning of articles with high dynamic precision, suitable for clean room and antistatic environments, while reducing maintenance complexity and costs.
Implementation Method 1
a gear plate (9) having at least one gear wheel (7) which is located below the ball plate (3) and is in frictional contact with the ball (2), wherein the at least one gear wheel (7) is rotatably mounted on the gear plate (9) and is driven by a drive gear wheel (10) which is in form-fitting engagement with the gear wheel (7)
Implementation Method 2
at least one ball (2) which at least partially extends through the ball plate (3) and thereby is in contact with the gear wheel (7), wherein the ball (2) is frictionally connected to the gear wheel (7)
Implementation Method 3
an base plate (11) arranged below the gear plate (9), with at least one displacement means (28) being located between the gear plate (9) and the base plate (11), which causes a movement in the X and/or Y direction of the gear plate (9) relative to the base plate (11)
Data Source
Figure 1
Figure 2a~2d
Figure 3
AI summary
Ball conveyor system (1) comprising a ball plate (3) with a surface (30) that is at least partially flat, wherein recesses (4) are provided in the ball plate (3) through which balls (2) at least partially pass, wherein the balls (2) are rotatably driven by a drive motor (17) and move an article (25) located on the surface (30), wherein the ball conveyor system (1) has a gear plate (9) which is arranged under the ball plate (3), wherein rotatably driven gears (7) are arranged on the gear plate (9) which are in frictional contact with the balls (2) and move them.