Rotating Surface Conveyor for Beverage Container Singulation
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Solution Overview
Problem
Existing devices fail to efficiently sort and process used beverage containers of different sizes and shapes in bulk, often forwarding multiple items together or leaving some unprocessed, requiring manual correction.
Innovation Solution
A device featuring a rotating surface and conveyor system that distributes containers towards the periphery, with a peripheral barrier and guiding elements to ensure individual singulation, where the conveyor narrows to allow only aligned containers to pass, and sensors control the conveyor speed based on container detection and receiving station readiness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional conveyor system is used to transport bulk containers, then the device complexity is low, but the singulation precision deteriorates (multiple items forwarded together or items left unprocessed)
Solution Approach 1:
The conveyor path is segmented into multiple sections (first section at lower level, second section at higher level) with different functions. The first section receives containers from the rotating surface, while the second section transports them away. This segmentation allows different handling strategies for different stages of the process, improving singulation precision without requiring complete system redesign.
Solution Approach 2:
A peripheral barrier is introduced as an intermediary element between the rotating surface and the conveyor system. This barrier mediates the transfer of containers by allowing them to pass from the rotating surface to the conveyor while preventing unauthorized access or improper placement, thereby improving singulation without significantly increasing overall device complexity.
2Manufacturing precision
If the conveyor is made narrow to allow only single-file passage, then the singulation precision improves (containers transported one by one), but the productivity deteriorates (narrower conveyor handles fewer containers)
Solution Approach 1:
The conveyor width is made dynamic through the use of adjustable guiding elements. These elements can be positioned to create narrow passages for singulation when needed, while allowing the conveyor to handle broader loads at other times. This dynamic adjustment resolves the contradiction between narrow-width precision and broad-width productivity.
Solution Approach 2:
Containers are preliminarily oriented and positioned on the rotating surface before entering the conveyor system. The rotating surface distributes containers towards the periphery in a controlled manner, ensuring they are properly aligned before reaching the narrow conveyor section. This preliminary action reduces the need for narrow conveyor sections, thereby maintaining productivity while achieving singulation precision.
3Manufacturing precision
If guiding elements are added to force container alignment, then the singulation precision improves, but the device complexity increases
Solution Approach 1:
The guiding elements are designed to work with the natural movement and orientation of containers as they travel along the conveyor. Rather than requiring complex active control mechanisms, the passive guiding structure allows containers to self-align through their own weight and movement dynamics, reducing the need for additional complex control systems while maintaining alignment precision.
4Manufacturing precision
If the conveyor gradually ascends to a higher level, then the singulation precision improves (containers forced into alignment), but the energy consumption increases
Solution Approach 1:
The conveyor system is designed to minimize energy consumption during the ascent by optimizing the gradient and path. The gradual ascent is engineered to work with the natural rolling movement of containers rather than against it, reducing the additional energy required beyond what is already needed to move the containers horizontally. This approach maintains singulation precision while minimizing extra energy consumption.
Data Source
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Figure 5a~5b
AI summary
A device and a method for singulation of used beverage received in bulk into individual objects and forwarding them towards a receiving station. The bottles have different shapes and sizes. The device includes a rotating surface, a conveyor (102, 121, 122) at least partly encircling said rotating surface and adapted to receive objects from the rotating surface and transport them away from the rotating surface; and an outer wall (104, 105) along the periphery of the conveyor at least along the part of the conveyor that encircles the rotating surface. The conveyor includes a first section (121) which receives objects from the rotating surface, and a second section (122) which is only capable of transporting objects one by one and aligned with the direction of movement of the conveyor or otherwise fall back onto the rotating surface due to the limitation of the width of the conveyor by a wall (105).