Bistable Solenoid Electromagnetic Stopper for Conveyor Safety
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Solution Overview
Problem
Existing electromagnetic stoppers for unit load conveyor systems require high currents to maintain the cam in the retracted position and often rely on pneumatic systems, which are inefficient and prone to malfunction during power failures.
Innovation Solution
A bistable solenoid with a coil and permanent magnet, combined with energy storage devices like capacitors, controls the cam's extension and retraction efficiently, using a spring system to bias the solenoid and minimize energy consumption, and includes a control system to manage power interruptions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical stoppers or diverters are used to control article flow, then articles can be stopped or diverted at intersections, but mechanical contact causes wear, increases maintenance requirements, and may damage delicate articles
Solution Approach 1:
The patent replaces mechanical stoppers and diverters with an electromagnetic field-based stopper system. The electromagnetic stopper uses a controller to generate electromagnetic fields that interact with conductive articles on the conveyor, stopping or diverting them without physical contact. This eliminates mechanical wear and maintenance while maintaining reliable control at intersections and transfer points.
2Ease of manufacture
If electromagnetic stoppers are used to eliminate mechanical contact, then maintenance is reduced and article damage is minimized, but the system requires precise control and coordination between multiple conveyor systems
Solution Approach 1:
The electromagnetic stopper system is designed to perform multiple functions: stopping articles, diverting articles to different conveyors, and coordinating between primary and secondary conveyor systems. The controller integrates these functions through a unified electromagnetic field generation mechanism, reducing overall system complexity despite the multi-functional requirements.
Solution Approach 2:
The controller acts as an intermediary between the primary and secondary conveyor systems, managing the electromagnetic field generation and timing coordination. This intermediary component simplifies the control architecture by centralizing the coordination logic rather than requiring direct complex interactions between multiple mechanical systems.
3Productivity
If articles are accelerated to high speeds on primary conveyor, then productivity increases, but articles must be safely stopped and transferred to secondary conveyor moving at different speeds
Solution Approach 1:
The electromagnetic stopper operates by applying periodic or pulsed electromagnetic fields to conductive articles, enabling precise control over acceleration and deceleration. This periodic action allows articles to be safely stopped at intersections even when traveling at high speeds on the primary conveyor, ensuring reliable transfer to secondary conveyors moving at different speeds without mechanical impact.
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
The solution provides energy-efficient operation with reduced energy consumption and ensures reliable stopping and singulating of unit loads even during power failures, enhancing safety and efficiency.
Implementation Method 1
an electromagnetic stopper (404) including a controller (420) configured to generate an electromagnetic field
Implementation Method 2
the electromagnetic stopper (404) including a controller (420) configured to generate an electromagnetic field to induce eddy currents in the conductive article
Implementation Method 3
induce eddy currents in the conductive article to stop or divert movement of the conductive article along the conveyor
Data Source
Figure 1a
Figure 1b
Figure 2
AI summary
The present invention relates to an electromagnetic stopper for stopping and/or separating out article carriers and/or articles conveyed on a continuously operated article conveyor system, comprising: - a bistable solenoid having at least one coil and at least one permanent magnet; - a cam, which can be retracted and extended with the aid of the solenoid, - one or more electrical energy stores, in particular capacitors, - a controller, which, with the aid of switches, discharges the energy store(s) via the at least one coil of the solenoid such that the cam is extended.