Compact Conveyor Plates for Tight Turns and Gap-Free Transfer
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Solution Overview
Problem
Conventional re-circulating conveyors are bulky, noisy, and not suitable for confined spaces like dining tables or work benches, with issues such as large unused spaces, uneven carrier device surfaces, and lack of low friction support, especially during turns, and inadequate control mechanisms.
Innovation Solution
A compact, re-circulating conveyor system with a train of asymmetrical, interlocking carrier plates and an endless drive member, allowing pivotal adjustment through turns, and guided by inner and outer rails, with control switches for direction and tension management to maintain a continuous, gap-free surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional re-circulating conveyors use large turning radii, then the conveyor can operate smoothly, but the system occupies large unused space at the center and becomes bulky
Solution Approach 1:
The patent employs crescent-shaped carrier plates with curved geometries that enable tight turning radii. The curved design allows the conveyor to navigate sharp turns while maintaining smooth operation, eliminating the need for large turning radii and reducing the overall footprint and unused space in the center of the conveyor system.
Solution Approach 2:
The conveyor system is divided into multiple discrete carrier plates linked in a chain configuration. Each carrier plate is an independent segment that can pivot and adjust individually, allowing the entire system to navigate tight turns through coordinated movement of segments rather than requiring a large overall turning radius.
2Productivity
If carrier devices are used to move articles, then articles can be transported, but the carrier device shapes do not maximize the surface area presented to articles and create gaps between devices
Solution Approach 1:
The carrier plates are designed with asymmetrical crescent shapes rather than uniform circular or rectangular forms. This asymmetrical geometry maximizes the load-bearing surface area while minimizing gaps between adjacent carriers. The varying width and curvature of each carrier plate are optimized to present maximum surface area to articles during transport.
Solution Approach 2:
Different portions of the carrier plates have different geometries optimized for their specific functions. The outer edges are shaped to maximize surface area for article contact, while the inner portions are designed to nest closely with adjacent carriers, minimizing gaps. This local optimization of geometry ensures maximum productivity without compromising surface area.
3Adaptability or versatility
If the gap between carrier devices changes as they traverse the conveyor path, then the conveyor can accommodate turning sections, but binding occurs at sharp turn sections without a mechanism to accommodate changing gaps
Solution Approach 1:
The carrier plates are designed with dynamic adjustment capabilities through pivotal connections to the drive chain. Each carrier plate can pivot and rotate to accommodate changing gap conditions as the conveyor traverses turning sections. This dynamic adaptation prevents binding by allowing the gap between carriers to vary smoothly according to the curvature of the path.
Solution Approach 2:
The system allows the gap parameter between carrier plates to change dynamically as they move through the conveyor path. The pivotal connection mechanism enables each carrier to adjust its position and orientation, changing the effective gap width to match the local curvature requirements, thereby preventing binding while maintaining adaptability to turning sections.
4Reliability
If U-shaped flange support mechanism is used in straight sections, then clockwise travel is supported, but the flange may bind or hang-up in counter clockwise direction at track entry
Solution Approach 1:
The support mechanism is designed to function effectively in both directions by inverting the approach used in conventional unidirectional systems. Rather than relying on a fixed U-shaped flange that works well in one direction, the patent employs carrier plates with pivotal connections that can adapt their orientation and contact points based on the direction of travel, eliminating binding issues in counter-clockwise operation.
Solution Approach 2:
The support mechanism transitions from a static U-shaped flange design to a dynamic pivotal connection system. Each carrier plate can rotate and adjust its support contact points dynamically based on the direction of travel, ensuring smooth operation in both clockwise and counter-clockwise directions without binding or hanging up at track entries.
5Productivity
If multiple belts or surfaces are used to transfer loads, then load transfer can occur, but small parts may be dropped during transferring
Solution Approach 1:
The patent merges the load transfer function into a single continuous surface formed by the chain of carrier plates, rather than using multiple separate belts or surfaces. This unified surface eliminates gaps and discontinuities where small parts could be dropped during transfer, while maintaining the productivity of load transfer through the coordinated movement of the carrier plate chain.
6Productivity
If conventional conveyors are designed for home or commercial dining applications, then they can move articles, but they are noisy and not of compatible décor
Solution Approach 1:
The carrier plates and conveyor components are designed with aesthetic considerations in mind, using materials and finishes that are visually compatible with home and commercial dining environments. The crescent-shaped carriers can be manufactured in various colors and materials that match décor requirements, transforming the conveyor from an industrial noise-making device into an aesthetically pleasing article.
Solution Approach 2:
The patent replaces noisy mechanical elements such as heavy chains, loud motors, and rigid linkages with quieter alternatives. The carrier plate chain uses low-friction pivotal connections and silent drive mechanisms, substituting traditional noisy mechanical systems with refined versions that maintain article movement capability while reducing noise to levels compatible with dining environments.
Data Source
AI summary
A conveyor system including a train of carrier plates arranged for movement along a conveyor path which possesses either rightward turns or leftward turns and each carrier plate defines a leading edge and a trailing edge. Each of the leading and trailing edges has an outer portion which is disposed adjacent a side of the carrier plate opposite the direction of turn of the conveyor path and an inner portion. Each carrier plate is pivotally mounted upon an endless drive member at a location along the carrier plate which is disposed between the leading and trailing edges of the plate, and is shaped so that the outer portion of each of its leading and trailing edges is longer than the inner portion of its leading and trailing edges. Gap plates cover any gap between two sequential conveyor plates as the train is moved through non-linear sections of the conveyor path.