Conveyor Belt Package Separation with Optical Speed Regulation
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Solution Overview
Problem
Existing systems for transferring and presenting packages in a longitudinal line are inefficient, particularly for unstable packages with high centers of gravity, and fail to achieve high throughput rates due to the use of expensive actuators and the complexity of handling nested packages, leading to traffic jams and reduced processing rates.
Innovation Solution
A method and device utilizing multiple conveyor belts with varying speeds and optical measurement systems to calculate and regulate the speed and spacing of packages, ensuring efficient transfer and presentation of packages in a longitudinal line without the need for expensive actuators, capable of handling unstable packages and achieving high throughput rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If grippers or pusher cylinders are used to transfer packages in single file, then packages can be transferred successfully, but the system becomes expensive, bulky, and prone to breakdowns
Solution Approach 1:
The patent replaces complex mechanical actuators (grippers, pusher cylinders) with a simplified conveyor belt system that uses friction-based traction. Packages are transferred by their interaction with the moving belt surface rather than direct mechanical manipulation, eliminating the need for expensive and fragile actuators while maintaining transfer reliability
Solution Approach 2:
The system allows packages to transfer themselves passively along the conveyor belt without active manipulation. The belt simply provides the moving surface, and packages follow along due to friction and gravity, making the system more reliable and less complex
2Productivity
If conventional conveyor systems are used for nested packages, then packages can be transferred, but throughput rates are limited to below 1,500 packages per hour due to traffic jams and collisions
Solution Approach 1:
The patent employs dynamically adjustable conveyor belt speeds at different sections. By varying the speed of individual belt segments, the system optimizes package flow continuously, preventing traffic jams and collisions even with nested packages, thereby achieving throughput rates exceeding 1,500 packages per hour
Solution Approach 2:
The system changes operational parameters (conveyor belt speeds) in real-time based on package detection and flow conditions. This dynamic parameter adjustment allows the system to maintain optimal throughput while preventing collisions, enabling processing rates greater than 1,500 packages per hour
3Productivity
If packages with high centers of gravity are transferred on conventional systems, then they can be moved, but they risk tipping and becoming unstable during transport
Solution Approach 1:
The conveyor belt design creates a stable, level transfer surface that minimizes disturbances to packages. By maintaining consistent elevation and smooth transitions between sections, the system prevents tipping of packages with high centers of gravity while maintaining transfer efficiency
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 enables efficient transfer and presentation of packages at rates exceeding 1,700 packages per hour with reduced risk of errors and maintenance costs, while maintaining package stability and preventing traffic jams, even with nested or unstable packages.
Implementation Method 1
a first conveyor assembly (9) conveying the packages in a first direction (10) on a second conveyor (11) for transferring said packages in a second direction (12)
Data Source
Figure 1~2
Figure 3A~3B
Figure 4~5
AI summary
The present invention relates to a method for presenting in a longitudinal line packages that were initially arranged in rows i, at a determined isolated-package pace D, using at least three successive conveyor belts, namely a regulating conveyor belt (16) and two line-forming conveyor belts (17, 18). After separating from one another rows that are adjacent in the longitudinal direction, each row i is presented in turn onto the regulating conveyor belt (16), the dimensions of the spaces between the end packages of the row i and the reference inside and outside dimensions with respect to the regulating conveyor belt (16) and the number of packages of row i on the belt are measured optically, the speed of the line-forming conveyor belts (17, 18) for maintaining the determined pace D is calculated, the paths of the packages are calculated and the moment at which to release the packages of row i from the regulating belt (16) onto the line-forming conveyor belts (17, 18) so that the inside package of row i does not catch up with the outside package of row i-1 is determined.