Conveyor Discharge Diverting Rollers for Package Sorting
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Solution Overview
Problem
In package-handling industries, sorting conveyors often face issues where packages destined for full collection bins fall onto the floor due to unemptied bins, leading to inefficiencies and potential damage.
Innovation Solution
A conveyor system with selectively oriented gravity rollers, where a diverter system includes freely rotatable rollers on an inclined plane, driven by an actuator to change orientation, directs articles by gravity to different destinations, ensuring accurate sorting and prevention of floor drops.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If packages are sorted onto discharge conveyors leading to collection bins, then sorting functionality is achieved, but packages may fall onto the floor when bins are full
Solution Approach 1:
A diverter component is introduced as an intermediary between the discharge conveyor and collection bin. This diverter includes an array of freely rotatable rollers that can be oriented to either allow packages to pass through to the bin or redirect them to an alternative destination, preventing floor drops when bins are full
Solution Approach 2:
The rollers in the diverter are made dynamically adjustable in orientation. A drive system with actuators can selectively change the roller orientation from a first orientation (allowing passage to bin) to a second orientation (redirecting to alternative destination), enabling real-time response to bin full conditions
2Productivity
If collection bins are used to collect sorted packages, then sorting efficiency is improved, but operational interruptions occur when bins need to be emptied or replaced
Solution Approach 1:
The diverter component provides multi-functionality by enabling packages to be directed to multiple destinations (collection bin or alternative destination). This allows the system to continue sorting operations without interruption by redirecting packages when bins need to be emptied or replaced
3Adaptability or versatility
If diverters with adjustable rollers are added to discharge conveyors, then package sorting flexibility is improved, but device complexity increases
Solution Approach 1:
The rollers are designed to be freely rotatable and self-orienting based on the drive system activation. The simplicity of the roller mechanism and its mounting on the diverter board minimizes complexity while providing the needed adaptability for directing packages to different destinations
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 system effectively sorts articles into designated collection bins, preventing packages from falling on the floor by selectively directing them based on roller orientation, enhancing operational efficiency and reducing waste.
Implementation Method 1
an array of freely rotatable rollers angling downward on an inclined plane from an upper end to a lower end... articles riding downward along the diverter by gravity atop the rollers
Data Source
AI summary
A sorting system having a main sorting conveyor sorting articles to discharge conveyors feeding articles to diverters having freely rotatable, gravity-activated rollers arranged in an inclined plane. The orientations of the rollers are selectably changed to divert articles riding downward along each diverter to different destinations. The main sorting conveyor comprises a roller belt with belt-roller actuators at sorting locations. The belt-roller actuators and the diverters are identical mechanisms.