Conveyor Drive Gapping for Unordered Simultaneous Goods Transport

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Solution Overview

Problem

Existing gapping systems in material flow systems are limited by the need for manual intervention, require significant space, and are inefficient in handling unordered or non-sequential conveyed goods, especially in establishing transverse distances and varying sizes, leading to bottlenecks in throughput.

Innovation Solution

A conveyor system with individually controllable conveyor drives, enabled by detection means and a control system, allows for dynamic gapping by moving conveyed goods in any direction on the conveying plane, adjusting distances based on parameters like size and orientation, and optimizing space usage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual gapping methods are used, then simplicity of implementation is maintained, but productivity and time efficiency deteriorate

Engineering Contradiction:

Improvesimplicity of implementationVSAvoidgapping speed

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The system enables automatic gapping where the conveyor system itself performs the spacing function through individually controllable conveyor drives that dynamically adjust positions of conveyed goods based on detection data, eliminating the need for manual intervention while maintaining high throughput

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual mechanical gapping operations are replaced with an automated control system that uses sensors to detect goods positions and electronically controls conveyor drive motors to achieve precise spacing, substituting human labor with an automated mechatronic system

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If conventional gapping systems are used, then existing functionality is maintained, but device complexity and space requirements increase

Engineering Contradiction:

Improvegapping functionalityVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The conveyor drives serve dual functions: they perform the primary function of transporting goods along the conveying direction while simultaneously executing the secondary function of establishing and maintaining predetermined distances between goods through individual velocity control, eliminating the need for separate dedicated gapping mechanisms

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The gapping function is merged with the conveying function by integrating the spacing capability into the existing conveyor drive system, combining transportation and spacing operations into a single unified system rather than using separate independent systems

Inventive Principle:

Principle #5Merging (Combining)

3Device complexity

If fixed-velocity conveyor belts are used, then structural simplicity is maintained, but adaptability to different goods sizes and unordered inputs deteriorates

Engineering Contradiction:

Improveconveyor structureVSAvoidadaptability to goods variation

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The conveyor drives transition from fixed-velocity operation to dynamic variable-velocity control, allowing each drive to independently adjust its speed based on real-time detection of goods positions, sizes, and orientations, enabling the system to adapt to diverse goods configurations while maintaining relatively simple conveyor hardware structure

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS12515887B2Apparatus and method for creating spacings between individual groups of conveyed goods during simultaneous transport of the groups of conveyed goods

Publication Date: 2026.01.06 CELLUMATION GMBH

AI summary

The invention relates to a method establishing distances (d) between a first conveyed-good unit (11) and a second conveyed-good unit during the simultaneous transport of the conveyed-good units in a conveying direction (z), comprising the following steps:Feeding of a plurality of at least the first conveyed-good unit (11) and the second conveyed-good unit in a first arrangement, wherein the first conveyed-good unit (11) and the second conveyed-good unit are fed in sections simultaneously in the conveying direction (z), and wherein the conveyed-good units of the conveyed good are fed orthogonally offset to each other in relation to the conveying direction (z) and have a first distance to one another,typifying detection (S1) of the conveyed-good units (11),determining a target position of the first conveyed-good unit (11a . . . 11d) and the second conveyed-good unit (S2),controlling or regulating a target distance (d) between the first conveyed-good unit (11a . . . 11d) and the second conveyed-good unit on the basis of the said target position (S3), andfor this purpose, moving the first conveyed-good units (11a . . . 11d) (S4) and the second conveyed-good unit using conveyor drives (2, 2a . . . 2c), which can move one or a plurality of conveyed-good units individually and in a variable manner in any direction of the conveying plane, in such a way that a target distance (d) between the first conveyed-good units (11a . . . 11d) and the second conveyed-good unit exists at the point of transfer to a subsequent conveyor section (16), wherein the target distance (d) is different from the first distance, the movement is dependent on control signals generated from the typifying detection (S1) of the first conveyed-good unit (11a . . . 11d) and the second conveyed-good unit and generated from the determination of the target positions of the first conveyed-good unit (11a . . . 11d) and the second conveyed-good unit (S2), wherein the first conveyed-good unit and the second conveyed-good unit are transported simultaneously in the conveying direction (z).