Conveyor Interfacing System with Accumulator and Movable Trays
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing conveyor systems struggle to seamlessly interface between different types, particularly when transferring objects between serial and parallel conveyors with varying object transport speeds and gap spacings, failing to adequately adjust gaps between objects for efficient processing and treatment.
Innovation Solution
The development of an interfacing system that accumulates batches of objects, adjusts gap spacings using spacer units and movable trays, and transfers them between conveyors, ensuring compatibility with each system's requirements, including the use of accumulator units, spacer units, and movable trays to adjust and transfer objects between serial and parallel conveyor systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If objects are transferred directly between serial and parallel conveyors without intermediate processing, then transfer speed is maintained, but gap spacing between objects cannot be adjusted to match different conveyor requirements
Solution Approach 1:
An intermediate transfer mechanism is introduced between the serial and parallel conveyors. This intermediary system includes transfer arms or carriers that receive objects from the serial conveyor, hold them temporarily, and release them onto the parallel conveyor. This mediator enables gap spacing adjustment by controlling the timing and positioning of object transfer, while isolating the complexity of the adjustment mechanism from both conveyor systems.
Solution Approach 2:
The transfer process is divided into discrete segments: object pickup from serial conveyor, intermediate holding/positioning, and release to parallel conveyor. Each segment can be independently controlled and optimized. The gap spacing adjustment is achieved by segmenting the transfer cycle into controllable phases, allowing precise control over object spacing without requiring complex integrated systems.
2Adaptability or versatility
If batch accumulation is implemented to adjust object pacing, then gap spacing between objects can be controlled, but continuous operation of conveyors may be interrupted
Solution Approach 1:
Objects are pre-positioned on transfer carriers or in intermediate holding positions before the actual transfer to the parallel conveyor occurs. This preliminary action allows the batch accumulation and pacing adjustment to be completed in advance, so that when transfer occurs, it can be done in a coordinated manner that maintains continuous flow. The pacing control is achieved through preliminary organization rather than during the transfer itself.
Solution Approach 2:
The transfer mechanism is designed to operate continuously by implementing overlapping transfer cycles. While one batch of objects is being transferred, the next batch is being prepared in the accumulation zone. Multiple transfer points or carriers operate in sequence, ensuring that the conveyors maintain continuous operation without idle waiting periods. The useful action of object transfer is sustained without interruption through this continuous cycling approach.
3Manufacturing precision
If multiple spacer units and movable trays are used to adjust gap spacings, then object alignment precision is improved, but the system complexity and number of components increases
Solution Approach 1:
Multiple spacer units and movable trays are merged into integrated assemblies where components work together as unified units. For example, movable trays are combined with spacer mechanisms into single integrated transfer carriers that perform both positioning and spacing functions simultaneously. This merging reduces the total number of separate components while maintaining the precision achieved through multiple spacing adjustments.
Solution Approach 2:
The spacer units and movable trays are designed with multi-functionality, where each component can serve multiple purposes in the object transfer and positioning process. A single movable tray can function as both a transport carrier and a spacing element, while spacer units can adjust gaps for different object sizes and configurations. This universality allows high alignment precision to be achieved with fewer versatile components rather than numerous specialized parts.
Data Source
AI summary
A system for interfacing between different types of conveyor systems that comprise a first serial conveyor system using a sequence of object carriers configured to transport a continuous serial stream of objects, and a parallel conveyor system configured to simultaneously transport one or more arrays of objects. A first accumulator unit can be used to accumulate a batch of the object carriers of the first serial conveyor system. Each of the object carriers can carry an object of the continuous serial stream of objects for accumulating a batch of the objects therein. Two or more first movable trays, each configured to receive an array of the objects from the batch of objects accumulated in the first accumulator unit, can be used to transfer the received array of objects to the parallel conveyor system, and load the objects thereby carried onto grippers of the parallel conveyor system.