Conveyor Loading System for Uniform Metallic Item Distribution
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Solution Overview
Problem
Current loading systems for continuous ovens result in imbalanced and inefficient distribution of metallic items, leading to inadequate treatment due to uneven loading and potential overlap, which affects the heating and drying processes.
Innovation Solution
A loading system comprising a first conveyor belt and a second conveyor belt arranged perpendicularly, with a mobile anti-falling retaining wall and a pneumatic actuator, ensures balanced distribution by unloading items onto the second belt and then into boxes, minimizing overlap and optimizing item placement within the oven.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If items are unloaded directly from a basket or another transportation carrier onto the conveyor belt, then the loading process is simple and fast, but the distribution of items on the conveyor belt is approximate and results in imbalanced filling of boxes
Solution Approach 1:
A vibratory conveyor belt is introduced as an intermediary device between the unloading end of the first conveyor belt and the boxes. This intermediate vibratory conveyor receives items from the first conveyor belt and distributes them uniformly across multiple boxes through vibration, thereby achieving both efficient loading and balanced distribution without requiring manual intervention
Solution Approach 2:
The second conveyor belt is designed to vibrate, creating mechanical oscillations that cause items to spread out and distribute evenly across the conveyor belt surface and into the boxes. The vibration frequency and amplitude are controlled to optimize the distribution effect, ensuring that items are evenly dispersed rather than clustered in imbalanced patterns
2Manufacturing precision
If items are loaded in substantially equivalent quantities in all boxes, then the distribution quantity is balanced, but the items are positioned inside boxes in an inconvenient manner for heating treatment, resulting in insufficient treatment of some items
Solution Approach 1:
The system ensures that each box receives items with appropriate spatial arrangement and orientation suitable for its specific heating treatment requirements. The vibratory conveyor allows items to be distributed not only uniformly in quantity but also in proper positioning within each box, creating locally optimized conditions for heat exchange and treatment effectiveness in different regions of the oven
Solution Approach 2:
The vibration of the second conveyor belt prevents items from overlapping or piling up in inconvenient positions. The oscillating motion distributes items in a way that ensures adequate spacing and orientation within each box, allowing heat to penetrate uniformly to all items during the heating treatment process
3Device complexity
If a single conveyor belt is used for loading, then the device complexity is low, but the item distribution is approximate and overlap occurs
Solution Approach 1:
The loading system is divided into two distinct conveyor belt segments: the first conveyor belt for efficient item transport and the second vibratory conveyor belt for precise distribution. This segmentation allows each component to perform its specialized function optimally - the first belt handles bulk transport while the second belt ensures precise, overlap-free distribution into boxes
Data Source
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AI summary
The present invention refers to a loading system (10) for continuous ovens particularly for the treatment of metallic items, characterised in that it comprises: a first conveyor belt (11) for advancing items to be treated in a first direction (X) towards an unloading end (13) of the same first conveyor belt (11); means (14) for the alternate translation of said first conveyor belt (11) in said first direction (X); a second conveyor belt (15) for advancing items to be treated in a second direction (Y) transversal with respect to said first direction (X), said second conveyor belt (15) being positioned below said unloading end (13) of said first conveyor belt (11) in an operative step of the same first conveyor belt (11); a mobile anti-falling retaining wall (16), positioned transversally to said second conveyor belt (15) and close to an unloading end (17) of said second conveyor belt (15); means (18) for the movement of said mobile anti-falling retaining wall (16) between a lowered configuration, for holding items to be treated on said second conveyor belt (15), and a raised configuration adapted for allowing the passage of said items to be treated towards said unloading end (17) of said second conveyor belt (15); moving means (19) for said items to be treated, configured to transit below said unloading end (17) of said second conveyor belt (15).