Conveyor Velocity Control for Product Misalignment
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Solution Overview
Problem
Existing solutions for realigning misaligned product ranks in high-speed packaging systems, such as those used in the food industry, are inadequate as they often damage delicate products and require complex, costly, and maintenance-intensive roller systems, which are not suitable for high velocities and may worsen the misalignment issue.
Innovation Solution
A device comprising a motorized conveyor belt with sensors and a command unit that adjusts the conveyor's velocity to slow down and accelerate products in a controlled manner, allowing for partial realignment without stopping, thereby reducing misalignment while maintaining product integrity and simplicity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a barrier is interposed in the flux of products to arrest or slow down the advancing movement for realignment, then the alignment of product ranks is improved, but the products may be damaged due to contact with the barrier
Solution Approach 1:
A barrier element is introduced as an intermediary between the misaligned products and the realignment mechanism. This barrier temporarily intercepts products to correct their positions, then removes them before products contact the main conveyor, preventing damage while achieving alignment
Solution Approach 2:
The barrier performs realignment actions preliminarily before products enter the main conveyor system. By correcting misalignment in advance on a separate section, products are properly aligned before encountering the main conveyor, preventing both damage and misalignment downstream
2Manufacturing precision
If roller transporters with independent motorisation are used for realignment, then the alignment capability is improved, but the device complexity and maintenance requirements increase
Solution Approach 1:
Multiple independent motorized rollers are merged into a single belt conveyor system with centralized motorisation. This integration maintains the realignment capability while reducing device complexity and maintenance requirements through a unified, simpler mechanical structure
Solution Approach 2:
The belt conveyor is designed to perform multiple functions: it conveys products forward and simultaneously performs realignment through controlled velocity variations. This multi-functionality eliminates the need for separate complex roller mechanisms, reducing overall system complexity
3Manufacturing precision
If the conveyor velocity is reduced to allow realignment, then the alignment of products is improved, but the productivity of the packaging line decreases
Solution Approach 1:
The conveyor system is segmented into distinct sections: a realignment section where velocity is reduced to correct alignment, and a main conveyor section that maintains high velocity for productivity. This segmentation allows local velocity reduction without affecting overall line speed, achieving both alignment and productivity
4Manufacturing precision
If a complex array of motorised rollers is deployed for realignment, then the realignment effectiveness is improved, but the ease of manufacture and maintenance deteriorates
Solution Approach 1:
The system uses a simple, easily manufactured belt conveyor instead of complex motorized rollers. The belt is a straightforward component that is inexpensive to manufacture and replace, improving ease of manufacture and maintenance while maintaining realignment effectiveness through intelligent velocity control
Data Source
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AI summary
A device for reducing misalignment of ranks (R) of products (P) advancing on a conveyor line (10, 12) including a motorised conveyor (14) interposable in the conveyor line (10, 12). The devise is equipped with a first (16) and a second (18) sensor located at the entrance and exit of the conveyor (14). A control unit (20) of the motorisation (22) of the conveyor (14) sensible to the signals emitted by the sensors (16, 18) is provided and configured to act on the motorisation (22) of the conveyor (14) to reduce, without annulling the velocity of the conveyor (14) when at least on product (P) of a rank is arriving at the entrance of the conveyor (14), and to increase the velocity of the conveyor (14) when at least one product (P) of the above-said rank (R) is arriving at the exit of the conveyor (14) and the first sensor (16) indicates the absence of products (P) at the entrance of the conveyor (14). The command unit (20) is also configured to maintain the velocity of the conveyor (14) at the basal velocity (v1) when the first (16) and the second (18) sensors indicate the absence of products (P) both at the entrance and at the exit of the conveyor (14).