Conveyor Belt Piston Array Item Singulation
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Solution Overview
Problem
Conveyor belt systems face challenges in sorting and routing items that are close to each other, as they must be sorted or routed simultaneously, making it difficult to maintain precise control over item positioning and spacing.
Innovation Solution
A conveyor belt system incorporating cameras and piston arrays, where cameras capture images of items and process them to determine distances, and pistons are actuated to adjust item spacing by deforming the conveyor belt, ensuring items are singulated by maintaining a specific distance apart.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple items are placed onto the conveyor belt at the same time, then the conveyor belt can transport multiple items simultaneously, but the items move in close proximity making it difficult to sort and route them individually
Solution Approach 1:
The system segments the continuous stream of items by using sensors to detect individual item positions and actuators to apply localized forces to specific items, enabling individual control while maintaining group transport
Solution Approach 2:
The system performs preliminary detection of item positions and spacing using sensors before sorting actions are taken, allowing the control system to plan and execute appropriate routing decisions for each item
2Manufacturing precision
If the conveyor belt speed is changed to affect item positioning, then item spacing can be adjusted, but all items experience equal speed changes making relative positioning unchanged
Solution Approach 1:
Instead of changing the speed of the entire conveyor belt, the system applies localized forces to individual items or specific regions using actuators, achieving differential positioning without affecting the overall belt speed
Solution Approach 2:
The system introduces actuators as intermediary devices between the conveyor belt and items, allowing precise control of item positions without directly controlling belt speed, thus decoupling positioning control from transport speed
3Productivity
If items are sorted and routed simultaneously due to close proximity, then all items can be processed at once, but precise control over individual item positioning is lost
Solution Approach 1:
The system continuously monitors item positions using sensors and uses this feedback information to adjust actuator commands in real-time, maintaining precise positioning control even while processing multiple items simultaneously
Solution Approach 2:
The system replaces traditional mechanical sorting mechanisms with a sensor-actuator control system that uses detected position information to dynamically control item routing, enabling both high throughput and precise positioning
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 achieves item singulation by precisely controlling the distance between items on the conveyor belt, allowing for efficient sorting and routing without altering the conveyor belt's speed or item positioning relative to each other.
Implementation Method 1
the one or more pistons may be actuated to apply a force to the item by deforming the conveyor belt
Data Source
AI summary
Systems, methods, and computer-readable media are disclosed for systems and methods for item singulation in a conveyor belt system. The singulation system may include one or more conveyor belts, one or more piston arrays disposed below the one or more conveyor belts, one or more cameras for generating image data of the conveyor belt, and a computing device for processing the image data and controlling the piston array. The singulation system may selectively actuate pistons of the piston array to achieve singulation of the items (e.g., packages) on the conveyor belt to ensure such items are separated by a certain distance. Multiple conveyor belts in series and with increasing velocities may be employed to increase separation between items.