Powered Pallet Conveyor Rail Switch for Continuous Movement
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Solution Overview
Problem
Conventional rail systems for powered pallet conveyors require the vehicle to stop during switching, limiting speed, increasing wear, and resulting in high maintenance costs due to frequent acceleration/deceleration and significant space requirements.
Innovation Solution
A rail system with a switch mechanism that allows continuous vehicle movement by using a first actuating means to position rigid rail portions at joining and continuation points, and a second actuating means to position rigid rail portions at crossing points, enabling the vehicle to travel along an electric cable on parallel rails without stopping, thus reducing wear and maintenance costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional switch means (quadro switch or rotation switch) are used, then the vehicle can be positioned and oriented on alternative pathways, but the vehicle must stop during switching which limits speed and increases wear
Solution Approach 1:
The switch means is designed to be actuated in advance before the vehicle reaches the switching point. The rail portions are repositioned ahead of time so that when the vehicle arrives, the new pathway is already ready, allowing continuous movement without stopping. This preliminary action eliminates the need for the vehicle to halt during switching operations.
Solution Approach 2:
The switch means employs movable rail portions that can be dynamically repositioned between different pathways. The rail system transitions from a static configuration to a dynamic one where rail segments can be shifted to different locations, allowing the vehicle to be guided continuously onto alternative pathways without interruption to its movement.
2Adaptability or versatility
If conventional switch means are used, then alternative pathways can be selected, but significant space requirements are needed and acceleration/deceleration causes increased wear
Solution Approach 1:
The switch means is divided into multiple independent rail portions that can be individually positioned. Instead of using a single large switching mechanism, the system employs segmented rail sections that can be independently actuated to create different pathway configurations. This segmentation reduces the overall space required while maintaining the ability to select between multiple alternative pathways.
3Ease of operation
If the vehicle stops during switching, then switching can be performed, but frequent acceleration/deceleration increases wear and maintenance costs
Solution Approach 1:
The switch means is designed to maintain continuous movement of the vehicle throughout the switching process. By pre-positioning rail portions and enabling continuous guidance onto alternative pathways, the system eliminates interruptions in the vehicle's motion. This continuity of useful action prevents the vehicle from stopping, thereby avoiding frequent acceleration and deceleration cycles that would increase wear and maintenance requirements.
Data Source
AI summary
A rail system for a powered pallet conveyor, which comprises alternative pathways having an electric cable provided on at least one of n parallel rails defining a travel pathway, wherein n≧2, whereby the rail system includes a switch for switching between m alternative travel pathways, wherein m≧2, and allowing the vehicle to continuously move across the switch after switching. The switch comprises a first actuator for selectively positioning (m*n) rigid rail portions bridging the distance between rail ends at (i) n joining points where the n parallel rails of each of the m alternative travel pathways subject to switching converge, and (ii) (m*n) continuation points where each alternative pathway subject to switching diverges downstream from the joining points A second actuator selectively positions [m(n−1)] rigid rail portions bridging the distance between rail ends, where each alternative pathway is discontinued downstream from the corresponding continuation points.