Conveyor Singulation via Speed Differential and Vertical Stacking
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Solution Overview
Problem
Existing material handling systems face challenges in article singulation, particularly in confined and non-linear spaces, where articles are often received in an unregulated manner, making it difficult to separate and align them into a single file stream efficiently.
Innovation Solution
The system comprises an intake conveyor, multiple conveyors positioned at different levels, and a switch conveyor that recirculates non-singulated articles, allowing each successive conveyor to operate at varying speeds and directions to singulate articles, with imaging and robotic devices for precise handling and sorting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If articles are received in an unregulated manner on a conveyor, then the system can handle high volumes of items, but it becomes difficult to separate and align them into a single file stream
Solution Approach 1:
The conveyor system is divided into multiple segments operating at different speeds. A first conveyor receives articles at high speed, while a second conveyor operates at a slower speed to create separation. This segmentation allows the system to maintain high throughput while enabling effective singulation through speed differential between segments.
2Area of stationary object
If a singulator is designed to work in a confined space, then the facility footprint is reduced, but the system cannot accommodate traditional linear conveyor arrangements
Solution Approach 1:
The conveyor system transitions from a traditional linear horizontal arrangement to a three-dimensional configuration with vertical stacking. The second conveyor is positioned below the first conveyor, utilizing vertical space to achieve singulation in a confined footprint while maintaining functional effectiveness.
Solution Approach 2:
The system incorporates a curved or angled transition between conveyors rather than sharp right angles. The second conveyor is positioned at an angle below the first, creating a smooth transitional path that accommodates the spatial constraints while enabling effective article separation.
3Manufacturing precision
If multiple conveyors operate at different speeds and directions, then article singulation is achieved, but the system complexity increases
Solution Approach 1:
The singulation function is extracted from a complex multi-conveyor system and achieved through a simplified two-conveyor arrangement. By isolating the essential singulation mechanism to just two conveyors with controlled speed differential and vertical positioning, the system achieves effective singulation while minimizing unnecessary complexity.
Data Source
AI summary
Methods and apparatuses for performing article singulation are provided. An article singulator can include an intake conveyor, an out-take conveyor, and multiple intermediate conveyors. The intake conveyor can receive multiple articles and convey the articles to the multiple intermediate conveyors. Further, the out-take conveyor may convey singulated articles from amongst the multiple articles (e.g. to an outfeed). Further, the multiple intermediate conveyors may include successive conveyors to convey the articles and provide the singulated articles to the out-take conveyor. In some examples, each successive conveyor of the multiple intermediate conveyors may be positioned at a lower level than a preceding conveyor. Further, each successive conveyor can convey the articles in a different direction and at a different speed than a preceding conveyor such that the articles are singulated upon conveyance by the article singulator.