Conveyor spacing control for single-head sod stacking

Solution Overview

Problem

The existing sod harvesting machines are limited by the need for multiple stacking heads to manage spacing between slabs, which increases complexity, cost, and maintenance, while using a single stacking head restricts the cutting speed due to required slab width adjustments.

Innovation Solution

A conveyor system with a control unit and sensors that adjusts the spacing between slabs on the conveyor, allowing a single stacking head to pick up multiple slabs simultaneously by advancing the conveyor to reduce slab spacing, enabling faster sod harvesting without the need for multiple stacking heads.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If multiple stacking heads are used to manage spacing between slabs, then the cutting speed increases, but the device complexity and maintenance costs increase

Engineering Contradiction:

Improvecutting speedVSAvoidnumber of stacking heads

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The conveyor system dynamically adjusts its speed to control slab spacing. The control unit varies the conveyor rotation speed to reduce spacing between slabs, allowing a single stacking head to efficiently handle slabs at optimized intervals, thereby achieving high productivity without multiple stacking heads

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes the operational parameters of the conveyor (rotation speed) to control the spacing between slabs. By adjusting the conveyor speed parameter, the system optimizes slab delivery timing to match the stacking head's operational cycle, enabling efficient single-head operation at high cutting speeds

Inventive Principle:

Principle #35Parameter changes

2Device complexity

If a single stacking head is used, then the device complexity decreases, but the cutting speed is restricted due to required slab width adjustments

Engineering Contradiction:

Improvenumber of stacking headsVSAvoidcutting speed

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The conveyor system dynamically adjusts its speed to control slab spacing. The control unit varies the conveyor rotation speed to reduce spacing between slabs, allowing a single stacking head to efficiently handle slabs at optimized intervals, thereby achieving high productivity without multiple stacking heads

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The conveyor system preliminarily positions and spaces slabs before they reach the stacking head. By pre-controlling slab spacing through variable conveyor speed, the system ensures that slabs are optimally positioned for the stacking head to process them efficiently, eliminating the need for speed restrictions

Inventive Principle:

Principle #10Preliminary action

3Productivity

If conveyor speed is increased to create gaps between slabs, then the spacing control improves, but the manufacturing precision of slab positioning deteriorates

Engineering Contradiction:

Improveconveyor speedVSAvoidslab positioning accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The control unit monitors conveyor operation and adjusts rotation speed based on detected slab positions and spacing requirements. This feedback mechanism ensures that even at high speeds, slabs are positioned with the required precision by continuously optimizing conveyor speed to maintain accurate spacing

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The conveyor system dynamically adjusts its speed to control slab spacing. The control unit varies the conveyor rotation speed to reduce spacing between slabs, allowing a single stacking head to efficiently handle slabs at optimized intervals, thereby achieving high productivity without multiple stacking heads

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS9078390B2Conveyor system for controlling spacing between sod slabs

Publication Date: 2015.07.14 FIREFLY ROBOTICS INC

AI summary

The present invention extends to a conveyor system that allows the spacing between slabs on a conveyor to be controlled. Because the spacing can be controlled, a single stacking head can be used to pick up and stack multiple slabs at the same time. In this manner, a harvesting machine employing the conveyor system of the present invention can utilize a single stacking head while still harvesting sod at least as quickly as harvesting machines employing multiple stacking heads.