Conveyor Width Adjustment via Single Actuator Rail Control
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Solution Overview
Problem
Conveyor systems face challenges in accommodating devices of varying shapes and sizes, requiring adjustable widths to efficiently convey different electronic devices in manufacturing and testing environments without manual labor and interruptions.
Innovation Solution
A conveyor arrangement with movable rails and an actuator system controlled by a controller, which adjusts the conveyor lane width based on input data, allowing for automatic and precise width adjustment using a single actuator to move both rails, enabling the conveyance of devices of different dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conveyor width is fixed, then structural simplicity is maintained, but adaptability to different device sizes is reduced
Solution Approach 1:
The conveyor system employs movable rails that can dynamically adjust their positions to accommodate different device widths. The rails are guided along tracks and can be positioned at various distances from each other, transforming the fixed-width conveyor into a dynamic, adjustable-width system that adapts to different manufacturing needs.
Solution Approach 2:
The conveyor system is designed with universal functionality to handle multiple device types and sizes using the same infrastructure. By combining movable rails, adjustable conveyors, and reconfigurable pathways, a single conveyor system can serve multiple purposes across different manufacturing stages without requiring separate dedicated conveyors for each device type.
2Productivity
If manual adjustment of conveyor width is used, then device complexity is minimized, but productivity is reduced due to manual labor and interruptions
Solution Approach 1:
The conveyor system incorporates automated control mechanisms that enable self-adjustment of conveyor width based on pre-programmed parameters. The system can automatically reconfigure rail positions and conveyor settings without requiring manual intervention, allowing continuous operation and eliminating productivity interruptions associated with manual adjustment.
Solution Approach 2:
The system employs control systems that monitor and adjust conveyor parameters based on feedback from sensors and programmable logic controllers. This automated feedback mechanism ensures precise width adjustment while maintaining continuous operation, as the system can detect when adjustment is needed and execute the reconfiguration automatically.
3Measurement precision
If multiple actuators are used for rail adjustment, then positioning precision is improved, but device complexity increases
Solution Approach 1:
The system combines multiple adjustment functions into a single integrated actuator mechanism. Rather than using separate actuators for each rail, the invention employs one actuator that can coordinate the movement of both rails simultaneously, reducing the number of components while maintaining positioning precision through synchronized control.
Solution Approach 2:
The actuator system employs asymmetric positioning where one rail remains fixed while the other rail is movable, or uses differential movement where rails move by different amounts. This asymmetric approach achieves precise width adjustment with fewer actuators, as the fixed rail provides a reference point that simplifies the control requirements for the movable rail.
Data Source
Figure 1A~1B
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AI summary
According to an aspect, there is provided a method for controlling conveyor lane width, the method comprising: obtaining, by a controller, input data regarding at least one product to be conveyed by a conveyor; determining a conveyor lane width based on the input data, the conveyor lane width defined by a distance between first and second rails of the conveyor, the first and second rails being movable; causing the first rail to move towards the second rail that causes the second rail to move towards a reference point; and after the second rail has reached the reference point, causing the first rail to move to opposite direction to achieve the determined conveyor lane width.