Conveyor System with Zone-Based Case Singulation
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Solution Overview
Problem
Conveyor systems in retail and warehouse environments face inefficiencies due to manual singulation methods and the need for high-power, permanent installations, which are not suitable for low-power, temporary setups, especially in spaces with limited power and frequent setup/teardown requirements.
Innovation Solution
A conveyor system with an elongated frame, individually-controllable motivators, and sensors that automatically maintain a minimum gap between cases for efficient scanning, powered by a low-voltage DC motor and adaptable to low-power environments, allowing for temporary and flexible deployment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual gapping is performed to maintain ideal gap distances between cases, then scanning accuracy is improved, but labor efficiency deteriorates due to human inconsistency and time consumption
Solution Approach 1:
The conveyor system performs automatic singulation and gapping of cases without human intervention. The motivators and sensors work autonomously to maintain proper spacing between cases, eliminating the need for manual gapping while ensuring consistent gap distances for accurate scanning.
Solution Approach 2:
The patent replaces manual mechanical gapping with an automated control system using sensors and motivators. The controller coordinates the motivators to maintain proper case spacing based on sensor feedback, substituting human labor with an automated electromechanical system.
2Measurement precision
If conventional automated singulation systems are installed to maintain case spacing, then scanning accuracy is improved, but device complexity and installation permanence increase
Solution Approach 1:
The conveyor system is divided into discrete linear zones along the frame, with each zone containing specific motivators and sensors. This segmentation allows the system to be modular and adaptable to different spaces while maintaining automated singulation functionality through coordinated control of individual zones.
Solution Approach 2:
The system uses individually-controllable motivators that can dynamically adjust their operation based on real-time sensor feedback and controller instructions. This dynamic control enables the system to adapt to varying case sizes and spacing requirements without requiring complex fixed infrastructure.
3Measurement precision
If conventional automated singulation systems are used to provide reliable case separation, then scanning accuracy is improved, but power consumption increases beyond available capacity in temporary environments
Solution Approach 1:
The motivators operate periodically rather than continuously, activating only when sensors detect cases that need separation or positioning. This periodic operation significantly reduces power consumption compared to continuous operation, enabling the system to function in temporary environments with limited power availability while maintaining reliable case singulation.
Data Source
AI summary
Embodiments of a conveyor system for separating cases of product are disclosed. An elongated, substantially horizontal frame extends from an entry point to an exit point and has a plurality of linear zones. A plurality of motivators is arranged along the frame, such that a case placed on one or more motivators will be moved forward toward the exit point by a coordinated movement of the motivators. A plurality of case sensors arranged along the frame detects the presence of one or more cases within each of the linear zones, and a controller activates the motivators such that a minimum time period elapses between cases delivered to the exit point. The system can include an AC/DC power supply configured to receive 110-120V alternating current power at 60 Hz and to provide direct current power to the controller, the plurality of case sensors, and the plurality of individually-controllable motivators.