Cross-belt Sortation Tray with Tilting Mechanism

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Solution Overview

Problem

Conventional package sorting conveyor systems face issues with wear, electrical communication, acceleration, deceleration, mechanical resistance, and lack convenient installation/maintenance and proper belt tracking.

Innovation Solution

A sorting conveyor system with a conveyor track and carts featuring a frame base, carrying tray, support, and a cross-belt assembly for unloading objects, including a tilting mechanism with cams and a tilt sensor, and a self-tensioning adjustment assembly for improved movement and unloading efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If conventional electric motors and belts are used for discharging objects, then objects can be discharged at particular destinations, but wear, electrical communication issues, acceleration, deceleration, and mechanical resistance challenges occur

Engineering Contradiction:

Improveobject discharge capabilityVSAvoidmechanical wear and electrical communication

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent replaces conventional electric motors and belts with a gravity-based tilt-tray mechanism. The tilt tray is pivotally mounted and uses gravitational force to discharge objects at destinations, eliminating the need for motors and belts, thereby solving wear, electrical communication, and mechanical resistance issues.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The tilt tray is designed to dynamically change its orientation from horizontal to tilted position. This dynamic adjustment allows the tray to discharge objects at specific destinations while returning to horizontal position for the next object, enabling repeated use without mechanical wear from continuous motor operation.

Inventive Principle:

Principle #15Dynamics

2Productivity

If conventional sorting conveyor systems are used, then objects can be transported and sorted, but convenient installation/maintenance and proper belt tracking are not provided

Engineering Contradiction:

Improveobject transport and sorting capabilityVSAvoidinstallation and maintenance convenience

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The conveyor system is divided into discrete modular units, each comprising a frame base, carrying tray, and tilt mechanism. These modular carts can be independently installed, maintained, or replaced without affecting the entire system, greatly improving installation and maintenance convenience.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The tilt tray mechanism is designed to be manually operable and self-contained within each cart module. Maintenance personnel can service individual carts independently without requiring system shutdown or complex disassembly, enabling easy field maintenance and repair.

Inventive Principle:

Principle #25Self-service

3Ease of operation

If a tilt tray mechanism is used for unloading objects, then objects can be discharged at specific destinations, but the mechanism complexity increases

Engineering Contradiction:

Improvedestination-specific discharge capabilityVSAvoidtilt tray mechanism structure

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The complex tilt mechanism is segmented into standardized components (pivot mounting, linkage arms, positioning features) that are pre-fabricated and assembled into modular carts. This segmentation reduces overall system complexity by breaking down the mechanism into manageable, interchangeable parts.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The tilt tray mechanism uses geometric parameter changes (angular positioning, linkage lengths) rather than complex active control systems. The mechanical geometry itself provides the intelligence for destination-specific discharge, simplifying the overall device by relying on passive mechanical design rather than active control complexity.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The system provides efficient and accurate unloading of objects at unloading stations adjacent the conveyor, reducing mechanical load and enhancing maintenance accessibility by using a self-tensioning adjustment assembly and tilting mechanism for independent cart operation.

Implementation Method 1

a timing belt tensioned by the drive roller

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 2

a tilting mechanism including at least one gear having at least one cam for tilting the carrying tray toward at least one side of the conveyor

Methodology Applied

Scientific EffectMechanical Advantage: Mechanical Advantage

Implementation Method 3

a tilt sensor

Methodology Applied

Scientific EffectGravitation: Gravitation

Data Source

PatentUS10577193B1Cross-belt sortation tray

Publication Date: 2020.03.03 MANTISSA CORP

AI summary

A sorting conveyor for transporting objects and unloading objects adjacent the conveyor. The sorting conveyor includes a conveyor track, conveyor carts having a sortation tray, and a drive motor. In particular embodiments, the cross-belt assembly includes a belt roller, a drive roller, a timing belt, and a removable transport belt to unload objects toward at least one side of the conveyor.