Curved Routing Element for Package Alignment in Sorters
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Solution Overview
Problem
In package conveyors and sorters, packages often protrude laterally or become twisted, leading to jams and increased risk of damage or injury due to high speeds and manual re-introduction requirements, causing disruptions and safety hazards.
Innovation Solution
A device with a routing element having a curved contact face that reconnects packages to their nominal track, utilizing a flexible design with a spring element and guide elements to adapt to package weight and shape, ensuring force transmission and preventing twisting, thus maintaining conveyor operation without the need for hinges or wearing parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If packages are conveyed at high speed, then productivity is improved, but packages may protrude laterally or become twisted causing jams and disruptions
Solution Approach 1:
The routing element is positioned upstream to realign packages before they can protrude or cause jams. By acting preemptively at an early stage, the device prevents misalignment from developing into problematic conditions, allowing high-speed operation without sacrificing reliability
Solution Approach 2:
The routing element acts as an intermediary component between the conveyor system and packages. It mediates the interaction by providing a curved contact face that gently guides packages back to proper alignment without disrupting the high-speed flow, resolving the conflict between speed and alignment stability
2Force
If a curved contact face is used, then force transmission is improved and packages are realigned earlier, but the routing element length must be optimized
Solution Approach 1:
The contact face is designed with a specific curvature that optimizes force transmission to packages. The curved geometry allows the routing element to apply corrective force more effectively and over a shorter distance, achieving realignment with a compact routing element length while maintaining high force transmission efficiency
3Adaptability or versatility
If the routing element is made flexible, then adaptability to package weight is improved, but structural complexity increases
Solution Approach 1:
The routing element's flexibility allows its physical parameters (deflection, contact force) to change dynamically in response to package weight. This passive adaptation through material properties achieves versatility without complex mechanisms, as the element automatically adjusts its behavior based on the load applied by different packages
4Force
If a fixed connection is used, then force transmission to heavy packages is improved, but the device cannot adapt to different package weights
Solution Approach 1:
The routing element employs a dynamic connection that combines fixed mounting with flexible deformation capability. The element is firmly anchored to maintain structural integrity and force transmission, while its flexible material allows it to deflect and adapt its contact characteristics based on package weight, achieving both strong force transmission and automatic adaptation
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 device effectively realigns packages back onto the conveyor track, reducing the risk of jams and damage, enhancing safety by minimizing manual intervention and maintaining conveyor efficiency with a compact, low-friction, and wear-resistant design.
Implementation Method 1
The curvature may provide a force transmission from the routing element onto the package, so that the package is moved back onto the nominal track of the package conveyor
Implementation Method 2
the routing element may be at least partially flexible. Thus, the routing element deflects according to the weight of the package. Because of the deflection of the routing element, optimal force transmission to the package can take place
Implementation Method 3
Because of the flexible design of the routing element, a return force may be generated. The return force is dependent on the weight of the respective package
Data Source
AI summary
A device for aligning packages, in particular in a sorter, with a first connecting element for connection to a package conveyor, and a routing element connected to the first connecting element, wherein the routing element forms a contact face which comes into contact with the packages for alignment, in particular for realignment, of the packages. Here, the contact face is formed at least partially curved.