Diagonal Diverting Assembly for Conveyor Sorting Reliability
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Solution Overview
Problem
Existing positive displacement sorters face issues with divert failures, leading to inefficiencies in article sorting due to the inability to effectively guide articles onto diverter spurs, resulting in overshooting and reduced system performance.
Innovation Solution
A conveyor system with a diagonally positioned diverting assembly featuring a vertically oriented belt and actuated diverting members that move between non-actuated and actuated positions, utilizing a flexible shaft coupling and high torque drive to laterally displace articles onto takeaway conveyors, with independent control for precise article diversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a positive displacement sorter uses a vertically oriented belt to guide articles, then article diversion reliability is improved, but device complexity increases due to the need for precise vertical positioning mechanisms
Solution Approach 1:
The patent employs a vertically oriented belt that dynamically moves between a lower non-diverting position and an upper diverting position. This dynamic positioning allows the belt to actively guide articles onto diverter spurs, improving diversion reliability while the vertical motion mechanism manages the complexity through controlled movement rather than static complex structures
Solution Approach 2:
The vertically oriented belt acts as an intermediary element between the conveying surface and the diverter spurs. It mediates the transfer of articles by providing a controlled vertical displacement that guides articles onto the spurs, thereby improving reliability without requiring direct complex interaction between the conveyor and diverters
2Productivity
If the diverting assembly is positioned diagonally across the conveying surface, then article spacing can be reduced for higher throughput, but manufacturing precision requirements increase for accurate lateral displacement
Solution Approach 1:
The patent positions the diverting assembly diagonally across the conveying surface, utilizing a two-dimensional arrangement (both longitudinal and lateral positioning) to achieve article diversion. This diagonal configuration allows articles to be diverted while maintaining reduced spacing, improving throughput by effectively using spatial dimensions to manage article flow and displacement accuracy
3Measurement precision
If multiple diverting members are independently actuated, then sorting precision is improved for selective diversion, but control system complexity increases
Solution Approach 1:
The patent divides the diverting function into multiple independently actuated diverting members, each capable of being controlled separately. This segmentation allows precise selection and diversion of specific articles based on their position and characteristics, improving sorting precision while the modular independent control structure manages complexity through distributed actuation rather than a monolithic control system
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 enhances sorting efficiency by reducing divert failures and increasing throughput, allowing for closer spacing of articles and improved control over diversion, capable of sorting up to 80 standard cartons per minute with sequential actuation of diverting members.
Implementation Method 1
The coupling may be a flexible shaft or a spline. The coupling may be a flexible shaft having a takeoff assembly between the flexible shaft and the motor.
Data Source
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AI summary
A conveyor system and method of laterally displacing articles includes a conveyor defining a conveying surface and conveying articles in a longitudinal direction with the conveying surface. A diverting assembly is positioned diagonally at least partially across the conveying surface. The diverting assembly travels generally vertically between a non-actuated position below the conveying surface and an actuated position extending above the conveying surface. The diverting assembly has a diverting surface that is adapted to laterally displace articles on the conveying surface when in the actuated position.