Diagonal Sorter With Selectively Rotatable Rollers
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Solution Overview
Problem
Conventional switch conveyors with rectangular designs waste space and face difficulties in transferring articles due to the need for large-diameter sprockets, which complicate the transfer process over the ends of the conveyor belt.
Innovation Solution
A diagonally disposed roller-belt sorter with selectively rotatable article-supporting rollers that can divert articles to multiple outbound lanes, reducing space requirements and enabling efficient transfer by using a diagonal sorting conveyor between the infeed and outbound lanes, with rollers actuated to align with the direction of belt travel for smooth operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a rectangular conveyor is used as the switch conveyor, then articles can be conveyed to multiple outbound paths, but the upstream portions of the conveyor are unused, requiring more square feet of conveyor material and taking up valuable floor space
Solution Approach 1:
The patent transitions from a conventional rectangular (2D) switch conveyor layout to a diagonal (oblique) arrangement that utilizes the conveyor belt length more efficiently. The diagonal configuration allows the belt to extend at an angle between the infeed and outbound conveyors, maximizing the use of available space in both dimensions and eliminating unused upstream portions while maintaining the ability to serve multiple outbound lanes
2Length of moving object
If a belt conveyor with a long pitch requiring large-diameter sprockets is used as the switch conveyor, then the conveyor can handle long-pitch requirements, but transfer over the ends of the conveyor belt at the location of the large sprockets is difficult
Solution Approach 1:
The patent introduces an intermediate transfer mechanism consisting of transfer rollers positioned at the ends of the diagonal conveyor belt. These intermediary rollers facilitate the transfer of articles between the diagonal conveyor and the infeed/outbound conveyors, eliminating the difficulty of direct transfer over large-diameter sprockets while maintaining compatibility with long-pitch belt requirements
3Area of stationary object
If a diagonal roller-belt sorter is used, then space requirements are reduced and transfer is facilitated, but the rollers must be selectively actuated to rotate perpendicular to the direction of belt travel
Solution Approach 1:
The patent employs dynamically adjustable rollers that can rotate between two extreme positions: parallel to the belt travel direction (for smooth conveyance) and perpendicular to the belt travel direction (for article diversion). This dynamic capability allows the same roller mechanism to perform multiple functions, reducing the need for separate actuation systems while maintaining the space-efficient diagonal configuration
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
This solution allows for efficient use of space, facilitates smooth article transfer without the need for large sprockets, and maintains throughput by enabling precise control over article diversion and alignment, reducing drift and slip.
Implementation Method 1
The roller belt is advanced in the conveying direction by a drive mechanism and the article-supporting rollers are selectively rotated in the direction perpendicular to the direction of belt travel in zones sequentially disposed along the length of the sorting conveyor
Implementation Method 2
the article-supporting rollers are selectively rotated in the direction perpendicular to the direction of belt travel in zones sequentially disposed along the length of the sorting conveyor
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
A conveyor system (100) includes a conveyor belt (102) having belt rollers (118) configured to divert articles on the belt (102) and a drive mechanism that engages the belt rollers (118). The drive mechanism is configured to drive the belt rollers (118) and is adjustable to selectively drive the belt rollers (118) in a first angular direction and, optionally, a second, opposite angular direction so that articles can be selectively diverted to either side of the belt at a desired angle. One version of the drive mechanism has drive rollers (308) mounted in cartridges (334) and rack gears (342) engaging pinion gears on the cartridges to adjust the orientation of the drive rollers (308) relative to the belt rollers. Such a conveyor system with a series of sequential roller actuation zones (430) driven by separately actuated drive mechanisms is arranged diagonally to an infeed conveyor (418) and a multi-lane outbound conveyor (424) to realize a switch conveyor.