Diagonal Discharge Sorter with Rotational Alignment
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Solution Overview
Problem
Existing parallel sorters face issues with article orientation mismatches between the conveying surface and take-away lanes, leading to jams, especially when articles make turns, due to the longitudinal orientation not aligning with the angled take-away lanes.
Innovation Solution
A positive displacement sorter with a diagonal take-away lane and a rotational system that includes angled rollers and a high-friction surface to align articles correctly, combined with a belt drive system maintaining the drive belt in a conical plane to reduce wear and increase longevity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If articles are diverted using parallel pusher shoes moving laterally across the conveying surface, then article diverting efficiency is improved, but article orientation mismatch with angled take-away lanes causes jams
Solution Approach 1:
The pusher assembly is segmented into multiple pusher shoes (leading pusher shoe, intermediate pusher shoes, trailing pusher shoe) that can be independently controlled. This segmentation allows the leading pusher shoe to apply force at an angle to rotate articles into proper orientation while intermediate and trailing shoes maintain parallel motion for efficient diverting, thus resolving the orientation mismatch problem while maintaining productivity
Solution Approach 2:
The system transitions from static parallel pusher motion to dynamic multi-mode operation where the leading pusher shoe can selectively apply rotational force when orientation correction is needed, while maintaining standard parallel diverting motion when orientation is already correct. This dynamic adjustment eliminates jams without sacrificing diverting efficiency
2Area of stationary object
If the drive belt is routed through curved conveyor rollers at angles, then space utilization is improved, but belt wear and fatigue increase
Solution Approach 1:
The drive belt is routed through a conical drive plane configuration where the belt maintains a consistent angular relationship with the conveyor rollers throughout the curve. This curved path geometry allows the belt to flex naturally along the cone surface, accommodating the angular routing through curved conveyor rollers while distributing stress evenly, thus preserving belt lifespan despite the angled configuration
Solution Approach 2:
The system changes the geometric parameters of the drive belt routing by introducing a conical drive plane with specific half-angles. This parameter change allows the belt to engage rollers at optimized angles that maintain effective power transmission while reducing lateral stress and fatigue, extending belt life despite the angled routing 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
The solution efficiently diverts articles by rotating the leading portion to match the take-away lane orientation, reducing jams and extending the conveyor belt's lifespan by minimizing stress and fatigue.
Implementation Method 1
The second portion may have a surface with a higher friction than the first portion. The second portion may be a high-friction belt or a plurality of high-friction parallel rollers.
Implementation Method 2
The belt drive system drives a belt, such as a v-belt or a double v-belt, within a conical drive plane, maintaining the orientation of the belt relative to the conical drive plane. The conical drive plane of the belt reduces wear and fatigue on the belt caused during operation of the system
Data Source
AI summary
A positive displacement sorter and method of diverting articles includes a conveying surface configured to convey articles in a longitudinal direction and at least one diagonal take-away lane, extending diagonally from the conveying surface to receive articles being diverted from said conveying surface. A plurality of pushers are configured to move together in a lateral direction in order to displace an item on the conveying surface to the diagonal take-away lane. A rotational system is configured to rotate a leading portion of a diverted article in the direction of the take-away lane. A belt drive system is provided for driving live roller conveyors about a curved section of a roller conveyor of the sorter. The drive belt is guided along a single conical drive plane that maintains the orientation of the drive belt relative to the single conical drive plane and limits twisting and stress in the drive belt.