Diverter Conveyor Paddle Mechanism for Automated Scrap Extraction
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Solution Overview
Problem
Conventional sheet stacking systems lack the ability to efficiently divert defective or scrap sheets from a stream of sheets produced by a rotary die cut machine for quality control and other purposes, as they typically require manual intervention or are not designed for automatic extraction.
Innovation Solution
A diverter conveyor system that can be integrated between conveyor sections, equipped with paddles actuated by a controller to divert sheets from the main path onto a rejection conveyor, allowing for selective extraction based on operator input, quality control criteria, or detected defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If conventional conveyor systems are used without diversion capability, then the system structure remains simple and operation is straightforward, but the ability to extract defective sheets is lost and manual intervention is required
Solution Approach 1:
The conveyor system is segmented into multiple independent components: a main conveyor for sheet transport, a diverter conveyor for extracted sheets, and paddle mechanisms for diversion. This segmentation allows automated extraction functionality to be added without redesigning the entire system, resolving the contradiction between automation and complexity.
Solution Approach 2:
The diverter conveyor is designed with multi-functionality, serving both as a diversion mechanism for defective sheets and as part of the overall conveyor system. The paddles can be actuated to divert sheets when needed while remaining passive during normal operation, providing automated extraction capability without requiring a completely separate extraction system.
2Productivity
If manual intervention is used to extract defective sheets, then the system structure remains simple, but productivity decreases and quality control efficiency is reduced
Solution Approach 1:
The diverter conveyor system is designed to operate automatically based on signals from quality control sensors or control systems. The paddles self-actuate to divert defective sheets without requiring manual intervention, thereby maintaining high productivity while eliminating the need for operators to manually extract sheets, resolving the contradiction between productivity and ease of operation.
3Speed
If the diverter conveyor is positioned at a steep angle, then diverted sheets are quickly removed from the main stream, but the mechanism requires more force and increases mechanical complexity
Solution Approach 1:
Instead of using a steep vertical angle for sheet diversion, the diverter conveyor is positioned at a gentler angle and uses the conveyor's motion to gradually guide sheets away from the main stream. This dimensional approach allows sheets to be diverted efficiently without requiring excessive force, resolving the contradiction between diversion speed and actuation force.
Data Source
AI summary
A diverter conveyor includes a frame supporting an upper conveyor that has an upstream end and a downstream end and that is configured to carry sheets in a first, downstream, direction. A plurality of nip rollers are mounted on the frame upstream of the upstream end of the upper conveyor and are spaced from the upstream end of the upper conveyor by a gap. The nip rollers feed the sheets along a main path to the upstream end of the upper conveyor. A rejection conveyor is supported by the frame and has a portion beneath the gap and extends away from the upper conveyor at an acute angle. A plurality of paddles are mounted at the first gap, and an actuator is operably connected to the paddles and configured to shift the paddles from a first position out of the main path to a second position in the main path.