Diverter Disc Non-Circular Grip Opening Reduces Friction
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Solution Overview
Problem
Conventional diverter discs require high power to divert pucks with multiple pucks bearing on each other due to friction and rotational forces, leading to inefficient energy use and potential operator injury, as they must overcome the collective force of the puck train during diversion.
Innovation Solution
A diverter disc with a non-circular grip opening forming discrete contact points to securely hold and divert pucks with a slide ring, allowing the puck to rotate freely and reducing the power required for diversion by distributing contact pressure effectively, and optionally incorporating protrusions and resilient means for enhanced grip and positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a conventional diverter disc with a semi-circular grip opening is used to divert pucks, then the puck can be gripped and moved out of the main flow, but the diverter disc requires high power to overcome the friction and rotational forces from multiple bearing pucks
Solution Approach 1:
The grip opening is designed with an asymmetric non-circular shape that does not match the circular puck geometry. This asymmetric configuration creates discrete contact points rather than continuous contact, reducing the frictional forces and rotational resistance during diversion. The asymmetric shape allows the puck to rotate more freely within the opening while being securely gripped at specific points.
Solution Approach 2:
The invention changes the geometric parameters of the grip opening from a conventional semi-circular shape to a non-circular shape with specific dimensional relationships. The opening is designed to be wider than the puck diameter, with side walls positioned at specific angles and distances from the center, creating optimal discrete contact points that reduce friction and power requirements during operation.
2Reliability
If the diverter disc grips the puck securely to move it out of the main flow, then the puck can be effectively diverted, but the friction between the puck and diverter disc increases the force required and causes wear
Solution Approach 1:
The continuous contact surface between the grip opening and puck is segmented into discrete contact points. The non-circular shape of the grip opening creates specific localized contact regions rather than continuous contact along the curved surfaces. This segmentation reduces the total frictional contact area while maintaining secure gripping at the discrete points, thereby reducing energy loss.
Solution Approach 2:
The grip opening design allows dynamic rotation of the puck within the opening during the diversion process. The asymmetric shape and discrete contact points enable the puck to rotate freely rather than being constrained in a fixed orientation, which reduces frictional forces and wear while maintaining reliable gripping throughout the motion.
3Productivity
If a strong motor is used to overcome the force from multiple bearing pucks, then the diversion can be achieved, but the total power requirement for the system becomes unnecessarily high
Solution Approach 1:
The asymmetric non-circular grip opening reduces the rotational resistance and frictional forces during puck diversion, allowing a weaker motor to achieve the same diversion capability. The asymmetric geometry creates favorable mechanical conditions that reduce the torque requirement, thereby lowering the power consumption of the stationary diverter disc mechanism.
Solution Approach 2:
By changing the geometric parameters of the grip opening to create discrete contact points and allow puck rotation, the invention reduces the force requirements for diversion. This parameter optimization enables effective diversion with lower power input, reducing the total energy consumption of the conveyor system's stationary components.
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 diverter disc achieves reduced power requirements, lower wear, and safer operation by allowing the puck to rotate relative to the diverter disc, enabling the use of a weaker drive motor and eliminating the need for additional stop functions, thus improving system performance and operator safety.
Implementation Method 1
the grip opening is shaped in a non circular shape such that a plurality of discrete contact points are formed in the grip opening
Implementation Method 2
allowing the puck to rotate freely and reducing the power required for diversion by distributing contact pressure effectively
Data Source
AI summary
Diverter disc for a conveyer system, comprising a circular outer periphery and an grip opening formed in the periphery of the diverter disc, where the grip opening is adapted to hold and divert a puck comprising a circular slide ring at the contact region and that the grip opening is shaped in a non circular shape such that a plurality of discrete contact points are formed in the grip opening. The advantage of the diverter disc is that it will be able to hold the slide ring of a puck in a more secure way due to the reduced contact surface compared with a conventional diverter disc.