Dual Conveyor Sorting System for Automated Object De-stacking
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Solution Overview
Problem
Manual sorting and de-stacking of objects on conveyor belts is time-consuming and costly, requiring additional labor in warehouse and assembly line settings.
Innovation Solution
A dual conveyor sorting system comprising two conveyor belts moving at different rates and directions, with adjustable speeds, angles, and orientations, and a sensor system to detect and correct object status, including orientation and obstruction, to automate the sorting process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual sorting and de-stacking is used, then labor flexibility is maintained, but processing time increases and productivity decreases
Solution Approach 1:
The patent replaces manual mechanical sorting operations with an automated dual-conveyor system where conveyor belts mechanically separate and sort objects based on their physical properties and positions, eliminating the need for human labor in the sorting process
Solution Approach 2:
The system uses sensor feedback to automatically detect object status and adjusts conveyor parameters self-adjusting speeds, angles, and orientations to achieve sorting without external manual intervention, allowing the system to service itself through automated control
2Productivity
If additional employees are hired for manual de-stacking, then sorting capability is improved, but operational cost increases
Solution Approach 1:
The patent replaces human workers with an automated mechanical dual-conveyor system that performs de-stacking and sorting functions, eliminating the need for additional employees while maintaining or improving sorting capability
Solution Approach 2:
The system changes operational parameters such as conveyor speed, angle, and orientation to optimize sorting performance, allowing the automated system to achieve the same or better productivity without the variable costs of human labor
3Productivity
If conveyor belts move at the same speed, then synchronization is maintained, but sorting efficiency decreases
Solution Approach 1:
The patent implements dynamic speed control for each conveyor belt independently, allowing real-time adjustment of velocities based on object detection and sorting requirements, enabling efficient sorting through variable speed coordination
Solution Approach 2:
The system uses sensor feedback to monitor object status and automatically adjusts conveyor belt speeds, angles, and orientations to achieve optimal sorting, creating a closed-loop control system that adapts to changing conditions
Data Source
AI summary
Apparatuses, systems, and methods are disclosed for a dual conveyor sorting system. An apparatus includes a first conveyor belt assembly that includes a first conveyor belt moving at a first rate in a first direction. An apparatus includes a second conveyor belt assembly that includes a second conveyor belt moving at a second rate in a second direction. The first rate is faster than the second rate and the first direction is the same as the second direction. The first conveyor belt assembly is positioned along a first axis perpendicular to the second conveyor belt assembly positioned along a second axis. A first edge of the first conveyor belt assembly is positioned substantially adjacent to a first edge of the second conveyor belt assembly.