Dynamic Gapping Conveyor Flight Spacing Control
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Solution Overview
Problem
Existing conveyor systems fail to dynamically control the spacing between objects of varying sizes, leading to inefficiencies in downstream processing such as sorting, as they cannot ensure only one object is on a diverter section at a time without maintaining the smallest possible gap between packages.
Innovation Solution
A dynamic gapping conveyor system utilizing flexible flights independently driven by drivers, which control the spacing between objects by varying the speed and position of these flights based on object length measurements, ensuring accurate diversion by creating a selected gap between objects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed gapping conveyor is used to space objects, then the conveyor structure is simple, but it cannot dynamically adjust spacing for objects of varying sizes
Solution Approach 1:
The patent applies dynamics by making the flight position adjustable along the conveying direction. The flight can be moved between a first position (closer to the object) and a second position (farther from the object), allowing dynamic adjustment of the gap created for objects of different sizes. This resolves the contradiction by enabling spacing adaptability while maintaining a relatively simple conveyor structure through localized adjustability rather than complete system complexity.
Solution Approach 2:
The conveyor system is segmented into distinct functional components: the conveying surface, the flight, and the positioning mechanism. The flight is separated as an independent element that can be positioned at different locations, allowing it to perform the specific function of creating gaps without complicating the entire conveyor system. This segmentation enables adaptability while controlling overall device complexity.
2Measurement precision
If the gap between packages is increased to ensure only one package on diverter section, then sorting accuracy is improved, but the spacing between packages increases reducing efficiency
Solution Approach 1:
The patent applies local quality by creating a localized gap only at the specific location where the flight intercepts the object, rather than increasing the overall spacing between all packages. The flight creates a precise, localized separation that ensures accurate diversion while maintaining minimal gap elsewhere, thus preserving processing efficiency. This resolves the contradiction by achieving diversion accuracy through localized intervention rather than global spacing increase.
3Manufacturing precision
If multiple flights are used to control spacing of objects with different lengths, then spacing precision is improved, but the device complexity increases
Solution Approach 1:
The patent applies dynamics by enabling a single flight to be dynamically positioned at different locations along the conveying direction based on object length. Rather than requiring multiple fixed flights for different object sizes, one flight can be moved to the appropriate position, achieving precise spacing control while reducing the number of physical components needed. This resolves the contradiction by improving spacing precision through dynamic repositioning rather than multiplying the number of flights.
Data Source
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Figure 3
Figure 4A~4C
AI summary
A conveying system employs independently controlled flights. The flights are controlled separately from a conveying surface. The conveying system includes a dynamic gapping conveyor for spacing conveyed objects in a selected manner. The dynamic gapping conveyor uses flexible flights independently driven by drivers to control the spacing between conveyed objects. The independent drivers allow the position of the flights to be controlled based on the length of a conveyed object.