Eddy Current Braking for Modular Conveyor Accumulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Modular belting systems face challenges in accumulating products without excessive backline pressure and damaging high friction products, with existing solutions either requiring large rollers or complex assembly processes.
Innovation Solution
A conveying assembly with a continuous belt of modules featuring roller axle supports and an accumulation zone utilizing eddy current braking to selectively manipulate the movement of objects, allowing for reduced friction and easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If rollers are rotatably mounted directly on the hinge pin connecting modules together, then backline pressure is reduced during accumulation, but the roller diameter becomes excessively large and pin wear increases
Solution Approach 1:
The system separates the roller support function from the hinge pin by introducing a dedicated roller support mechanism. The roller is mounted on a support structure that is distinct from the hinge pin connection, allowing the roller diameter to be optimized for accumulation without being constrained by the hinge pin location. This segmentation resolves the contradiction by enabling independent optimization of both the connection mechanism and the accumulation mechanism.
Solution Approach 2:
A roller support structure acts as an intermediary between the module frame and the roller. This intermediary component provides a dedicated mounting point for the roller that is not constrained by the hinge pin location, allowing the roller to be positioned optimally for reducing backline pressure during accumulation while maintaining a reasonable diameter.
2Force
If rollers are supported by roller cradles between modules, then backline pressure is reduced, but assembly complexity increases due to multiple components and fastening requirements
Solution Approach 1:
The roller support structure is integrated with the module frame as a unified component rather than being a separate assembly. The support structure is formed as part of the module construction, eliminating the need for separate cradles, axles, and fastening operations. This merging reduces assembly complexity while maintaining the ability to reduce backline pressure during accumulation.
Solution Approach 2:
The roller support structure serves multiple functions: it provides structural support for the module, enables roller rotation for product contact, and facilitates easy assembly through integration with the frame. This multi-functionality reduces the number of separate components needed, thereby reducing assembly complexity while maintaining accumulation capability.
3Ease of manufacture
If hinge pins support rollers between hinge members, then module connection is simplified, but undesirable pin wear occurs
Solution Approach 1:
The roller support function is extracted from the hinge pin, allowing the hinge pin to focus solely on its primary function of connecting modules. The hinge pin is no longer required to support the roller, which eliminates the wear caused by roller mounting while maintaining simplified module connection through the hinge pin mechanism.
Solution Approach 2:
A dedicated roller support structure serves as an intermediary that carries the roller load, separating this function from the hinge pin. The hinge pin continues to provide simplified module connection, while the intermediary support structure handles roller mounting, preventing pin wear while maintaining ease of manufacture.
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 effectively reduces backline pressure and minimizes product damage by using roller axle supports and eddy current braking, enabling precise control over the accumulation zone and reducing pin wear, while allowing for easy assembly and operation.
Implementation Method 1
an accumulation zone defined along the path and arranged to interact with the modules via eddy current braking to affect the movement of the object along the path
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An accumulation system for a conveyor that supports an object for movement along a path. The accumulation system including a clutch mechanism that selectively manipulates the operation of the conveyor via eddy currents to affect the movement of the object. One embodiment provides a conveying assembly that includes a plurality of modules including a body having a top surface, a driven axle mounted to the body for conveyance therewith, a roller fixed to the driven axle, and a rotor fixed to the driven axle. An electromagnet defines a gap through which the rotor is sized to pass, and is arranged to be selectively energized such that a magnetic field is produced through the gap. The electromagnet and the rotor are configured such that an eddy current is formed in the rotor as the rotor passes through the gap to affect rotation of the driven axle.