Egg Handling System with Offset Solenoid Timing
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Solution Overview
Problem
Existing egg transfer systems are volume-limited and cannot accommodate increased throughput due to the controller mechanism's inability to simultaneously release eggs at desired parameters, leading to limitations in processing speed and throughput.
Innovation Solution
The system modifies solenoid/plunger and brush roll spacing to 4 inches on center, with a controller-activated offset delay for egg release, combined with extended spool bars and redesigned brush wheels with softer inner and stiffer outer bristles to ensure accurate egg trajectory and reduced migration, allowing for increased conveyor speed and volume processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the solenoid/plunger and brush roll spacing is increased to 4 inches on center to accommodate higher throughput, then the processing speed and volume capacity improve, but the precision of egg positioning and trajectory control deteriorates
Solution Approach 1:
The controller applies an offset delay to the solenoid/plunger actuation timing, anticipating the position of the egg basket relative to the brush roll. This preliminary timing adjustment compensates for the increased spacing, ensuring the egg is released at the correct moment to maintain accurate trajectory control despite the wider 4-inch spacing between components.
2Productivity
If the conveyor speed is increased to achieve higher throughput, then the processing volume improves, but the stability of egg transfer and positioning deteriorates
Solution Approach 1:
The system pre-calculates and applies an offset delay to the solenoid actuation based on the conveyor speed and basket position. This allows the egg release timing to be precisely synchronized with the moving basket's position, maintaining stable and accurate egg transfer even at increased conveyor speeds for higher throughput.
3Area of stationary object
If the spool bar length is extended to cover larger processing areas, then the system coverage and capacity improve, but the structural rigidity and egg protection deteriorate due to sagging
Solution Approach 1:
The extended spool bar is divided into multiple segments by introducing intermediate drive supports at strategic locations along its length. This segmentation prevents excessive sagging in any single span while maintaining the overall extended coverage, thus preserving both the large area capability and the structural rigidity needed to protect eggs during transfer.
Data Source
AI summary
A transfer system for providing faster and increased volume processing of eggs having an overhead positioned egg conveyor. A rotating brush wheel positioned underneath the conveyor receives eggs and includes a first and second pluralities of bristles having, respectively, lesser and greater stiffness. An egg receiving reservoir exhibits a receiving lane positioned underneath and in alignment with the brush wheel for receiving and redirecting the eggs in a lane dedicated fashion to a subsequent egg handling operation. A plurality of spool bars are arranged in parallel extending and spaced apart fashion and defining a number of individual egg conveying lanes and each further include first and second spool bar portions secured in end-to-end fashion to establish an overall dimension. First and second drive supports are arranged at opposite ends of the spool bar portions, a third drive support arranged within the egg transfer mechanism and supporting opposing and intermediate engaging ends of each pair of spool bar portions. The intermediate drive support prevents sagging of the intermediate ends of the spool bar portions.