Electric Motor Suction Pad Control for Aluminum Sheet Separation

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Solution Overview

Problem

Conventional material separation devices, particularly those using air cylinders for suction pads, fail to adequately reduce the incidence of taking up double sheets during the separation of non-ferrous materials like aluminum sheets.

Innovation Solution

A material separation device equipped with an electric motor-driven suction component that controls suction pads to specific positions with adjustable speed and acceleration, allowing for precise control to minimize double sheet uptake, including the use of input components to customize separation based on material conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If air cylinders are used to drive suction pads, then the device structure is simple, but the incidence of taking up double sheets cannot be sufficiently reduced

Engineering Contradiction:

Improvedevice structureVSAvoidseparation accuracy

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent replaces the conventional air cylinder (pneumatic system) with an electric motor-driven system. The electric motor drives a screw mechanism that converts rotational motion into linear motion of the suction pads. This substitution enables precise control of the suction pad's movement speed and acceleration, allowing the system to reduce double sheet uptake by carefully controlling the separation process dynamics.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces dynamic control capabilities through the electric motor and screw mechanism, which can adjust the speed and acceleration of the suction pads during the separation process. By dynamically controlling the movement parameters (speed, acceleration, deceleration), the system adapts to different material conditions and optimizes the separation process to prevent double sheet uptake, unlike the static air cylinder system.

Inventive Principle:

Principle #15Dynamics

2Productivity

If suction pads are raised quickly to increase processing speed, then productivity increases, but the incidence of taking up double sheets increases

Engineering Contradiction:

Improveprocessing speedVSAvoidseparation accuracy

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent employs periodic action through the screw mechanism, which converts continuous rotational motion into periodic linear motion of the suction pads. The screw mechanism naturally provides acceleration and deceleration phases during each rotation cycle, creating a periodic motion pattern. This allows the system to achieve high processing speeds while maintaining separation accuracy, as the periodic acceleration and deceleration prevent sudden movements that could cause double sheet uptake.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The patent changes the motion parameters (speed, acceleration, deceleration) of the suction pads by adjusting the electric motor's rotational speed and the screw mechanism's pitch. By optimizing these parameters, the system achieves a balance between processing speed and separation accuracy, allowing fast processing while minimizing double sheet uptake through controlled motion dynamics.

Inventive Principle:

Principle #35Parameter changes

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

Significantly reduces the incidence of taking up double sheets, especially with non-ferrous materials, while allowing for optimized processing speed and separation efficiency by adjusting suction pad speed and acceleration according to material viscosity and other conditions.

Implementation Method 1

The blower blows air at the sheets of material placed on the placement component to float at least part of the uppermost sheet

Methodology Applied

Scientific EffectAir flow: Fluid Spray

Implementation Method 2

The suction component has a plurality of suction pads and uses these suction pads to chuck and hold the uppermost sheet of material from above

Methodology Applied

Scientific EffectSuction: Suction

Data Source

PatentUS10471495B2Material separation device and material separation method

Publication Date: 2019.11.12 KOMATSU SANKI

AI summary

A material separation device comprises a placement component, a blower, a suction component, a suction pad driver, and a controller. The blower blows air at a plurality of aluminum sheets that have been stacked on the placement component to float an uppermost aluminum sheet. The suction component uses suction pads to chuck and hold the uppermost aluminum sheet from above while the air is being blown. The suction pad driver drives the suction component up and down, using servomotors as a drive source. The controller performs control so that the suction pads chucking the aluminum sheet are raised to a temporary stopping position by the suction pad driver, and the suction pads are stopped for a predetermined length of time at the temporary stopping position while the air is stopped, and the suction pads are then raised by the suction pad drivers to a conveyance position.