Electro-adhesion Sorter Drive Eliminates Mechanical Wear
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Solution Overview
Problem
Existing sorter drive systems experience noise, wear, and alignment issues due to the need for significant upward force against slats, which is mitigated by using lugs or cleats but results in tight tolerances that are difficult to maintain as wear occurs.
Innovation Solution
An electro-adhesion system is integrated with an endless drive member to increase attraction between the drive member and travelling members, reducing the required force and eliminating the need for lugs or cleats by providing continuous and constant attraction through a single zone of energization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If significant upward force is applied by the belt against the slats, then thrust force is achieved, but noise and wear increase
Solution Approach 1:
The patent replaces the conventional mechanical friction-based drive system with an electro-adhesive drive system. Electro-adhesive pads mounted on the belt surface generate electrostatic attraction forces to propel the slats, eliminating the need for high mechanical friction forces that cause noise and wear. The electro-adhesive mechanism provides sufficient thrust force through electrical fields rather than mechanical contact pressure.
Solution Approach 2:
The invention changes the fundamental parameter of force generation from mechanical friction (requiring high normal force) to electrostatic attraction (requiring electrical field strength). This parameter change allows thrust force to be achieved without the harmful side effects of high mechanical contact forces, thereby reducing noise and wear while maintaining effective slat propulsion.
2Force
If lugs or cleats are added to the belt to reduce upward force requirement, then force requirement is reduced, but alignment tolerances become tight and difficult to maintain
Solution Approach 1:
By replacing the mechanical lug/cleat engagement system with an electro-adhesive system, the patent eliminates the tight alignment tolerance requirements. The electro-adhesive pads can engage the slat surfaces without requiring precise mechanical alignment, as the electrostatic field can accommodate minor position variations while maintaining effective force transmission.
Solution Approach 2:
The change from mechanical interlocking (lugs/cleats requiring precise alignment) to electrostatic attraction allows for greater tolerance in positioning. The electro-adhesive force is distributed across the contact area and does not depend on precise point-to-point alignment, thereby relaxing manufacturing and maintenance tolerance requirements.
3Force
If lugs or cleats are used on the belt, then upward force requirement is reduced, but wear causes tolerance exceedance and performance degradation
Solution Approach 1:
The electro-adhesive system replaces the wear-prone mechanical lugs/cleats with electrostatic pads that have no mechanical contact wear. This substitution maintains the reduced upward force requirement while eliminating the reliability issue of tolerance degradation over time, as electro-adhesive components do not suffer from mechanical wear that would compromise alignment.
Solution Approach 2:
The electro-adhesive system provides continuous and consistent force application without the intermittent slippage and variable engagement that occurs with worn mechanical lugs or cleats. This continuity maintains reliable performance over time, as the electro-adhesive properties do not degrade through normal operation in the same way mechanical contact surfaces do.
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
This solution reduces noise and wear while maintaining alignment, allowing for efficient propulsion of sorter slats without the need for lugs or cleats, ensuring consistent thrust force and improved system performance.
Implementation Method 1
The electro-adhesion system increases attraction of the endless drive member and the travelling members
Data Source
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AI summary
A sorter drive for propelling travelling members of a sorter along a path, in which the sorter has a plurality of interconnected travelling members that travel along a path and sortation members carried by the travelling members, with the sortation members adapted to discharge articles to particular destinations, according to an aspect of the invention, includes an endless drive member and an electro-adhesion system. The endless drive member engages the travelling members. The electro-adhesion system increases attraction of the endless drive member and the travelling members.