Electromagnetic Roller Conveyor for Continuous Weight Sorting
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Solution Overview
Problem
Conventional checkweighers in production lines require stopping and gapping of conveyor belts for accurate weight measurements, which slows down production and is inefficient for continuous weighing of multiple cases.
Innovation Solution
A conveyor system with electromagnetically activated rollers that divert articles based on weight by using a linear-induction motor to rotate rollers perpendicular to the belt direction, allowing for continuous operation and sorting of objects without stopping, using a side rail to guide diverted objects and sensors to measure lateral displacement for weight determination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional checkweighers are used to weigh cases, then accurate weight measurements can be obtained, but the production line must be stopped and cases must be gapped, which slows down production
Solution Approach 1:
The patent replaces the traditional mechanical stopping and gapping system with an electromagnetic roller propulsion system. The rollers use electromagnetic induction to propel cases laterally off the main conveyor based on their weight, eliminating the need to stop the production line for weighing. This substitution maintains measurement accuracy while preserving continuous production flow.
Solution Approach 2:
The patent introduces electromagnetic rollers as an intermediary mechanism between the main conveyor and the weighing/sorting function. These rollers act as a mediator that can selectively propel cases based on weight without interrupting the main conveyor's continuous operation, thus resolving the contradiction between accurate measurement and continuous production.
2Measurement precision
If cases are separated by gaps or stopped for weighing, then accurate weight measurement is possible, but production efficiency decreases
Solution Approach 1:
The patent enables continuous weighing and sorting operation by keeping the main conveyor in constant motion. The electromagnetic rollers provide continuous lateral propulsion to selected cases based on their weight, allowing the weighing and sorting function to operate continuously without stopping or gapping cases, thus eliminating time loss while maintaining measurement accuracy.
3Measurement precision
If multiple cases are weighed consecutively with stopping and gapping, then each case can be measured accurately, but the overall production speed decreases
Solution Approach 1:
The patent introduces dynamic control through electromagnetic rollers that can be activated selectively and continuously along the conveyor. This dynamic system allows different cases to be propelled at different times and positions based on their weight, enabling accurate measurement of multiple consecutive cases while maintaining constant conveyor speed and overall production flow.
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
Enables continuous and efficient weight-based quality control by sorting objects based on weight without interrupting the production line, allowing for accurate measurement and rejection of non-conforming items while maintaining high production throughput.
Implementation Method 1
WO 2013/169343 discloses conveyor rollers rotated by electromagnetic induction to propel articles conveyed atop the rollers
Implementation Method 2
The traveling flux wave induces eddy currents in the electrically conductive material of the rollers 14. The currents produce a reaction magnetic field that interacts with the stator flux wave to cause a constant torque in the rollers 14
Implementation Method 3
The currents produce a reaction magnetic field that interacts with the stator flux wave to cause a constant torque in the rollers 14
Data Source
Figure 1~6B
Figure 2A~2D
Figure 3A~3D
AI summary
A conveyor and a method for weighing conveyed objects or sorting them by weight. The conveyor comprises a conveyor belt having electrically conductive rollers that are rotated with a constant torque in a lateral direction by a linier-induction stator defining a roller-activation zone along a carryway. Because the lateral acceleration of a conveyed object is inversely proportional to the object's weight, lighter objects are displaced laterally farther and at greater speeds than heavier objects. So their weights can be determined from the lateral acceleration, speed, or displacement. And objects can be sorted off the side of the belt by weight.