Flexible Conveyor Power Bus for Complex Track Courses
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Solution Overview
Problem
Conventional conveyor systems face limitations in implementing complex conveyor track courses, such as curved, inclined, and helical paths, due to rigid conductor rail arrangements, which restrict the flexibility of motorized rollers and make it difficult to achieve these configurations.
Innovation Solution
The conveyor system employs current conductors with a form factor between 0.88 and 1.00, made from easily bendable materials like PVC-U, and uses a connecting cable with spring-loaded contacts that can be plugged into connection boxes, allowing for flexible placement and reduced contact resistance, enabling the implementation of complex track courses and flexible roller placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional rigid conductor rails are used, then the structure is simple and easy to manufacture, but the conveyor system cannot easily implement complex track courses such as curved, inclined, and helical paths
Solution Approach 1:
The patent applies this principle by using flexible conductor cables instead of rigid conductor rails. The cables can be bent and routed to create complex track courses including curved, inclined, and helical paths, while maintaining electrical connectivity throughout the conveyor system.
Solution Approach 2:
The patent implements dynamics by making the conductor arrangement adaptable and flexible rather than fixed and rigid. The cable-based system can be dynamically configured to match various conveyor track geometries, allowing the same basic system to serve multiple track layout requirements.
2Adaptability or versatility
If rigid conductor rails are used, then the installation is straightforward, but the motorized rollers cannot be flexibly placed at various positions along the conveyor track
Solution Approach 1:
The flexible cable system allows motorized rollers to be placed at any position along the conveyor track, as the cables can be routed to reach any location. This eliminates the constraint of fixed roller positions that would be required with rigid conductor rails.
Solution Approach 2:
The system transitions from a static, fixed-position conductor rail arrangement to a dynamic, flexible cable system that can accommodate roller placement at any desired location along the track, enabling versatile system configuration.
3Loss of energy
If conventional conductor connections are used, then the assembly is simple, but the contact resistance is high and current transfer efficiency is reduced
Solution Approach 1:
The patent applies segmentation by dividing the connection system into modular components: cable segments with standardized connectors. This allows for optimized contact interfaces at each connection point, reducing contact resistance through dedicated electrical contacts while maintaining overall system simplicity through modular assembly.
Solution Approach 2:
The patent uses an intermediary connector system that provides optimized electrical contact between cable segments. These connectors serve as intermediaries that ensure low contact resistance and efficient current transfer, bridging the connection points between flexible cable sections.
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 allows for the easy realization of complex conveyor track courses, including curved and helical paths, while ensuring flexible motorized roller placement and efficient current transfer, as the conductors exhibit consistent bending behavior and the contact system compensates for unevenness.
Implementation Method 1
The plugs comprise contacts that spring-loaded around the conductors
Data Source
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AI summary
The invention relates to a conveyor system (1) comprising two spaced-apart frame profiles (2, 3), several motorized conveyor rollers (4) arranged between them, an insulator (19) extending along at least one frame profile (2) with several longitudinally open receptacles, and several conductors (20) arranged in the insulator, which are electrically connected to the drive electronics of the conveyor rollers (4), wherein one conductor (20) is mounted in each receptacle. The form factor f of a conductor, which is defined as the quotient of the circumference of a circle with an area equivalent to the cross-section of the conductor and the circumference of said cross-section of the conductor, is selected in the range of f = 0.88 to f = 1.00. The insulator comprises several longitudinally open receptacles, and one conductor is mounted in each receptacle. The insulator with the open receptacles and the conductors forms a power supply bus (15).It is provided that different sections of the power supply bus are connected to each other via a connecting cable (16), the connecting cable being equipped with plugs (17, 18) which can be inserted into connection boxes (11). The plugs comprise contacts (25) that spring-loadedly grip the current conductors.