Helical Conveyor Buffering With Independent Drive Control
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Solution Overview
Problem
Existing spiral conveyors face challenges in maintaining a continuous and flexible flow of containers with consistent spacing, often requiring additional linear storage devices that increase cost, space, and complexity, and are prone to failures.
Innovation Solution
A conveying system with a spiral conveyor featuring two independently operable transport paths, each with its own drive and carrier, equipped with sensors and a control unit to manage container flow dynamically, allowing for flexible and responsive buffering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a linear storage device is used to buffer containers, then the continuous flow of containers can be maintained, but the space required for the system increases
Solution Approach 1:
The patent transitions from a linear storage device (one-dimensional extension) to a spiral conveyor system that utilizes three-dimensional space. By arranging transport paths in a helical configuration around machine axes, the system achieves buffering capacity without linear extension, effectively solving the space requirement contradiction while maintaining continuous container flow.
2Reliability
If a linear storage device with gripping devices is used, then containers can be buffered, but the device complexity and cost increase
Solution Approach 1:
The patent extracts and eliminates the complex gripping device mechanism from the system. Instead of using discrete gripping devices to load and unload containers from a linear storage device, the invention employs a continuous spiral conveyor system where containers are transported along helical paths, removing the need for complex mechanical gripping components while maintaining buffering capability.
Solution Approach 2:
The spiral conveyor system serves multiple functions simultaneously: it conveys containers continuously, buffers containers by storing them in the helical transport paths, and eliminates the need for separate loading/unloading mechanisms. This multi-functionality reduces overall system complexity compared to dedicated linear storage devices with gripping mechanisms.
3Quantity of substance
If a linear storage device is used, then containers can be stored, but the response time of the system increases
Solution Approach 1:
The spiral conveyor system maintains continuous operation without interruption. Containers move continuously along the helical transport paths from the inlet to the outlet, eliminating the discontinuous loading and unloading cycles inherent in linear storage devices with gripping mechanisms. This continuous action reduces response time while maintaining adequate storage capacity in the spiral paths.
Data Source
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AI summary
A conveying system 30 is described, comprising a spiral conveyor 1 for conveying containers 2 along a transport section 3 extending between a container inlet 4 and a container outlet 5. The transport section 3 has at least: a first transport section 3.1 helically enclosing a first machine axis MA1, a second transport section 3.2 helically enclosing a second machine axis MA2, and a transfer section 3.3, wherein the transfer section 3.3 extends between the first transport section 3.1 and the second transport section 3.2; at least one first and one second carrier, wherein the first carrier 14.1 can be brought into operative contact with the containers that can be arranged on the first transport section and the second carrier 14.2 can be brought into operative contact with the containers that can be arranged on the second transport section.The conveyor system 30 also comprises at least one first drive 20 for conveying containers 2 along the first transport section 3.1, wherein the first carrier 14.1 is designed to be driven by the first drive, and at least one second drive 21 for conveying containers 2 along the second transport section 3.2, wherein the second carrier 14.2 is designed to be driven by the second drive. The first drive and the second drive can be operated independently of each other. The conveyor system also includes a first sensor device 31 arranged in the area of the container inlet 4 and a second sensor device arranged in the area of the container outlet 5. The sensor devices are designed to detect the number and direction of movement of the containers entering the container inlet and exiting the container 5, respectively.Containers passing the container outlet, and for sending a signal, wherein the signal represents the detected number and the detected direction of movement of the containers, as well as a control unit 35 having a signal interface 36. The sensor devices are in signal communication with the signal interface and the control unit is configured to control the first drive and the second drive independently of each other, based on the signals transmitted by the sensor devices and based on a demand signal transmitted by a plant control system.