Irregular Roller Conveying Device for Logistics Sorting
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Solution Overview
Problem
Existing conveying devices for logistics sorting and object transportation are complex, costly, and energy-intensive, with high labor costs and inefficiencies in sorting and transportation processes.
Innovation Solution
A conveying device with a simple structure, utilizing a combination of regular and irregular rollers or conveyor belts, driven by DC motors, featuring a roller axle support system and eccentric cross-section rollers that allow for flexible movement and low-cost operation, enabling efficient sorting and transportation of a wide range of goods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional conveying devices are used for logistics sorting and object transportation, then the transportation function is achieved, but the structure becomes complex, cost increases, and energy consumption rises
Solution Approach 1:
The conveying device is divided into multiple independent conveying channels, each capable of autonomous operation. The frame structure supports multiple channels that can be independently configured and adjusted, allowing the system to handle different sorting requirements without requiring a complete system redesign, thus reducing overall complexity while maintaining high sorting efficiency
Solution Approach 2:
The conveying device is designed with universal components that can serve multiple functions. The same frame structure and channel design can accommodate different types of objects and sorting configurations. The irregular rollers and adjustable channels can adapt to various transportation needs, eliminating the requirement for multiple specialized devices and reducing structural complexity
2Ease of manufacture
If conventional conveying devices are used, then transportation is achieved, but production cost and manufacturing cost increase
Solution Approach 1:
The device employs simple, easily manufactured components such as irregular rollers made from common materials and modular channel sections that can be produced at low cost. These components are designed for ease of fabrication using standard manufacturing processes, reducing production costs while maintaining sufficient reliability for sorting operations
Solution Approach 2:
The conveying channels and roller configurations can be adjusted by changing geometric parameters such as channel width, roller diameter, and spacing. This allows the same basic structure to be adapted for different sorting requirements without requiring completely different manufacturing processes, thereby reducing both manufacturing cost and ensuring reliable performance across various applications
3Use of energy by moving object
If conventional conveying devices are used, then transportation is achieved, but energy consumption increases
Solution Approach 1:
The conveying device utilizes periodic motion through the rotation of irregular rollers, which naturally create alternating contact and release phases for objects. This periodic action reduces the continuous energy input required compared to conventional continuous-motion systems, while the adjustable channel configurations maintain operational flexibility for different sorting patterns
Solution Approach 2:
The irregular roller design allows objects to be passively directed and sorted through their own weight and the geometric configuration of the rollers, rather than requiring active propulsion for every object. The system uses gravity and mechanical geometry to perform sorting functions, reducing energy consumption while maintaining ease of operation through simple roller rotation
4Ease of operation
If irregular rollers with eccentric cross-section are used, then flexible movement and smooth sorting are achieved, but device complexity increases
Solution Approach 1:
The rollers are designed with asymmetric irregular cross-sections that create natural variation in contact points with objects during rotation. This asymmetry provides flexible movement and smooth sorting by allowing objects to be gently guided and redirected based on their position and orientation, while the roller shape itself remains a simple geometric form that does not complicate the overall device structure
Solution Approach 2:
Instead of using complex mechanical mechanisms to achieve flexible movement and object redirection, the invention inverts the approach by using the simple geometric shape of the rollers themselves to create the desired motion effects. The irregular cross-section does the work of flexible guidance that would otherwise require complex articulated mechanisms, thereby reducing overall device complexity
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
The device achieves high sorting efficiency, low production costs, and flexible movement, capable of handling a wide range of goods with smooth sorting and transportation, while being driven by ordinary DC motors, reducing energy consumption and labor costs.
Implementation Method 1
the cross-section of the irregular roller perpendicular to a rotation center line of the irregular roller is non-circular or eccentric, and the non-circular cross-section is substantially an ellipse, a regular polygon or another shape; a rotation center line of the eccentric cross-section does not pass through its center
Implementation Method 2
the roller axles of the irregular rollers are provided on the frame via a roller axle support system
Data Source
AI summary
A conveying device including a frame, a transportation channel, and a branch conveying mechanism, the transportation channel and the branch conveying mechanism are driven by their respective driving units, and the transportation channel is provided with a number of rows of regular rollers, or at least a conveyor belt, or a combination of regular rollers and a conveyor belt, the branch conveying mechanism includes at least one group of irregular rollers, when the irregular roller rotates, the highest point of a top of the roller is higher than an upper surface of an adjacent transportation channel during the rotation, and the lowest place of a top horizontal plane of the roller is lower than the upper surface of the adjacent transportation channel; when the irregular roller does not rotate, the top of the roller substantially stops at the lowest place of the top horizontal plane of the roller during rotation; the transportation channel and the branch conveying mechanism are provided alternately.