Level Right Angle Transfer Module for Retail Logistics
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Solution Overview
Problem
Retail supply chains face inefficiencies in product transfer systems, particularly in maintaining a level and perpendicular product flow, which can lead to bottlenecks and product jams due to the need for flexible handling of various shapes and sizes without altering the product's orientation.
Innovation Solution
A transfer module with nested shuttles and a cam system that synchronizes the vertical motion of rollers and pulleys, allowing products to enter and exit at the same height while being redirected in multiple directions without lifting or lowering, using camshafts with out-of-phase cams to alternately raise and lower the shuttles and maintain a consistent product plane.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional product transfer systems are used to redirect products at 90 degree angles, then direction change is achieved, but products are lifted and lowered causing the 'water-fall effect' and reducing transfer efficiency
Solution Approach 1:
The transfer module maintains products at a constant elevation throughout the 90-degree transfer process. The nested shuttles with rollers and pulleys move products horizontally without vertical displacement, eliminating the water-fall effect and ensuring smooth, continuous product flow at equipotential level.
Solution Approach 2:
The invention achieves 90-degree direction change through horizontal movement in two perpendicular dimensions rather than vertical movement. The nested shuttle mechanism allows product flow to transition from one horizontal plane to another at the same elevation, avoiding vertical lifts and lowers.
2Adaptability or versatility
If flexible handling of various product shapes and sizes is implemented, then adaptability is improved, but system complexity increases due to multiple handling requirements
Solution Approach 1:
The nested shuttle mechanism with rollers and pulleys serves multiple functions: it handles various product shapes and sizes, achieves 90-degree direction change, maintains constant product elevation, and provides synchronized motion control. This universal mechanism eliminates the need for multiple specialized handling devices.
Solution Approach 2:
The transfer module employs nested shuttles where one shuttle is positioned within another, allowing compact arrangement of multiple functional elements. The nested structure enables complex synchronized motion patterns while maintaining a compact footprint and reducing overall system complexity.
3Productivity
If nested shuttles with cam systems are used to maintain level product transfer, then transfer efficiency is improved, but device complexity increases
Solution Approach 1:
The invention merges the direction change function, elevation maintenance function, and synchronization function into a single integrated nested shuttle mechanism. The cam systems control both shuttles simultaneously, combining multiple control functions into unified mechanical elements that improve productivity without proportionally increasing complexity.
Solution Approach 2:
The cam-driven nested shuttle system automatically maintains synchronized motion and constant product elevation through mechanical self-regulation. The out-of-phase cam configuration ensures that as one shuttle moves, the other compensates, maintaining level product transfer without requiring external active control for each individual component.
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 ensures smooth and efficient product transfer by maintaining products at a consistent height, reducing the 'water-fall effect' and enabling flexible direction changes, thereby enhancing the speed and accuracy of product handling in retail supply chains.
Implementation Method 1
A transfer module with nested shuttles and a cam system that synchronizes the vertical motion of rollers and pulleys
Data Source
AI summary
Enclosed herein are embodiments of a product transfer module and product transfer systems. In one embodiment, a product transfer module comprises a first shuttle, the first shuttle including a plurality of rollers, wherein the plurality of rollers are connected by one or more belts and includes a plurality of driven rollers and at least one driving roller; a second shuttle, the second shuttle including a plurality of rows of pulleys and a pulley drive positioned beneath the plurality of pulleys; and a cam system for raising and lowering the first and second shuttles; wherein the first shuttle directs product flow along a first flow path and the second shuttle directs product flow in a second flow direction.