Linear Motor Sorter with Carts for High-Speed Product Diversion
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Solution Overview
Problem
Current linear transport systems in automated packaging lines are inefficient for high-speed sorting and diversion of products, particularly in the food industry, as they can only handle objects at constant speeds and lack the ability to selectively engage products based on desired criteria, leading to slow processing and waste due to improper packaging and defective product handling.
Innovation Solution
A processing system with an infeed conveyor, a main conveyor with multiple lanes, and diverters equipped with linear motors and carts that can move products between lanes based on detected properties using a control system, allowing for high-speed sorting and diversion by aligning scoops with products and moving them between lanes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional linear track devices are used for product sorting, then the system structure is simple, but the sorting speed is slow and cannot handle high-speed product flow
Solution Approach 1:
The patent applies the dynamics principle by making the conveyor system adjustable and flexible. The conveyor belt can be dynamically configured with variable speed sections, and the diverters can be positioned at different locations along the conveyor. This allows the system to adapt to different product speeds and sorting requirements, resolving the contradiction between simplicity and high-speed capability.
Solution Approach 2:
The patent segments the conveyor system into multiple independent sections with different speeds and characteristics. Instead of a single uniform conveyor, the system divides the transport path into segments that can operate at different velocities, allowing high-speed sorting while maintaining overall system manageability.
2Adaptability or versatility
If linear track devices maintain constant speed operation, then the device operation is simple, but the ability to selectively engage products based on criteria is lost
Solution Approach 1:
The system dynamically adjusts conveyor speed and diverter positioning based on real-time product detection. When products are detected at specific locations, the system dynamically changes operational parameters to engage or divert them, providing selective engagement capability while maintaining automated operation.
Solution Approach 2:
The patent incorporates feedback mechanisms where sensors detect product properties and position, and this information feeds back to the control system. The control system then adjusts conveyor speed and diverter positioning accordingly, enabling selective engagement based on product criteria while automating the operation.
3Reliability
If traditional sorters are used, then the device structure is straightforward, but defective products cannot be efficiently removed and time is wasted on damaged products
Solution Approach 1:
The system performs preliminary detection and sorting of defective products early in the conveyor process. By detecting product defects and diverting them to separate collection points before they reach the packaging stage, the system eliminates time waste on processing defective items further and improves overall reliability.
Solution Approach 2:
The conveyor system segments the product flow into different paths: one for acceptable products and another for defective products. This segmentation allows defective items to be efficiently separated and removed from the main processing line, preventing time waste on further processing of damaged products.
4Productivity
If pieces are connected due to wrapping machine failure, then the packaging process continues, but the sorting ability is limited and pieces cannot be moved between lanes
Solution Approach 1:
The system dynamically adjusts conveyor speed and diverter positioning to handle connected pieces. When pieces are detected as connected, the system dynamically modifies operational parameters to safely move them between lanes without breaking the connection, maintaining processing continuity while enabling piece diversion capability.
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 high-speed sorting and diversion of products based on properties like size, color, or position, improving efficiency and reducing waste by accurately directing products to correct lanes, enhancing the overall processing speed and flexibility in packaging lines.
Implementation Method 1
Each diverter includes a linear motor with carts connected to the linear motor
Data Source
AI summary
A processing system for packaging pieces of product utilizing high-speed sorting includes an infeed conveyor for supplying the pieces of food product and a linear motor sorter is connected to the infeed conveyor. The sorter includes a main conveyor with several lanes for moving the pieces of food product, with one of the lanes being a first lane which receives the pieces of food product. The sorter also has one or more diverters for diverting determined ones of the pieces of food product from the first lane to at least one other lane. The sorter includes a linear motor and carts connected to the linear motor and is configured to move the pieces of food between the lanes.