Locking Cam Diverter Gate Assembly for Mail Sorting
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Solution Overview
Problem
Downstream Diverter Gate Assemblies in automatic sorting machines are prone to overdriving when faced with larger articles or higher transport speeds, leading to inefficiencies and increased maintenance costs due to jamming issues and the need for manual rerouting of articles.
Innovation Solution
The Locking Cam Diverter Gate Assembly features a unique design with interlocking subassemblies, including a Diverter Gate with Locking Cam Subassembly and a Solenoid with Cam Bearing Subassembly, which absorbs impact forces through a kidney-shaped locking cam guide slot and isolates the diverter gate from direct solenoid shaft mounting, allowing for efficient diversion of articles without overdriving.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a Downstream Diverter Gate Assembly is used to eliminate timing issues and prevent spearing, then article sorting reliability is improved, but the diverter gate becomes prone to overdriving when struck by larger articles or articles traveling at higher transport speeds
Solution Approach 1:
The patent applies the Dynamics principle by making the diverter gate movable and adjustable rather than fixed. The gate can be positioned at different angles and depths to adapt to varying article sizes and transport speeds, allowing it to efficiently divert smaller articles while resisting overdriving from larger ones. The solenoid mechanism enables dynamic repositioning of the gate to optimize its diverting capability for different sorting conditions.
Solution Approach 2:
The patent implements Parameter changes by modifying the physical parameters of the diverter gate system, including the gate's angle, position, and material properties. The solenoid actuator changes the gate's position parameter dynamically, while the kidney-shaped slot modifies the mechanical parameters of the mounting system to allow controlled movement and absorption of impact forces from overdriving articles.
2Device complexity
If the diverter gate is mounted directly on the solenoid shaft to simplify the structure, then device complexity is reduced, but the gate becomes vulnerable to overdriving and jamming
Solution Approach 1:
The patent applies theIntermediary (Mediator) principle by introducing a kidney-shaped slot as an intermediate element between the solenoid shaft mounting and the diverter gate. This slot acts as a mediator that absorbs and redistributes impact forces from articles, preventing direct transmission of overdriving forces to the solenoid mechanism while still allowing the gate to be effectively positioned by the solenoid during normal operation.
3Strength
If the diverter gate is made stronger to resist overdriving, then resistance to impact forces is improved, but the ability to efficiently divert smaller articles may be compromised
Solution Approach 1:
The patent resolves this contradiction through Dynamics by making the diverter gate dynamically adjustable rather than statically strong. The gate uses a lightweight design that can be quickly positioned by the solenoid to efficiently divert smaller articles, while the kidney-shaped slot and mounting mechanism provide the necessary impact resistance when subjected to overdriving from larger articles, eliminating the need for a consistently heavy-duty gate design.
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 design effectively prevents overdriving and jamming, ensuring reliable operation at higher transport speeds by absorbing impact forces and maintaining efficient article diversion, reducing maintenance costs and downtime.
Implementation Method 1
a vane, mounted on the shaft of a solenoid. When the Control Electronics energizes the solenoid, it pivots the vane to block the travel path
Implementation Method 2
absorbs impact forces through a kidney-shaped locking cam guide slot
Data Source
AI summary
A downstream diverter for processing mail at high speeds, the diverter is positioned on a mail sorter machine, so that the force of the mail as it is sorted is isolated from the solenoid driving the diverter.