Magnetic Conveyor Layout for Quiet Article Alignment and Diversion
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Solution Overview
Problem
Conventional roller-belt and slat conveyors are noisy due to rollers and shoe mechanisms, which also contribute to noise pollution.
Innovation Solution
A magnetic conveyor system utilizing an array of stator elements with electromagnetic flux waves to propel movers with permanent magnets, forming an endless conveying path with reversible segments, allowing for quiet operation and precise article alignment and diversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If roller-belt conveyors or slat conveyors are used to convey articles, then articles can be aligned, gapped, and diverted, but the rollers and shoe mechanisms generate significant noise
Solution Approach 1:
The patent replaces the mechanical roller-belt or slat conveyor system with an electromagnetic propulsion system. Stator elements generate electromagnetic flux waves that interact with permanent magnets in movers to propel articles without contact-based mechanical components. This substitution eliminates the noise generated by rollers and shoe mechanisms while maintaining the ability to convey, align, and divert articles through controlled electromagnetic forces.
Solution Approach 2:
The patent introduces electromagnetic flux waves as an intermediary between the power source and the articles. The stator elements generate these flux waves that travel along the conveying path and interact with the permanent magnets in movers, providing a noiseless medium for force transmission. This intermediary approach allows article manipulation without direct mechanical contact that would generate noise.
2Productivity
If rollers and shoe mechanisms are used for article manipulation, then conveying functions are achieved, but device complexity increases due to additional actuation mechanisms and guide tracks
Solution Approach 1:
The patent replaces complex mechanical actuation mechanisms and guide tracks with a simplified electromagnetic system. The stator elements, when energized in specific sequences, can propel movers forward, redirect them sideways, or reverse their direction without requiring separate mechanical actuators or physical guide tracks. This integration of multiple functions into a single electromagnetic system reduces overall device complexity.
Solution Approach 2:
The stator elements are designed to perform multiple functions through different energization patterns. The same stator elements can generate flux waves for forward propulsion, lateral diversion, or reverse movement by simply changing the activation sequence of the coils. This multi-functionality eliminates the need for separate mechanical mechanisms for each operation, reducing device complexity while maintaining productivity.
3Productivity
If conventional mechanical conveyors are used, then articles can be conveyed and manipulated, but noise levels increase due to mechanical contact and friction
Solution Approach 1:
The patent replaces mechanical contact-based conveyance with electromagnetic field-based propulsion. The interaction between the electromagnetic flux waves from the stators and the permanent magnets in movers creates force without physical contact or friction. This eliminates the noise generated by mechanical contact while maintaining the ability to convey and manipulate articles effectively.
Solution Approach 2:
The electromagnetic flux wave serves as a noiseless intermediary that transfers energy and momentum from the stator system to the movers without mechanical contact. This intermediary field allows for article manipulation without the friction and impact noises characteristic of conventional mechanical conveyors, achieving quiet operation while maintaining productivity.
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 magnetic conveyor system effectively conveys articles with reduced noise, precise alignment, and selective diversion, enhancing operational efficiency and quietness.
Implementation Method 1
The stator elements are energizable to produce electromagnetic flux waves. Movers have permanent magnets with magnetic fields that interact with the electromagnetic flux waves to move along and across the conveying path
Implementation Method 2
Movers have permanent magnets with magnetic fields that interact with the electromagnetic flux waves to move along and across the conveying path
Data Source
AI summary
A magnetic conveyor (30) comprising article-supporting movers (80) propelled by an array of stator elements (72) arranged in rows and columns. The movers include permanent magnets (82) whose magnetic fields interact with electromagnetic waves produced by the stator elements. Some of the stator elements produce electromagnetic waves that travel parallel to a conveying direction and others produce electromagnetic waves that can be controlled to travel in any direction. Movers are arranged in a formation of rows and columns in a staging area. An article (34) is transferred onto a group of movers in forward rows of the formation in the staging area. The group separates from the staging area as it conveys the article in the conveying direction. Stator elements are energized to replenish the staging area with movers to fill the gaps left by the article-conveying group of movers.