Magnetically Actuated Conveyor Rollers for Flexible Material Handling
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Solution Overview
Problem
Conveyor belts lack efficient mechanisms for performing material handling functions such as product diversion, sorting, singulation, separation, and orientation, particularly in transferring items between conveyor belts, as existing technologies rely on mechanical means that are limited in flexibility and control.
Innovation Solution
The use of magnetically actuated rollers with switched reluctance motors, where rotors are ferrous or magnetic and encapsulated in plastic, allowing for controlled rotation within magnetic fields to perform selected material handling functions, including diversion, acceleration, and deceleration of packages between conveyor belts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If magnetically actuated rollers with switched reluctance motors are used, then material handling flexibility and control are improved, but device complexity increases
Solution Approach 1:
The patent replaces traditional mechanical drive systems with magnetic fields generated by switched reluctance motors. The stators positioned beneath the conveyor belt generate magnetic fields that actuate the rollers without mechanical contact, enabling flexible control of roller rotation for various material handling functions while eliminating complex mechanical transmission components.
Solution Approach 2:
The switched reluctance motor system provides multi-functionality by enabling the same roller array to perform multiple material handling operations including diversion, sorting, singulation, separation, orientation, and acceleration. The magnetic field can be selectively activated to rotate specific rollers for different functions, making the system universally applicable to various material handling needs.
2Measurement precision
If rollers are rotated using magnetic fields, then precision control of roller rotation is improved, but energy consumption increases
Solution Approach 1:
The switched reluctance motors utilize periodic magnetic field activation to rotate rollers. The stators are energized in sequences that create rotating magnetic fields, which periodically act on the ferrous or magnetic rotors to produce controlled rotation. This periodic magnetic actuation provides precise control while allowing energy to be applied only when needed for rotation rather than continuous energy consumption.
Solution Approach 2:
The magnetic field system provides self-service control where the magnetic fields automatically interact with the ferrous or magnetic rotors to produce rotation without requiring additional mechanical control mechanisms. The rotors are naturally attracted to and rotated by the magnetic fields generated by the stators, enabling precise control through magnetic field modulation alone.
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 precise and efficient material handling by allowing rollers to rotate transversely or obliquely, facilitating smooth transfer and alignment of articles between conveyor belts, enhancing flexibility and control over material flow.
Implementation Method 1
Stators positioned to couple magnetic fields to the rotors of the rollers form switched reluctance motors with the rotors. The rollers are controlled by the switched reluctance motors to rotate about their axes of rotation as the rollers encounter the magnetic fields produced by the switched reluctance motors.
Implementation Method 2
Stators positioned to couple magnetic fields to the rotors of the rollers form switched reluctance motors with the rotors.
Implementation Method 3
A permanent magnet or electromagnet will attract a soft magnet material such as iron or steel by virtue of the lines of magnetic flux achieving the path of least resistance. (Resistance to magnetic flux is called reluctance.)
Data Source
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AI summary
A modular conveyor belt and method provides a conveyor belt having rollers with metallic or magnetic rotors (20). A magnet or metallic element next to the conveyor belt is positioned to rotate the rotor (20). A magnetic field (45) produced by the magnet or by the magnetic rotor rotates the rollers as they pass the magnetic field (45) or as the magnetic field (45) is changed. In one embodiment, the magnetic field (45) is in the form of one or more switched reluctance motors.