Matrix Conveyor Roller Modules for Sorting and Palletizing
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Solution Overview
Problem
Existing conveyor systems, such as the WAVE system, face issues with high adhesive friction, limited conveying velocity, complex control requirements, low simultaneous handling capacity, and inability to rotate goods at a single spot, making them unsuitable for tasks like sorting and forming load arrangements.
Innovation Solution
A matrix conveyor with a regular grid structure and individual roller modules, each with all-side wheels, that can be driven in specific directions, allowing for flexible path planning and simultaneous handling of multiple goods, including rotational movements, with a decentralized control system for efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a conveying membrane is used to push conveying goods, then the goods can be transported along a path, but the adhesive friction between the membrane and goods limits conveying velocity and requires complex control
Solution Approach 1:
The conveying system is divided into discrete roller modules arranged in a grid, where each module can be independently controlled. This segmentation replaces the continuous membrane approach with modular units, simplifying control while enabling higher speeds through parallel operation of multiple modules.
Solution Approach 2:
The roller modules can dynamically change their rotation direction and speed independently, allowing the system to adapt to different conveying paths and goods types. This dynamic capability enables complex motion patterns without requiring complex membrane deformation control.
2Productivity
If lifting pins are extracted and retracted to push conveying goods on a membrane, then the goods can be moved, but the membrane is stressed strongly reducing its lifetime
Solution Approach 1:
The force application is distributed across multiple independent roller modules rather than concentrating stress on a single membrane. Each roller module applies force locally through its wheels, eliminating the high-stress membrane deformation and extending system lifetime.
Solution Approach 2:
The mechanical membrane pushing system is replaced with a roller-based system where goods are moved by friction between the roller wheels and the goods. This substitution eliminates the need for membrane deformation and associated stress.
3Reliability
If the material thickness of the conveying membrane is increased, then the lifetime is increased, but the flexibility and sensitivity are decreased
Solution Approach 1:
Instead of relying on a single thick membrane for both strength and flexibility, the system uses multiple thin roller modules. Each module maintains flexibility while the array provides overall structural integrity, eliminating the need for thick membranes.
Solution Approach 2:
The roller modules can independently adjust their position and rotation, providing dynamic adaptability that replaces the static flexibility of a thick membrane. This allows the system to handle various goods types without sacrificing reliability.
4Ease of operation
If the wave conveyor uses slide conveyance, then goods can be pushed, but the system cannot rotate goods at one and the same spot
Solution Approach 1:
The roller modules can dynamically change rotation direction and speed independently, enabling goods to be rotated at any position on the grid. This dynamic control provides both conveying and rotation capabilities, unlike the fixed wave conveyor mechanism.
Solution Approach 2:
The roller modules serve multiple functions: they can convey goods in any direction, rotate goods in place, and position goods precisely. This multi-functionality replaces the single-purpose wave conveyor while maintaining ease of operation.
5Productivity
If the conveying membrane mountains are arranged close to each other, then more goods can be transported, but the membrane lifts automatically between the mountains
Solution Approach 1:
The system uses discrete roller modules instead of continuous membrane waves, allowing dense arrangement of handling points without causing membrane instability. Each module is independently supported, preventing the lifting issue that occurs with closely spaced membrane deformations.
Solution Approach 2:
The membrane wave system is replaced with independently supported roller modules. This substitution eliminates the membrane stability issue while enabling higher simultaneous handling capacity through parallel operation of multiple modules.
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 matrix conveyor enables efficient transportation of goods along planned paths, allows for rotational movements, and can handle multiple goods simultaneously, reducing friction and operational complexity, while maintaining flexibility and adaptability in handling goods of varying sizes and weights.
Implementation Method 1
The individual roller modules have at least one all-side wheel and can be driven in only one of the at least two basic conveying directions
Implementation Method 2
directly adjacent ones of the individual roller modules are respectively drivable in another one of the at least two basic conveying directions
Data Source
AI summary
It is disclosed a matrix conveyor (10) comprising: a plurality of individual roller modules (28), wherein respectively one roller module (28) is arranged at each point of intersection of a regular grid-shaped structure (68), and wherein the roller modules (28) commonly define a conveying plane (30), which is substantially planar, for transporting a conveying good (72) thereon; and a superordinated control device (12) being adapted to individually control each of the individual roller modules (28) so that the conveying good (72) can be transported along a path (74), which can be planned in advance, wherein a shape of the path (74) is defined by a plurality of overlaps of at least two basic conveying directions (60, 62) of the conveying plane (30); wherein the at least two basic conveying directions (60, 62) geometrically span the conveying plane (30), and wherein each of the roller modules (64) is drivable in only one of the at least two basic conveying directions (60), wherein directly adjacent roller modules (66) are respectively drivable in the other one of the at least two basic conveying directions (62).