Modular Conveyor System with Alternating Drive Devices
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Solution Overview
Problem
Conveyor systems that transport pallets at a constant speed are inefficient due to the need for frequent adjustments in length, which increases man-hours and requires high-power motors to account for power loss during transmission, making it difficult to adapt to changing lengths and restricts the system's use in applications like engine assembly lines.
Innovation Solution
A conveyor system with at least two driving devices that engage with pallets at the upstream end and push multiple pallets simultaneously, using actuators with retractable rods and anti-back pawls to maintain constant speed and reduce power requirements, allowing for easy length adjustments by adding or removing transport portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If motors and drive transmitting portions are arranged along the length of the conveyor system to transmit power to rollers, then the conveyor system can transport pallets, but the man-hours required to change the length increase due to wiring and adjustment work
Solution Approach 1:
The conveyor system is divided into multiple transport mechanisms that can be independently arranged and connected in series. Each transport mechanism is a modular unit containing rollers and drive transmitting portions, allowing the system length to be changed by simply adding or removing modules without complex wiring or adjustment work
Solution Approach 2:
Multiple transport mechanisms are merged into a single continuous conveyor system where the drive transmitting portions of adjacent mechanisms are coupled together. This merging allows power to be transmitted through the coupled mechanisms without requiring separate wiring for each motor, reducing the man-hours needed for length changes
2Power
If power is transmitted from motors to rollers via gears and shafts, then the rollers can be driven, but power loss occurs during transmission requiring high-power motors
Solution Approach 1:
A drive transmitting portion acts as an intermediary mechanism between motors and rollers, using gears and shafts to transmit power efficiently. The drive transmitting portion is designed to minimize power loss during transmission while providing the necessary mechanical advantage to drive the rollers
Solution Approach 2:
The patent replaces direct mechanical coupling with a more efficient power transmission system using motors coupled to drive transmitting portions. This substitution optimizes the mechanical system to reduce power loss while maintaining the ability to drive rollers effectively
3Productivity
If pins are reciprocally moved to intermittently transport pallets, then pallets can be transported, but the system cannot maintain constant speed required for assembly lines
Solution Approach 1:
The drive transmitting portions perform periodic pushing actions on pallets in a coordinated sequence. Multiple drive transmitting portions operate in alternating cycles, with each one pushing a pallet when the previous one has completed its push and returned to the starting position. This periodic action maintains continuous constant speed transport while enabling intermittent engagement with pallets
Data Source
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AI summary
A conveyor system (10) that transports a plurality of pallets includes: at least two driving devices (30L and 30R) that each have an engaging portion (37) to be engaged with the pallet located at an upstream-side end portion in a pallet transport direction and that moves the engaging portion (37) in a state where the engaging portion (37) is engaged with the pallet to thereby simultaneously push the plurality of pallets; and a transport portion (20) on which the plurality of pallets are mounted and that is able to transport the plurality of pallets pushed by the driving devices (30R and 30L). The conveyor system (10) is configured to transport the plurality of pallets at a constant speed by engaging the engaging portion (37) of one of the driving devices (30R) with the pallet and causing the one of the driving devices to start pushing the plurality of pallets by the time when another one of the driving devices (30L) completes pushing the plurality of pallets.