Modular Conveyor System for Variable Width Transport
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Solution Overview
Problem
Conveyor systems are inefficient when transporting items smaller than the maximum size due to underutilization of width, as they are designed to accommodate the largest possible product, leading to wasted space and reduced efficiency.
Innovation Solution
A modular conveyor system comprising independently driven narrow conveyor modules that can be arranged in various configurations to match the width of items, with each module featuring a looped track, drive mechanism, product scanners, and communication capabilities for decentralized operation and data sharing, allowing modules to work in unison to convey items of varying widths and lengths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conveyor systems are designed to accommodate the largest possible product, then the maximum product size is supported, but space is wasted and efficiency is reduced when transporting smaller items
Solution Approach 1:
The conveyor system is divided into multiple independently driven narrow conveyor modules that can be arranged in different configurations. Each module has a standardized width (e.g., 300mm) and can be positioned side-by-side to match the width of items being transported, eliminating wasted space while maintaining the ability to handle various product sizes.
2Productivity
If a single wide conveyor is used, then large items can be transported efficiently, but smaller items result in underutilization of the conveyor width
Solution Approach 1:
The conveyor system transitions from a fixed wide configuration to a dynamic modular arrangement where narrow modules can be independently positioned and configured. This allows the system to adapt its effective width to match the actual cargo dimensions, optimizing space utilization for each transport task while maintaining the capacity to handle large items when needed.
3Productivity
If multiple narrow conveyors are used instead of a single wide conveyor, then space utilization is optimized, but system complexity increases
Solution Approach 1:
Each narrow conveyor module is designed as a universal, independently driven unit with standardized dimensions and capabilities. The modules can function individually or be combined in various configurations to handle different product sizes, reducing the need for multiple specialized conveyors and simplifying the overall system architecture while maintaining flexibility.
Data Source
AI summary
A conveyor module includes an elongate frame to which a looped conveyor track is mounted. The frame includes first and second end housings which include end pulleys for the conveyor track. The frame also includes a drive housing located at a mid-portion thereof which houses the drive motor for the conveyor track. The conveyor module is a discrete independently driven unit with an upper portion (running surface) of the conveyor track in a planar orientation for conveying items thereon in use. The conveyor module can include additional smart features. A warehouse floor arrangement uses a plurality of side by side conveyor modules being identical and grouped into banks.