Modular Rocker Lever for Overhead Conveyor Occupancy Detection
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Solution Overview
Problem
Conventional methods for detecting the occupancy status of accumulation sections in overhead conveyor systems, such as light scanners and mechanical rockers, face limitations including color-dependent light beam reflection, operator interference, and the need for multiple rocker lengths due to varying hanging sides and widths, leading to inefficiencies and errors in inventory management.
Innovation Solution
A modular occupied rocker with an interrogation sword and adjustable length, featuring a pivotable design with a bearing and rib-shaped slots for length adjustment, along with a flag for counterweight and sensor integration, allowing for universal use regardless of hanging side or width, and ensuring safe operation by preventing false triggering from operators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If light scanners are used to detect occupancy status, then detection can be performed without physical contact, but the detection fails when hanging goods have specific colors that do not reflect the light beam properly
Solution Approach 1:
The patent replaces the optical detection system (light scanner) with a mechanical detection system (rocking lever). The rocking lever uses physical contact and mechanical movement to detect the presence of hanging goods, eliminating the color-dependent limitations of optical sensors. When goods are present, they physically interact with the lever, causing it to rock and trigger a detection signal regardless of color.
2Reliability
If light scanners are positioned vertically, then occupancy detection is possible, but operating personnel can walk under or stand under them causing false detection signals
Solution Approach 1:
The patent repositions the detection mechanism from a vertical orientation (light scanner above) to a horizontal/oriented configuration along the conveyor path. The rocking lever is positioned to detect goods passing by horizontally, making it insensitive to personnel movement vertically underneath, thus eliminating false signals from operators walking under the detection zone.
3Reliability
If mechanical rockers are used with fixed lengths, then they can detect occupancy, but multiple rocker lengths must be kept in stock to accommodate different hanging sides and widths
Solution Approach 1:
The patent introduces an adjustable-length rocking lever that can be dynamically configured to match different application requirements. The lever length can be modified by removing links from the lever assembly, allowing a single standardized component to adapt to various hanging sides, widths, and conveyor configurations, eliminating the need to stock multiple fixed-length rockers.
4Speed
If lightweight hanging goods are used on inclined drop bars, then they can slide to collection points, but they cannot lift the cradle to pass through mechanical rockers
Solution Approach 1:
The patent modifies the rocking lever mechanism to reduce the lifting force requirement. By adjusting the lever's center of gravity, adding counterweights, or optimizing the pivot point position, the system creates a mechanical advantage that allows lightweight hanging goods to easily lift the lever during passage, maintaining high-speed flow through the detection zone without interruption.
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 modular rocker effectively detects occupancy status without operator interference, accommodates varying widths and sides, and reduces the need for multiple rocker lengths, enhancing operational efficiency and reducing errors in inventory management.
Implementation Method 1
an interrogation sword (20) having an elongate body the length of which has opposite first and second ends... a bearing (26) on which the sword (20) rests hanging downwards in a normal state when the sword (20) is not in contact with a bracket (18)... the sword (20) is mounted pivotably around the socket (24) in order to be permanently raised in the occupied state by a jammed conveying material
Implementation Method 2
The sword has rib-shaped slots spaced along the longitudinal direction, which allow a length of the sword to be adjusted by breaking off an unwanted part of the sword
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3B
AI summary
Occupied rocker (10) for indicating an occupancy status of a buffer zone (14) for suspended conveyed goods, wherein each conveyed good is suspended from a bracket (18), comprising: a sensing sword (20) with an elongated body, wherein the sword (20) is arranged within an area (52) which is traversed by the conveyed goods when the conveyed goods pass the rocker (10); and a bearing (26) which has a horizontally oriented bushing, wherein the sword (20) is pivotably mounted about the bushing.