Modular Sanitary Conveyor for Produce Sorting
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Solution Overview
Problem
Current produce sorting systems face challenges in achieving high speed, efficiency, accuracy, reliability, and low maintenance while ensuring food safety and sanitation, particularly in the handling and weighing of fruits and vegetables.
Innovation Solution
A produce sorting system comprising a conveyor line with carrier units that include a carrier frame, a produce roller, and a produce cup configured to tip and move vertically for weighing, supported by a weighing member with a load cell, and linked by a chain of plastic and stainless steel components for enhanced stability and sanitation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional conveyor systems with metal chains and multiple contact points are used, then structural strength and durability are improved, but maintenance requirements increase and food safety is compromised
Solution Approach 1:
The patent removes metal chains and drive/idler sprockets from the conveyor system, extracting the problematic components that caused maintenance issues and food safety concerns. The conveyor is redesigned to operate without these traditional mechanical elements, using alternative mechanisms that eliminate contamination risks and reduce maintenance needs.
Solution Approach 2:
The patent applies different material qualities to different parts of the conveyor system. Plastic carrier units with stainless steel components are used in food contact areas to ensure sanitation and durability, while avoiding metal chains in areas where maintenance and contamination are concerns. This localized material selection optimizes both food safety and maintenance characteristics.
2Productivity
If high-speed sorting is implemented, then productivity increases, but accuracy in weighing and sorting deteriorates
Solution Approach 1:
The conveyor is divided into distinct functional segments including weighing segments and sorting segments. This segmentation allows each section to be optimized for its specific function - the weighing segment for accurate measurement and the sorting segment for high-speed sorting - while working together to achieve both productivity and precision.
Solution Approach 2:
The patent employs dynamic carrier units that can tip and move vertically during operation. These carriers are designed to be stable during weighing but can rapidly transition to tipping positions for sorting, enabling the system to adapt its dynamics to match operational requirements and maintain accuracy during critical measurement phases.
3Ease of repair
If modular carrier design with minimal contact points is used, then maintenance is reduced and food safety is improved, but structural stability deteriorates
Solution Approach 1:
The carrier units are constructed as composite structures combining plastic components with stainless steel elements. This composite design provides the structural stability needed for reliable produce handling while maintaining the benefits of minimal contact points and ease of cleaning. The stainless steel components reinforce the plastic structure without requiring traditional metal chain support systems.
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 system achieves increased speed, accuracy, and reliability in sorting and weighing produce items while reducing maintenance and improving food safety through the use of a modular, sanitary conveyor design that minimizes wear points and contact with drive and idler sprockets.
Implementation Method 1
a produce cup supported by a weighing member when the produce cup is in the upright state, the weighing member including a weighing contact surface configured to contact a load cell of the weighing segment
Data Source
Figure 1
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Figure 3A
AI summary
Produce sorting systems and methods that utilize a conveyor system to move produce through stages such as singulation, camera inspection, weight, and sorting. The sorting systems and methods may utilize conveyor systems having carrier segments that provide for increased speed, efficiency, accuracy, reliability, durability, and lower maintenance. The conveyor system comprises a plurality of carrier units linked to the conveyor system, each including a link assembly (20), a roller assembly (40), and a cup assembly (60). At the weighing station, the cup is vertically movable with respect to the link assembly so it is only supported by the weighing surface in order to increase accuracy of measure.