Motorized Backstop Strike Plate Dynamics
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Solution Overview
Problem
Existing mechanical backstops are inadequate for decelerating rapidly moving products without causing damage, as they fail to control forces effectively and recover in time to receive successive products, especially at increased conveyor speeds, leading to potential product damage and inefficiencies in assembly line productivity.
Innovation Solution
A backstop system featuring a longitudinally moveable strike plate controlled by an electric motor with position feedback, allowing precise deceleration and retraction of the strike plate to manage kinetic energy absorption and ensure timely recovery for the next product, utilizing a programmable power cycle to optimize deceleration and positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the discharge speed of the conveyor is increased to improve productivity, then the production efficiency is improved, but the risk of product damage increases exponentially due to higher kinetic energy at impact
Solution Approach 1:
The backstop is designed as a dynamic system with a movable contact surface that can retract along the path of product motion. This dynamic structure allows the backstop to adapt to different product speeds and energies, reducing impact forces by moving backward upon impact rather than remaining rigidly fixed, thereby preventing product damage while maintaining high-speed conveyor operation
Solution Approach 2:
The system changes the physical state and position parameters of the contact surface dynamically. The contact surface transitions from an extended position (for normal operation) to a retracted position (for impact absorption), and can be controlled to move at variable speeds. This parameter change allows the backstop to match and control the forces applied to products across a range of velocities, enabling safe deceleration of high-speed products
2Object-affected harmful factors
If the contact surface retracts across a longer distance to control forces applied to the product, then the product damage risk is reduced, but the time required for the backstop to return to its extended position increases
Solution Approach 1:
The backstop operates in periodic cycles: extending to the forward position ready to receive products, retracting upon impact to absorb kinetic energy, then rapidly returning to the extended position. This periodic action ensures that the backstop is ready for the next product while minimizing the time spent in the retracted position, thus balancing force control with recovery time
Solution Approach 2:
The contact surface performs a rapid return motion to the extended position after retracting to absorb impact. This rushing through of the recovery phase minimizes the time the backstop remains retracted, ensuring that the system is quickly ready to receive the next product while still providing sufficient deceleration distance for the current product
3Object-affected harmful factors
If the settling time is increased to allow the product to come to rest safely, then the product damage risk is reduced, but the time between successive product impacts increases, reducing productivity
Solution Approach 1:
The dynamic backstop extends the deceleration distance by retracting during impact, allowing products to slow down gradually over a longer period without increasing the time between successive impacts. This dynamic extension of the stopping distance enables safe settling while maintaining high throughput by not requiring extended idle time between products
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 effectively decelerates rapidly moving products without causing damage, allowing for efficient stacking and packaging by controlling force application and recovery time, significantly reducing the risk of product damage and enhancing assembly line productivity.
Implementation Method 1
an electric motor having a longitudinally moveable output shaft the end of which is joined to the strike plate such that the motor can control movement of the strike plate
Implementation Method 2
the surface of the backstop will vibrate for a short period of time as some of the energy of the impact is dissipated
Data Source
AI summary
A backstop for stopping the movement of a product as it comes off a conveyor of a manufacturing line includes a motor connected by a linkage to a longitudinally moveable strike plate. The motor applies force to the strike plate in accordance with a predetermined curve to bring the product to a soft stop.