Multi-level Conveyor System for Object Singulation
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Solution Overview
Problem
In material handling facilities, the intermingling of objects from multiple orders on conveyor systems poses a challenge for efficient sorting, as existing methods rely on manual singulation or require complex automated systems to reorient objects from side-by-side or stacked orientations to sequential arrangements.
Innovation Solution
A multi-level conveyor system with upper, intermediate, and lower conveyor levels, featuring conveyor segments and knock-down devices to reorient objects, and undulation conveyors to separate stacked items, ensuring efficient automatic singulation by leveraging gravity and conveyor design to rearrange objects into sequential orientations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual singulation is used to rearrange objects into sequential orientation, then sorting accuracy is improved, but productivity decreases due to slow processing speed
Solution Approach 1:
The patent replaces manual mechanical singulation with an automated optical-mechanical system using cameras to detect object positions and actuators to perform knock-down actions, thereby increasing processing speed while maintaining sorting accuracy through automated control
Solution Approach 2:
The system enables objects to self-organize into sequential orientation through gravity-assisted knock-down mechanisms where objects naturally fall into proper positions without requiring precise manual placement, improving both speed and automation level
2Productivity
If complex automated systems are used to reorient objects, then productivity increases, but device complexity increases
Solution Approach 1:
The conveyor system is divided into multiple levels (upper, intermediate, lower) with dedicated singulation zones at each level, allowing parallel processing of different object groups and improving overall throughput without requiring a single complex monolithic system
Solution Approach 2:
The intermediate conveyor level serves as a mediator that receives objects from the upper level and transfers them to the lower level, enabling a modular multi-stage singulation process that breaks down complexity into manageable sequential steps
3Area of stationary object
If objects are arranged in side-by-side or stacked orientation on conveyor, then space utilization is improved, but sorting difficulty increases due to intermingling from multiple orders
Solution Approach 1:
The system transitions objects from two-dimensional side-by-side or stacked arrangements on the upper conveyor to a one-dimensional sequential arrangement on lower conveyor levels through gravity-assisted knock-down, maintaining space efficiency while enabling easier detection and sorting
Solution Approach 2:
The system performs preliminary singulation actions at multiple intermediate stages before final sorting, gradually transforming object arrangements from dense packed configurations to sequential orientations, making the final sorting task easier and more accurate
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 significantly increases the rate of item singulation, enhancing operational efficiency and meeting customer demands by automating the rearrangement process, reducing manual intervention and improving sorting speed and accuracy.
Implementation Method 1
an undulation conveyor configured to undulate objects received in a stacked orientation so as to dislodge the objects from the stacked orientation
Implementation Method 2
a knock-down device configured to knock down objects that are stacked on top of one another so as to arrange the objects in a sequential orientation
Implementation Method 3
The subsequent conveyor level is disposed at least partially below the upper conveyor level so as to receive objects falling from the upper conveyor level
Data Source
AI summary
In one embodiment, a conveyor system reorients objects from a side-by-side orientation to a sequential orientation. The system has an upper conveyor level and a subsequent conveyor level disposed below the upper level. The upper level has an upper conveyor segment that has an upstream end, a downstream end opposite the upstream end along a flow direction, a pair of lateral sides, a top side, and a bottom side. The upper conveyor segment defines an conveying surface that is between the pair of lateral sides and that carries objects aligned therewith along the flow direction. The upper conveyor segment also defines a discharge opening that is between the conveying surface and one of the lateral sides. The discharge opening extends through the upper conveyor segment along a vertical direction so as to discharge objects onto the subsequent conveyor level that are aligned with the discharge opening.