Multi-Level Sorter with Cam Crossbands for Compact Material Handling
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Solution Overview
Problem
Current conveyor and sorting technologies face inefficiencies in conveying and sorting materials, particularly in handling both regular and irregular cases, and there is a need for more efficient means to manage materials in facilities.
Innovation Solution
A modular handling system with multi-level sorters and diverters that include conveyor units, bins, and crossbands with cam portions to facilitate the diversion and sorting of cases, allowing for multiple vertical and horizontal transfers and alignment with conveyor outlets to efficiently sort and distribute materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If traditional fixed conveyors and sorting equipment are used, then material transport between locations is achieved, but the system occupies excessive floor space and lacks flexibility in configuration
Solution Approach 1:
The patent transitions from traditional horizontal conveyor layouts to a vertical multi-level configuration. Conveyors are arranged at different heights with vertical transfer mechanisms connecting them, allowing the system to occupy less floor space while maintaining transport capacity. This dimensional change enables compact arrangement of sorting stations and reduces the overall footprint of the material handling system.
Solution Approach 2:
The conveyor system is divided into multiple independent modules that can be vertically stacked and configured in different arrangements. Each module includes conveyors, diverters, and sorting stations that can be independently positioned at different levels. This segmentation allows flexible reconfiguration of the system to adapt to changing facility layouts and material flow requirements without requiring complete system replacement.
2Productivity
If conventional single-level sorting systems are used, then basic material sorting is achieved, but sorting rates are limited and handling of irregular cases is inefficient
Solution Approach 1:
The patent implements multi-level sorting stations where diverters and bins are arranged at different vertical heights. This allows multiple sorting operations to occur simultaneously at different levels, dramatically increasing the overall sorting rate. Irregular cases can be handled efficiently by directing them to appropriate vertical levels where specialized sorting mechanisms are positioned, enabling parallel processing of diverse materials without proportionally increasing system complexity.
3Adaptability or versatility
If fixed conveyors bolted to the floor are used, then stable material transport is achieved, but the system lacks mobility and adaptability to facility changes
Solution Approach 1:
The patent employs conveyors with adjustable and movable mounting mechanisms that can be repositioned along facility walls or on movable platforms. The conveyors maintain stable operation during transport through active positioning systems and rigid connection mechanisms, while simultaneously allowing relocation and reconfiguration when facility layouts change. This dynamic capability enables the system to adapt to different operational requirements without sacrificing transport reliability.
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 enhances inventory flow, increases sorting rates, and handles difficult-to-convey items efficiently, providing superior transfer rates and compact configurations that reduce floor space while improving product flow and cost savings.
Implementation Method 1
The cam portion has an incline at a contact end thereof engagable with a bottom of the cases to lift and push the cases as the continuous loop advances about the drive rollers whereby the cases are selectively diverted from the conveyor
Data Source
AI summary
A multi-level sorter of a handling system for transporting cases. The handling system has conveyors extending between locations of a facility. The multi-level sorter includes a multi-level frame positionable adjacent at least one outlet of at least one of the conveyors, at least one diverter carried by the multi-level frame, and at least one bin supported about at least one of the levels of the multi-level frame. Each of the outlets of the conveyors aligned with a level of the multi-level frame to pass the cases thereto. The diverter has rollers to pass the cases along a main path and crossbands to selectively divert the cases from the main path. Each of the bins is alignable with the diverter to receive the diverted cases therefrom whereby the cases are sorted.