Oblique Singulator Rollers Prevent Parcel Restacking
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Solution Overview
Problem
Traditional singulator conveyors allow envelopes and packages to restack, leading to inefficiencies in throughput and issues with automated handling and barcode reading due to obscured lower parcels.
Innovation Solution
A singulator conveyor with three-dimensionally obliquely skewed driven rollers angularly offset from a primary feeding direction, combined with a vertically higher downstream conveyor belt, directs parcels in an upwardly angled and converging manner to prevent stacking and improve throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional singulator conveyors with horizontally coplanar rollers are used, then the structure is simple, but parcels restack upon each other causing throughput inefficiency and obscured barcode reading
Solution Approach 1:
The patent transitions from two-dimensional horizontally coplanar rollers to three-dimensionally obliquely skewed rollers that are angularly offset from the primary feeding direction. This dimensional change allows rollers to direct parcels in an upwardly angled and converging manner, preventing restacking while maintaining structural feasibility
Solution Approach 2:
The patent changes the orientation parameters of the rollers from horizontal and coplanar to oblique and angularly offset. Specifically, the rollers are skewed at angles (e.g., 15-45 degrees) relative to the feeding direction and positioned at different vertical heights, creating a three-dimensional arrangement that improves parcel separation and prevents restacking
2Reliability
If parcels are conveyed on a flat horizontal surface, then the conveyor structure is simple, but side-by-side parcels restack obscuring barcodes for automated reading
Solution Approach 1:
The patent introduces vertical dimension variation by positioning downstream conveyor belt or rollers at a higher vertical level than the outboard skewed rollers. This creates an upwardly angled conveyance path that separates side-by-side parcels vertically, ensuring barcodes remain visible for automated reading while adding structural complexity
Solution Approach 2:
The patent creates an asymmetric conveyor configuration where the downstream conveyor surface is vertically offset from the upstream roller surface. This asymmetric arrangement causes parcels to be directed at angles rather than moving parallel to each other, preventing restacking that would obscure barcodes
3Productivity
If conventional singulator rollers are used, then the device is simple to manufacture, but recirculation burden increases due to restacking issues
Solution Approach 1:
The patent applies preliminary separation action through the oblique roller configuration that directs parcels onto the downstream conveyor at angles before they can restack. This preliminary angular diversion prevents the formation of stacked configurations that would require recirculation, thereby reducing time loss and improving throughput
Data Source
AI summary
A conveyor machine (21) is provided. In another aspect, a singulator conveyor (25; 125; 225; 325) employs three-dimensionally obliquely skewed driven rollers (65) angularly offset from a primary feeding and downstream direction (89; 361), outboard of an adjacent driven conveyor (51; 151; 251; 351) having a top surface (53; 187; 253) moving in the primary feeding and downstream direction (89; 361). A further aspect provides a downstream moving conveyor belt (51; 151; 351) or rollers (251) which are vertically higher than the adjacent outboard skewed and converging driven rollers (65; 165; 265; 365).