Orthogonally Offset Conveyor Sorting with Dynamic Velocity Control
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Solution Overview
Problem
Current material flow systems struggle to efficiently sort disorderly or non-pre-aligned conveyed goods while maintaining high throughput and requiring minimal space, as existing systems are either mechanically complex, slow, or require significant space due to fixed movement directions and inadequate flexibility in handling different sizes and orientations of goods.
Innovation Solution
A conveyor system with orthogonally offset feeding and dynamically controlled conveyor drives that can move conveyed goods in any direction on the conveying plane, allowing for flexible sorting and rearrangement without the need for extensive reorientation or additional space, using detection means to determine target positions and control the movement of goods for efficient sorting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conveyed goods are fed in single file with large gaps between units, then sorting quality and reliability are improved, but conveying throughput and productivity deteriorate
Solution Approach 1:
The patent applies dynamics by enabling the conveyor system to dynamically adjust the velocity of individual conveyed goods during transport. The control system regulates the velocity of each good based on its target position, allowing the system to handle goods in a more continuous and flexible manner rather than requiring fixed large gaps between units. This dynamic velocity adjustment enables higher throughput while maintaining sorting accuracy.
2Extent of automation
If mechanical pushers are used for sorting, then automated sorting is achieved, but device complexity and sorting time increase due to mechanical extension and return movements
Solution Approach 1:
The patent replaces the traditional mechanical pusher system with a velocity-controlled conveyor system. Instead of using mechanical pushers that physically extend and return to sort goods, the invention uses a control system that regulates the velocity of each conveyed good on the conveyor belt. This substitution eliminates the complex mechanical extension and retraction mechanisms while achieving the same sorting function through differential velocity control.
3Adaptability or versatility
If conveyor belts are used for sorting, then flexible velocity control is possible, but the conveying area requires large space due to multiple conveyor belts arranged one behind the other
Solution Approach 1:
The patent applies segmentation by dividing the conveying area into multiple virtual lanes or zones within a single conveyor belt system. Instead of requiring multiple physical conveyor belts arranged one behind the other, the invention segments the control of individual goods, allowing each good to be independently velocity-controlled to different destinations. This reduces the physical space required while maintaining the flexibility of differential velocity control.
4Device complexity
If sorting is performed with fixed movement directions, then system structure is simplified, but adaptability to different sorting patterns and destinations deteriorates
Solution Approach 1:
The patent applies dynamics by making the movement direction and velocity of each conveyed good dynamically adjustable during transport. The control system can regulate both the speed and direction of individual goods based on their target positions and sorting requirements. This dynamic control enables the system to adapt to various sorting patterns and destinations without requiring complex mechanical reconfiguration, achieving versatility through software-based velocity and direction regulation.
Data Source
AI summary
The invention relates to a method for sorting a first conveyed-good unit (11) and a second conveyed-good unit (z) while simultaneously transporting the conveyed-good units in a conveying direction z, comprising the following steps:Feeding of a plurality of at least the first conveyed-good units (11) and the second conveyed-good unit in a first arrangement, wherein the first conveyed-good unit (11) and the second conveyed-good unit are fed in sections simultaneously in the conveying direction (z), and wherein the conveyed-good units are fed orthogonally offset to each other in relation to the conveying direction (z),typifying detection (S1) of the conveyed-good units (11),determining a target position of the first conveyed-good unit (11a . . . 11d) and the second conveyed-good unit (S2),controlling and regulating a movement of the first conveyed-good units (11a . . . 11d) and the second conveyed-good unit on the basis of the said target position (S3), andfor this purpose, moving the first conveyed-good units (11a . . . 11d) and the second conveyed-good unit (S4) using conveyor drives (2, 2a . . . 2c), which can move one or a plurality of conveyed-good units individually and in a variable manner in any direction of the conveying plane in such a way that a sorted arrangement of the first conveyed-good units (11a . . . 11d) and the second conveyed-good unit exists at the time of transfer to one or a plurality of subsequent conveyor section (s) (16), wherein the movement takes place depending on control signals generated from the typifying detection of the first conveyed-good units (11a . . . 11d) and the second conveyed-good unit and generated from the determination of the target positions of the first conveyed-good units (11a . . . 11d) and the second conveyed-good unit, wherein the first conveyed-good unit and the second conveyed-good unit are transported simultaneously in the conveying direction (z).