Piezoelectric Switch Assembly for Sortation Conveyor Actuation

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Solution Overview

Problem

Existing sortation conveyor systems face inefficiencies in diverting articles due to slow actuation times, high power consumption, and increased maintenance costs, particularly in high-volume distribution and fulfillment operations.

Innovation Solution

The implementation of a piezoelectric switch assembly that selectively engages with pusher elements to divert articles from a primary conveying path to a secondary path, utilizing a piezoelectric actuator that provides faster actuation, reduced power consumption, and lower maintenance requirements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If traditional switch mechanisms are used to divert articles, then the sortation conveyor can perform article diversion, but the actuation time is slow and power consumption is high

Engineering Contradiction:

Improveactuation speedVSAvoidpower consumption

Core Design Contradiction:

SpeedVSUse of energy by moving object

Solution Approach 1:

The patent replaces traditional mechanical switch mechanisms with a piezoelectric actuator that uses electrical fields to generate mechanical motion. The piezoelectric element converts electrical energy directly into mechanical displacement, eliminating the need for complex mechanical linkages, motors, and actuators. This substitution achieves faster actuation response times and significantly reduces power consumption while maintaining the article diversion function.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the actuation mechanism from mechanical to piezoelectric, fundamentally altering the physical parameter conversion method. Instead of using electromagnetic motors or pneumatic systems, the invention employs piezoelectric materials that convert electrical voltage directly into mechanical strain, enabling precise control with minimal energy input and extremely fast response times in the millisecond range.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If traditional switch mechanisms are used to divert articles, then the sortation conveyor can perform article diversion, but maintenance costs increase

Engineering Contradiction:

Improvemaintenance requirementsVSAvoidmaintenance costs

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

By replacing mechanical switch mechanisms with a piezoelectric actuator, the patent eliminates numerous moving parts such as gears, belts, motors, and linkages that require lubrication, alignment, and replacement. The piezoelectric element has no moving parts and solid-state construction, making it inherently more reliable and requiring minimal maintenance, thus reducing maintenance costs despite potentially higher initial manufacturing complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If conventional actuators are used for pusher element diversion, then articles can be diverted to secondary paths, but throughput efficiency decreases

Engineering Contradiction:

Improvearticle throughputVSAvoiddiversion time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent changes the actuation speed parameter by employing piezoelectric materials that respond to electrical fields almost instantaneously. The piezoelectric actuator can achieve full stroke in milliseconds compared to the slower response of conventional motors or pneumatic actuators. This rapid actuation enables the sortation conveyor to divert articles at higher speeds, increasing overall system throughput and reducing the time loss associated with each diversion event.

Inventive Principle:

Principle #35Parameter changes

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

This solution enhances article throughput, reduces switch actuation time, lowers power consumption, and decreases assembly and maintenance costs, enabling higher conveyor speeds and increased efficiency in sortation processes.

Implementation Method 1

a piezoelectric actuator positioned adjacent the second conveying path and configured to selectively engage with at least one pusher element

Methodology Applied

Scientific EffectPiezoelectric effect: Piezoelectric Effect

Data Source

PatentUS9038809B2Sortation conveyor with piezoelectric actuation

Publication Date: 2015.05.26 INTELLIGRATED HEADQUARTERS LLC

AI summary

A sortation conveyor for transporting and diverting a plurality of articles includes a first conveying path and a second conveying path angularly positioned relative to the first conveying path. A plurality of pusher elements may be selectively diverted laterally across the first conveying path to divert articles to the second conveying path. A piezoelectric actuated switch assembly positioned adjacent to the second conveying path selectively engages the pusher elements to divert the selected article to the second conveying path.