Pivotable Trolley Crossbelt Sorter Spiral Track
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Solution Overview
Problem
Existing crossbelt sorter systems lack flexibility in configuration and operation, particularly in navigating spiral tracks and accommodating vertical loading, which limits their ability to efficiently sort articles in compact footprints.
Innovation Solution
The system incorporates trolleys that can pivot in two directions, supported by spherical bearings and biasing members, with a propulsion system using drive fins and a hitch assembly that allows for thermal expansion compatibility, and includes a divert trigger for precise article discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional crossbelt sorter systems use fixed rigid structures, then structural stability is maintained, but flexibility in configuration and operation is limited
Solution Approach 1:
The system divides the carrier structure into modular components: carriers are segmented with individual trolleys at corners, each trolley being independently pivotable. This segmentation allows each module to adapt to track geometry changes while maintaining overall system stability, resolving the contradiction between flexibility and complexity.
Solution Approach 2:
The patent introduces dynamic elements through pivotable trolleys that can rotate to accommodate spiral and curved track portions. The trolleys transition from fixed to movable configurations, enabling the rigid carrier structure to adapt to varying track geometries without increasing overall system complexity.
2Area of stationary object
If the track assembly includes spiral portions, then compact footprint is achieved, but vertical loading and structural stress increase
Solution Approach 1:
The patent employs spherical bearings in the trolley assemblies to accommodate the curved and spiral portions of the track. The spherical geometry allows smooth navigation of vertical and horizontal curves, distributing vertical loading forces evenly across multiple contact points and reducing peak stress on the track structure.
Solution Approach 2:
The biasing members provide counteracting forces to balance vertical loading on spiral portions. By pre-loading the trolley assemblies with biasing springs, the system compensates for the additional vertical stresses generated during navigation of compact spiral track configurations.
3Adaptability or versatility
If trolleys are constrained to fixed positions, then structural stability is maintained, but ability to navigate spiral tracks is lost
Solution Approach 1:
The trolleys are designed with controlled mobility through spherical bearings and biasing members. They can pivot dynamically to follow spiral track geometry while the biasing members maintain constant contact with the track, ensuring structural stability is preserved during navigation of curved portions.
Solution Approach 2:
The spherical bearing acts as an intermediary between the fixed track structure and the movable trolley. It mediates the transition from rigid to flexible connection, allowing the trolley to pivot and follow spiral tracks while maintaining reliable structural connection through the bearing's constrained rotational movement.
4Adaptability or versatility
If carriers are made from different materials, then thermal expansion compatibility is improved, but manufacturing complexity increases
Solution Approach 1:
The carrier system employs composite construction with carriers made from one material (e.g., aluminum alloy) and trolleys made from another material (e.g., steel or polymer). This composite approach allows each component to be optimized for its specific thermal expansion characteristics, with the hitch assembly accommodating differential expansion between materials through flexible connections.
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 configuration enables flexible sorting operations on spiral tracks, absorbs vertical loading, and allows for compact track layouts, enhancing the system's ability to efficiently sort articles across various orientations and locations.
Implementation Method 1
Each trolley is mounted with a spherical bearing in order to pivot that trolley in the two different directions
Implementation Method 2
A biasing member is provided to bias that trolley into lateral engagement with said track assembly. The biasing member may also absorb changes in vertical loading in order to assist the associated carrier moving through spiral portions
Implementation Method 3
Each of the carriers may include a connection member extending and hitch assemblies may be made substantially from the same particular material as the track assembly. This provides thermal expansion and contraction of the carriers that is compatible with thermal expansion and contraction of the track assembly
Data Source
Figure 1
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AI summary
A crossbelt sorter system and method of sorting articles includes a track assembly and a plurality of carriers attached to each other to travel along the track assembly. Each of the carriers includes at least front and rear corner portions thereof and a trolley at each of the front and rear corner portions. Each trolley is configured to travel along the track assembly. A hitch assembly joins adjacent ones of the carriers. A propulsion system propels the carriers along the track assembly. Each trolley is mounted to the associated carrier to pivot in at least two different directions. In this manner, the track assembly may have one or more spiral portions thereof. Each trolley is adapted to pivot in the two different directions to support the associated carrier as it moves through the spiral portion.