Profile Singulator Friction Roller Automation

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Solution Overview

Problem

Conventional manufacturing logistics for limp and flexible profiles, such as those used in motor vehicle door and window seals, rely heavily on manual singulation and positioning, leading to inefficiencies and increased costs due to the disorderly and entangled state of profiles, making automated handling unreliable.

Innovation Solution

A profile singulator system featuring a first conveying device and a conveyor roller with distinct friction properties and surface features, such as teeth or smooth surfaces, to unravel and separate profiles, combined with adjustable conveying sections and sensors for enhanced automation and singulation efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If manual singulation and positioning is used for limp profiles, then handling flexibility is maintained, but labor costs and time consumption increase significantly

Engineering Contradiction:

Improveautomation of singulation processVSAvoidreliability of automated handling

Core Design Contradiction:

Extent of automationVSReliability

Solution Approach 1:

The patent changes the friction parameter by providing a conveyor roller with a friction coefficient that is higher than that of the first conveying device. This parameter change enables the roller to selectively retain individual profiles from a disorderly mass, achieving reliable automated singulation of limp profiles without requiring manual intervention

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The system dynamically adjusts the conveying speeds of different components. The conveyor roller rotates at a speed different from the first conveying device, creating relative motion that facilitates the separation and singulation of profiles. This dynamic speed control enables automated handling to reliably process limp profiles in various states

Inventive Principle:

Principle #15Dynamics

2Area of stationary object

If profiles are fed in a disorderly state, then space requirements are reduced, but singulation difficulty increases

Engineering Contradiction:

Improvespace required for profile storageVSAvoidcomplexity of singulation mechanism

Core Design Contradiction:

Area of stationary objectVSDevice complexity

Solution Approach 1:

The patent introduces a second conveying device with a lower friction coefficient than the conveyor roller. This creates a friction parameter gradient: the high-friction roller singulates profiles from the disorderly mass, while the low-friction second device receives and transports the singulated profiles efficiently. This parameter differentiation simplifies the overall singulation mechanism

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The conveying system is segmented into distinct functional zones: a first conveying device for feeding, a conveyor roller for singulation, and a second conveying device for output. This segmentation allows each component to be optimized for its specific function, reducing overall system complexity while handling disorderly profiles

Inventive Principle:

Principle #1Segmentation

3Manufacturing precision

If a conveyor roller with high friction is used for singulation, then profile separation is improved, but energy consumption increases

Engineering Contradiction:

Improveprecision of profile singulationVSAvoidenergy consumed by conveyor roller

Core Design Contradiction:

Manufacturing precisionVSUse of energy by moving object

Solution Approach 1:

The patent optimizes the friction coefficient of the conveyor roller to be higher than the first conveying device but lower than a threshold that would cause excessive energy consumption. This parameter optimization achieves precise profile singulation while maintaining reasonable energy efficiency

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The conveyor roller rotates periodically, creating cycles of high-friction contact that grab individual profiles and release them to the second conveying device. This periodic action achieves precise singulation through repeated low-energy cycles rather than continuous high-energy operation

Inventive Principle:

Principle #19Periodic action

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 significantly reduces manual labor and space requirements by automating the singulation process, ensuring profiles are handled accurately and efficiently, even when entangled, thereby lowering manufacturing costs and improving handling precision.

Implementation Method 1

The conveyor roller (5) is configured such that a friction coefficient of the conveyor roller (5) is higher than a friction coefficient of the first conveying device (3)

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS11802007B2Profile singulator

Publication Date: 2023.10.31 STEFAN PFAFF WERKZEUG & FORMENBAU

AI summary

Additional automation in the form of a profile singulator for singulating profiles is proposed which includes: a first conveying device for feeding the profiles in a disorderly state over a first conveying section, a conveyor roller for unraveling the large quantity of fed profiles into individual profiles, wherein the conveyor roller is situated downstream from the first conveying device in the direction of transport. The profiles can be limp, flexible, or semi-flexible; moreover, they can have or not have a carrier.