Roller Conveyor Brake-Roller Singulation for Consistent Unit Spacing
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Solution Overview
Problem
Existing roller conveyors face challenges in effectively separating and maintaining a consistent distance between storage units, particularly when heavy units follow lighter ones, without using complex electrical sensors or actuators.
Innovation Solution
A roller conveyor system utilizing brake rollers that act as both decelerators and position holders, activated by an activation unit through a coupling element, ensuring storage units remain equidistant by locking or blocking the brake rollers using friction or positive locking mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If brake rollers are arranged in discrete positions among support rollers to decelerate storage units, then the braking effect is achieved, but the device complexity increases due to additional components
Solution Approach 1:
The brake rollers are designed to serve dual functions: they act as support rollers for carrying storage units and as brake rollers for decelerating them. This multi-functionality eliminates the need for separate brake mechanisms, reducing device complexity while maintaining effective speed control of storage units on the inclined conveyor.
2Reliability
If separation devices with locking elements are inserted into the movement range of storage units, then collision prevention is achieved, but the device complexity increases due to additional separation mechanisms
Solution Approach 1:
The separation function is merged with the existing brake roller mechanism. The same brake roller that decelerates storage units also serves as the locking element for separation. When a storage unit activates the coupling element, it blocks the brake roller, creating a separation effect without requiring additional locking devices or mechanisms.
Solution Approach 2:
The brake roller is designed to perform multiple functions: supporting storage units, decelerating them through friction, and serving as a separable locking element when blocked by the coupling mechanism. This multi-functionality eliminates the need for separate separation devices, reducing overall system complexity while maintaining reliable collision prevention.
3Ease of operation
If an activation unit with coupling element is added to block brake rollers for singulating storage units, then the separation function is achieved, but the device complexity increases due to additional activation mechanisms
Solution Approach 1:
The activation unit is designed to be automatically triggered by the storage units themselves. When a storage unit contacts the activation lever, it automatically activates the coupling element, which in turn blocks the brake roller. This self-activating mechanism requires no external control systems, sensors, or actuators, keeping the device complexity low while providing easy operation for singulating storage units.
4Reliability
If purely mechanical operating principles are used without electrical sensors or actuators, then robustness and durability are improved, but the precision of storage unit spacing may worsen
Solution Approach 1:
The mechanical system incorporates inherent feedback through the coupling element and brake roller interaction. When a storage unit contacts the activation lever, it triggers the brake roller blocking mechanism, which automatically regulates the spacing of subsequent storage units. This mechanical feedback loop ensures consistent spacing precision without requiring electrical sensors or complex control systems, maintaining both robustness and precision.
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 achieves simple and durable separation of storage units with minimal components, allowing smooth movement and consistent spacing without electrical sensors, using brake rollers for both speed regulation and positional fixation.
Implementation Method 1
brake rollers, which, in contact with the underside of the bearing units, generate a braking effect
Implementation Method 2
The roller conveyors are usually mounted with a gradient, allowing the bearing units to move along the conveyor in their conveying direction due to gravity
Data Source
Figure 1a~1c
Figure 2a~2c
Figure 3a~3c
AI summary
The invention relates to a roller conveyor (1) for guiding several storage units (100) arranged one behind the other, in particular for a flow rack, with at least two spaced-apart roller strips (10), comprising a plurality of rollers (11) for supporting the storage units (100) and a number of brake rollers (12) for braking the storage units (100), and wherein at least one device (13) is provided for singulating the storage units (100). According to the invention, the device (13) for singulating the storage units (100) comprises an activation unit (14) which can be activated when a storage unit (100) overflows, and wherein the device (13) comprises a brake unit (15) for acting on the brake roller (12), which can be blocked by the activation unit (14) via a coupling element (16) and in order to bring a subsequent storage unit (100) into contact with the brake roller (12) to a standstill.