Modular Scroll Cam Conveyor System for Flexible Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional conveyor systems face limitations such as speed constraints, inability to vary acceleration and velocity profiles for individual pallets, lack of flexibility, and limited data acquisition capabilities, leading to suboptimal manufacturing line design and reduced throughput.
Innovation Solution
A modular conveyor system with independently controlled moving elements and workstations, allowing for multi-mode conveying and multi-pitch movement, utilizing a track section with a control system, drive system, and magnetic or scroll cam drive mechanisms to manage pallets and workstations with varying cycle times and pitches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional belt conveyors are operated at high speed, then throughput is improved, but mechanical impact between pallets and stop mechanisms increases causing damage to parts
Solution Approach 1:
The patent replaces mechanical stop mechanisms with a magnetic field-based braking system. Magnets embedded in the conveyor belt create magnetic fields that gently decelerate and stop pallets without mechanical contact, eliminating impact damage while maintaining high-speed operation capability
Solution Approach 2:
The system dynamically adjusts magnetic field strength and braking force parameters based on pallet position, load type, and speed requirements. This allows controlled deceleration profiles that stop pallets smoothly at workstations without mechanical impact, while maintaining high throughput
2Productivity
If conventional belt conveyors use uniform speed for all pallets, then system simplicity is maintained, but empty pallets cannot be accelerated aggressively while loaded pallets require gentle acceleration
Solution Approach 1:
The system uses sensors to detect pallet presence, load weight, and position, then feeds this information back to the control system which adjusts magnetic field strength and acceleration profiles for each pallet individually. This enables empty pallets to be accelerated aggressively while loaded pallets receive gentle acceleration
Solution Approach 2:
The conveyor system transitions from static uniform speed operation to dynamic variable speed control. Each pallet can have its acceleration and velocity profile independently adjusted based on real-time conditions, allowing optimal throughput while protecting delicate loads
3Adaptability or versatility
If conventional belt conveyors are used, then basic conveying function is provided, but flexibility for multiple stopping locations and quick reconfiguration is limited
Solution Approach 1:
The magnetic field-based conveyor system provides multiple functions within a single mechanism: conveying, accelerating, decelerating, stopping, and reversing pallets at any location along the belt. The same magnetic field system serves all these functions, enabling multiple stopping locations and quick reconfiguration without adding complex mechanical components
Solution Approach 2:
The system uses programmable magnetic field control to dynamically create stopping locations and adjust conveyor parameters. This allows quick reconfiguration of the manufacturing line by changing control software rather than physical reconfiguration, maintaining simplicity while achieving high flexibility
4Loss of information
If conventional belt conveyors are used, then basic transport function is provided, but data acquisition capabilities and real-time pallet location tracking are limited
Solution Approach 1:
The patent replaces mechanical tracking mechanisms with magnetic field-based sensing and RFID/NFC tags on pallets. This electronic data acquisition system provides real-time pallet location, speed, and status information without complex mechanical sensors, reducing overall system complexity while improving data capabilities
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
Enables flexible and efficient movement of pallets with precise control, improved throughput, and enhanced data tracking, allowing for optimized manufacturing line design and operation.
Implementation Method 1
Each track section may be provided with a magnetic drive system
Implementation Method 2
a magnetic drive system having the same configuration as the linear drive track section but wherein the linear drive is replaced with a scroll cam drive system
Implementation Method 3
a scroll cam drive system having the same configuration as the linear drive track section but wherein the linear drive is replaced with a scroll cam drive system
Data Source
AI summary
A modular multi-mode conveyor system includes at least one linear drive track section configured such that moving elements are independently controlled and moved along the track section and at least one mechanical drive track section having the same configuration as the linear drive track section but where the linear drive is replaced with a scroll cam drive system and moving elements are controlled and moved along the track section by the scroll cam drive system. The scroll cam conveyor system includes a scroll cam. The scroll cam includes a cylindrical cam, a plurality of cam grooves formed on the cylindrical cam, a drive system for rotating the scroll cam, and a moving element. The moving element includes a plurality of cam followers. The plurality of cam grooves are configured to contact with respective ones of the plurality of cam followers to move the moving element.