Segmented Air-Film Chute for Package Sorting Versatility
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Solution Overview
Problem
Conventional package sorting conveyor systems lack versatility and require significant floor space, struggling to handle various items with different friction coefficients and weights, especially when mixed products like shoes and apparel are sorted, and are affected by humidity changes that cause issues with low-density polyethylene packaging.
Innovation Solution
An air-film lubricated segmented conveying system with a plenum, air-film lubricated entrance and secondary chutes, and a positioner assembly that can adjust the outlet position, using ambient air under pressure to create an air-film for low-friction movement and optional braking, and featuring low-friction, wear-resistant polymeric materials for adaptable operation across different humidity levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional tilt tray sorters with fixed pitch angles are used for each chute, then each product type can be discharged properly, but the system lacks versatility when sorting mixed products with different friction coefficients and weights
Solution Approach 1:
The patent introduces an air-film lubrication system that dynamically adjusts friction characteristics by controlling air flow through the plenum and apertures. This allows the conveying surface to adapt its friction properties in real-time, enabling the same chute to handle different product types (shoes, apparel, mixed sorts) with varying friction coefficients and weights without requiring multiple fixed-angle chutes
Solution Approach 2:
The system changes the friction parameter by introducing or removing air flow through the apertures in the plenum. By varying the air flow rate, the effective friction coefficient between the package and conveying surface is modified, allowing the same physical chute geometry to accommodate different product characteristics
2Ease of manufacture
If apparel in plastic packaging is used with conventional chutes, then packaging is reduced, but the apparel may cling to chute surfaces due to humidity changes
Solution Approach 1:
The patent uses a pneumatic air-film system to create a lubricating layer between the package and chute surface. This air film prevents direct contact and adhesion between the plastic packaging and chute material, eliminating the clinging problem that occurs with humidity changes while maintaining the benefit of reduced packaging
3Strength
If large boxes are used for packages, then product protection is improved, but the boxes may bridge curved secondary chutes and not have sufficient contact for proper discharge
Solution Approach 1:
The air-film lubricated conveying surface acts as an intermediary between the large protective boxes and the chute system. The air film reduces friction and enables large boxes to slide smoothly along the chute without bridging or getting stuck, maintaining both protection and discharge efficiency
4Device complexity
If conventional conveying surfaces are used, then system simplicity is maintained, but significant floor space is required for package sorting
Solution Approach 1:
The air-film lubricated chute system provides multi-functionality, allowing a single chute to handle multiple product types and sorting scenarios that previously required multiple dedicated chutes. This increases sorting capacity and reduces floor space without significantly increasing system complexity
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 provides a versatile and space-efficient solution for sorting diverse packages by reducing friction and ensuring proper discharge across varying weights and packaging materials, maintaining effectiveness in different humidity conditions.
Implementation Method 1
a segmented conveying surface in communication with the apertures, wherein the segmented conveying surface includes at least one air-film lubricated bottom surface and at least one air-film lubricated side wall
Implementation Method 2
using ambient air under pressure to create an air-film for low-friction movement
Implementation Method 3
featuring low-friction, wear-resistant polymeric materials for adaptable operation across different humidity levels
Data Source
AI summary
A package sorting system. The package sorting conveyor system includes a conveying track, at least one unloading station and an air-film lubricated entrance chute upstream of the unloading station to receive the package. In one embodiment, the entrance chute includes a plenum including a plurality of spaced apart apertures and an opening for communicating with an air supply; and a segmented conveying surface in communication with the apertures, wherein the segmented conveying surface includes at least one air-film lubricated bottom surface and at least one air-film lubricated side wall substantially perpendicular to the at least one bottom surface. In one embodiment, the apparatus further includes a positioner assembly for selectively positioning the outlet of the entrance chute.