Side Thrust Wheels Reduce Drag on Positive Displacement Sorter Web
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Solution Overview
Problem
Positive displacement sorters experience increased drag, leading to higher electrical current consumption and mechanical resistance, which is difficult to diagnose and resolve, often resulting in ineffective solutions that may cause oil discharge.
Innovation Solution
The method involves auditing the sorter to determine slat skew and modifying the chain assemblies and non-driven sprocket assembly by adding side thrust wheels and locking sprockets to reduce drag, including adjusting the positions of low friction bars to prevent lateral movement and optimizing oil application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If oil is applied to chains to reduce drag, then mechanical resistance decreases, but oil discharge to the floor occurs
Solution Approach 1:
The patent extracts the oil application function from the chain system by introducing side thrust wheels that run against the slats. This removes the harmful oil discharge while maintaining the drag reduction effect through mechanical contact instead of lubrication.
Solution Approach 2:
The side thrust wheels act as an intermediary between the chains and slats, providing the necessary mechanical interaction to reduce drag without requiring oil lubrication. The wheels transfer forces mechanically rather than through lubricated contact.
2Loss of energy
If the web is constrained to reduce lateral movement, then drag decreases, but the structure becomes more complex
Solution Approach 1:
The side thrust wheels serve multiple functions: they constrain lateral movement of the web, reduce drag through proper alignment, and provide a mechanism for adjusting web tension. This multi-functionality reduces overall system complexity despite adding components.
Solution Approach 2:
The confinement surfaces are made adjustable rather than fixed, allowing dynamic adaptation to different web tensions and operating conditions. This maintains optimal drag reduction while accommodating variations in system state.
3Loss of energy
If slat skew is corrected by modifying chain assemblies, then drag reduces, but manufacturing complexity increases
Solution Approach 1:
The side thrust wheels are pre-installed on the chain assemblies during manufacturing, allowing skew correction to be built into the component itself rather than requiring field modifications. This preliminary action simplifies installation and reduces manufacturing complexity.
4Productivity
If motor power is increased to compensate for drag, then productivity is maintained, but energy consumption increases
Solution Approach 1:
The patent changes the physical parameters of the web system by correcting slat skew and reducing lateral movement through side thrust wheels and adjustable confinement surfaces. These parameter changes reduce the energy required to maintain productivity without sacrificing sorting capacity.
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 approach effectively identifies and reduces drag on the sorter web, minimizing electrical current draw and mechanical resistance, while preventing oil discharge and maintaining operational efficiency.
Implementation Method 1
adding side thrust wheels on opposite sides of the web
Implementation Method 2
adjusting positions of at least some of the bars to adjust the spacing between the confinement surfaces. The confinement surfaces may be defined by low friction bars
Data Source
AI summary
A method of reducing drag on the web of a positive displacement sorter is used with a web made up of a plurality of parallel slats interconnected at their opposite ends with chain assemblies in an endless loop. A plurality of pusher shoes each travel along at least one of said slats. The sorter further includes a driven sprocket assembly and a non-driven sprocket assembly. Each of the sprocket assemblies includes at least two sprockets on a shaft, each for engaging one of the chain assemblies. The sprocket assemblies support the chain assemblies at opposite ends of the web. The method includes auditing the sorter including determining if the slats are skewed with respect to the direction of travel of the web. If it is determined that the slats are skewed, then the chain assemblies and the non-driven sprocket assembly are modified. The chain assemblies are modified by adding side thrust wheels on opposite sides of the web. The non-driven sprocket is modified by locking the sprockets to the shaft such that the sprockets rotate together.