Singulation Conveyor Rollers With Different Cross-Sectional Profiles
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Solution Overview
Problem
In material handling environments, singulation conveyors face challenges in efficiently de-shingling items that are shingled or overlapping, as existing systems often fail to effectively separate items with varying degrees of overlap, leading to obscured indicia and reduced scanning accuracy.
Innovation Solution
A singulation conveyor system featuring rollers with different cross-sectional profiles, where each roller is actuated based on specific rotation patterns and speeds to selectively separate shingled items, utilizing a combination of high-friction and smooth surfaces to manipulate and separate items effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If existing singulation conveyor systems are used, then items can be conveyed, but they fail to effectively separate shingled or overlapping items, resulting in obscured indicia and reduced scanning accuracy
Solution Approach 1:
The patent applies local quality by using rollers with different cross-sectional profiles (e.g., crowned vs. flat) at specific positions along the conveyor. These localized variations in roller geometry create targeted manipulation zones that address specific shingling patterns without affecting the entire conveyor system, thereby improving both separation effectiveness and scanning accuracy.
Solution Approach 2:
The system dynamically adjusts roller rotation speeds independently for different rollers based on real-time detection of shingling conditions. This dynamic control allows the conveyor to adapt to varying degrees of overlap and shingling patterns, ensuring reliable item separation while maintaining optimal scanning conditions.
2Adaptability or versatility
If uniform rollers are used on the singulation conveyor, then the system structure is simple, but they cannot provide tailored manipulation for different shingling patterns
Solution Approach 1:
Different roller cross-sectional profiles are implemented at specific locations along the conveyor based on the expected shingling patterns in those zones. This localized differentiation provides adaptability to varying shingling conditions while limiting complexity to only where needed, rather than making all rollers complex.
Solution Approach 2:
The system changes physical parameters of the rollers (cross-sectional profile geometry and rotation speed) to match different shingling patterns. By varying these parameters selectively across the conveyor system, the patent achieves high adaptability without requiring complete system complexity.
3Force
If high-friction surfaces are used on all rollers, then grip on items is maximized, but it becomes difficult to create desired gaps between items for scanning
Solution Approach 1:
The patent uses high-friction roller surfaces in zones where item acquisition and initial manipulation is needed, then transitions to low-friction surfaces in zones where items need to be released and gaps created. This localized friction variation allows the system to maximize grip where needed while enabling gap creation for scanning in other zones.
Solution Approach 2:
The conveyor system periodically alternates between high-grip and low-grip zones as items move through different roller sections. This periodic variation in friction characteristics allows the system to repeatedly apply grip force for manipulation, then release for gap creation, cycling through these actions as items progress along the conveyor.
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 precise movement and tailored singulation actions for each shingle instance, varying grip as needed to effectively de-shingle items, improving item separation and scanning accuracy by creating desired gaps between items.
Implementation Method 1
a second surface of the second roller and a fourth surface of the fourth roller can comprise a higher coefficient of friction than a third surface of a third roller
Data Source
AI summary
A singulation conveyor is described. The singulation conveyor includes multiple rollers, for example, a first roller and a second roller. In some example embodiments, the first roller can be of a first roller cross-sectional profile and the second roller can be of a second roller cross-sectional profile. The first roller cross-sectional profile can be defined by a sleeve mounted around a circumference of the first roller and a dowel positioned between the sleeve and the first roller. Further, in some examples, the first roller cross-sectional profile can be different from the second roller cross-sectional profile. Furthermore, according to some examples, the first roller and the second roller can be configured to be rotated based on a first rotation pattern and a second rotation pattern respectively, to cause singulation of a shingled item.