Singulator With Inclined Roller Conveyers For Article Separation
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Solution Overview
Problem
Existing singulators face challenges in correctly singulating articles that are superimposed and require large dimensions and complex control systems, leading to increased costs and reduced reliability.
Innovation Solution
A singulator design featuring a converger module with a central zone and inclined roller conveyors, and a diverger module with an ascent zone to separate superimposed articles, along with a compact selector module using conveyor belts with varying coefficients of friction to manage article alignment and movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a complex apparatus with cameras and individually movable conveyor belts is used to scan and control article positions, then article singulation precision is improved, but device complexity and cost increase significantly
Solution Approach 1:
The patent extracts and removes the complex control system (cameras, control units, individual motor control for each conveyor belt) from the singulator design. Instead, it uses a simplified mechanical approach with inclined roller conveyors that passively guide articles to the central zone through gravity and geometry, achieving singulation without active electronic control or monitoring systems.
Solution Approach 2:
The inclined roller conveyors are designed to automatically guide articles to the central singulation zone using gravity and the inclined geometry, without requiring external control systems. The articles self-organize into single-file lines through the mechanical design of the conveyor paths, eliminating the need for active monitoring and control.
2Manufacturing precision
If a high-friction central conveyor belt with recirculating belts is used to handle superimposed articles, then singulation capability is improved, but device dimensions and volume increase
Solution Approach 1:
The patent introduces an vertical dimension through the inclined roller conveyors, which angle downward toward the central zone. This inclined geometry allows articles to be guided from lateral positions into the central singulation area without requiring large horizontal recirculating belt systems, effectively using the vertical drop to achieve what would otherwise require extensive horizontal space.
3Manufacturing precision
If multiple independently movable conveyor belts with individual motors are used, then article positioning precision is improved, but reliability decreases due to increased mechanical parts
Solution Approach 1:
The patent merges multiple conveyor functions into unified inclined roller conveyor systems that guide articles passively. Instead of having multiple independently controlled belts with individual motors, the design uses integrated inclined paths that collectively achieve article positioning and singulation through their geometric arrangement, reducing the number of independent mechanical drive systems.
4Manufacturing precision
If cameras and control units are used to monitor and drive conveyor belts at differentiated speeds, then article spacing and orientation precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces the electronic monitoring and control system (cameras, control units, motor control circuits) with a purely mechanical solution. The inclined roller conveyors use gravitational force and geometric positioning to automatically space and orient articles, substituting electronic control with passive mechanical guidance that achieves the same positioning precision without complex electronics.
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
Ensures effective singulation of articles, reduces device size and complexity, and enhances reliability by minimizing active control functions and mechanical parts, while maintaining high throughput.
Implementation Method 1
a first converger station consisting of a central high-friction conveyor belt flanked on both sides by two respective roller conveyors
Implementation Method 2
a central high-friction conveyor belt... designed to receive the articles that have been brought to the central zone
Data Source
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AI summary
A singulator has been realised which comprises a diverger module having a first zone (13) configured to impart to articles (5) resting thereon an advancement motion along a main advancement direction, a second zone (14) flanking the first zone (13) along the advancement direction. The second zone (14) is configured to impart to the articles (5) resting thereon an advancement motion along the main direction and a lateral movement away from the first zone (13). The first zone (13) of the diverger module projects, at least for a length, away from a prevalent average plane of extension of the second zone (14) in the direction of the articles (5) to be supported so as to define an ascent zone of the diverger module, the ascent zone comprising an ascending ramp (44a) and a descending ramp (44b) consecutively disposed along the advancement direction.