Singulator Ports Divert Thin Items to Prevent Conveyor Jams
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Solution Overview
Problem
Conveyor systems in fulfillment centers face jams and operational shutdowns due to items with small thicknesses that cannot navigate the standard conveyor path, requiring manual intervention and system restarts.
Innovation Solution
The conveyor system incorporates a singulator with a side wall and ports that divert items with specific thicknesses along the side wall, preventing them from reaching the conveyor path and allowing for manual scanning and processing, thereby preventing equipment jams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If items with small thickness are transported on the standard conveyor path, then the conveyor system can handle all items, but equipment jams occur requiring manual intervention and system shutdowns
Solution Approach 1:
The singulator divides the item flow into separate paths: items meeting thickness criteria are diverted through ports away from the conveyor path, while other items continue on the standard path. This segmentation prevents thin items from causing jams while maintaining overall system productivity
Solution Approach 2:
The singulator acts as an intermediary device between the incoming item stream and the conveyor path. It mediates by selectively diverting problematic thin items through ports before they can reach the conveyor, thereby protecting the conveyor system from jams while allowing continuous operation
2Reliability
If all items are processed through the standard conveyor path, then the system structure remains simple, but items with small thickness cause operational shutdowns
Solution Approach 1:
The system is segmented into a main conveyor path and a diverter path with ports. This segmentation adds only the necessary complexity to handle thin items while keeping the majority of the system structure simple and unchanged
Solution Approach 2:
The singulator introduces a vertical dimension with ports that open upward to divert items. This dimensional change allows thin items to be redirected without significantly complicating the horizontal conveyor system layout
3Reliability
If items with small thickness are diverted through ports, then equipment jams are prevented, but the system requires additional singulator components
Solution Approach 1:
The singulator applies local quality by creating specific diversion points (ports) only where needed in the side wall. This localized approach handles thin items effectively without requiring complex modifications throughout the entire system
Data Source
AI summary
Disclosed are various embodiments for a singulator that has a port for diverting items. An item is received on at least one conveyor segment of a singulator. The item is transported using at least one conveyor segment to a side wall of the singulator. The item is transported using at least one conveyor segment through a port in the side wall of the singulator.