Sortation Conveyor Pusher Diversion Control
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Solution Overview
Problem
Conveyor systems face challenges in sorting articles with small gaps between them, as existing sortation devices struggle to accurately assign and divert pusher elements across the conveying surface at the right time, affecting throughput.
Innovation Solution
A sortation conveyor apparatus with a control system that assigns multiple pusher elements to each article and activates them at the correct location to divert articles onto branch lines, even when adjacent articles are spaced closer than the width of a single pusher element, using a single activating mechanism and guide tracks to guide the pusher elements diagonally across the surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single pusher element is used to divert articles, then the device complexity is reduced, but the productivity decreases because larger gaps between articles are required
Solution Approach 1:
The pusher element is divided into multiple independently controllable segments or zones along its length. Each segment can be activated separately to push articles of different sizes or to handle multiple articles simultaneously, allowing smaller gaps between articles while maintaining manageable device complexity through modular control.
Solution Approach 2:
The pusher element transitions from a static, uniform structure to a dynamic, selectively actuated mechanism. Different portions of the pusher can be activated at different times or with different forces based on real-time detection of article characteristics, enabling higher throughput by reducing required gaps while keeping the overall device structure relatively simple.
2Productivity
If the gap between adjacent articles is reduced to increase throughput, then the productivity increases, but the reliability of accurate pusher assignment and timing deteriorates
Solution Approach 1:
Articles are pre-scaned and classified upstream of the sortation point using sensors or vision systems. The control system pre-calculates the optimal pusher assignment and timing before the articles reach the divert location, allowing accurate differentiation even when gaps are minimal. This preliminary information gathering ensures reliable pusher element assignment despite reduced spacing.
Solution Approach 2:
Real-time feedback from sensors monitoring article position, speed, and characteristics is continuously fed to the control system. This feedback loop allows dynamic adjustment of pusher activation timing and selection, ensuring accurate article-divert location matching even when articles are closely spaced, thereby maintaining high reliability at increased throughput.
3Reliability
If multiple pusher elements are assigned to each article to ensure proper diversion, then the reliability of article diversion improves, but the device complexity increases
Solution Approach 1:
Multiple pusher elements that would traditionally require independent control are merged into a single integrated pusher assembly with selective actuation capability. The control system manages this unified structure by activating specific segments or zones of the pusher rather than controlling entirely separate elements, reducing control complexity while maintaining the ability to reliably divert articles through coordinated segment activation.
Data Source
AI summary
Sortation conveyor apparatus and methods for selectively diverting articles from a primary conveying surface onto branch lines are provided. In one embodiment, a method comprises assigning memory cells to first and second articles based upon the location of the articles along the primary conveyor, and determining if the second article is to be diverted to the same location as the first article, and if so, assigning the trailing cell assigned to the trailing end of the first article to other than the first article.