Sorter Cart Couplings with Pivot Points to Reduce Polygon Effect
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Solution Overview
Problem
Existing line sorters face challenges in reducing energy consumption and acoustic noise while maintaining high performance and reliability, often resulting in increased wear and vibrations due to the polygon effect caused by varying cart velocities and accelerations.
Innovation Solution
The implementation of a line sorter with pivot points in the couplings between sorting carts, allowing them to pivot relative to each other, which reduces the polygon effect by varying acceleration and tension in the closed loop, thereby minimizing unwanted wear and noise without affecting sorting capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the sorter operates at high speed to maintain high sorting capacity, then productivity is improved, but acoustic noise and energy consumption increase due to the polygon effect
Solution Approach 1:
The coupling between carts is made dynamic by introducing pivot points that allow relative movement. This enables the cart sequence to adapt its configuration during operation, transforming the rigid polygon structure into a flexible system that can absorb velocity variations without generating excessive noise or energy consumption.
Solution Approach 2:
The invention changes the geometric parameters of the cart coupling by positioning pivot points at specific distances from cart ends. This parameter modification alters the kinematic characteristics of the cart sequence, reducing the polygon effect's impact on noise and energy while preserving sorting capacity.
2Reliability
If rigid couplings are used between carts to maintain structural stability, then reliability is improved, but wear and vibrations increase due to the polygon effect
Solution Approach 1:
The coupling is transformed from a rigid connection to a dynamic articulation with pivot points. This allows the cart sequence to flex and adapt during motion, reducing vibrations and wear while maintaining the structural integrity needed for reliable operation.
Solution Approach 2:
The coupling mechanism incorporates flexible elements through the pivot point design, allowing controlled relative movement between carts. This flexibility reduces the transmission of vibrations and shocks through the cart sequence, decreasing wear on components while preserving system reliability.
3Object-generated harmful factors
If the polygon effect is reduced by modifying cart couplings, then acoustic noise and energy consumption decrease, but sorting capacity may be affected
Solution Approach 1:
The dynamic coupling with pivot points maintains the ability of the cart sequence to move efficiently through the sorting system while reducing the polygon effect. The articulated design allows smooth motion transitions that preserve sorting capacity without the excessive noise and energy consumption associated with rigid couplings.
Solution Approach 2:
By optimizing the position of pivot points relative to cart ends, the invention achieves a balance between reducing the polygon effect and maintaining sorting capacity. The specific parameter choices ensure that noise is reduced while the system continues to handle items at the required throughput.
Data Source
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AI summary
In order, e.g., to provide a line sorter in which acoustic noise resulting from the polygon effect is reduced, there is disclosed a sorter (102) for sorting items of various shapes, sizes and weights, such as postal parcels or airport baggage. The sorter includes a closed loop comprising a plurality of sorting carts (302 )for moving along an upper track section, a lower track section and end track sections in a moving direction. The plurality of carts are coupled at couplings (312), which enable the carts to pivot relatively to each other in at least one plane when in operation. Each cart is able to pivot relatively to an adjacent cart at two or more pivot points (404, 414, 1002) where the two or more pivot points are positioned a pivot point distance greater than zero apart in the moving direction of the carts.