Positive Displacement Sorter Gate Noise Reduction
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Solution Overview
Problem
Conveyor systems with positive displacement sorters are often noisy due to the opening and closing of gates, necessitating improved control mechanisms for smoother operation.
Innovation Solution
A positive displacement sorter featuring a rotary actuator with a slip joint and electronic divert control that adjusts activation and return control signals for critical damping, combined with redundant diverters, to minimize noise and mechanical shock during gate transitions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional gate mechanisms are used in positive displacement sorters, then the sorting function is achieved, but noise is generated during gate opening and closing
Solution Approach 1:
The patent applies beforehand cushioning by introducing a flexible gate design with elastomeric material and a cushioning mechanism that absorbs impact energy before the gate fully opens or closes. The flexible member is configured to deflect during operation, creating a cushioning effect that reduces noise and mechanical shock during gate transitions between states.
Solution Approach 2:
The patent changes the physical parameters of the gate by replacing rigid construction with flexible elastomeric material. This parameter change allows the gate to deform elastically during operation, absorbing impact energy and reducing noise. The flexible gate can stretch and compress to provide smooth motion control, transforming the gate from a rigid noise-generating component to a flexible noise-reducing element.
2Speed
If faster gate operation is implemented, then conveyor speed increases, but mechanical shock and noise increase
Solution Approach 1:
The cushioning mechanism is positioned to engage before the gate completes its motion, absorbing the remaining kinetic energy and preventing harsh impacts. This allows faster operation while maintaining smooth transitions, as the cushioning acts as a pre-planned energy absorption system that prevents mechanical shock regardless of gate speed.
Solution Approach 2:
The flexible elastomeric material changes the dynamic parameters of the gate system by introducing elasticity and damping. This allows the gate to operate faster while the material's viscoelastic properties dissipate energy, preventing mechanical shock and noise even at higher speeds. The parameter change from rigid to flexible enables speed increase without proportional increase in harmful effects.
3Strength
If rigid gate structures are used, then structural strength is maintained, but noise and mechanical shock increase during operation
Solution Approach 1:
The gate employs composite construction combining rigid structural elements for strength with flexible elastomeric materials for noise reduction. The composite structure maintains the necessary structural integrity while the elastomeric portion absorbs impact energy and reduces noise. This combination allows the gate to be both strong and quiet during operation.
Solution Approach 2:
The patent changes the material parameters by substituting rigid material with flexible elastomeric material in specific portions of the gate. This parameter change reduces noise and mechanical shock while the overall gate structure maintains sufficient strength through the flexible member's elastic properties and structural design. The parameter change transforms the gate from a purely rigid noise-generating structure to a flexible noise-reducing structure with adequate strength.
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 solution reduces noise and extends the lifespan of components by ensuring smooth gate operation and faster conveyor speed, while also providing redundancy for reliable sorting.
Implementation Method 1
A slip joint may be provided between the rotary actuator and the gate. The slip joint resists diverting motion being transferred from the gate to the rotary actuator.
Implementation Method 2
The control monitors the sensor and adjusts the activation control signal as a function of the movement of the gate. The control may adjust the activation control signal to provide critical damping of movement of the gate between states.
Implementation Method 3
The flexible member absorbs impact from contact between the diverting member and the diverting surface.
Data Source
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AI summary
A positive displacement sorter and method of diverting articles includes providing a plurality of interconnected parallel slats defining an endless web that travels in a longitudinal direction, an upper surface of which defines an article-conveying surface and a plurality of pusher shoes. Each of the shoes travels along at least one of the slats in order to laterally divert articles on the conveying surface. Each of the shoes has a diverting member extending below the conveying surface. A plurality of diverting rails below the conveying surface are each capable of engaging the diverting member to cause the associated shoe to travel laterally to divert an article. A plurality of diverters are provided for selectively diverting at least one of the diverting members from a non-diverting path extending longitudinally along the sorter to one of said diverting rails in a diverting state. At least one of the diverters has a gate.