Sorting Conveyor Bridge With Four Degrees Of Freedom
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Solution Overview
Problem
Existing sorting conveyor systems lack the flexibility and precision to efficiently sort items into discrete collecting stations with multiple orientations, limiting their ability to handle diverse items and optimize unloading processes.
Innovation Solution
A sorting conveyor system with a primary conveyor and multiple unloading stations, equipped with a sorting bridge that offers four degrees of freedom, including axial displacement, pivotal motion, and linear belt-driven transfer mechanisms, allowing for precise item deflection and routing to designated unloading stations using an item recognition system and controller for efficient sorting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional sorting conveyor system with fixed orientation is used, then the system structure is simple, but the system lacks flexibility to handle diverse items and cannot optimize unloading processes for multiple orientations
Solution Approach 1:
The sorting bridge is designed with four degrees of freedom including pivotal motion capability, allowing it to dynamically adjust its orientation angle relative to the conveying plane. This enables the system to adapt to diverse item types and orientations by changing the bridge's angular position, resolving the contradiction between system simplicity and adaptability
Solution Approach 2:
The invention introduces pivotal motion as an additional degree of freedom, adding rotational capability about an axis normal to the conveying plane. This dimensional addition allows the sorting bridge to operate at multiple orientations, significantly enhancing system versatility without proportionally increasing complexity
2Manufacturing precision
If a sorting bridge with multiple degrees of freedom is implemented, then sorting precision and efficiency are improved, but the device complexity increases
Solution Approach 1:
The sorting bridge mechanism is segmented into independent degrees of freedom (axial displacement, vertical displacement, pivotal motion, and lateral transfer). Each degree of freedom is controlled separately, allowing precise positioning through coordinated movement of individual components, which maintains sorting precision while managing complexity through modular control
Solution Approach 2:
The sorting bridge with four degrees of freedom serves multiple functions: it can sort items to different lateral positions, adjust orientation angles, control vertical passage through the bridge, and deflect items to right or left unloading stations. This multi-functionality achieves high sorting precision while consolidating multiple operations into a single versatile mechanism
3Ease of operation
If fixed orientation sorting is used, then the system is easy to operate, but the system cannot optimize unloading processes for different item orientations
Solution Approach 1:
The item deflecting mechanism is configured to automatically deflect items to the appropriate unloading station based on the sorting requirements. The system self-adjusts by coordinating the pivotal motion and lateral transfer of the sorting bridge, reducing the need for complex manual operation while maintaining ease of use through automated orientation optimization
Data Source
AI summary
A sorting conveyor system comprising a primary conveyor extending along a conveying plane and configured with an item loading location and a plurality of unloading locations extending along the conveying plane, and at least one sorting bridge configured with an item sorting mechanism. The item sorting mechanism is configurable for displacing in four distinct orientations, wherein the first displacement orientation is associated with displacing the item sorting mechanism along the conveying plane. The second displacement orientation is associated with controlling passages of an item through the sorting bridge, the third displacement orientation is associated with controlled unloading of an item at an unloading location, the fourth displacement orientation is associated with controlling an impact angle of the item sorting mechanism with an item.