Sorting Conveyor Pivoting Flap Amplitude Control
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Solution Overview
Problem
Existing sorting conveyor systems for postal parcels with pivoting flaps face issues of premature wear, noise pollution, and high electrical consumption due to repeated maximum amplitude openings, which can lead to package jams and the 'rebound effect' from heterogeneous objects.
Innovation Solution
A sorting conveyor with pivoting flaps controlled by a unit that adjusts the opening amplitude based on object thickness, using a toothed belt and motor system to reduce vibrations and opening time, and featuring upstream and downstream flaps to manage object diversion efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the opening amplitude of the flaps is set to maximum to avoid package jams, then the reliability of parcel evacuation is improved, but the flaps generate strong vibrations causing premature wear of crank rods and significant noise pollution
Solution Approach 1:
The patent applies dynamics by making the flap opening amplitude variable rather than fixed. The control unit adjusts the opening amplitude dynamically based on the thickness of each parcel, allowing the system to adapt its operation to different object characteristics. This resolves the contradiction by enabling reliable evacuation of thick parcels with maximum amplitude while using reduced amplitude for thin parcels, thereby minimizing vibrations and noise without compromising evacuation reliability.
Solution Approach 2:
The patent changes the parameter of opening amplitude from a constant maximum value to a variable parameter that depends on parcel thickness. The control unit retrieves thickness data from memory and determines the appropriate opening amplitude accordingly. This parameter change allows the system to maintain reliable parcel evacuation while reducing harmful vibrations and noise by using smaller amplitudes for thin parcels.
2Adaptability or versatility
If the opening amplitude of the flaps is set to maximum to handle heterogeneous objects, then the adaptability to different parcel thicknesses is improved, but the motor torque requirement and electrical consumption increase
Solution Approach 1:
The system uses dynamic control of the motor-driven toothed belt to adjust flap opening amplitude in real-time based on parcel thickness. This dynamic approach maintains high adaptability to heterogeneous objects while reducing energy consumption by avoiding unnecessary maximum amplitude openings for thin parcels.
Solution Approach 2:
The patent changes the operating parameter of opening amplitude from a fixed maximum to a variable parameter determined by parcel thickness data. This parameter optimization reduces the motor torque requirements and electrical consumption while maintaining the ability to handle heterogeneous objects effectively.
3Productivity
If the opening amplitude of the flaps is set to maximum to ensure complete evacuation, then the productivity of the sorting system is improved, but the opening time increases
Solution Approach 1:
The control unit dynamically adjusts the opening amplitude based on parcel thickness, allowing thin parcels to be evacuated with smaller, faster openings. This dynamic optimization reduces the time required for each opening operation while maintaining high sorting throughput by using maximum amplitude only when necessary for thick parcels.
Solution Approach 2:
By changing the opening amplitude parameter from a fixed maximum to a variable value based on parcel thickness, the system reduces the time required for flap operations on thin parcels while maintaining effective evacuation for thick parcels, thereby optimizing overall sorting productivity.
4Reliability
If the opening amplitude of the flaps is set to maximum to prevent jams, then the reliability of parcel evacuation is improved, but the wear of crank rods increases causing premature failure
Solution Approach 1:
The patent implements dynamic control where the opening amplitude is adjusted based on parcel thickness data retrieved from memory. This dynamic approach ensures reliable evacuation of thick parcels with maximum amplitude openings while using reduced amplitude for thin parcels, significantly reducing the mechanical wear on crank rods and extending their service life.
Solution Approach 2:
The control unit changes the opening amplitude parameter from a constant maximum to a variable parameter determined by parcel thickness. This parameter optimization maintains reliable parcel evacuation while minimizing the wear on crank rods, thereby extending their operational lifespan.
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
This solution reduces vibrations, minimizes the 'rebound effect', and optimizes conveying homogeneity by varying flap opening amplitudes, enabling the efficient sorting of a large number of heterogeneous objects while reducing wear and energy consumption.
Implementation Method 1
at least one toothed belt attached to each flap to make it pivot around an axis of rotation, said belt being driven in rotation by a motor controlled by the control/command unit
Data Source
Figure 1~3
Figure 4~6
AI summary
The invention relates to a sorting conveyor (6) with pivoting flaps (7, 7a, 7b) for sorting postal parcel-type objects (2) into sorting outlets (4) according to a sorting indication affixed to said objects. The conveyor includes a control unit (11) designed to control the pivoting of each flap between a closed position in which the flap forms a conveying section capable of transporting an object in a certain conveying direction (D1), and an open position in which the flap interrupts the conveying of an object on said conveyor to divert it to a suitable sorting outlet (4). The control unit (11) is further arranged to retrieve into memory an indicative value of a certain thickness of said object (2) to be diverted and to control, in turn, the pivoting of the flap in the open position through a certain opening amplitude determined according to said thickness value of the object to be diverted.