Sorting Conveyor With Self-Tensioning Pivot Blocks
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Solution Overview
Problem
Conventional package sorting conveyors face challenges such as requiring skilled operators for setup and maintenance, causing package damage due to rough handling, and experiencing operational issues like 'cascading errors' and high energy consumption from linear induction motors.
Innovation Solution
A sorting conveyor system with pivot block assemblies and a self-tensioning adjustment assembly, featuring a train of conveyor carts with tiltable support apparatuses and an opposed roller motor assembly, which includes cantilevered drive rollers and a braking system to ensure precise positioning and gentle package discharge, reducing energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional laterally tilting conveyor carriers are used to dump packages into outfeed chutes, then the package sorting function is achieved, but the packages are roughly tumbled or rolled causing damage to package contents
Solution Approach 1:
The tilting mechanism is divided into two independent stages: lateral tilting to position the package over the chute, and then longitudinal tilting to gently release the package. This segmentation of the tilting function eliminates the rough tumbling effect while maintaining sorting productivity.
Solution Approach 2:
Instead of tilting the carrier forward to dump packages (conventional method), the invention tilts the carrier backward to gently release packages. This inversion of the tilting direction allows packages to be released in a controlled manner rather than being forcefully dumped, reducing damage.
2Speed
If packages are unloaded from the carrier while traveling at full conveyor speed, then the sorting speed is maintained, but packages slam into the forward retaining wall of the outfeed chute causing damage
Solution Approach 1:
The carrier is tilted in advance to position the package over the chute before release, and the tilting action continues during the unloading process. This preliminary positioning and controlled tilting during travel allows packages to be gently placed into chutes even while moving at full conveyor speed, preventing impact damage.
3Reliability
If the outfeed chute is made relatively wide to accommodate full-speed package unloading, then packages do not miss the chute, but the overall size of the conveyor system increases unnecessarily
Solution Approach 1:
The unloading process is segmented into lateral positioning (tilting carrier side-to-side) and longitudinal release. This allows packages to be precisely positioned over narrower chutes through lateral tilting before being released, eliminating the need for wide chutes and reducing overall system size while maintaining delivery accuracy.
4Device complexity
If conventional conveyor carriers with single horizontal tilt axis are used, then the structure is simple, but the packages are roughly handled and the conveyor system size increases
Solution Approach 1:
The tilt mechanism is segmented into two independent tilt axes: one for lateral movement and one for longitudinal movement. This segmentation enables gentle package handling while maintaining relatively simple carrier structure, avoiding the need for oversized systems.
Solution Approach 2:
The carrier incorporates dynamic tilting capabilities with two adjustable tilt axes that can operate independently. This dynamic structure allows adaptive control of package release while maintaining structural efficiency, avoiding the need for overly complex or oversized designs.
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 system improves setup and maintenance efficiency, reduces package damage through gentle handling, and decreases energy usage by optimizing the mechanical load distribution and motor operation.
Implementation Method 1
a fin extending downwardly between the two drive rollers
Implementation Method 2
a braking assembly adapted to slow and stop the carts
Data Source
AI summary
A sorting conveyor for transporting objects and unloading objects at one or more unloading stations adjacent the conveyor. The sorting conveyor includes a conveyor track, a train of conveyor carts connected end-to-end, and an opposed roller motor assembly. The opposed roller motor assembly may include a motor; a support frame attached to the conveyor track for supporting the motor; and a pair of cantilevered, drive rollers connected to the motor and to one pivot block assembly and another pivot block assembly adapted for positioning the drive roller adjacent to one surface of an extended fin driven member. The pivot block assemblies may be coupled together with a self-tensioning adjustment assembly. In some examples, the self-tensioning adjustment assembly may be adapted so that movement of each pivot block assembly mirrors movement of the other pivot block assembly.