Article Sorting Equipment Position Detection via Light-Blocking Plates

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Solution Overview

Problem

Conventional article sorting systems face issues with precise lateral pushing of articles due to inaccuracies in calculating the moving distance of articles on endless chains, leading to potential accidents, reduced efficiency, and delayed detection of shoe damage, which affects sorting accuracy and speed.

Innovation Solution

The system incorporates detected plates on article supporters that are detected by a detection device, allowing for precise positioning and movement of article lateral pushers, preventing accidents and enabling early detection of shoe damage through light-blocking mechanisms, ensuring accurate sorting and increased efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If the moving distance of articles is calculated based on pulse encoder counts, then the sorting position can be controlled, but the measurement precision deteriorates due to chain extension causing inaccurate distance calculation

Engineering Contradiction:
Improvemoving distance measurement precisionVSAvoidsorting position accuracy
Core Design Contradiction:
Measurement precisionVSReliability

Solution Approach 1:

The patent replaces the mechanical pulse encoder-based distance calculation system with an optical detection system. Detected plates attached to article supporters block light beams from detection devices, providing direct positional feedback without relying on chain length or pulse counting. This substitution eliminates measurement errors caused by chain extension and provides accurate real-time position detection.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If shoes are moved along slats to laterally push articles, then sorting efficiency is improved, but the risk of accidents increases when articles are not properly aligned

Engineering Contradiction:
Improvesorting efficiencyVSAvoidaccident risk from article misalignment
Core Design Contradiction:
ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent implements a feedback mechanism where detection devices continuously monitor the position of article supporters and shoes. The system receives detection results and determines whether to actually move shoes based on this feedback. This closed-loop control prevents accidental shoe movement when articles are not properly positioned, eliminating the harmful effect while maintaining sorting efficiency.

Inventive Principle:
Principle #23Feedback

3Measurement precision

If the detection device uses light-blocking detected plates, then the positioning precision is improved, but the device complexity increases due to additional components

Engineering Contradiction:
Improveposition detection precisionVSAvoiddetection system complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The patent uses simple detected plates that copy the function of complex mechanical encoders. Instead of using intricate pulse counting mechanisms, the system employs straightforward light-blocking plates that provide equivalent positional information through optical detection. This simplifies the overall system while achieving high precision, as the detected plates are basic components that can be easily manufactured and maintained.

Inventive Principle:
Principle #26Copying

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 ensures reliable lateral pushing of articles at predetermined points, prevents accidents by maintaining proper article alignment, and enhances sorting efficiency by promptly identifying and addressing shoe damage, thus optimizing the sorting process.

Implementation Method 1

detected plates respectively attached to the article supporters, and a detection device for detecting the detected plates

Methodology Applied
Scientific EffectLight-blocking mechanism: Absorption (EM radiation)

Data Source

PatentUS8776982B2Article sorting equipment
Publication Date: 2014.07.15 DAIFUKU CO LTD
  • US8776982B2 patent drawing
  • US8776982B2 patent drawing
  • US8776982B2 patent drawing

AI summary

Article sorting equipment of the present invention comprises: a rotation drive device; endless chains rotated on a conveyance route by the rotation drive device; a plurality of slats on which the article is placed and conveyed; and shoes attached to the slats. In the present invention, detected plates are attached to the slats, and a detection device for detecting the detected plates is provided. Based on timing of detecting the detected plates, positions of the slats are obtained.