Sorting Machine Crate Interception Damping Mechanism
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Solution Overview
Problem
Existing sorting machines for crates with folding side walls suffer from low operational performance and reliability at higher conveyor belt speeds, leading to crate misalignment, jamming, and inability to handle multiple crate models efficiently.
Innovation Solution
Incorporation of blocking devices with damping functions, ejection devices that operate on both sides, stacking devices with dwell areas, and a modular machine design allowing expansion or reduction of crate interception and ejection units, combined with image recognition and light barriers for precise tray positioning and model detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conveyor belt speed is increased to improve productivity, then sorting throughput increases, but crate alignment and ejection accuracy deteriorate due to rebound and tilting
Solution Approach 1:
A damping element is introduced between the blocking device and the crate to absorb impact energy during blocking. This cushioning mechanism prevents rebound of the crate when blocked at higher conveyor speeds, maintaining alignment accuracy while enabling increased throughput.
Solution Approach 2:
The damping element acts as an intermediary between the blocking device and the crate. It mediates the interaction by softening the impact, preventing direct rigid contact that causes rebound and misalignment, thereby allowing high-speed operation without sacrificing precision.
2Device complexity
If lateral ejection is used to simplify the ejection mechanism, then device complexity is reduced, but ejection accuracy and reliability worsen at higher speeds due to tilted crate positions
Solution Approach 1:
The damping element is positioned to act before ejection, ensuring the crate is properly cushioned and aligned during the blocking phase. This preliminary cushioning prevents tilting that would otherwise occur during lateral ejection at high speeds, maintaining reliability without increasing mechanism complexity.
3Device complexity
If single-sided stacking is used to reduce device complexity, then stacking mechanism complexity is reduced, but productivity is limited due to inability to receive crates during unloading
Solution Approach 1:
The stacking device is designed with a dwell area that extends in the direction of crate movement, creating an additional spatial dimension for crate reception. This allows crates to be stacked continuously during unloading operations, increasing productivity while maintaining relatively simple single-sided stacking mechanics.
4Adaptability or versatility
If modular design with multiple interception units is implemented to increase adaptability, then versatility for handling different crate models is improved, but device complexity increases
Solution Approach 1:
The sorting machine is divided into modular interception units, each capable of handling specific crate models. These standardized modules can be added or removed based on the variety of crate types to be sorted, providing adaptability while keeping individual module complexity manageable through standardization.
Solution Approach 2:
Each interception unit is designed with universal components (conveyor belt, blocking device, damping element, ejection mechanism) that can handle different crate models. This multi-functionality allows the same basic module to be reused across different sorting configurations, reducing overall system complexity despite increased versatility.
Data Source
Figure 1
Figure 2
Figure 3~3b
AI summary
Sorting machine for crates with movable folded side walls or with fixed side walls, comprising a conveyor belt (1) with a loading area for the crates (X) to be sorted according to model, color, or structural and/or dimensional characteristics, a recognition station (A) for the crate model, and at least one intercepting and stacking unit (B1, B2, B3) for the crates (X) recognized based on the model, wherein the intercepting and stacking unit consists of a stop element (4s, 41s, 42s) movable between an upper rest position (H) and a lowered active intercepting position (I) for the crate (1a) (X) conveyed on the conveyor belt (1), which in a first phase, after assuming the intercepting position (I), progressively decelerates the movement of the crate (1a) pushed by the conveyor belt (1) against the said stop element. then stopping the same in one,the position (T) corresponding to the lateral arrangement of the stacking device (5, 5a, 5b, 5d, 5e) and consists of a gripping and transfer device for the trays (X) equipped with jaws (3g), wherein the transfer movement (Xh) transverse to the conveyor belt (1) and the movement of the release (Xv) of the trays (X) in a horizontal position above the stacking device are effected.