Sorting Apparatus Pneumatic Workpiece Transfer
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Solution Overview
Problem
Existing sorting apparatuses struggle to efficiently sort sheet-like workpieces formed by piled-up unwoven fabrics, such as disposable diapers and sanitary napkins, at high speeds due to bending and jamming issues caused by collisions with rotating flaps and air gaps between conveyance routes.
Innovation Solution
A sorting apparatus with a conveyor mechanism and a transferring mechanism using guide members and rotation supporting units to smoothly transfer workpieces from one conveyance route to another without collision, ensuring continuous and secure conveyance by abutting one surface of the workpiece and using suction and blower systems to maintain tight adherence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a rotating flap is used to sort out workpieces at high speed, then sorting speed is improved, but the workpiece collides with the flap causing bending and jamming
Solution Approach 1:
The patent replaces the mechanical rotating flap system with a suction-based conveying system. Instead of using mechanical collision to redirect workpieces, the invention uses suction holes to create negative pressure that actively draws workpieces onto the conveying belt, eliminating collision-induced bending and jamming while maintaining high-speed sorting capability
Solution Approach 2:
The patent employs pneumatic principles through suction holes and airflow control to achieve workpiece conveyance. By controlling air flow through suction holes, the system creates pressure differential that reliably guides workpieces without mechanical contact, resolving the contradiction between high-speed operation and workpiece integrity
2Ease of operation
If the flap rotates upward to sort workpieces, then sorting function is achieved, but air gaps cause workpiece distal end to enter space and cause jamming
Solution Approach 1:
The patent introduces a suction-based conveying belt as an intermediary between the sorting decision and the final conveyance destination. This intermediary system actively manages the transition of workpieces through controlled suction, preventing the distal end from entering air gaps and causing jamming, while maintaining smooth and reliable conveyance
3Productivity
If soft workpieces are conveyed at high speed through a rotating flap system, then sorting efficiency is improved, but the soft workpiece bends easily causing inability to pass and jamming
Solution Approach 1:
The patent replaces mechanical collision-based sorting with a pneumatic suction system that maintains workpiece shape stability. By using controlled air pressure through suction holes, the system guides soft workpieces without mechanical impact, preserving their structural integrity while achieving high-speed sorting efficiency
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 apparatus ensures smooth and reliable sorting of high-speed workpieces by preventing bending and jamming, allowing for precise transfer to designated conveyance routes based on quality criteria, even with soft materials like unwoven fabrics.
Implementation Method 1
a suction hole 13c configured to suck external air
Implementation Method 2
a blower 91 configured to blow air to the workpiece W
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The belt conveyer 10 includes guide members 100F and 100R. The guide members 100F and 100R are disposed between the endless belts 13A and 13B. The belt conveyer has a suction box 81 and a blower 91. The belt conveyor 10 becomes able to suction the air via the conveyance surface 10A that is the workpiece holding surface.