Sorting System Electromagnetic Drive Latching Mechanism
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Solution Overview
Problem
Conveyor belts in sorting systems, used for transporting and sorting piece goods, face inefficiencies due to friction losses, gear backlash, movement inaccuracies, and maintenance-intensive geared motors, leading to poor performance and reliability.
Innovation Solution
A sorting system utilizing a direct drive mechanism with a conveyor rotor and local stator for the cross belt, employing electromagnetic interaction to provide a latching moment and prevent piece goods from falling, especially in curves and inclines, using a latching device with soft-magnetic material and a winding system to enhance holding torque.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a geared motor is used to drive the conveyor belt, then the conveyor belt can be driven, but friction losses, gear backlash, movement inaccuracies, and wear occur leading to poor efficiency and maintenance-intensive operation
Solution Approach 1:
The patent replaces the mechanical geared motor system with an electromagnetic drive system consisting of a conveyor rotor with permanent magnets and a local stator. This substitution eliminates mechanical friction and gear backlash by using electromagnetic fields to directly drive the conveyor belt, thereby reducing energy losses and improving reliability.
Solution Approach 2:
The patent extracts and removes the geared motor mechanism from the drive system. By eliminating the gearbox and mechanical transmission components, the system avoids friction losses, wear, and maintenance issues associated with mechanical gears while maintaining the driving function through electromagnetic interaction.
2Manufacturing precision
If a geared motor is used to drive the conveyor belt, then the conveyor belt can be driven, but movement inaccuracies occur
Solution Approach 1:
The electromagnetic drive system provides more precise control over the conveyor belt movement compared to mechanical gearing. The electromagnetic field can be precisely controlled to achieve accurate speed and position control, eliminating the movement inaccuracies caused by gear backlash and mechanical play.
3Reliability
If a latching device is added to prevent piece goods from falling in curves and inclines, then security of transport is improved, but device complexity increases
Solution Approach 1:
The latching device is integrated into the existing electromagnetic drive system, serving multiple functions. It not only provides the primary driving force through electromagnetic interaction but also acts as a latching mechanism to prevent piece goods from falling during curves and inclines, thereby reducing overall system complexity through multi-functionality.
Solution Approach 2:
The patent merges the drive function and the latching function into a single integrated system. The local stator and conveyor rotor combination serves both to drive the conveyor belt and to provide latching action, eliminating the need for separate mechanical braking or latching mechanisms.
4Device complexity
If complex energy transmission and mechanical brakes are eliminated, then system simplicity and cost are improved, but the ability to control the conveyor belt may be reduced
Solution Approach 1:
The electromagnetic drive system provides inherent control capabilities through electrical control of the electromagnetic field. This replaces complex mechanical transmission and braking systems with simpler electromagnetic control, maintaining or even improving control capability while reducing mechanical complexity.
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 solution simplifies, lightens, and reduces costs by eliminating the need for complex energy transmission and mechanical brakes, ensuring secure transportation of piece goods through curves and inclines without electrical energy supply, and reduces wear and maintenance.
Implementation Method 1
at least one conveyor rotor with at least one permanent magnet, preferably a plurality of permanent magnets, for driving the conveyor element, with the transport unit being designed to move on the transport path in one direction of movement, with the conveyor rotor being designed to rotate about an axis of rotation when the conveyor rotor is in electromagnetic interaction with arrives at the local stator
Implementation Method 2
the transport path having at least one latching device which is designed in such a way that a latching moment acts on the conveyor rotor when the conveyor rotor comes into electromagnetic interaction with the latching device
Implementation Method 3
at least one conveyor rotor with at least one permanent magnet, preferably a plurality of permanent magnets
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a sorting system (10), in particular for transporting and/or sorting unit loads (14), comprising: at least one transport track (5), comprising at least one local stator (30), and at least one transport unit (1), comprising at least one conveying element (2), in particular for loading and/or unloading unit loads, and at least one conveying rotor (6) with at least one permanent magnet (7), preferably a plurality of permanent magnets (7), for driving the conveying element (2), wherein the transport unit (1) is configured for movement on the transport track (5) in a direction of movement (4), and wherein the conveying rotor (6) is configured to rotate about an axis of rotation (R) when the conveying rotor (6) comes into electromagnetic interaction with the local stator (30). The invention further relates to a locking device (8) for a sorting system (10) and a transport unit (1) for a sorting system (10).