Tilt Tray Sorter With Strain Wave Gear for Low-Maintenance Tilting
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Solution Overview
Problem
Existing tilt tray sorters are complex and require frequent maintenance, leading to increased operational costs.
Innovation Solution
A tilt tray sorter incorporating a strain wave gear system with a wave generator, flexspline, and circular spline, which reduces the number of components and facilitates precise, controlled rotation of the tray assembly for efficient package unloading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional tilt tray sorters with expansion joints and drive chains are used, then the sorting function is achieved, but the device complexity increases and maintenance frequency increases
Solution Approach 1:
The patent combines multiple traditional components (drive chains, expansion joints, multiple gears) into a single integrated strain wave gear mechanism. The strain wave gear inherently provides both the driving function and the expansion/contraction motion needed for tray tilting, eliminating the need for separate drive chains and expansion joints. This merging of functions directly reduces component count and maintenance requirements while maintaining the sorting capability.
Solution Approach 2:
The strain wave gear serves multiple functions simultaneously: it acts as the drive mechanism, provides the expansion and contraction motion, controls the tray tilting angle, and enables the sorting function. This multi-functionality eliminates the need for multiple specialized components, thereby reducing overall device complexity and maintenance frequency while achieving the same sorting objective.
2Device complexity
If a strain wave gear system is implemented, then device complexity is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent utilizes the inherent elastic deformation characteristics of the flexspline material to achieve the necessary expansion and contraction motions. By carefully selecting material properties and geometric parameters of the flexspline, the system converts small precision rotations of the wave generator into larger tray tilting motions, thereby reducing the overall manufacturing precision requirements for the entire mechanism while maintaining component count reduction.
3Power
If the flexspline rotates within the circular spline, then torque is increased and speed is reduced, but the meshing precision requirements increase
Solution Approach 1:
The patent employs the dynamic elastic deformation of the flexspline as it engages and disengages with the circular spline teeth. This dynamic interaction allows for smooth torque transmission and speed reduction while accommodating minor manufacturing variations through the flexible nature of the flexspline, thereby achieving high torque multiplication without requiring extremely tight meshing precision.
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
Reduces maintenance frequency and operational costs through component optimization, while ensuring efficient and controlled package sorting.
Implementation Method 1
The strain wave gear comprises a wave generator coupled to a motor, and the wave generator is configured to rotate upon actuation of the motor. Further, the strain wave gear comprises a flexspline mounted around the wave generator and a circular spline positioned around the flexspline. The flexspline is configured to rotate within the circular spline in response to the rotation of the wave generator.
Implementation Method 2
The flexspline is configured to increase torque and reduce speed in comparison to the motor.
Implementation Method 3
the outer gear profile of the flexspline meshes with the inner gear profile of the circular spline to provide the rotational movement to the flexspline
Data Source
Figure 1
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Figure 2B
AI summary
A tilt tray sorter is disclosed. The tilt tray sorter comprises a housing and a tray coupled to the housing. A strain wave gear is positioned within the housing. The strain wave gear comprises a wave generator coupled to a motor, and the wave generator is configured to rotate upon actuation of the motor. Further, the strain wave gear comprises a flexspline mounted around the wave generator and a circular spline positioned around the flexspline. The flexspline is configured to rotate within the circular spline in response to the rotation of the wave generator. Further, the tilt tray sorter comprises a tilt tray shaft assembly coupled to the flexspline of the strain wave gear. The tilt tray shaft assembly is configured to rotate when the flexspline rotates. The housing and the tray are configured to pivot when the tilt tray shaft assembly is rotated.