Tilt Tray Sorter Strain Wave Drive for Precise Tray Rotation
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Solution Overview
Problem
Existing tilt tray sorters are complex, leading to frequent maintenance and increased operational costs due to their numerous components.
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 existing tilt tray sorters with numerous components are used, then the sorting function is achieved, but the device complexity increases leading to frequent maintenance
Solution Approach 1:
The patent combines multiple drive mechanisms into a single strain wave gear system. The strain wave gear integrates the wave generator, flexspline, and circular spline into one compact unit that replaces multiple separate drive components, thereby reducing overall device complexity while maintaining reliable tray tilting functionality.
Solution Approach 2:
The strain wave gear serves multiple functions simultaneously: it provides torque multiplication, speed reduction, and precise angular positioning for the tilt tray mechanism. This multi-functionality eliminates the need for separate components to perform these functions, reducing maintenance frequency while achieving the sorting objective.
2Productivity
If existing tilt tray sorters with numerous components are used, then the sorting function is achieved, but operational costs increase
Solution Approach 1:
The strain wave gear consolidates multiple drive components into a single integrated mechanism, reducing the number of parts that require maintenance and replacement. This integration directly reduces operational costs while maintaining efficient package sorting capability.
3Device complexity
If a strain wave gear system is used, then the number of components is reduced, but the manufacturing complexity of individual components increases
Solution Approach 1:
The flexspline is manufactured as a thin-walled flexible component with gear teeth formed on its inner surface. This thin-film approach allows the flexspline to be produced using standard machining or forming processes, offsetting the complexity of integrating it with the wave generator and circular spline.
Solution Approach 2:
The strain wave gear utilizes curved, elliptical geometry in the wave generator and corresponding curved gear teeth in the flexspline and circular spline. These curved surfaces are manufactured using standard rotational forming and gear cutting processes, making the individual components manufacturable despite the overall system integration 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
Reduces maintenance frequency and operational costs while ensuring efficient and controlled package sorting with improved operational efficiency.
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.
Data Source
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.