Variable Angled Rollers for Singulating Mass Flow
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Solution Overview
Problem
Conventional singulating conveyors are noisy and prone to wear, and require complex drive assemblies and belt arrangements to de-cluster articles effectively, which complicates the process.
Innovation Solution
A conveyor system with one or more belts featuring rollers that protrude beyond the surface and rotate on oblique axes, forming different acute angles to exert force vectors oblique to the transport direction, allowing for efficient de-clustering of articles without the need for multiple belts or complex drive systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional roller conveyors are used for singulating articles, then articles can be separated from bulk flow, but the system generates excessive noise and experiences rapid wear
Solution Approach 1:
The patent replaces conventional mechanical roller conveyors with a belt-driven system where rollers are mounted on a moving belt. This substitution eliminates the need for stationary roller bearings and complex drive assemblies, reducing noise and wear while maintaining article separation capability. The rollers rotate freely on the belt surface rather than being mounted on fixed shafts with bearings.
Solution Approach 2:
The patent changes the operational parameters by using a moving belt carrier for the rollers instead of a fixed mechanical structure. The belt moves at controlled speed, carrying the rollers through the article flow zone. This parameter change from stationary to mobile roller mounting reduces friction and wear while maintaining separation efficiency.
2Ease of operation
If modular roller-top conveyor belts with oblique rollers are used to direct articles, then articles can be separated to side or center, but multiple belts in series or parallel are required creating complicated drive assembly
Solution Approach 1:
The patent merges multiple belt functions into a single integrated system. One continuously moving belt carries rollers that perform both conveying and directing functions. The oblique rollers on the single belt replace what would require multiple separate belts, simplifying the drive assembly to a single motor and belt drive mechanism while maintaining the ability to direct articles to side or center positions.
Solution Approach 2:
The single conveyor belt system performs multiple functions: it conveys articles forward while simultaneously using its oblique rollers to direct articles laterally to side or center positions. This multi-functional design eliminates the need for separate directing mechanisms or multiple belts, reducing overall system complexity while maintaining operational versatility.
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 system effectively converts a mass flow of articles into a separated stream, reducing noise and wear while simplifying the drive assembly and belt arrangement, thus addressing the shortcomings of conventional conveyors.
Implementation Method 1
The salient portions of the rollers protruding beyond the underside roll on the bearing surface in rolling contact as the one or more belts advance in the direction of belt travel
Implementation Method 2
The rollers are arranged to rotate about oblique axes that form at least two different acute angles measured in the same direction from the direction of belt travel
Data Source
Figure 1~2
Figure 3A~3B
Figure 4~5C
AI summary
A conveyor (10) constructed of a single belt (12) or a plurality of abutting belts arranged side by side in the conveyor, in which the belt or belts have rollers (34) arranged to rotate on axes (36, 35') oriented at multiple angles (alpha, alpha' , beta, beta') oblique to the direction of belt travel (26). A gradual or monotonic, stepped change in the axes of the rollers across the width of the conveyor can be used to make a conveyor capable of converting a mass flow of articles into a single stream of separated articles.