Variable Velocity Drive Belt for Mailpiece Singulation
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Solution Overview
Problem
Mailpiece sorters face inefficiencies in singulating mailpieces, leading to double-feeds, increased wear, and maintenance, which hinder throughput and reliability, especially when handling mailpieces of varying thickness and friction coefficients.
Innovation Solution
A mailpiece feed system utilizing a dual conveyance mechanism with a singulating and drive belt, coupled with an array of sensors to detect gap signals and control the velocity and force applied, ensuring consistent spacing and preventing double-feeds by varying the torque and acceleration based on sensor data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fixed-velocity drive belt is used, then the structure is simple, but singulation reliability deteriorates for mailpieces of varying thickness and friction coefficients
Solution Approach 1:
The drive belt velocity is made variable rather than fixed. The system dynamically adjusts the drive belt velocity based on real-time gap signals from sensors, allowing the system to adapt to different mailpiece thicknesses and friction coefficients. This dynamic adjustment improves singulation reliability by optimizing the driving conditions for each mailpiece type.
Solution Approach 2:
The system incorporates sensors that continuously monitor the spacing between mailpieces and provide gap signals to the control system. This feedback mechanism allows the control system to detect when mailpieces are too close together or when a mailpiece is stuck, and automatically adjust the drive belt velocity accordingly, improving reliability without requiring complex mechanical adjustments.
2Duration of action of stationary object
If constant force is applied by the singulating belt, then the mechanism is simple, but wear increases and maintenance frequency increases
Solution Approach 1:
The singulating belt force is transformed from a constant value to a variable one that dynamically adjusts based on operational conditions. The control system modifies the force applied by the singulating belt in response to gap signals and mailpiece characteristics, preventing excessive wear on both the belt and mailpieces while maintaining effective singulation.
Solution Approach 2:
The system changes the physical parameter of force applied by the singulating belt from a fixed value to an adjustable parameter. By varying the force based on detected mailpiece properties and spacing conditions, the system optimizes the balance between effective singulation and minimizing wear, thereby extending component service life.
3Productivity
If minimum spacing between mailpieces is maintained, then throughput is optimized, but singulation reliability decreases when mailpieces vary in thickness
Solution Approach 1:
The system dynamically adjusts the spacing between mailpieces based on real-time detection. When thinner mailpieces are detected, the system increases the gap to prevent double-feeds and ensure proper singulation. When thicker mailpieces are detected, the system maintains optimal spacing for throughput. This dynamic spacing adjustment allows the system to maintain both high throughput and reliable singulation across varying mailpiece types.
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 singulates mailpieces, reduces wear and maintenance, and optimizes throughput by maintaining optimal spacing and preventing double-feeds, even with varying mailpiece thickness and friction coefficients.
Implementation Method 1
a singulating and drive belt. The singulating and drive belts define a throat or singulating a mailpiece from the stack of mailpieces
Implementation Method 2
a series of sensors extending from the first to the second conveyance for issuing a gap signal indicative of the relative spacing between sequential mailpieces along the feed path
Implementation Method 3
a means to vary the velocity of the drive belt based upon the location of the gap signal along the series of sensors
Data Source
AI summary
A system for conveying mailpieces along a feed path including first and second conveyances. A first conveyance is operative to convey mailpieces along the feed path and includes a singulating and drive belt. The singulating and drive belts define a throat or singulating a mailpiece from the stack of mailpieces. A second conveyance accepts mailpieces from the first conveyance and conveys singulated mailpiece downstream of the first conveyance. The system further includes a series of sensors extending from the first to the second conveyance for issuing a gap signal indicative of the relative spacing between sequential mailpieces along the feed path. Additionally, the system includes a means to vary the velocity of the drive belt based upon the location of the gap signal along the series of sensors.