A novel underactuated smart surface for parts feeding and sorting

Abstract In material handling, numerous solutions have been proposed to enhance the flexibility and adaptability of transport systems. Among these solutions, smart surfaces stand out as one of the most interesting responses, utilizing an array of actuators for common feeding tasks. The current paper focuses on a novel system within this category, notable for its distinguishing factor of being underactuated. With this characteristic, the concept leads to a simplified cost-effective design and a not actively driven functioning, leveraging gravity or object own velocity to manipulate the material flow maintaining top class performances, as the sorting rate reaches 4000 pcs/h. Specifically, the article begins with an introduction of the concept design and its digital model, followed by a description of the experimental setup built to test the surface’s functionality and evaluate the predictions of the virtual counterpart. On top of that, a method to determine the essential parameters for the surface simulation is proposed and applied. As a result, the prototype successfully completed the three main intralogistic tasks experimented, i.e., sorting, slowing, and stopping of packages. Lastly, the digital model outcomes of the same operations were computed and compared with the measured results, demonstrating an accuracy of prediction with displacements and time errors below 7%.