U.S. patent application number 10/407314 was filed with the patent office on 2003-11-13 for article unscrambler with high speed tapered roller.
Invention is credited to Brouwer, Gerald A., Johnson, James P..
Application Number | 20030209407 10/407314 |
Document ID | / |
Family ID | 29250480 |
Filed Date | 2003-11-13 |
United States Patent
Application |
20030209407 |
Kind Code |
A1 |
Brouwer, Gerald A. ; et
al. |
November 13, 2003 |
Article unscrambler with high speed tapered roller
Abstract
An unscrambler conveyor including a frame, a plurality of
tapered rollers rotatably supported by the frame for unscrambling
packages, and means for driving the rollers. Each of the rollers
has a longitudinal axis and a polyurethane body that extends along
the longitudinal axis to form a tapered outer surface. The tapered
outer surfaces of the rollers define a conveying surface and have
variations in concentricity of less than 0.01 inches.
Inventors: |
Brouwer, Gerald A.;
(Grandville, MI) ; Johnson, James P.; (Rockford,
MI) |
Correspondence
Address: |
VAN DYKE, GARDNER, LINN AND BURKHART, LLP
2851 CHARLEVOIX DRIVE, S.E.
P.O. BOX 888695
GRAND RAPIDS
MI
49588-8695
US
|
Family ID: |
29250480 |
Appl. No.: |
10/407314 |
Filed: |
April 4, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60369975 |
Apr 4, 2002 |
|
|
|
Current U.S.
Class: |
198/457.02 ;
198/786 |
Current CPC
Class: |
B65G 47/244 20130101;
B65G 47/22 20130101; B65G 47/082 20130101; B65G 13/07 20130101;
B65G 39/07 20130101; B65G 13/04 20130101; B65G 47/28 20130101 |
Class at
Publication: |
198/457.02 ;
198/786 |
International
Class: |
B65G 047/26 |
Claims
The embodiments of the invention in which an exclusive property
right or privilege is claimed are defined as follows:
1. An unscrambler conveyor assembly comprising: a frame; a
plurality of tapered rollers rotatably supported by said frame for
unscrambling packages; and means for driving said rollers, each of
said rollers having a longitudinal extent extending along a
longitudinal axis from a proximate first end to a distal second
end, each of said rollers having a polyurethane body extending
along said longitudinal axis substantially across said longitudinal
extent and forming a tapered outer surface, said tapered outer
surfaces of said rollers defining a conveying surface and having
variations in concentricity of less than 0.01 inch.
2. The unscrambler conveyor assembly according to claim 1, wherein
said variations are less than 0.008 inches.
3. The unscrambler conveyor assembly according to claim 1, wherein
said variations are about 0.005 inches or less.
4. The unscrambler conveyor assembly according to claim 1, wherein
each of said rollers includes a base, said polyurethane bodies
being one of adhered to and molded on said bases.
5. The unscrambler conveyor assembly according to claim 4, wherein
said bases comprise straight rollers, said polyurethane body of
each respective tapered roller comprising a polyurethane body
having a thickness, said thicknesses increasing at a generally
uniform rate along said longitudinal axes of said tapered rollers
to form said tapered outer surfaces.
6. The unscrambler conveyor assembly according to claim 1, wherein
said polyurethane body of each of said rollers comprises a
sleeve.
7. The unscrambler conveyor assembly according to claim 1, wherein
said wherein said means drives said rollers at a speed of at least
900 rpm.
8. The unscrambler conveyor assembly according to claim 1, wherein
said wherein said rollers have a high side and a low side, packages
being unscrambled by said rollers moving toward said low side when
unscrambled, and said means driving said high side thereby
minimizing interference between said means and the packages being
unscrambled.
9. The unscrambler conveyor assembly according to claim 1, wherein
said longitudinal axes of said rollers lie in a non-horizontal
plane whereby said conveying surface defined by said tapered outer
surfaces is angled at a greater angle than a taper angle of the
tapered outer surfaces of said rollers.
10. The unscrambler conveyor assembly according to claim 1, wherein
said tapered outer surfaces comprise tapered outer polyurethane
surfaces.
11. An unscrambler conveyor assembly comprising: a frame; a
plurality of tapered rollers rotatably supported by said frame,
each of said rollers having a longitudinal axis and a longitudinal
extend extending from a proximal first end to a distal second end,
each of said rollers including a polyurethane body extending along
said longitudinal axis from adjacent said distal end to adjacent
said proximal end and forming a tapered outer surface, said tapered
outer surfaces defining a conveying surface; and means for driving
said rollers, when operated said means driving said rollers at a
speed of at least 900 rpm.
12. The unscrambler conveyor assembly according to claim 11,
wherein said means drives said rollers at a speed of at least 1000
rpm.
13. The unscrambler conveyor assembly according to claim 11,
wherein said means drives said rollers at a speed of at least 1100
rpm.
14. The unscrambler conveyor assembly according to claim 11,
wherein said means comprises a belt drive system.
15. The unscrambler conveyor assembly according to claim 11,
wherein said rollers have a high side and a low side, packages
being unscrambled by said rollers moving toward said low side when
unscrambled, and said means driving said high side thereby
minimizing interference between said means and the packages being
unscrambled.
16. The unscrambler conveyor assembly according to claim 11,
wherein said outer surfaces of said rollers have variations in
concentricity of less than 0.01 inch.
17. The unscrambler conveyor assembly according to claim 16,
wherein said variations are about 0.005 inches or less.
18. The unscrambler conveyor assembly according to claim 10,
wherein said longitudinal axes of said rollers lie in a
non-horizontal plane whereby said conveying surface defined by said
tapered outer surfaces of said rollers is angled at a greater angle
than a taper angle of the tapered outer surfaces.
19. An unscrambler conveyor assembly comprising: a frame; a
plurality of tapered rollers rotatably supported by said frame,
each of said rollers having a conveying surface having a conveying
width between a proximal first end to a distal second end, and each
of said rollers having a polyurethane body forming a tapered outer
surface extending across the full width of said conveying surface,
said rollers having a high side and a low side, packages being
unscrambled by said rollers moving toward said low side when
unscrambled; and means for driving said rollers at said high side
to thereby minimize interference between said means and the
packages being unscrambled.
20. The unscrambler conveyor assembly according to claim 19,
wherein each of said rollers includes a base, said polyurethane
bodies being one of adhered to and molded on said bases.
21. The unscrambler conveyor assembly according to claim 19,
wherein said bases comprise straight rollers, said polyurethane
body of each respective tapered roller having a thickness, said
thicknesses increasing at a generally uniform rate along said
longitudinal axes of said tapered rollers to form said tapered
outer surfaces.
22. The unscrambler conveyor assembly according to claim 19,
wherein said tapered outer surfaces comprise tapered outer
polyurethane surfaces.
23. The unscrambler conveyor assembly according to claim 19,
wherein said outer surfaces of said rollers have variations in
concentricity of less than 0.01 inch.
24. The unscrambler conveyor assembly according to claim 19,
wherein said polyurethane bodies comprise polyurethane sleeves.
25. The unscrambler conveyor assembly according to claim 24,
wherein said sleeves extend across said rollers along said
longitudinal axes to define the width of the conveying surface of
the unscrambler conveyor assembly.
26. The unscrambler conveyor assembly according to claim 21,
wherein said wherein said means drives said rollers at a speed of
at least 900 rpm.
27. The unscrambler conveyor assembly according to claim 19,
wherein said longitudinal axes of said rollers lie in a
non-horizontal plane whereby the conveying surface defined by said
tapered outer surfaces of said rollers is angled at a greater angle
than a taper angle of the tapered outer surfaces.
28. The unscrambler conveyor assembly according to claim 23,
wherein said means drives said rollers at a speed of at least 900
rpm.
29. The unscrambler conveyor assembly according to claim 28,
wherein said means drives said rollers at a speed of at least 1000
rpm.
30. The unscrambler conveyor assembly according to claim 20,
wherein said means drives said rollers to generate a conveying
speed of at least 500 ft/minute.
31. The unscrambler conveyor assembly according to claim 30,
wherein said means drives said rollers to generate a conveyor speed
of at least 600 ft/minute.
32. The unscrambler conveyor assembly according to claim 19,
wherein said means comprises a belt drive system.
33. An unscrambler conveyor assembly comprising: a frame; a
plurality of tapered rollers rotatably supported by said frame,
each of said tapered rollers having a longitudinal axis and
defining a substantially continuous tapered conveying surface, each
of said rollers including a base roller having a monolithic
polyurethane body extending along said longitudinal axis to form
said tapered conveying surface; and means for driving said tapered
rollers.
34. The unscrambler conveyor assembly according to claim 33,
wherein each of said outer surfaces has a variation in
concentricity of less than 0.01 inches.
35. The unscrambler conveyor assembly according to claim 34,
wherein said variations are less than 0.008 inches.
36. The unscrambler conveyor assembly according to claim 33,
wherein said polyurethane bodies are one of adhered to and molded
on said base rollers.
37. The unscrambler conveyor assembly according to claim 36,
wherein said base rollers comprise straight base rollers, said
polyurethane body of each respective tapered roller having a
thickness, said thicknesses increasing at a generally uniform rate
along said longitudinal axes of said tapered rollers to form said
tapered outer surface.
38. The unscrambler conveyor assembly according to claim 37,
wherein each of said polyurethane bodies comprises a sleeve.
39. The unscrambler conveyor assembly according to claim 38,
wherein said wherein said means drives said rollers at a speed of
at least 900 rpm.
40. The unscrambler conveyor assembly according to claim 33,
wherein said wherein said rollers have a high side and a low side,
packages being unscrambled by said rollers moving toward said low
side when unscrambled, and said means driving said high side
thereby minimizing interference between said means and the packages
being unscrambled.
41. The unscrambler conveyor assembly according to claim 37,
wherein said longitudinal axes of said rollers lie in a
non-horizontal plane whereby the conveying surface defined by said
tapered outer surfaces of said rollers is angled at a greater angle
than a taper angle of the tapered outer surfaces.
42. The unscrambler conveyor assembly according to claim 33,
wherein said means for driving comprises a drive belt, said drive
belt drivingly engaging said base rollers to thereby drive said
rollers.
43. An unscrambler conveyor assembly comprising: a frame; a
plurality of tapered rollers rotatably supported by said frame,
each of said tapered rollers having a longitudinal axis and
comprising a straight base roller with an outer surface with
terminal ends and a monolithic polyurethane body extending along
said longitudinal axis from adjacent one of said terminal ends to
adjacent to another of said terminal ends, each of said
polyurethane bodies having a thickness, said thicknesses increasing
across said longitudinal axes at a generally uniform rate to form
continuous tapered outer surfaces; and means for driving said
tapered rollers.
44. The unscrambler conveyor assembly according to claim 43,
wherein said polyurethane bodies are one of adhered to and molded
on said base rollers.
45. The unscrambler conveyor assembly according to claim 44,
wherein said polyurethane bodies extend across said rollers along
said longitudinal axes to define the width of the conveying surface
of the unscrambler conveyor assembly.
46. The unscrambler conveyor assembly according to claim 44,
wherein said wherein said means drives said rollers at a speed of
at least 900 rpm.
47. The unscrambler conveyor assembly according to claim 44,
wherein said outer surfaces of said rollers have variations in
concentricities of less than 0.01 inch.
48. The unscrambler conveyor assembly according to claim 43,
wherein said longitudinal axes of said rollers lie in a
non-horizontal plane whereby the conveying surface defined by said
tapered outer surfaces of said rollers is angled at a greater angle
than a taper angle of the tapered outer surfaces.
49. The unscrambler conveyor assembly according to claim 48,
wherein said means drives said rollers at a speed of at least 900
rpm.
50. The unscrambler conveyor assembly according to claim 49,
wherein said means drives said rollers at a speed of at least 1000
rpm.
51. The unscrambler conveyor assembly according to claim 43,
wherein said means drives said rollers to generate a conveying
speed of at least 500 ft/minute.
52. The unscrambler conveyor assembly according to claim 51,
wherein said means drives said rollers to generate a conveying
speed of at least 600 ft/minute.
53. The unscrambler conveyor assembly according to claim 43,
wherein said means comprises a belt drive system.
54. The unscrambler conveyor assembly according to claim 53,
wherein said belt drive system includes a drive belt, said drive
belt drivingly engaging said base rollers to thereby drive said
tapered rollers.
Description
[0001] The present application claims priority from provisional
application Serial No. 60/369,975, filed Apr. 4, 2002, which is
herein incorporated by reference in its entirety.
TECHNICAL FIELD AND BACKGROUND OF THE INVENTION
[0002] The present invention relates to conveyors and, more
particularly, to conveyors used to unscramble articles that are
received in a random order.
[0003] Unscrambling conveyors are positioned between an input
conveyor, which delivers articles to the induct or charge end of
the unscrambler conveyor, and an output conveyor, which receives
articles at the discharge end of the unscrambler conveyor.
Unscrambler conveyors typically use skewed rollers that transport
articles, which are received at the induct end, in a longitudinal
and lateral direction across the conveying surface of the
unscrambling conveyor towards one side of the conveyor to align the
articles and thereafter discharge the articles from the discharge
end of the unscrambling conveyor to the output conveyor.
Furthermore, existing unscrambling conveyors use tapered rollers,
which define a low side and a high side of the conveyor and move
the articles toward the low side when unscrambled. The rollers are
typically driven by a belt drive system, which heretofore, has
driven the rollers at their low side. As a result, on occasion, the
drive assembly may interfere with the unscrambling of the
articles.
[0004] As conveyor systems increase their efficiency, the speed of
the components of conveyor systems has increased. This increase in
speed, however, places more of a demand on some components than
others. Typically the rollers of unscrambler conveyors must operate
at faster speeds than the rollers of the input or output conveyors.
For example, most unscrambler conveyors operate at twice the speed
of the input and output conveyors in order to maintain the flow of
articles through the system. Until recently, these tapered rollers
have been metal rollers or straight metal rollers with segmented
polyethylene sheathes that are mounted and stacked on the
respective rollers to define the conveying surface of the conveyor.
The tapered metal rollers, though capable of operating at higher
speeds, generate high and usually unacceptable noise levels when
operated at higher speeds. For example, when these metal rollers
operated to generate a conveyor speed of 400 ft/minute or greater
to meet input/output conveyor speeds of about 200 ft/minute, the
noise generated by these metal rollers is unacceptable. Rollers
with segmented polyethylene sheathes have been found to deteriorate
with use over a relatively short period of time and, further, are
not durable or impact resistant. Furthermore, when the operated at
higher speeds, for example to produce a conveyor speed of 400
feet/minute, the segmented sleeves have been found to deteriorate
even faster.
[0005] With input and output conveyors operating at conveyor speeds
of 200 feet/minute or greater, it has been found that the current
unscrambler conveyor designs cannot, therefore, support these
increased conveyor speeds without deteriorating or generating
unacceptable noise levels. As noted above, typically, an
unscrambling conveyor must be operated at a higher speed than the
input conveyors, such as twice the speed, in order to provide a
continuous throughput for the conveyor system. Therefore, the
existing unscrambler conveyors have become a limiting factor in
current high speed conveyor systems.
[0006] Accordingly, there exists a need for an unscrambling
conveyor that can effectively unscramble a large volume of packages
at a rate that is commensurate with the existing high speed
conveyor equipment without generating unacceptable noise levels
and, further, in a manner to provide increased longevity to the
components.
SUMMARY OF THE INVENTION
[0007] Accordingly, the present invention provides an unscrambling
conveyor that can operate at significantly higher speeds than
conventionally known unscrambling conveyors and, further, in a
manner which generates acceptable noise levels.
[0008] In one form of the invention, an unscrambling conveyor
assembly of the present invention includes a frame, a plurality of
tapered rollers, which are rotatably supported by the frame for
unscrambling packages, and means for driving the rollers. Each of
the rollers has a longitudinal axis and a polyurethane body, which
extends along the longitudinal axis to form a tapered outer
surface. The tapered outer surfaces define the conveying surface of
the unscrambling conveyor and have variations in concentricities of
less than 0.01 inches.
[0009] In one aspect, the concentricities of the outer surfaces
vary less than 0.008 inches and, more preferably, about 0.005
inches or less.
[0010] In other aspects, each of the rollers includes a cylindrical
base, with the polyurethane bodies being either adhered to or
molded on the cylindrical bases of the rollers. For example, the
cylindrical bases may comprise straight rollers, with the
polyurethane bodies of each respective tapered roller comprising a
polyurethane body having a thickness that increases at a generally
uniform rate along the longitudinal axis of the tapered rollers to
form the tapered outer surfaces. In a further aspect, the
polyurethane body of the respective rollers comprises a unitary
sleeve.
[0011] According to yet another aspect, the means for driving the
rollers drives the rollers at a speed of at least 900 rpm.
[0012] In yet another aspect, the rollers have a high side and a
low side, with the packages unscrambled by the rollers moving
toward the low side when unscrambled. In addition, the means that
drives the rollers drives the high side of the rollers to thereby
minimize interference between the driving means and the
packages.
[0013] According to yet another aspect, the longitudinal axes of
the rollers lie in a non-horizontal plane wherein the conveying
surface defined by the tapered outer surfaces is angled at a
greater angle than the taper angle of the tapered outer surfaces of
the rollers or wherein the conveying surface is substantially
horizontal.
[0014] According to another form of the invention, an unscrambler
conveyor assembly includes a frame, a plurality of tapered rollers,
which are rotatably supported by the frame, and means for driving
the rollers. When the means for driving the rollers is operated,
the rollers are driven at a speed of at least 900 rpm, more
preferably, at least 1,000 rpm and, most preferably, at least 1,100
rpm.
[0015] In another form of the invention, an unscrambler conveyor
assembly includes a frame, a plurality of tapered rollers, which
are rotatably supported by the frame, and means for driving the
rollers at a high side of the rollers to thereby minimize
interference between the driving means and the packages being
unscrambled, which move toward the low side of the rollers when
unscrambled.
[0016] In one aspect, the means that drives the rollers generates a
conveying speed of at least 500 feet per minute and, more
preferably, at least 600 feet per minute. In preferred form, the
means to drive the rollers comprises a drive belt system.
[0017] In yet another form of the invention, an unscrambler
conveyor assembly includes a frame, a plurality of tapered rollers,
which are rotatably supported by the frame, and a means for driving
the tapered rollers. Each of the tapered rollers has a longitudinal
axis and comprises a base roller with a monolithic polyurethane
body extending along the longitudinal axis to form a continuous
tapered outer surface.
[0018] In one aspect, the means for driving the rollers comprises a
belt drive system and, further, includes a belt that drivingly
engages the base rollers to thereby drive the tapered rollers.
[0019] According to yet another form of the invention, an
unscrambling conveyor includes a frame, a plurality of tapered
rollers, which are rotatably supported by the frame, and means for
driving the tapered rollers. Each of the tapered rollers has a
longitudinal axis and comprises a straight base roller with a
monolithic polyurethane body extending along the longitudinal axis,
with the polyurethane body having a thickness that increases along
the longitudinal axis of the respective roller at a generally
uniform rate to form a continuous tapered outer surface.
[0020] From the foregoing, it can be appreciated that the
unscrambling conveyor of the present invention can be operated at
far higher speeds than conventional unscrambling conveyors without
generating the noise levels associated with conventional metal
rollers. These and other objects, advantages, purposes, and
features of the invention will become more apparent from the study
of the following description taken in conjunction with the
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a plan view of a conveyor system incorporating the
unscrambling and aligning conveyor of the present invention;
[0022] FIG. 2 is a plan view of an unscrambler conveyor of FIG.
1;
[0023] FIG. 3 is a side elevation view of the unscrambler conveyor
of FIG. 2;
[0024] FIG. 3A is an enlarged perspective view of a portion of the
unscrambling conveyor of FIG. 2 illustrating the high side of the
conveyor;
[0025] FIG. 3B is an enlarged top perspective view of a portion of
the conveyor of FIG. 2 illustrating the low side of the
conveyor;
[0026] FIG. 4 is a plan view of another embodiment of the
unscrambler conveyor of the present invention;
[0027] FIG. 5 is a side elevation view of the unscrambler conveyor
of FIG. 4;
[0028] FIG. 6 is an enlarged end view of the conveyor of FIG. 4 as
viewed from lines VI-VI;
[0029] FIG. 6A is a cross-section view taken along line VIA-VIA of
FIG. 4;
[0030] FIG. 7 is a cross-section view taken along line VII-VII of
FIG. 4;
[0031] FIG. 8 is a cross-section view taken along line VIII-VIII of
FIG. 4;
[0032] FIG. 9 is a partial fragmentary plan view of detail IX-IX of
FIG. 4;
[0033] FIG. 10 is a plan view of yet another embodiment of the
unscrambled conveyor of the present invention;
[0034] FIG. 11 is a side elevation view of the unscrambler conveyor
of FIG. 10;
[0035] FIG. 12 is an end view of the unscrambler conveyor of FIG.
10;
[0036] FIG. 13 is a cross-section view taken along line XIII-XIII
of FIG. 10; and
[0037] FIG. 14 is a partial cross-section view taken alone line
XIV-XIV of FIG. 10.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] Referring to FIGS. 1-3, the numeral 10 generally designates
an unscrambling and aligning conveyor 10 of the present invention.
Unscrambling and aligning conveyor 10 is particularly suitable for
placing inline between an input conveyor 12, which delivers
articles to the induct or charge end of conveyor 10, and an output
conveyor 14, which receives articles discharged from the discharge
end of conveyor 10. Furthermore, similar to the unscrambling and
aligning conveyor described in co-owned U.S. Pat. No. 6,253,905
(which is herein incorporated by reference in its entirety),
unscrambling and aligning conveyor 10 may have similar, if not the
same, width dimensions as input and output conveyors 12 and 14 so
that conveyor 10 can be placed in an existing conveyor system with
a one-for-one replacement with a conventional straight run
conveyor. As will be more fully described below, unscrambling and
aligning conveyor 10 operates at a faster speed than input conveyor
12 to thereby create a space or gap between the articles delivered
to unscrambling and aligning conveyor 10. When side-by-side
articles are delivered to unscrambling and aligning conveyor 10,
articles that align with the enlarged end of the tapered rollers
will accelerate relative to the articles conveyed on the lower end
of the tapered rollers to generate a gap between two articles,
which enables the articles to be singulated and aligned along the
lower side of conveyor 10.
[0039] Referring to FIGS. 2 and 3, unscrambling and aligning
conveyor 10 includes a frame 16, which supports a plurality of
tapered rollers 18. Tapered rollers 18 are skewed, with their
longitudinal axes 118a being generally non-orthogonal to the
longitudinal axis 10a of conveyor 10. Furthermore, longitudinal
axes 18a of rollers 18 are preferably aligned along a horizontal
plane with respect to the support surface (S) (FIG. 3) on which
conveyor 10 rests so that the angle of the conveying surface lies
in a plane that is angled at the same angle as the taper angle of
the individual rollers 18. Consequently, when articles are
delivered from input conveyor 12 to conveyor 10, the articles will
tend to be singulated along an axis over the lower side 20 of
conveyor 10. However, the respective longitudinal axes of the
rollers may lie in a non-horizontal plane such that the angle of
the conveying surface is either greater or less than the taper
angle of the rollers or, for example, so that the conveying surface
is horizontal. Furthermore, as will be more fully described below,
unscrambling and aligning conveyor 10 can operate at speeds that
far exceed conventional roller unscrambler conveyors and with noise
levels at or below maximum acceptable levels.
[0040] In preferred form, rollers 18 are driven by a drive assembly
21, which drives rollers 18 at the high side 22 of conveyor 10.
With this configuration, conveyor 10 minimizes the interference
between articles conveyed on conveying surface 10b and drive
assembly 21. In the illustrated embodiment, the motor and
associated gear of drive assembly 21 are located below rollers 18,
but it should be understood that they may be upstream for example,
under input conveyor 12 or output conveyor 14, as will more fully
described in reference to another embodiment illustrated in FIGS.
10-12.
[0041] As best understood from FIG. 3, drive assembly 21 comprises
a belt drive system and includes a motor 24, a gear reducer 26, and
a pair of drive pulleys or sheaves 28. Drive system 21 further
includes a plurality of guide pulleys or sheaves 30 and pressure
pulleys or sheaves 32, which support a pair of closed loop drive
belts 34 around a closed loop path, with pressure pulleys 32 urging
belts 34 to engage rollers 18 to thereby drive the rollers. In
addition, drive assembly 21 includes return pulleys or sheaves 36,
38 that are mounted to frame 16 at opposed ends of frame 16 and,
further, inward from distal ends 16a and 16b of frame 16. In
addition, drive assembly 21 includes pairs of redirection pulleys
40, 42, and 44 which redirect belts 34 from drive pulleys 28 so
that belts 34 extend around the closed loop path over support
pulleys 30 and pressure pulleys 32. As noted above, pressure
pulleys 32 support and urge drive belts 34 into frictional
engagement with rollers 18 at high side 22. In preferred form,
belts 34 drivingly engage the proximate ends of the base of the
respective rollers 18, as will be more fully described below.
[0042] Referring to FIG. 4, each roller 18 includes a polyurethane
body 52. Each polyurethane body 52 preferably comprises a
monolithic body-in other words, the body is cast or formed as a
single piece and formed of a polyurethane material without joints
or seams. Each roller 18 further includes a base 50, such as a
metal base roller, to which the polyurethane body is applied or
formed. Optionally, polyurethane body 52 maybe formed as a sleeve
in a mold, such as by casting or injection molding, and thereafter
mounted on base 50 and, preferably, secured thereto by an adhesive.
The surface of the base roller may be physically or chemically
treated, such as by scuffing or by forming or providing a knurled
surface or by applying a primer, to increase adhesion of the
polyurethane body to the base roller. Alternately, polyurethane
body 52 may be provided by forming polyurethane body 52 on base 50,
such as by injection molding. In preferred form, base 50 comprises
a straight metal roller, with polyurethane body 52 having a
thickness that decreases across the roller longitudinal axis from a
high side 22 to low side 20 at a substantially generally uniform
rate to thereby form tapered outer surface 18b of rollers 18. For
example, for a thirty-six inch roller, body 52 may have a thickness
in a range of about 1.5 to 0.75 inches, more preferably, in a range
of about 1.0 to 0.9 inches, which then tapers down to a thickness
in a range of about 0.25 to 0.0625 inches and, more preferably, in
a range of about 0.20 to 0.15 inches. However, it should be
understood that these thicknesses may be adjusted as needed,
including to accommodate longer or shorter rollers. In addition the
length of body 52 may vary with each length of roller. For example,
for a thirty-six inch roller, the length is preferably in a range
of 28 inches to 32 inches. Alternately, base 50 may comprise a
tapered roller, with body 52 having a generally uniform thickness
across longitudinal axis 18a, with a thickness in a range of 2.0 to
0.125 inches, for example.
[0043] In the illustrated embodiment, each polyurethane body 52
extends from adjacent a first end of the roller to adjacent a
second end of the roller so that it extends substantially across
the width of conveyor 10 to define the conveying surface but
preferably terminates before the proximate end of base 50 to expose
the proximate ends of bases 50 so that, as previously described,
they can be driven by drive belts 34. In order to eliminate
interference between conveyor 10 and the input and output
conveyors, redirection pulleys or sheaves 16a and 16b are mounted
inward from the distal end 16a and 16b of frame 16. Therefore, in
order to drive the end rollers, the first and last rollers 18c and
18d are driven by the adjacent rollers with an O-ring belt 60 (best
seen in FIG. 3A). In this manner, assembly 10 may be positioned in
close proximity to input conveyor 12 and output conveyor 14.
[0044] In the illustrated embodiment, frame 16 comprises a pair of
spaced apart side members 62 and 64, which in the illustrated
embodiment comprise channel-shaped members. Side members 62 and 64
are supported above surface S by sub-frames 70. Sub-frames 70 may
comprise any number of configurations but preferably include a pair
of legs 70a, which are braced by transverse member 70b. Rollers 18
are supported on upper flanges 62a, 64a of side members 62 and 64
with their respective shafts journaled in axle supports 72, which
are mounted to flanges 62a, 64a. Optionally, frame 16 may include,
mounted thereto, cover plates, such as illustrated in reference to
the second and third embodiments, which at least partially cover
the space between the exposed bases 50 to reduce the risk of
articles falling between the increased space between the exposed
bases 50.
[0045] In preferred form, the variation in concentricity of outer
surface 16b of rollers 18 is less than 0.01 inches and, preferably,
less than 0.008 inches and, most preferably, about 0.005 inches or
less. The variation in concentricity as used herein refers to the
deviation of the points of the circles defined by the outer surface
of the roller from their center, which is the longitudinal axis
(18a) of the roller, with the ideal variation in concentricity
being zero. As will be understood by those skilled in the art, the
smaller the variation in the concentricity the more accurate the
surface of the roller. This low variation in concentricity is
achieved either by the molding process or by machining of the
polyurethane body once it is applied (whether it is applied by
molding or by adhesive in the case of the sleeve) to the base.
Furthermore, the polyurethane material forming body 52 is
semi-rigid and preferably has a durometer in a range of 40A to 95A
durometer.
[0046] It has been found that driver assembly 21 can drive rollers
18 to speeds that far exceed heretofore achieved using conventional
unscrambling conveyors, such as 800 rpm, more preferably, 900 rpm
and, most preferably, at speeds that include 1,000 rpm and 1,100
rpm and greater. At these roller speeds, conveyor 10 generates
conveying speeds of greater than 300 feet per minute, more
preferably, greater than 400 feet per minute and, most preferably,
more than 500 feet per minute. In preferred form, conveyor 10
generates conveying speeds greater than 600 feet per minute. As a
result, conveyor 10 is particularly suitable for use with newer
existing high speed conveyor equipment, which include input and
output conveyors that operate at speeds greater than 200 feet per
minute, more preferably, greater than 250 feet per minute and, most
preferably, greater than 300 feet per minute. With such high
conveying speeds, the conveyor system can dramatically increase its
throughput and hence speed delivery of the articles conveyed by the
conveying system.
[0047] As previously noted, accumulating and aligning conveyor 10
accelerates articles delivered to conveyor 10 from input conveyor
12 to create a space or gap between the article and the article
behind it. For example, when side-by-side articles are received by
conveyor 10, the article that is aligned on the high side of the
conveyor will be accelerated with respect to an article received on
the low side of the conveyor so that the article on the high side
of the conveyor can be moved ahead of the article of the low side
of the conveyor and eventually moved to the low side of the
conveyor to thereby align the articles on the low side of the
conveyor.
[0048] Referring to FIG. 4, the numeral 110 is a second embodiment
of the unscrambling and aligning conveyor of the present invention.
Unscrambling and aligning conveyor 110 is similar to conveyor 10
and is suitable for placing inline between an input conveyor and an
output conveyor. Furthermore, unscrambling and aligning conveyor
110 may have similar width dimensions as the input and output
conveyors so that conveyor 10 can be placed in an existing conveyor
system with a one-for-one replacement with a conventional straight
run conveyor. Similar to conveyor 10, conveyor 110 operates at a
faster speed than either the input or output conveyor to thereby
create a space or gap between the articles delivered to
unscrambling and aligning conveyor 110. Preferably, liked conveyor
10, conveyor 110 operates at approximately twice the speed of the
input and output conveyors.
[0049] As best seen in FIG. 4, conveyor 110 includes a plurality of
tapered rollers 118, which are skewed relative to the longitudinal
axis 110a of conveyor 110. For further details of rollers 118,
reference is made to the previous embodiment. Rollers 118 are
driven by a drive assembly 121, which is positioned below rollers
118 and preferably contained between the charge end and the
discharge end of conveyor 110 similar to the previous
embodiment.
[0050] Referring to FIGS. 4 and 5, drive assembly 121 includes a
motor 124 with a gearbox reducer 126 and a pair of drive pulleys
128. Drive assembly 121 further includes a plurality of support
pulleys or sheaves 130 and a plurality of pressure pulleys or
sheaves 132, which support a pair of closed loop drive belts 133.
In addition, drive assembly 121 includes redirection pulleys 138 at
one end of conveyor 110, which redirects drive belts 133 from
pusher pulleys or sheaves 132 over support sheaves or rollers 130.
Drive assembly 121 further includes pairs of intermediate
redirection pulleys 140 and 142 which direct drive belts 133 over
support pulleys or sheaves 130. Furthermore, drive assembly 121
includes adjustable redirection pulleys 144 that direct drive belts
133 from drive pulleys or sheaves 128 to redirection pulleys 140,
which in turn direct drive belts 133 over support pulleys 130. In
the illustrated embodiment, end pressure pulleys or sheaves 132a
act as redirection pulleys and direct drive belt 133 over pressure
pulleys 132 for driving rollers 118. It should be understood that
the path of drive belt 133 is exemplary only and that the path of
drive belts 133 may vary.
[0051] As best seen in FIG. 5, motor 124 and gear box 126 along
with adjustable redirection pulley 144 are mounted below frame 113
and, as previously noted, are supported inward from the charge and
discharge ends of conveyor 110. Frame 113 is of similar
construction to frame 13 and includes side frame members 160, which
are interconnected or braced by transverse members 115.
[0052] Referring again to FIG. 5, redirection pulleys 144 are
adjusted by a pair of cylinders 146, preferably pneumatic cylinders
and, more preferably, double acting pneumatic cylinders, which are
actuated by a control system to move redirection pulleys 144 along
parallel adjustment axes 144a to thereby increase or decrease the
tension on belts 133, as would be understood by those skilled in
the art.
[0053] Referring to FIG. 9, redirection pulleys or sheaves 144 are
each respectively rotatably mounted on a support member 148 to
which rod end of cylinder 146 is coupled, for example, by a pin
148a. Support members 148 are movably mounted on tracks 151a (FIG.
7), which in turn are mounted to a sub-frame 156 that is mounted to
frame 113 below rollers 116. Sub-frame 156 preferably houses and
encloses cylinders 146 and redirection pulleys 144. In the
illustrated embodiment, gear box 126 and motor 124 are mounted to a
lower flange 113b of frame 113, with gear box 126 and driver sheave
128 preferably housed in compartment 158 adjacent sub-frame 156 and
below frame 113.
[0054] Similar to the previous embodiment, drive assembly 121 is
preferably aligned with the high side of conveyor 110 to minimize
interference with packages being unscrambled and singulated by
conveyor 110. In addition, drive belts 133 drivingly engage the
respective bases 150 of roller 118.
[0055] As best seen in FIG. 6, pressure pulleys or sheaves 132 are
mounted to the web 160a of side frame member 160 of frame 113 below
rollers 118. Support pulleys 130 are similarly mounted to web 160a
below pressure pulleys 132 so that, as previously noted, drive
belts 133 are aligned with the high side of conveyor 110 to engage
exposed portion of bases 150. As best seen in FIG. 6, motor 124 and
gear box 126 are mounted to frame 113 and to a transverse support
structure 162, which forms compartment 158. Transverse support 162
includes an upper flange 164, which is mounted to lower flanges
113b of frame 113 and, further, is reinforced by gusset plates 166
and 168, with gusset plate 168 extending transversely across
conveyor 110.
[0056] As best seen in FIG. 7, support members 148 comprise
generally channel-shape members with downwardly depending flanges
148b. Upper flanges 148c and downwardly depending flanges 148b
include guide members 149a and 149b, respectively, which guide
support members 148 along tracks 151a and 151b. Tracks 151a are
mounted to sub-frame 156 by support members 152a, such as angle
members, which are attached to the vertical webs 156a of sub-frame
156, for example by fasteners or the like. Rails 151b are directly
mounted to webs 156a of sub-frame 156 and together with rails 151a
support redirection pulleys 144 for movement along parallel axes
144a to adjust the tension on the respective drive belts 133. It
should be understood that cylinders 146 may be individually
actuated to provide individual adjustment to the respective drive
belts. Alternately, cylinders 146 may be actuated by a single
control to provide individual adjustment to the respective drive
belts.
[0057] As best seen in FIG. 8, redirection pulleys 140 are
similarly mounted to web 160a of side frame member 160 and are
positioned below pressure sheaves or pulleys 132. Furthermore,
redirection pulleys 140 (as well as redirection pulleys 142) extend
below frame 113 and into sub-frame 156.
[0058] Referring to FIGS. 3A and 3B, as previously noted in
reference to the first embodiment, rollers 118 are mounted to the
upper flanges 113a of side frame members 160 by axle supports 172.
Extending over axle supports 172 on both ends of rollers 118 are
angle members 174, which are mounted to flanges 113a, for example,
by bolts or the like. Angle members 174 provide a barrier to the
rotating ends of the rollers but are optional. In addition, the
angles (174) positioned on the high-side of conveyor 110 may
include projecting plates mounted thereto, which are aligned
between the respective bases 150 of rollers 118--in this way, the
gaps between the exposed bases of the rollers are reduced to avoid
snagging or jamming of articles.
[0059] Referring to FIGS. 10 and 11, the numeral 210 designates
another embodiment of the unscrambling and aligning conveyor of the
present invention. Conveyor 210 includes a plurality of rollers 218
similar to rollers 18, 118 of the previous embodiments. Rollers 216
are supported on frame 213, similar to frame 113, which includes a
pair of opposed side frame members 260 that are interconnected by
transverse members 215. Similar to the previous embodiments,
rollers 218 are driven on their high side by a driver assembly
212.
[0060] In the illustrated embodiment, driver assembly 212 includes
a plurality of pressure pulleys or sheaves 232 and support sheaves
or pulleys 230 similar to the previous embodiment and, further,
redirection pulleys or sheaves 238 which together support and
direct a pair of drive belts 233 through conveyor 210 to drive the
exposed bases 250 of rollers 218 on the high side of conveyor 210.
However, in the illustrated embodiment, the motor and drive gear
for driving belts 233 are located under an adjacent conveyor
section, such as the input or output conveyor. Therefore, conveyor
section 210 is adapted to cooperate with the drive mechanisms of an
adjacent conveyor section to simplify conveyor 210. In this manner,
conveyor 210 has reduced clearance requirements and has a more
compact configuration than the previous embodiments.
[0061] While several forms of the invention have been shown and
described, other forms will now be apparent to those skilled in the
art. For example, the drive assemblies described herein are
intended to be exemplary only and not intended to be limiting.
Furthermore, the configurations of the frame and its components are
exemplary only. Therefore, it will be understood that the
embodiments shown in the drawings and described above are merely
for illustrative purposes, and are not intended to limit the scope
of the invention which is defined by the claims which follow as
interpreted under the principles of patent law including the
doctrine of equivalents.
* * * * *