U.S. patent application number 11/260803 was filed with the patent office on 2006-05-04 for apparatus and methods for conveying objects.
This patent application is currently assigned to Materials Handling, Inc.. Invention is credited to Matthew L. Fourney.
Application Number | 20060090986 11/260803 |
Document ID | / |
Family ID | 34591437 |
Filed Date | 2006-05-04 |
United States Patent
Application |
20060090986 |
Kind Code |
A1 |
Fourney; Matthew L. |
May 4, 2006 |
Apparatus and methods for conveying objects
Abstract
Disclosed are conveyors and methods for making the conveyors. In
one embodiment, a conveyor comprises a modular conveyor belt that
includes a plurality of mat-top chains having a plurality of
cavities and a plurality of first rollers disposed in the cavities
of the mat-top chains. The conveyor further includes at least one
second roller that operatively couples to the first rollers such
that the first rollers rotate as the conveyor belt travels along
the second roller. The invention can also be construed as providing
the method for conveying objects. The method can comprise the steps
of driving a modular conveyor belt in a direction of belt travel;
rotating a plurality of first rollers disposed into the modular
conveyor belt in a manner in which slippage of the first rollers is
reduced; and conveying objects on the modular conveyor belt using
the rotating first rollers.
Inventors: |
Fourney; Matthew L.;
(Laurel, MD) |
Correspondence
Address: |
THOMAS, KAYDEN, HORSTEMEYER & RISLEY, LLP
100 GALLERIA PARKWAY, NW
STE 1750
ATLANTA
GA
30339-5948
US
|
Assignee: |
Materials Handling, Inc.
|
Family ID: |
34591437 |
Appl. No.: |
11/260803 |
Filed: |
October 27, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10719805 |
Nov 21, 2003 |
6968941 |
|
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11260803 |
Oct 27, 2005 |
|
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Current U.S.
Class: |
198/779 ;
198/370.03; 198/384 |
Current CPC
Class: |
B65G 2201/02 20130101;
B65G 17/24 20130101; B65G 17/08 20130101; B65G 47/34 20130101; B65G
17/40 20130101 |
Class at
Publication: |
198/779 ;
198/370.03; 198/384 |
International
Class: |
B65G 17/00 20060101
B65G017/00 |
Claims
1. A conveyor comprising: a conveyor belt including a plurality of
cavities and a plurality of diverting rollers, each diverting
roller being disposed in a cavity; and a transverse roller that is
configured to operatively couple to at least some of the diverting
rollers to cause those diverting rollers to rotate as they travel
along the transverse roller.
2. The conveyor as defined in claim 1, wherein the transverse
roller is located underneath the conveyor belt and the transverse
roller rotates in a direction transverse to the rotational
direction of the diverting rollers.
3. The conveyor as defined in claim 1, wherein the transverse
roller is positioned to rotate substantially perpendicular to a
direction of belt travel.
4. The conveyor as defined in claim 1, wherein the conveyor belt
comprises mat-top chains that include hinge elements that link
multiple mat-top chains together to form the conveyor belt.
5. The conveyor as defined in claim 4, wherein the hinge elements
comprise interleaved hinge elements having axially-aligned
holes.
6. The conveyor as defined in claim 1, further comprising a
plurality of support members that support the conveyor belt.
7. The conveyor as defined in claim 1, wherein the transverse
roller is vertically displaceable toward or away from the conveyor
belt, wherein when the transverse roller is displaced toward the
conveyor belt to engage the at least some diverting rollers, the
transverse roller rotates the at least some diverting rollers.
8. A conveyor as defined in claim 7, wherein the transverse roller
is vertically displaced toward or away from the conveyor belt using
an air actuator, hydraulic actuator, ball screw actuator, or
solenoid actuator.
9. The conveyor as defined in claim 1, wherein rotation of the
transverse roller causes the at least some diverting rollers to
rotate with reduced slippage.
10. The conveyor as defined in claim 1, wherein the diverting
rollers are aligned in the cavities at an angle that is different
from a direction of belt travel enabling the diverting rollers to
convey objects toward the sides or the middle of the conveyor
belt.
11. A conveyor comprising: a conveyor belt including a plurality of
mat-top chains having a plurality of cavities and a plurality of
diverting rollers, each diverting roller being disposed in a cavity
of the mat-top chains; and transverse rollers that operatively
couple to the diverting rollers causing the diverting rollers to
rotate as they travel along the transverse rollers and the
transverse rollers to rotate in a direction transverse to the
rotational direction of the diverting rollers, wherein the rotation
of the transverse rollers causes the diverting rollers to rotate
with reduced slippage.
12. The conveyor as defined in claim 11, wherein the transverse
rollers are located underneath the conveyor belt.
13. The conveyor as defined in claim 11, wherein the transverse
rollers are positioned to rotate substantially perpendicular to a
direction of belt travel.
14. The conveyor as defined in claim 11, wherein the conveyor belt
comprises mat-top chains that include hinge elements that link
multiple mat-top chains together to form the conveyor belt.
15. The conveyor as defined in claim 14, wherein the hinge elements
comprise interleaved hinge elements having axially-aligned
holes.
16. The conveyor as defined in claim 11, further comprising a
plurality of support members that support the conveyor belt.
17. The conveyor as defined in claim 11, wherein the transverse
rollers are vertically displaceable toward or away from the
conveyor belt, wherein when the transverse rollers are displaced
toward the conveyor belt to engage the diverting rollers, the
transverse rollers rotate the diverting rollers.
18. A conveyor as defined in claim 17, wherein the transverse
rollers are vertically displaced toward or away from the conveyor
belt using an air actuator, hydraulic actuator, ball screw
actuator, or solenoid actuator.
19. The conveyor as defined in claim 11, wherein the diverting
rollers are aligned in the cavities of the mat-top chains at an
angle that is different from a direction of belt travel enabling
the diverting rollers to convey objects toward the sides or the
middle of the conveyor belt.
20. A method for conveying objects, the method comprising: driving
a conveyor belt in a direction of belt travel; rotating a plurality
of diverting rollers disposed in the conveyor belt in a manner in
which slippage of the diverting rollers is reduced; and conveying
objects on the conveyor belt using the rotating diverting
rollers.
21. The method as defined in claim 20, wherein rotating the
diverting rollers comprises engaging the diverting rollers with a
transverse roller.
22. The method as defined in claim 20, wherein rotating the
diverting rollers comprises rotating a transverse roller in a
direction substantially transverse to the rotational direction of
the diverting rollers.
23. The method as defined in claim 20, wherein rotating the
diverting rollers comprises selectively rotating the diverting
rollers with a transverse roller.
24. The method as defined in claim 23, wherein selectively rotating
the diverting rollers comprises vertically displacing the
transverse roller toward the conveyor belt and engaging the
diverting rollers, the transverse roller rotating the diverting
rollers.
25. The method as defined in claim 20, wherein rotating the
diverting rollers comprises rotating the diverting rollers at an
angle that is different from the direction of the belt travel.
26. The method as defined in claim 20, wherein conveying objects on
the conveyor belt comprises conveying objects toward the sides or
the middle of the conveyor belt.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of co-pending U.S.
utility application entitled, "Apparatus and Methods for Conveying
Objects," having Ser. No. 10/719,805, filed Nov. 21, 2003, which is
entirely incorporated herein by reference.
TECHNICAL FIELD
[0002] The invention generally relates to power-driven
conveyors.
DESCRIPTION OF THE RELATED ART
[0003] Switch conveyors have been developed that include a modular
conveyor belt that includes rows of rollers. The rollers are
disposed in the modular conveyor belt and are angled relative to
the direction of travel of the belt such that they can laterally
divert objects placed on the belt. The conveyor includes fixed
longitudinal wear strips that are located below the conveyor belt.
As the conveyor belt travels, the rollers travel along the
longitudinal wear strips causing the rollers to rotate for the
purpose of diverting objects.
[0004] The use of the wear strips to rotate the rollers causes the
rollers to slip in that the rollers intermittently slide along the
wear strips. Such slippage is undesirable in that it results in
inconsistent or inefficient diverting of the objects.
SUMMARY
[0005] Disclosed are conveyors and methods for conveying objects.
In one embodiment, a conveyor comprises a modular conveyor belt
that includes a plurality of mat-top chains having a plurality of
cavities and a plurality of first rollers disposed in the cavities
of the mat-top chains. The conveyor further includes at least one
second roller that operatively couples to the first rollers such
that the first rollers rotate as the conveyor belt travels along
the second roller.
[0006] In one embodiment, a method comprises driving a modular
conveyor belt in a direction of belt travel; rotating a plurality
of first rollers disposed into the modular conveyor belt in a
manner in which slippage of the first rollers is reduced; and
conveying objects on the modular conveyor belt using the rotating
first rollers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The disclosed apparatus and methods can be better understood
with reference to the following drawings. The components in the
drawings are not necessarily to scale.
[0008] FIG. 1 is a perspective view of an embodiment of a section
of a conveyor that includes a conveyor belt having a plurality of
first rollers that are operatively coupled to a second roller.
[0009] FIG. 2 is a detail view of a section of the conveyor of FIG.
1.
[0010] FIG. 3 is a top view of an embodiment of a section of the
conveyor of FIG. 1.
[0011] FIG. 4 is a front view of an embodiment of a section of the
conveyor of FIG. 1.
[0012] FIG. 5 is a flow diagram that illustrates an embodiment of a
method for conveying objects.
[0013] FIG. 6A is a perspective view of an example embodiment of a
first roller.
[0014] FIG. 6B is a side view of the roller of FIG. 6A.
DETAILED DESCRIPTION
[0015] Disclosed are conveyors and methods for conveying objects
that reduce slippage of conveyor rollers. Due to that reduced
slippage, the conveyors more effectively divert objects on the
conveyor belt. In some embodiments, the conveyor includes first
rollers disposed in the conveyor belt and at least one second
roller located underneath the conveyor belt that can rotate in a
direction transverse to the direction of travel of the conveyor
belt. As the conveyor belt travels along the second roller, the
second roller operatively couples with the first rollers causing
the first rollers and the second roller to rotate. Because of the
rotation of the second roller, the first rollers rotate with
reduced slippage.
[0016] Referring now in more detail to the figures in which like
referenced numerals identifying corresponding parts, FIG. 1
illustrates a perspective view of an embodiment of a section of a
conveyor 100 in which a plurality of first rollers 104 are disposed
in a conveyor belt 102. As indicated in this figure, the conveyor
belt 102 is modular and includes at least one mat-top chain 110.
The mat-top chain 110 has a plurality of cavities 114, in which the
first rollers 104 are disposed. By way of example, the first
rollers comprise plastic wheels that include outer rubber layers or
tires (see discussion of FIGS. 6A and 6B). That configuration
increases friction between the first rollers 104 and surfaces that
the rollers contact (i.e., the surfaces of the second rollers 106
described below) so as the reduce slippage of the first rollers.
The first rollers 104 are aligned at an angle .alpha. (shown in
FIG. 3) relative to the direction of the travel of the conveyor
belt 102 so as to laterally divert objects conveyed by the conveyor
belt. By way of example, .alpha. may range from approximately 20 to
70 degrees. Because the first rollers 104 are used to divert
objects, the first rollers may be designated as diverting rollers.
The mat-top chain 110 of FIG. 1 includes hinge elements 112 that
can be used to link other mat-top chains 110 to form a continuous
conveyor belt 102.
[0017] With further reference to FIG. 1, the conveyor 100 further
includes a plurality of second rollers 106 and support members 108.
The second rollers 106 are located underneath the conveyor belt 102
between the support members 108 and are free to rotate in a
direction that is transverse, e.g., substantially perpendicular, to
the direction of travel of the conveyor belt indicated by arrow A.
By way of example, the second rollers 106 comprise elongated metal
rollers that include eurethane outer sleeves. Because the second
rollers 106 rotate in a direction that is transverse to the
direction of travel of the conveyor belt 102, the second rollers
106 may be designated as transverse rollers. As the conveyor belt
102 travels in direction A along the second rollers 106, the second
rollers can be positioned to engage the first rollers 104. Such
engagement causes the first rollers 104 and the second rollers 106
to rotate. That rotation is facilitated by the high coefficient of
friction that exists between the rubber layers of the first rollers
104 and the eurethane sleeves of the second rollers 106. As the
first rollers 104 rotate along the second rollers 106, the first
rollers pass over from first ends 118 to second ends 120 of the
second rollers to trace a helical path 308 (shown in FIG. 3) on the
second rollers. Because the second rollers 106 rotate when they
engage the first rollers 104 as opposed to being fixed as prior art
wear strips, the first rollers rotate with reduced slippage. In
fact, after an initial start up period, the first rollers 104
rotate along the second rollers 106 with nearly no slipping. This,
in turn, enables more effective diverting of the objects carried by
the conveyor belt 102. For example, objects can be diverted more
quickly, in a shorter amount of space (i.e., length of conveyor),
or both.
[0018] In some embodiments, the second rollers 106 are vertically
displaceable so as to be capable of being moved toward or away from
the mat-top chain 110 to engage or disengage the first rollers 104.
The vertical movement of the second rollers 106 can be facilitated
by various components such as an air actuator, hydraulic actuator,
ball screw actuator, or solenoid actuator. Alternatively, however,
in cases in which the first rollers 104 are always to be driven,
the second rollers 106 are not displaceable such that they
continuously engage the first rollers as the conveyor belt 102
travels in direction A. In yet a further alternative, the second
rollers 106 are horizontally displaceable so as to be brought into
and out of contact with first rollers 104. Such an arrangement may
be particularly advantageous in situations in which the conveyor
belt is provided with transverse rows of first rollers 102 that
alternatingly face different directions (e.g., a leftward
direction, rightward direction, the leftward direction, and so
forth across the row)). Horizontal displacement of the second
rollers 106 in such a case may enable switching between diversion
of objects in two separate (e.g., opposite) directions (e.g., from
a leftward direction to a rightward direction and vice versa).
[0019] FIG. 2 is a detailed view of a section of the conveyor of
FIG. 1. As shown in FIG. 2, the mat-top chain 110 includes hinge
elements 112 that have multiple interleaved hinge elements 206,
each of which has a hole 208 that is axially aligned with the hole
208 of an adjacent element 206. In order to link two mat-top chains
110, the axially-aligned holes 208 of the chains 110 are aligned
and a rod (not shown) is placed through the axially-aligned holes
208. A plurality of mat-top chains 110 may therefore be linked
together to form a continuous conveyor belt 102.
[0020] As described above, the mat-top chain 110 further includes
cavities 114 in which the first rollers 104 are disposed and in
which the first rollers can rotate. As the conveyor belt 102
travels in direction A, the second rollers 106 can be made to
engage the first rollers 104 causing the first rollers to rotate in
direction B. The objects on the conveyor belt 102 can therefore be
conveyed in a direction C. Notably, the second rollers rotate in
direction D.
[0021] FIG. 3 is a top view of an embodiment of a section of the
conveyor of FIG. 1. In FIG. 3, the first rollers 104 are arranged
along the axes 302. The mat-top chain 110 includes first roller
axles 306 that are aligned on the rotational axes 304. The first
roller axles 306 are coupled with the mat-top chain 110 and
disposed within the cavities 114. The first roller axles 306 extend
through openings of the first rollers 104 to enable the first
rollers 104 to rotate about their axes 302 when engaged with the
second rollers 106. The alignment of the first rollers 104 enables
the first rollers 104 from below to convey objects on the conveyor
belt 102 at an angle .alpha. relative to the direction of travel
A.
[0022] As is further depicted in FIG. 3, the second rollers 106 are
located underneath the conveyor belt 102 such that the second
rollers 106 can engage the first rollers 104 from below as the belt
travels in direction A along the second rollers 106.
[0023] FIG. 4 is a front view of an embodiment of a section of the
conveyor of FIG. 1. The mat-top chain 110 has a height dimension
402 that is smaller than the height dimension 404 of the first
rollers 104. As the belt 102 travels in direction A and the first
rollers 104 engage the second rollers 106, the first rollers rotate
in direction B and the second rollers 106 rotate in an opposing
direction D (counterclockwise in the orientation shown in FIG.
4).
[0024] FIG. 5 is a flow diagram that illustrates an embodiment of a
method 500 for conveying objects on a conveyor belt. Beginning with
block 502 of FIG. 5, the method 500 includes driving a conveyor
belt in first direction.
[0025] In block 504, first rollers within the conveyor belt are
rotated in a manner in which slippage of the first rollers is
reduced. For example, as the conveyor belt travels in direction A,
the first rollers engage second rollers that are likewise free to
rotate.
[0026] In block 506, the objects on the conveyor belt 102 are
diverted in a second direction using the first rollers. The objects
can be displaced towards either the sides or the middle of the
conveyor belt.
[0027] FIGS. 6A and 6B illustrate an example embodiment for the
first rollers described above. As indicated in these figures, a
roller 600 comprises an inner wheel 602 surrounded by an outer tire
604. By way of example, the inner wheel is constructed of a
lightweight, rigid material, such as a plastic or metal, and the
outer tire 604 is made of a resilient material having a high
coefficient of friction, such as a rubber. The outer-tire 604 is
provided around an outer surface 608 of the inner wheel 602 (FIG.
6B). The inner wheel 602 also comprises an opening 606 through
which a roller axle may pass to rotatably mount the roller 600 in a
conveyor belt (e.g., belt 102). Due to the outer tire 606, improved
gripping of a surface, such as that of the second rollers, can be
achieved thereby reducing slippage.
[0028] It should be emphasized that the above-described embodiments
are merely possible examples. Many variations and modifications may
be made to the above-described embodiments. All such modifications
and variations are intended to be included herein within the scope
of this disclosure.
* * * * *