U.S. patent application number 16/268976 was filed with the patent office on 2020-08-06 for mechanically locking diverter.
This patent application is currently assigned to National Presort, Inc.. The applicant listed for this patent is National Presort, Inc.. Invention is credited to Brent Daboub.
Application Number | 20200247619 16/268976 |
Document ID | / |
Family ID | 1000004970201 |
Filed Date | 2020-08-06 |
![](/patent/app/20200247619/US20200247619A1-20200806-D00000.png)
![](/patent/app/20200247619/US20200247619A1-20200806-D00001.png)
![](/patent/app/20200247619/US20200247619A1-20200806-D00002.png)
![](/patent/app/20200247619/US20200247619A1-20200806-D00003.png)
![](/patent/app/20200247619/US20200247619A1-20200806-D00004.png)
![](/patent/app/20200247619/US20200247619A1-20200806-D00005.png)
![](/patent/app/20200247619/US20200247619A1-20200806-D00006.png)
![](/patent/app/20200247619/US20200247619A1-20200806-D00007.png)
![](/patent/app/20200247619/US20200247619A1-20200806-D00008.png)
![](/patent/app/20200247619/US20200247619A1-20200806-D00009.png)
United States Patent
Application |
20200247619 |
Kind Code |
A1 |
Daboub; Brent |
August 6, 2020 |
MECHANICALLY LOCKING DIVERTER
Abstract
A mechanically locking diverter utilizes a rotational actuator
to translate a pin, thereby moving a diverter flipper between a
divert position and a non-divert position. The diverter flipper
moves a roller attached to a pin attached to a shoe that translates
along a slat.
Inventors: |
Daboub; Brent; (Fort Worth,
TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
National Presort, Inc. |
Fort Worth |
TX |
US |
|
|
Assignee: |
National Presort, Inc.
Fort Worth
TX
|
Family ID: |
1000004970201 |
Appl. No.: |
16/268976 |
Filed: |
February 6, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65G 47/844 20130101;
B65G 2201/02 20130101 |
International
Class: |
B65G 47/84 20060101
B65G047/84 |
Claims
1. A diverter for an automated sorting machine, the diverter
comprising: a diverter block; an actuator coupled to the diverter
block; an actuator arm coupled to the actuator, the actuator arm
being operable between a first position and a second position; a
diverter flipper pivotally coupled to the diverter block, the
diverter flipper having a slot and being operable between a
non-divert position corresponding to the first position of the
actuator arm and a divert position corresponding to the second
position of the actuator arm; and a pin coupled to the actuator arm
and being disposed within the slot of the diverter flipper, such
that rotation of the actuator arm between the first position and
the second position pivots the diverter flipper between the
non-divert position and the divert position; wherein the first
position and the second position of the actuator arm are separated
by approximately 90 degrees, thereby creating a mechanical lock
that holds the diverter flipper in either the non-diverted position
or the diverted position.
2. The diverter according to claim 1, wherein the actuator is
recessed into the diverter block.
3. The diverter according to claim 1, wherein the pin only moves in
response to rotation of the actuator.
4. The diverter according to claim 1, further comprising: a channel
located in the diverter block; wherein a portion of the diverter
flipper is recessed within the channel.
5. The diverter according to claim 1, wherein the actuator arm
rotates through an angle that is greater than 90 degrees.
6. The diverter according to claim 1, wherein the actuator arm
rotates through an angle that is approximately 180 degrees.
7. An automated sorting machine, comprising: at least one
longitudinal rail; a plurality of transverse slats configured to
travel longitudinally along the rail; at least one shoe slidingly
retained on at least one of the slats; at least one diverter rail;
and at least one diverter disposed along the longitudinal rail, the
diverter comprising: a diverter block; an actuator coupled to the
diverter block; an actuator arm coupled to the actuator, the
actuator arm being operable between a first position and a second
position; a diverter flipper pivotally coupled to the diverter
block, the diverter flipper having a slot and being operable
between a non-divert position corresponding to the first position
of the actuator arm and a divert position corresponding to the
second position of the actuator arm; and a pin coupled to the
actuator arm and being disposed within the slot of the diverter
flipper, such that rotation of the actuator arm between the first
position and the second position pivots the diverter flipper
between the non-divert position and the divert position; wherein
the first position and the second position of the actuator arm are
separated by at least 90 degrees, thereby creating a mechanical
lock that holds the diverter flipper in either the non-diverted
position or the diverted position.
8. The automated sorting machine according to claim 7, wherein the
pin only translates in response to rotation of the actuator.
9. The automated sorting machine according to claim 7 wherein the
shoe does not translate along the diverter rail when the diverter
flipper is in the non-divert position, but the shoe does translate
along the diverter rail when the diverter flipper is in the divert
position.
10. The automated sorting machine according to claim 7, wherein the
actuator arm is rotated greater than 90 degrees.
11. The automated sorting machine according to claim 7, further
comprising: a diverter pin guide; wherein the diverter block abuts
the diverter pin guide and the diverter flipper.
12. The automated sorting machine according to claim 7, further
comprising: a channel located in the diverter block; wherein a
portion of the diverter flipper is recessed within the channel.
13. A divert rail system for an automated sortation machine having
a generally longitudinal main rail, a plurality of generally
transverse slats, a plurality of shoes, each shoe being configured
to travel along a corresponding slat, each slat terminating in a
side wall, the divert rail system comprising: a plurality of divert
rails branching off from the main rail, each divert rail forming an
angle of about 21 degrees or more with the main rail and
terminating at and end, such that the divert rail does not curve
back toward the longitudinal direction; wherein the length of each
divert rail is selected, such that the each shoe travels
transversely past the end of the divert rail and stops at a
transverse stopping position that is at least 1.5 inches away from
the side wall of the slat; at least one diverter disposed along the
main rail, the diverter comprising: a diverter block; an actuator
coupled to the diverter block; an actuator arm coupled to the
actuator, the actuator being operable between a first position and
a second position; a diverter flipper pivotally coupled to the
diverter block, the diverter flipper having a slot and being
operable between a non-divert position corresponding to the first
position of the actuator arm and a divert position corresponding to
the second position of the actuator arm; and a pin coupled to the
actuator arm and being disposed within the slot of the diverter
flipper, such that rotation of the actuator arm between the first
position and the second position pivots the diverter flipper
between the non-divert position and the divert position; wherein
the first position and the second position of the actuator arm are
separated by at least 90 degrees, thereby creating a mechanical
lock that holds the diverter flipper in either the non-diverted
position or the diverted position.
14. The divert rail system of claim 13, wherein the end of each
divert rail is located a selected distance away from the side wall
of the slat, so as to form a gap between the end of the divert rail
and the side wall that is sized to receive a roller and a pin
carried by the shoe.
15. The diverter according to claim 1, wherein the slot is
straight.
Description
BACKGROUND
1. Technical Field
[0001] This invention relates to a sortation conveyor system, in
particular, diverters used in such sortation conveyor systems for
diverting shoes, such as letters, flats, parcels, and polybags,
along conveyor systems sorter in automatic sorting machines.
2. Description of Related Art
[0002] Machines for automatically sorting articles, such as mail,
into one of an array of selected bins or compartments, are common.
Typically, such sorting machines have a feeding mechanism that
inducts articles one-at-a-time into belts and/or onto conveyors.
Sensing components along the travel path monitor and track the
movement of the articles. When necessary, control electronics
command a diverting gate assembly or other redirecting mechanisms
to reroute the article into a specific destination compartment or
bin.
[0003] Conventional diverter gates move by either a solenoid or
linear actuator. Unfortunately, the actuation of the conventional
diverter gate causes the diverter to bounce during actuation.
Having a loose diverter gate or an unexpected gate move at an
unexpected time while the transport belt is moving could cause
potential damage to such mechanism and or the system as a whole.
Accordingly, there exists a need for a mechanically locking
diverter that cannot move or bounce inadvertently.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] The novel features believed a characteristic of the system
of the present application is set forth in the present application.
However, the system itself, as well as a preferred mode of use, and
further objectives and advantages thereof, will best be understood
by reference to the following detailed description when read in
conjunction with the accompanying drawings, wherein:
[0005] FIG. 1 is a general view of the preferred embodiment of a
mechanically locking diverter that is located in the not diverted
position according to the present application.
[0006] FIG. 2 is a general view of the preferred embodiment of a
mechanically locking diverter that is located in the diverted
position according to the present application.
[0007] FIG. 3 is an enlarged view of the preferred embodiment of a
mechanically locking diverter that is located in the diverted
position according to the present application illustrating a slot
to pin connection.
[0008] FIG. 4 is a perspective view of the preferred embodiment of
a mechanically locking diverter according to the present
application.
[0009] FIG. 5 is a perspective view of the preferred embodiment of
an actuator according to the present application.
[0010] FIG. 6 is a perspective view of the preferred embodiment of
an arm according to the present application.
[0011] FIG. 7 is a perspective view of the preferred embodiment of
a pin according to the present application.
[0012] FIG. 8 is a perspective view of the preferred embodiment of
a diverter flipper according to the present application.
[0013] FIG. 9 is a perspective view of the preferred embodiment of
a diverter pin guide according to the present application.
[0014] FIG. 10 is a perspective view of the preferred embodiment of
a diverter block according to the present application.
[0015] FIG. 11 is a partial cut out view of a Mechanically locking
diverter diverting a shoe according to the present application.
[0016] FIG. 12 is a partial plan view of the preferred embodiment
of a conveyor sortation system according to the present
application.
[0017] FIG. 13 is a partial plan view of a conventional conveyor
sortation system.
[0018] While the system of the present application is susceptible
to various modifications and alternative forms, specific
embodiments thereof have been shown by way of example in the
drawings and are herein described in detail. It should be
understood, however, that the description herein of specific
embodiments is not intended to limit the method to the particular
forms disclosed, but on the contrary, the intention is to cover all
modifications, equivalents, combinations, and alternatives falling
within the spirit and scope of the present application.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0019] Illustrative embodiments of the system of the mechanically
locking diverter of the present application are described below. In
the interest of clarity, not all features of an actual
implementation are described in this specification. It will, of
course, be appreciated that in the development of any such actual
embodiment, numerous implementation-specific decisions must be made
to achieve the developer's specific goals, such as compliance with
system-related and business-related constraints, which will vary
from one implementation to another. Moreover, it will be
appreciated that such a development effort might be complex and
time-consuming, but would nevertheless be a routine undertaking for
those of ordinary skill in the art having the benefit of this
disclosure.
[0020] Reference may be made herein to the spatial relationships
between various components and to the spatial orientation of
various aspects of components as the devices are depicted in the
attached drawings. However, as will be recognized by those skilled
in the art after a complete reading of the present application, the
devices, members, apparatuses, etc. described herein may be
positioned in any desired orientation. Thus, the use of terms such
as "above," "below," "upper," "lower," or other like terms to
describe a spatial relationship between various components or to
describe the spatial orientation of aspects of such components
should be understood to describe a relative relationship between
the components or a spatial orientation of aspects of such
components, respectively, as the device described herein may be
oriented in any desired direction.
[0021] Referring now to FIGS. 1 and 2 in the drawings, the
preferred embodiment of a mechanically locking diverter 101
according to the present application is illustrated. Diverter 101
is comprised of a diverter block 103, a diverter pin guide 105, a
diverter flipper 107, an actuator arm 109, and an actuator 111.
Diverter flipper 107 pivots about a pivot pin 108, such that
diverter 101 is operable between a non-divert position in which
diverter flipper 107 is in line with diverter pin guide 105, as
shown in FIG. 1; and a divert position, in which diverter flipper
107 is angled relative to diverter pin guide 105, as shown in FIG.
2. Depending upon the position of diverter flipper 107, a shoe 805
(see FIG. 11) will progress in the direction of the bold arrows
shown in FIGS. 1 and 2.
[0022] Referring now also to FIG. 3 in the drawings, mechanically
locking diverter 101 is shown in the divert position. Diverter
flipper 107 includes a slot 115 configured to receive a pin 113.
Although slot 115 is shown as straight, it will be appreciated that
the shape of slot may be varied depending upon the desired movement
and/or acceleration of diverter flipper 107. Pin 113 is coupled to
diverter arm 109, which is rotatably driven by actuator 111.
Actuator 111 is preferably recessed below diverter block 103. As
actuator 111 rotates actuator arm 109 and pin 113, diverter flipper
107 is rotated between the non-diverted position and the diverted
position. Because pin 113 is located in slot 115, the position of
diverter flipper 107 is controlled by the rotational placement of
pin 113 in relation to slot 115. Therefore, even when actuator 111
is without power, diverter flipper 107 will remain in the last
controlled position. It is preferred that actuator arm 109 rotates
approximately 90 degrees between the divert position and the
non-divert position. Another embodiment of this design allows for
the actuator arm to rotate approximately 180 degrees. This
configuration creates a mechanical lock that holds diverter flipper
107 in either the divert position, the non-divert position, or
both.
[0023] Referring now also to FIG. 4 in the drawings, mechanically
locking diverter 101 is shown in the non-diverted position. As is
shown, a base portion 505 (see FIG. 8) of diverter flipper 107 is
recessed within diverter block 103, while a tab portion 507 of
diverter flipper 107 extends above diverter block 103.
[0024] Referring now also to FIG. 5 in the drawings, actuator 111
is illustrated. Actuator 111 selectively rotates a shaft 203. Shaft
203 is configured for coupling to actuator arm 109. Actuator 111 is
preferably configured and/or programmed to rotate shaft 203 back
and forth between and angle of approximately 90 degrees or
more.
[0025] Referring, now also to FIG. 6 in the drawings, actuator arm
109 is illustrated. Actuator arm 109 is coupled to shaft 203,
preferably via a clevis connection 301 forming a rotational axis
305, thereby selectively rotating pin 113. Actuator arm 109
includes a mount 303 for a pin 401 (see FIG. 7). Mount 303 is a
specific distance away from rotational axis 305 of actuator arm
109, such that a 90-degree or more rotation about rotational axis
305 will correspond with a significant enough rotation in diverter
flipper 107 to divert shoes 805 or let shoes 805 pass by.
[0026] Referring now also to FIG. 7 in the drawings, pin 401 is
shown. Pin 401 is disposed between actuator arm 109 and diverter
flipper 107. Pin 401 is of sufficient length to connect actuator
arm 109 to diverter flipper 107 via a pin-and-slot connection
located on diverter flipper 107.
[0027] Referring now also to FIG. 8 in the drawings, diverter
flipper 107 is illustrated. As is shown, diverter flipper 107 moves
between the divert position and the non-divert position based upon
the location of pin 401 in slot 115. As is shown, base portion 505
is shaped and dimensioned to be recessed within diverter block 103,
while tab portion 507 extends above diverter block 103. Diverter
flipper 107 features a deflector 509, either a pin deflector, a
roller deflector, or both. Deflector 509 is a face or component
that comes into contact with the pin or roller on shoe 805, thereby
causing shoe 805 to divert down a different path. Deflector 509 is
sufficiently strong to withstand the force of the pin or the roller
being diverted by deflector 509. Slot 115 of diverter flipper 107
is of sufficient width to allow pin 113 to slide within the bounds
of slot 115. Slot 115 is long enough to allow at least 90 degrees
or more of rotation about the axis of actuator 111. In addition,
slot 115 is located far enough away from the rotational axis of
diverter flipper 107 to allow for diverter flipper 107 to divert
shoe 805 or let shoe 805 pass by.
[0028] Referring now also to FIG. 9 in the drawings, diverter pin
guide 105 is illustrated. Diverter pin guide is coupled to the top
of diverter block 103. Diverter pin guide 105 works with diverter
flipper 107 to direct shoes 805 down one of two different rail
paths, so that shoes 805 may push packages into a selected sort
locations.
[0029] Referring now also to FIG. 10 in the drawings, diverter
block 103 is illustrated. Diverter block 103 includes of a diverter
flipper channel 703, an actuator mount 705, and a shaft 707.
Diverter flipper channel 703 is large enough to receive and allow
diverter flipper 107 to rotate enough to divert shoe 805 let it
shoe 805 pass by. Channel 703 is configured such that actuator arm
109 is close to the wall of the channel when diverter flipper 107
is diverting shoes 805 and when diverter flipper 107 is not
diverting shoes 805. The configuration of actuator arm 109 being
perpendicular (or just beyond perpendicular) to the wall of channel
703 creates a mechanical lock between the diverter flipper 107 and
diverter block 103. Thus, actuator arm 109 operates between a first
position corresponding to the non-divert position of diverter
flipper 107, and a second position corresponding to the divert
position of diverter flipper 107. Such lock prohibits external
forces on diverter flipper 107 from moving diverter flipper 107.
The lock can only be released by rotating actuator arm 109 out of a
perpendicular angle from the wall, which allows diverter flipper
107 to be freely moved until actuator arm 109 is perpendicular to
the other wall of channel 703. Actuator mount 705 is located far
enough away from a central axis to acquire the desired rotation of
diverter flipper 107. Shaft 707 is of sufficient size to fit into
the rotational axis of diverter flipper 107. Diverter block 103 may
include one or more ports, channels, and/or apertures for allowing
dust and debris to fall out and/or be removed.
[0030] Referring now also to FIG. 11 in the drawing, the preferred
embodiment of a an automated sorting machine 801 according to the
present application is illustrated. Sorting machine 801 includes at
least one longitudinal rail 802, at least one transverse slat 803,
at least one shoe 805 that is slidingly retained on slat 803, and
at least one shortened diverter rail 811. Packages ride on slats
803 of sorting machine 801. Slats 803 terminate at a side wall 804,
and may include a bumper member (not shown) to prevent damage to
shoes 805 as shoes 805 contact side walls 804. Shoes 805 include a
roller 807 and a pin 809, by which mechanically locking diverter
101 controls the path of shoe 805. In response to appropriate
signals, diverter 101 is actuated into the divert position,
whereupon shoe 805 is caused to move transversely along diverter
rail 811, thereby selectively kicking the package off into a
specific location or bin. Shoes 805 are returned to the inner
position on slats 803 by appropriate re-divert rails (not
shown).
[0031] It will be appreciated that the solenoid or linear actuator
accelerates diverter 101 to high speeds upon actuation. Due to this
high speed, typical diverters tend to bounce upon impact of a hard
stop. Additionally it will be appreciated that shoes 805 are quite
massive and move at very high speeds along rails 802 and slats 803.
Another advantage of the unique locking feature of mechanically
locking diverter 101 is that diverter flipper 107 is mechanically
locked into either the divert position or the non-divert position
by pin 113 and slot 115. This locking configuration helps to
prevent diverter flipper 107 from bouncing when diverter flipper
107 is actuated or impacted by pin 809 of shoe 805 as shoe 805
passes by diverter flipper 107. Without this unique locking
feature, diverter flipper 107 would be susceptible to undesirable
movement and/or damage when impacted by pin 809.
[0032] Referring now also to FIG. 12 in the drawings, a conveyor
sortation system according to the present application is
illustrated. For reference, FIG. 13 shows a conventional standard
diverter rail design. As is shown in FIG. 12, the diverter rails
901 are shortened, compared to the diverter rails 1001 of FIG. 13.
In addition, divert rails 901 do not turn back in the longitudinal
direction. By utilizing shortened diverter rails 901, the distance
that the shoe is guided is reduced. As is shown in FIG. 13, the
terminal divert position 1003 is the maximum final position of a
diverted shoe, such as shoe 805, with respect to the linear axis of
movement of the shoe along a corresponding slat, such as slat 803.
In the system of FIG. 13, the shoes slam into the side walls of the
slats. Another advantage of shortened diverter rails 901 is that
the corresponding shoes, i.e., shoes 805, remain at least 1.5
inches away from the terminal divert position 905, i.e. side walls
804 of slats 803. As shoes 805 travel past the ends of divert rails
901, the friction of shoes 805 along slats 803 causes shoes 805 to
stop or slow down prior to contacting side walls 804 of slats 803.
This prevents shoes 805 from being damaged by repeated contacting
of side walls 804. In addition, it is preferred that the angle
between a straight portion of the diverter rail 901 and a
centerline 903 of the main rail be at least 21 degrees or
greater.
[0033] The particular embodiments disclosed above are illustrative
only, as the application may be modified and practiced in different
but equivalent manners apparent to those skilled in the art having
the benefit of the teachings herein. Furthermore, no limitations
are intended to the details of construction or design herein shown,
other than as described in the claims below. It is therefore
evident that the particular embodiments disclosed above may be
altered, combined, and/or modified, and all such variations are
considered within the scope and spirit of the application.
Accordingly, the protection sought herein is as set forth in the
claims below. It is apparent that a system with significant
advantages has been described and illustrated. Although the system
of the present application is shown in a limited number of forms,
it is not limited to just these forms but is amenable to various
changes and modifications without departing from the spirit
thereof.
* * * * *