Referring now specifically to the drawings and the illustrative embodiments depicted therein, a curved belt conveyor 10 includes a plurality of curved portions, sections, zones or segments 12 positioned along and between an outer curved sidewall or side frame 14a and an inner curved sidewall or side frame 14b, and is operable to convey articles in a direction of conveyance A (
A typical belt curve consists of a curved frame having curved opposite sidewalls or side channels that hold tapered rollers that support a belt. As the belt is driven around the rollers, the belt tends to move along the tapered rollers and toward the center of the curve or toward the inner sidewall of the curved conveyor. Traditional belt curves use a mechanical system to hold the belt in place to keep the belt from moving towards the center of the curve. Such mechanical systems typically engage an edge of the belt to retain the belt at the desired or appropriate position around the rollers.
The curved belt conveyor of the present invention includes a curved frame or curved sidewalls and may be divided into 15 degree conically belted zones (or other curvatures, such as discussed below) consisting of two tapered idler rollers and a tapered drive roller. Unlike conventional belt curves, the curved belt conveyor of the present invention does not use a mechanical system that engages the edge of the belt to hold the belt in the correct or tracked position/orientation. Instead, the curved belt conveyor and tracking device or roller adjustment device of the present invention controls and tracks the belt by changing the angle formed by the two end rollers. For example, the upstream end tapered idler roller may be adjustable by the tracking device and allowed to travel or pivot away from the tapered drive roller (at the downstream end of the zone), thus decreasing the angle of contact of the rollers. This may be accomplished by changing the axle location of the idler roller at the inner side channel of the conveyor. When the contact angle is decreased, the conical belt will move away from the center of the curve and toward the outer sidewall of the conveyor. Thus, by controlling the angle of the rollers (and desirably by controlling the angle or orientation of the upstream idler roller relative to the sidewalls), the position of the belt around the rollers can be controlled.
As the belt moves away from the center of the curve (such as in response to the angle of the upstream roller being adjusted), the belt begins to “climb” the tapered rollers toward the outer sidewall. As the belt climbs the tapered rollers (i.e. moves toward the larger diameter ends of the rollers), the tension on the belt increases (due to the larger curved distance or arc or dimension between the outer ends of the end rollers compared to the curved distance or arc or dimension between the inner ends of the end rollers). The tension created in the belt during such movement of the belt along the rollers can be used to control the angle of the tapered rollers. As the tension increases, it creates a reaction force that attempts to push the two outside rollers towards each other. Thus, the tracking device of the present invention includes a biasing element or spring placed at the inner side channel or sidewall and counters the force generated by the tension in the belt. As the belt moves outward toward the outer sidewall, the tension in the belt may increase to the point that the generated force of the belt is greater than the compression force of the spring. When the tension in the belt meets or exceeds the spring force, the spring begins to compress allowing the tapered end idler roller's position at the inner side channel to change. As the tapered end idler roller moves or pivots (such as by moving the inner end of the upstream end roller toward the downstream end of the conveyor), the angle between the two end rollers increases and the belt moves back towards the center of the curve. As the belt moves toward the center of the curve, the tension in the belt decreases, and the spring may then urge the inner end of the end idler roller in the opposite direction or toward the upstream end of the conveyor, whereby the decrease in angle of the end rollers results in the belt again moving outward along the rollers and toward the outer sidewall of the conveyor. The biasing element or spring of the tracking device of the present invention thus acts to balance the tension on the belt to control the position of the belt around the rollers.
Each belted segment or zone 12 of curved belt conveyor 10 may be independently operable to accumulate articles on the curved segment or to move articles in the direction A onto a next, adjacent curved segment or to a discharge area or onto another conveyor, such as another belt conveyor, or a roller conveyor, slider bed, or the like, or any other means for receiving articles from a discharge end of the last zone or segment of the curved belt conveyor 10. Curved belt conveyor 10 may, for example, convey articles onto an adjacent straight belted conveyor, such as the types disclosed in U.S. Pat. Nos. 6,811,018 and 7,093,709, and U.S. patent application Ser. No. 11/504,509, filed Aug. 15, 2006 by Cotter et al. for BELT CONVEYOR (Attorney Docket DEM04 P-100C), which are hereby incorporated herein by reference in their entireties, or onto another curved belted conveyor, such as of the types disclosed in U.S. Pat. Nos. 6,971,510 and 7,150,352, which are hereby incorporated herein by reference in their entireties, or any other known or conventional straight or curved conveyor or conveying surface or the like.
Optionally, the belt may have a low modulus characteristic and may have at least approximately a 0.75 percent initial stretch in its lengthwise direction when the belt is reeved or positioned around the rollers, such as a belt of the types described in U.S. Pat. Nos. 6,811,018; 6,971,510; 7,093,709 and 7,150,352, and U.S. patent application Ser. No. 11/504,509, filed Aug. 15, 2006 by Cotter et al. for BELT CONVEYOR (Attorney Docket DEM04 P-100C), which are hereby incorporated herein by reference in their entireties. The low modulus characteristic of the belt may provide approximately a 2 percent to 4 percent or more stretch capability or characteristic to the belt. This may provide a substantially greater amount of stretch over conventional conveyor belts, which may typically only provide approximately a 1 percent stretch capability or characteristic, and which are typically reeved around the rollers with only about a 0.25 percent initial stretch. The low modulus belt may be made from urethane extrusions or urethane with polyester or nylon tension members encapsulated, and may be similar to the type of belts commercially available from Nitta Corporation for use in graphic arts and letter mail sorting. The low modulus characteristic of the belt may allow the belt to remain in its proper position or orientation or to remain tracked around the rollers, such that belt engaging tracking devices and wider conveyor portions of conventional curved belt conveyors are not required in the curved belt conveyor of the present invention. Because separate tracking devices are not required at the belt to maintain the low modulus belt in place on the rollers, the curved belt conveyor of the present invention may be designed within the confines of standard width conveyors.
In the illustrated embodiment, each zone 12 includes two end rollers, with one of the end rollers being adjustable via the roller adjustment device 24 and the other end roller being non-adjustably mounted to and between the opposite sidewalls 14a, 14b. In the illustrated embodiment, the downstream or lead roller 20 is non-adjustable and the upstream or trailing end roller 22 is adjustable. As shown in
Driven roller 20 may comprise a self driven or motorized roller with an internal motor which is operable to rotate a roller portion relative to a shaft portion of the roller, such as a motorized roller of the types commercially available from various sources. For example, driven roller 20 may comprise a DC motorized roller, such as a 12 volt DC motorized roller or the like, such as a roller of the type disclosed in U.S. Pat. No. 6,244,427, the disclosure of which is hereby incorporated herein by reference in its entirety. Optionally, the motorized roller may comprise a 24 volt DC motorized roller or a 42 volt DC motorized roller or a 48 volt DC motorized roller or the like. It is further envisioned that the motorized roller may comprise other DC powered motorized rollers, or may comprise an AC powered motorized roller, such as described in U.S. Pat. No. 5,442,248, the disclosure of which is hereby incorporated herein by reference in its entirety, without affecting the scope of the present invention. The motor of the motorized roller may drive the roller directly, such as disclosed in U.S. Pat. No. 6,244,427, or may drive the roller via a gear train or the like, such as disclosed in U.S. Pat. No. 5,442,248, the disclosures of which are hereby incorporated herein by reference in their entireties. Because the rollers 16 of curved belt conveyor 10 may include such a driven roller 20, curved belt conveyor 10 also may not include an external drive motor positioned beneath the belt and rollers or positioned along the curve and radially inwardly or outwardly of the conveyor sidewalls. Optionally, however, the driven roller may comprise any other suitable rotatably driven roller that is rotatably driven (either via an internal motor or an external drive motor and associated drive belt or band or shaft or the like) to rotate a roller portion of the roller about the axle or shaft of the roller to drive the belt along the conveyor.
Driven roller 20 thus is operable to rotate the rotatable roller portion of the roller to drive continuous conveyor belt 18, which moves along the idler rollers 22, 21 which may generally freely rotate about their axle or shaft portions to guide and support the belt 18 around the zone or segment 12. The idler rollers 22, 21 may be any type of rollers, such as conventional, freely rotating rollers, such as the types also commercially available from various sources. Although shown in
Belt 18 may be routed around the rollers 16 such that the upper run 18a of belt 18 is routed over and along the upper surface 16d of the rollers and the lower run 18b of belt 18 is routed under the rollers and along the lower surface 16c, as can be seen with reference to
Optionally, and as shown in
Mounting bracket 21 thus provides a shaft support for the end of the roller shaft such that the end of the shaft or axle or axle portion is positioned at the inner side of outer sidewall 14a and does not extend through outer sidewall 14a, as the opposite end of the shaft or axle or axle portion may through inner sidewall 14b, and as may typically occur with conventional rollers and sidewalls. Because the roller shafts do not extend through the outer sidewall 14a of conveyor 10, the shafts do not interfere with the area outside of outer sidewall 14a. The mounting bracket 21 thus may facilitate positioning a control box or other equipment or component (not shown in
As best shown in
Movable roller mounting element 30 is thus movable along the posts 34a, 34b, such as via sliding movement along the posts, which extend through apertures or passageways through movable roller mounting element 30. As best shown in
As can be seen in
Optionally, when mounting element 32 is mounted to the inner sidewall 14b, an aperture (such as a hexagonal-shaped aperture or passageway) through mounting element 32 may be generally aligned with an aperture or opening in sidewall 14b so that a stub axle or axle portion 25 of another roller (such as another idler roller 21 adjacent to and upstream from the end roller 22) may be received through the aperture of mounting element 32 to mount the inner end of the roller 21 (such as the middle roller of the three-roller zone in the illustrated embodiment) to the inner sidewall 14b and mounting element 32 when adjustment device 24 is mounted to sidewall 14b of conveyor 10. A set screw or retaining pin or screw or fastener 42 may be inserted into mounting element 32 to substantially secure or retain axle portion 25 in aperture 32c.
Similarly, when adjustment device 24 is mounted to inner sidewall 14b, an aperture (such as a hexagonal-shaped aperture or passageway) through movable roller support element 30 is generally aligned with an aperture or slot 14c (shown in
In the illustrated embodiment of
Optionally, for example, and as shown in
As can be seen with reference to
Roller adjustment device 24 thus may adjust the tension in the belt 18 of the respective zone 12 to properly track belt 18 around the rollers of the zone. Roller adjustment device 24 may function to increase/decrease the tension in the belt and change the angle of the upstream roller by moving the inner end of the upstream roller along the sidewall so as to cause the belt to move or track toward/away from the outer sidewall of the conveyor or conveyor zone. Thus, the roller adjustment device or tracking device may function to draw or track the belt radially outward along the curve and toward the outer ends 16a of the rollers in response to driving of the driven roller in a forward direction (which drives the belt to convey articles in the direction of conveyance A) until the belt is properly positioned around the rollers. When properly positioned, the belt may be substantially taught or tight around the inner ends 16b of the rollers to limit further outward movement of the belt along the rollers during operation of the motorized roller in the forward direction. If the belt moves outward beyond an appropriate position along the rollers, the tension in the belt may overcome the spring force of the biasing element and urge the inner end of the upstream roller in the opposite direction along the inner sidewall so that the belt moves toward the inner sidewall until the belt is again tracking around the rollers at the desired or appropriate location along the rollers. The tracking device or roller adjustment device of the present invention thus may continually or substantially continually adjust the location of the inner end of the upstream roller (and thus the angle of the roller) to maintain or track the continuous conveying belt around the rollers of the conveyor or conveyor zone.
Optionally, and with reference to
Movable roller support element 130 is pivotally mounted to planar portion 132a via pivot pin 131, and extends upwardly from the pivot pin and includes a shaft receiving portion, 130a at an end opposite from pivot pin 131. Shaft receiving portion 130a includes a passageway therethrough (such as a hexagonal-shaped passageway or other suitable passageway or aperture) for non-rotatably receiving a stub axle or shaft portion 123 of the roller therein or therethrough. In the illustrated embodiment, a retaining fastener or pin or element 148 (
Roller adjustment device 124 includes a guide rod or post 134 (or could include two rods or posts if desired) that extends from mounting flange 132b (such as through passageway 132c) and extends through a passageway 130b of movable roller support element 130. A spring or biasing element 138 is positioned along rod 134 and functions to bias or urge movable roller support element 130 toward the upstream end of the conveyor or conveyor zone (such as in the opposite direction of the direction of conveyance of the zone or conveyor). In the illustrated embodiment, the biasing element 138 is positioned along rod 134 and between a stop element or washer 134a at an end of the rod 134 (such as at a threaded end of the rod with a female fastener or nut 134b (and such as two female fasteners as shown in
Thus, mounting element 132 of roller adjustment device 124 is mounted to the inner sidewall of the conveyor or conveyor zone so that the planar portion 132a is generally at or against the inner sidewall and the mounting flange 132b is at the upstream end of the roller adjustment device. The shaft receiving portion 130a of movable roller support element 130 is positioned or oriented so that the aperture or passageway is generally aligned with an aperture or slot along the inner sidewall (such as a slot similar to slot 14c of inner sidewall 14b discussed above). Biasing element 138 thus biases or urges pivotal movement of movable roller support element 130 toward the mounting flange 132b of mounting element 132 and thus toward the upstream end of the conveyor or conveyor zone, and thus roller adjustment device 124 functions in a similar manner as described above with respect to roller adjustment device 24. Mounting portion 132 may be mounted to the inner sidewall of the conveyor via fasteners through planar portion 132a or may be mounted to a mounting element at the inner sidewall via fasteners through mounting flange 132b, or may be otherwise mounted to or at the inner sidewall, without affecting the scope of the present invention. Although shown as being pivotally mounted to the mounting element 132, it is envisioned that the movable support element of the tracking device may be slidably mounted to a pair of rods or posts extending from the mounting flange of the mounting element so as to be substantially translationally movable along the posts in response to the biasing element and/or tension in the conveying belt, while remaining within the spirit and scope of the present invention.
In the illustrated embodiment of
Optionally, and as shown in
In a similar manner as described above, a spring or biasing element 138′ is positioned along rod 134′ and functions to bias or urge movable roller support element 130′ toward the upstream end of the conveyor or conveyor zone. In the illustrated embodiment of
Although shown and described as adjusting or moving the inner end of the upstream roller along the inner sidewall of the conveyor to track the conveying belt around the rollers, it is envisioned that a tracking or roller adjustment device or devices of the present invention may be located at the outer end of the upstream roller while remaining within the spirit and scope of the present invention. The outer end of the upstream roller may then be moved or adjusted to adjust the angle in the roller and/or tension in the belt, and the roller adjustment device may bias or urge or move the end of the roller in the appropriate direction along the outer sidewall of the conveyor or conveyor zone. Optionally, it is envisioned that a tracking device or roller adjustment device in accordance with the present invention may be located at the inner end or outer end of the downstream or rotatably driven roller to adjust the end of the driven roller in a similar manner as described above with respect to the upstream idler roller to track the belt around the rollers of the conveyor or conveyor zone, while remaining within the spirit and scope of the present invention.
Although shown and described as having a biasing element or spring that urges the end of the roller in the appropriate direction, it is envisioned that the end or ends of the roller or roller may be otherwise moved or adjusted in the appropriate direction to track the belt. For example, an electro-mechanical device or motorized device may automatically move or adjust the end of the roller, such as in response to a detection of one or more threshold tension levels in the conveyor belt, such as may be detected by a sensor or sensors at the belt. The device may continuously or substantially continuously adjust the end or ends of one of the rollers (such as the upstream roller) to maintain the tension in the belt at or near a desired or appropriate or targeted level to track the belt around the rollers.
Optionally, and desirably, each curved zone of the curved belt conveyor may provide approximately a 15 degree angle or curve. This angle may be selected because multiples of this angle may provide standard or desired curves, such as 15, 30, 45, 60 and/or 90 degree curves (or other curves, such as greater curves or lesser curves, depending on the particular application of the belt conveyor), which are often desired or required in conveyor layouts. Optionally, each curved zone may provide any other curve or angle, such as a 10 degree curve, a 22.5 degree curve, a 30 degree curve or the like, without affecting the scope of the present invention. By limiting the size of the angle of the curved zone, the continuous conveying belt may also be limited to a relatively small size, which helps to maintain the belt in its proper position around the rollers, and may reduce the load on the driven roller, such as a motorized or powered roller having an internal motor. Although shown and described as being implemented on short curved zones or sections, it is envisioned that the roller adjustment device may be implemented at other curved conveyors or conveyor sections and/or at straight or substantially straight conveyors or conveyor sections, while remaining within the spirit and scope of the present invention.
Each curved zone or segment (such as curved zones 12 of
Optionally, the curved belt conveyor of the present invention may provide an increased coefficient of friction between the belted conveying surface and the products being conveyed therealong over the friction provided by rollers of conventional roller conveyors. The curved belt conveyor of the present invention thus may be operable at a greater speed than conventional roller conveyors, without causing the products to slide radially outwardly around the curved zone or segment. The curved belt conveyor of the present invention may also provide enhanced capability to move and accumulate articles along each zone individually.
The curved belt conveyor of the present invention thus may be operable to accumulate articles on one or more of the curved segments or zones of the conveyor. Optionally, the curved belt conveyor may be operable on an incline or decline and may accumulate articles on the incline or decline. It is further envisioned that the curved belt conveyor may be operable to move articles, such as upward along an incline, as the articles are required by a downstream device or system. It is envisioned that the curved sections or zones of the conveyor may combine to form a generally spiral-shaped incline or decline.
Therefore, the curved belt conveyor of the present invention is operable to track or maintain the belt in its proper or desired or appropriate position on the rollers as the belt is driven around the rollers via the driven roller or motorized roller. The tracking device or roller adjustment device of the present invention is located at the sidewall of the conveyor and moves or adjusts the position of the roller axle or axle portion to maintain the appropriate tension in the belt and thus to track the belt along the conveyor, such that no additional tracking devices or components are necessary along the outer or inner edges of the belt to maintain the belt in position around the rollers.
Optionally, one or more of the rollers may include a crown or other form of raised portion of the roller surface, such that the crown protrudes outwardly from the generally cylindrical or conical roller surface of the roller toward and into engagement with the interior surface of the conveyor belt, such as by utilizing aspects of the curved belt conveyors of the types described in U.S. Pat. Nos. 6,971,510 and 7,150,352, which are hereby incorporated herein by reference in their entireties. The crown or tracking means may assist in tracking or maintaining the conveyor belt at the desired and appropriate position about rollers. Optionally, and desirably, the crown or tracking means may provide a small crown or bump or ridge so that the crown or bump or ridge on the roller surface does not form a bump or ridge on the belt and at the outer surface of the conveyor belt. Optionally, it is envisioned that the crown or tracking means may be a barrel crown extending substantially along the length of the roller, without affecting the scope of the present invention. Optionally, the tracking means may include several crowns or raised portions spaced along a tapered or cylindrical roller. Optionally, it is envisioned that a roller, such as a tapered roller, may comprise multiple separate sleeves or sections, which may be assembled to form the roller. Optionally, one or more of the sleeves or sections may comprise a crowned sleeve or section, while the other sleeves or sections may comprise straight or uncrowned sleeves or sections, such as described in U.S. Pat. Nos. 6,971,510 and 7,150,352, which are hereby incorporated herein by reference in their entireties.
Optionally, the curved belt conveyor of the present invention may include a tracking means or tracking member positioned on and/or around at least one of the rollers and/or at the interface between the roller surface and the belt which functions to maintain the belt in the desired and appropriate position around the rollers. For example, one or more of the rollers of the conveyor may have a roller surface characteristic, while the interior surface of the belt may have a belt surface characteristic. The surface characteristics at the interface of the roller and the belt may function to track and guide the belt at the desired or appropriate orientation or location on the roller. The surface characteristics may comprise corresponding ridges, grooves or crowns in or on the respective surfaces of the belt and/or roller, which generally resist lateral movement of the belt along the roller surface. The surface characteristic or tracking means may be a separate component, such as a band or the like, around the roller and between the roller surface and the interior surface of the belt, without affecting the scope of the present invention. Optionally, the belt may have a stretch quality or characteristic which also functions to track or assist in tracking the belt on the rollers.
The curved belt conveyor of the present invention may provide a plurality of independently operable curved zones or segments which may operate together as a generally continuously running curved belt conveyor or may operate individually as an accumulating conveyor with zone control and photo eyes or article sensors. The present invention thus provides a zone controlled curved belt conveyor which may operate in a similar manner as a zone controlled roller conveyor, but which includes a belt around the rollers rather than multiple O-rings or the like connecting the idler rollers to the motorized roller of each zone. The curved belt conveyor of the present invention thus may be capable of accumulating articles on an incline or decline. The belt conveying surface may also facilitate operation of the conveyor at greater speeds over the speed of conventional curved roller conveyors. Also, because the motorized roller of each zone or segment may only control or drive a small belt section, such as a belt around approximately two, three or four rollers, the load and wear on the motorized roller may be minimized to provide a longer life cycle for the motorized roller.
Therefore, the present invention provides a means or device for tracking a belt around at least two rollers of a curved segment or section or zone of a conveyor. The rollers of each zone may include a rotatably driven roller operable to drive the belt around the rollers. The tracking device or roller adjustment device of the present invention may maintain or track the belt in its proper position or orientation around the rollers, such that the tracking guide elements and wider conveyor portions of conventional curved belt conveyors are not required in connection with the curved belt conveyor of the present invention. Because the separate tracking or guide elements or devices that engage the belt are not required to maintain the belt in place on the rollers, the curved belt conveyor of the present invention may be designed within the confines of standard width conveyors and conveyor sidewalls.
Changes and modifications in the specifically described embodiments may be carried out without departing from the principles of the present invention, which is intended to be limited only by the scope of the appended claims, as interpreted according to the principles of patent law.
The present application claims benefit of U.S. provisional application Ser. No. 60/849,164, filed Oct. 2, 2006, which is hereby incorporated herein by reference in its entirety.
Number | Date | Country | |
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60849164 | Oct 2006 | US |