Patent Grant
8960587
The present disclosure relates generally to machinery and methods for rolling large mats, carpets, rugs, and the like.
Mat rolling machines are typically used in the field of commercial rug cleaning. Large rugs and mats of the sort typically found in the lobbies, foyers and hallways of commercial, retail and industrial enterprises are sometimes removed for off-site cleaning. Once cleaned, these rugs may be rolled on a mat rolling machine to quickly shape the rug into a generally cylindrical form for ease of delivery.
A typical prior art mat rolling machine may be seen in U.S. Pat. No. 4,573,644 and U.S. Pat. No. 4,973,010, hereby incorporated by reference. The mat rolling machines of the above-cited references have a frame and a hood housing a first set of horizontal or slightly inclined belts interleaved with a second set of generally vertical belts. The first set of belts moves the rug towards the second set of belts, which then moves the rug upward. The front edge of the rug travels upwards towards a set of fingers which curve the front edge of the rug back over to begin forming the rug into a cylindrical roll. Once the initial cylinder shape is formed, the action of the first set of belts and the second set of belts continue to roll the rug into a cylindrical shape. There is a control panel positioned generally below the first set of belts, and there are emergency stop buttons located on the hood above the fingers. These mat rolling machines can roll a rug such that the hollow interior of the roll is about 3 to 5 inches in diameter.
There is an ongoing need for an improved mat rolling machine and components thereof to roll rugs and mats.
A mat rolling machine includes a frame defining a front and a rear of the machine. At least one first drive belt may feed the mat towards a plurality of second drive belts, a plurality of third drive belts, and a plurality of fourth drive belts. The mat may contact each of the belts in succession as the mat travels a path through the mat rolling machine. At least one support member may be disposed between adjacent second drive belts to guide the mat upward as the mat travels into the mat rolling machine. The mat rolling machine includes a set of primary fingers and a set of secondary fingers. The set of secondary fingers has a smaller radius than the set of primary fingers. Both sets of fingers are deployed when a mat is fed into the machine, and the set of secondary fingers forms a tight initial cylinder as the mat is rolled into a generally spiral configuration. After a predetermined period of time, the set of secondary fingers rotates up and the set of primary fingers, which have a larger radius, remains down to guide the mat as the rolled cylinder grows larger. One or more of the drive belts may be coupled together by a plurality of belt fastening means at an oblique angle relative to a direction of travel of the belt.
A method of rolling a mat includes obtaining a mat rolling machine. A mat may be disposed upon the at least one first drive belt. The belts may be activated independently, at the same time, or in any combination thereof. The mat may be fed into the mat rolling machine. The plurality of primary fingers and the plurality of secondary fingers may be actuated into a lowered mat-rolling position. The fingers may cooperate with the drive belts to initiate a roll into a generally spiral configuration. After initiating the roll, the secondary fingers may be raised out of contact with the mat, and the primary fingers may remain in the lowered mat-rolling position to maintain the roll and form the mat into the generally spiral configuration. The primary fingers may then be raised out of contact with the mat. The belts may be stopped independently, together, or in any combination thereof. After stopping the belts, at least one pusher may be actuated to discharge the rolled mat from the rear of the mat rolling machine.
The invention may be more completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which:
While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention.
For the following defined terms, these definitions shall be applied, unless a different definition is given in the claims or elsewhere in this specification.
All numeric values are herein assumed to be modified by the term “about”, whether or not explicitly indicated. The term “about” generally refers to a range of numbers that one of skill in the art would consider equivalent to the recited value (i.e., having the same function or result). In many instances, the term “about” may include numbers that are rounded to the nearest significant figure. The recitation of numerical ranges by endpoints includes all numbers within that range (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, and 5).
As used in this specification and the appended claims, the singular forms “a”, “an”, and “the” include plural referents unless the content clearly dictates otherwise. As used in this specification and the appended claims, the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise.
The following description should be read with reference to the drawings wherein like reference numerals indicate like elements throughout the several views. The drawings, which are not necessarily to scale, depict illustrative embodiments of the claimed invention.
The at least one first drive belt 20 may comprise a first set of at least two spaced-apart parallel rollers 22, at least one first endless belt 28 disposed about the first set of at least two spaced-apart parallel rollers 22, and a first drive means 24. The first drive means 24 may be operatively connected to one of the at least two spaced-apart parallel rollers 22. The first drive means 24 may be configured to rotate the at least one first endless belt 28 in a first direction via the one of the at least two spaced-apart parallel rollers 22. In the view shown in
A plurality of second drive belts 30 may be disposed at least partially rearward of the at least one first drive belt 20, as seen in
A plurality of third drive belts 40 may be disposed above the plurality of second drive belts 30, as seen in
A plurality of fourth drive belts 50 may be disposed at least partially rearward of the plurality of third drive belts 40 and at least partially above the plurality of second drive belts 30, as seen in
The positional relationship of the at least one first drive belt 20, the plurality of second drive belts 30, the plurality of third drive belts 40, and the plurality of fourth drive belts 50 is such that none of the parallel rollers 22, 32, 42, 52 are shared among different pluralities of drive belts. Each plurality of drive belts is independent from another plurality of drive belts. That is, the parallel rollers 32 support only the plurality of second drive belts 30, the parallel rollers 42 support only the plurality of third drive belts 40, and so on. In other words, the belt surfaces, when viewed from the side (such as in
In some embodiments, a generally forward-facing surface 96 of the at least one support member 90 may extend from below the plurality of second drive belts 30, to an upper tip at a position above the plurality of fourth drive belts 50, where the at least one support member 90 may transition to a generally rearward- and upward-facing surface 98 that extends to below an upper surface of the plurality of fourth drive belts 50. The upper tip of the at least one support member 90 may be disposed about one-quarter inch, about one-half inch, about 1 inch, about 2 inches, about 3 inches, or more vertically above the forwardmost fourth roller 52. At least a portion of the rearward- and upward-facing surface 98 of the at least one support member 90 may be arranged at an angle of about 30 to about 60 degrees, about 40 to about 50 degrees, or about 45 degrees relative to horizontal, at a position where the at least one support member 90 intersects the plurality of fourth drive belts 50 when viewed from the side, for example as seen in
In some embodiments, the mat rolling machine 10 may further comprise at least one generally rearward- and upward-facing pusher 92 adapted to discharge the mat from the rear 110 of the mat rolling machine 10 in the generally spiral configuration. The generally rearward- and upward-facing pusher 92 may be disposed between and laterally offset from adjacent fourth endless belts 58. In some embodiments, the at least one pusher 92 may form a portion of the at least one support member 90. In other embodiments, the at least one pusher 92 may be an element separate from the at least one support member 90. The at least one pusher 92 may be actuated by at least one pneumatic cylinder, hydraulic cylinder, electric actuator, or other suitable means. In some embodiments, the at least one pusher 92 may be activated manually, or the at least one pusher 92 may be activated automatically in response to a particular sensor input or a time delay from another function, action, or sensor input of the mat rolling machine 10.
The mat rolling machine 10 may include a plurality of primary fingers 60 configured to be moveable as a set between a first raised position 66 and a first lowered position 68. Each of the plurality of primary fingers 60 may be oriented generally rearward and has a first radius of curvature on a generally concave lower face 64. The plurality of primary fingers 60 may be attached to a first rod 62, which can pivot to actuate the plurality of primary fingers 60 between the first raised position 66 and the first lowered position 68 (shown in phantom), as seen in
The mat rolling machine 10 may further include a plurality of secondary fingers 70 configured to be moveable as a set between a second raised position 76 and a second lowered position 78. Each of the plurality of secondary fingers 70 may be oriented generally rearward and has a second radius of curvature on a generally concave lower face 74 that is smaller than the first radius of curvature on the generally concave lower face 64 of the plurality of primary fingers 60, as seen in
In some embodiments, a first sensor (not shown) may be provided at the rearward end of the at least one first drive belt 20 to sense when the leading and/or trailing edge of the mat has moved past the rearward end of the at least one first drive belt 20. The sensor may be a photo-detector, an opto-electronic sensor, or other suitable sensor. In some embodiments, the sensor may include a light transmitter (not shown) and receiver or reflector. In some embodiments, the at least one first drive belt 20 may be automatically stopped at a predetermined period of time after the trailing edge of the mat has traveled along the path past the at least one first drive belt 20.
In some embodiments, a second sensor (not shown) may also, or alternatively, be provided within the hood 18 such that the sensor can detect when the leading and/or trailing edge of the mat has moved past a point between the plurality of second drive belts 30 and the plurality of fourth drive belts 50. The sensor may be a photo-detector, an opto-electronic sensor, or other suitable sensor. In some embodiments, the sensor may include a light transmitter (not shown) and receiver or reflector. Such a sensor, if provided, may be positioned to point between the at least two third endless belts 48, and a reflector, if provided, may be positioned under the plurality of fourth drive belts 50 and rearward of the at least one support member 90. In some embodiments, the sensor feedback may be used to actuate the plurality of primary fingers 60 and/or the plurality of secondary finger 70 from their respective raised positions 66, 76 to their respective lowered positions 68, 78. In some embodiments, when the sensor detects the trailing edge of the mat, a timer will be initiated to shut down the mat rolling machine 10, thereby ending the mat rolling cycle.
In some embodiments, a third sensor (not shown) may be provided within the hood 18 to detect the presence or absence of a rolled mat on the upper surface of the plurality of fourth drive belts 50. The sensor may be a photo-detector, an opto-electronic sensor, or other suitable sensor. In some embodiments, the sensor may include a light transmitter (not shown) and receiver or reflector. A reflector for such a sensor, if provided, may be disposed, for example, on the at least one pusher 92 or at a suitable position between the at least two fourth endless belts 58. A sensor detecting the presence or absence a rolled mat on the upper surface of the plurality of fourth drive belts 50 may be used to initiate or delay the start of a new mat rolling cycle. If a rolled mat is present, the at least one first drive belt 20 may not be permitted to re-start to initiate a new mat rolling cycle. If a rolled mat is absent, the at least one first drive belt 20 may be permitted to start, thereby initiating a new mat rolling cycle.
One of ordinary skill in the art will appreciate that the above-described sensors, where present, may be moved, repositioned, or modified to accommodate a desired operation of the mat rolling machine 10.
In some embodiments, the first or second sensor, where provided, may communicate with the control panel 12 to actuate the plurality of primary fingers 60 from the first raised position 66 to the first lowered position 68 as the leading edge of the mat is detected. The plurality of secondary fingers 70 may be actuated from the second raised position 76 to the second lowered position 78 in response to the same or a different sensor input, or in response to a time delay from the sensor input that activates the plurality of primary fingers 60. Alternatively, the plurality of primary fingers 60 and the plurality of secondary fingers 70 may be actuated to the first lowered position 68 and the second lowered position 78, respectively, upon initial activation of the mat rolling machine 10, simultaneously, independently, or as otherwise provided herein.
In use, the plurality of secondary fingers 70 may remain in the second lowered position 78 for a brief period of time, which may be as little as a fraction of a second to a few seconds in length, or about 0.1 second to 10 seconds or more. The period of time may be predetermined, or may be determined by sensor feedback obtained during operation of the mat rolling machine 10. The plurality of secondary fingers 70, in the second lowered position 78, contacts the leading edge of the mat and cooperates with the plurality of fourth drive belts 50 to initiate a roll into a generally spiral configuration. The leading edge of the mat is tightly curved around to rest on a following portion of the mat. After the roll has been initiated, or after the passage of a predetermined period of time, the plurality of secondary fingers 70 is actuated to the second raised position 76. The remainder of the mat is rolled into the generally spiral configuration through the cooperation of the plurality of primary fingers 60 and the plurality of fourth drive belts 50. The plurality of fourth drive belts 50 carry the following portion of the mat in a forward direction, where the mat is guided upward by the rearward- and upward-facing surface of the at least one support member 90 and into contact with the generally concave lower face 64 of the plurality of primary fingers 60. With each successive coil or roll of the mat, the outer diameter of the generally spiral configuration increases.
The general path of the mat through the mat rolling machine 10 and the generally spiral configuration formed may be seen in
It will be appreciated that the exact timing and/or order of the actuation of the plurality of primary fingers 60 and the plurality of secondary fingers 70 may be modified as needed to obtain the desired generally spiral configuration. In some embodiments, the generally spiral configuration may include a hollow interior having a diameter of about 1 inch up to about 2 inches, 3 inches, 4 inches, 5 inches, or more. In some embodiments, the plurality of primary fingers 60 and the plurality of secondary fingers 70 may be actuated to their respective lowered positions at the same time.
As seen in
A foot pedal (not shown) may be provided to activate, cycle, and/or stop the mat rolling machine 10. The foot pedal may connect to the control panel 12. Depressing the foot pedal may activate the mat rolling machine 10. In some embodiments, the foot pedal may need to remain depressed throughout the entire machine cycle, and releasing the foot pedal may immediately stop the mat rolling machine. In other embodiments, the foot pedal may be released immediately upon activation of the mat rolling machine 10. In other embodiments, a second depression of the foot pedal may deactivate or stop the mat rolling machine 10.
In some embodiments, the mat rolling machine 10 may be configured to operate in a manual mode or an automatic mode. In the manual mode, the mat rolling machine 10 may function in a single-cycle operation, where each mat rolling cycle is initiated by input at the foot pedal or the control panel 12. Following each mat rolling cycle, the mat rolling machine 10 remains shut down until a new mat rolling cycle is manually initiated. In the automatic mode, the mat rolling machine 10 may utilize a pre-programmed cycle within the control panel 12 to automatically start a new mat rolling cycle once a rolled mat has been discharged from the rear 110 of the mat rolling machine 10. In the automatic mode, the at least one first drive belt 20 may be stopped once the trailing edge of the mat has moved past the at least one first drive belt 20 so that a new mat may be loaded into position for the next mat rolling cycle. At the new mat is being loaded into position on the at least one first drive belt 20, the plurality of second, third, and fourth drive belts 30, 40, and 50, continue operating to roll the mat into the generally spiral configuration. After the plurality of second, third, and fourth drive belts 30, 40, and 50 have stopped, and the at least one pusher 92 has discharged the rolled mat from the rear 110 of the mat rolling machine 10, a new mat rolling cycle may be automatically initiated.
At the rear 110 of the mat rolling machine 10, there may be a moveable shelf or accumulator mechanism 80. Moveable shelf or accumulator mechanism 80 may retain a predetermined quantity of rolled mats, after the rolled mats have been discharged from the rear 110 of the mat rolling machine 10, until the rolled mats can be removed. In some embodiments, the mat rolling machine 10 may be provided with a bin container or a conveyor system at the rear 110 of the mat rolling machine 10 for removal and/or storage of the rolled mats.
A method of rolling a mat may include obtaining a mat rolling machine 10, such as that described above. A mat may be disposed on the at least one first drive belt 20. The at least one first drive belt 20 may be activated by depressing the foot pedal. The plurality of second drive belts 30, the plurality of third drive belts 40, and the plurality of fourth drive belts 50 may be activated concurrently with the at least one first drive belt 20 (via the foot pedal), or may be activated after a predetermined time delay or in response to a sensor input indicating the leading edge of the mat has reached the rear end of the at least one first drive belt 20. The plurality of primary fingers 60 may be actuated into a first lowered mat-rolling position 68. The mat may be fed into the machine along a path of travel. The plurality of secondary fingers 70 may be actuated into a second lowered mat-rolling position 78 to contact the mat and cooperate with the plurality of fourth drive belts 50 to initiate a roll into a generally spiral configuration.
After initiating the roll, the plurality of secondary fingers 70 may be actuated into a second raised position 76 out of contact with the mat, such that the plurality of primary fingers 60 in the first lowered mat-rolling position 68 and the plurality of fourth drive belts 50 maintain the roll and form the mat into the generally spiral configuration as the mat is fed through the mat rolling machine 10 along the path of travel. The plurality of primary fingers 60 may be actuated into a first raised position 66 out of contact with the mat. The at least one first drive belt 20 may be stopped. The plurality of second drive belts 30, the plurality of third drive belts 40, and the plurality of fourth drive belts 50 may be stopped concurrently with, or independently of, the at least one first drive belt 20. After the plurality of fourth drive belts 50 has been stopped, at least one pusher 92 may be actuated to discharge the mat from the rear 110 of the mat rolling machine 10 in the generally spiral configuration. After discharging the mat from the rear 110 of the mat rolling machine 10, the at least one pusher 92 may be automatically or manually actuated back to its original position.
In some embodiments, such as may be seen in
In some embodiments, belt fastening means 26 may include a bridge element attached to each of the first end 25 and the second end 27 with a screw, a bolt, or other mechanical fastener, and the like, such as that shown in
It should be understood that this disclosure is, in many respects, only illustrative. Changes may be made in details, particularly in matters of shape, size, and arrangement of steps without exceeding the scope of the invention. The invention's scope is, of course, defined in the language in which the appended claims are expressed.
This application claims priority to U.S. Provisional Application No. 61/491,001, filed May 27, 2011, and U.S. Provisional Application No. 61/492,984, filed Jun. 3, 2011, and U.S. Provisional Application No. 61/531,821, filed Sep. 7, 2011.
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