Patent Application
20240150133
This invention relates to singulating conveyors, and their method of operation, which conveyors can receive multiple packages, containers and parcels (hereinafter collectively “parcels”) in a random flow at one location adjacent the conveyor's entry end and transport the packages to a second location while at the same time organizing the parcels to exit in a single file at the conveyor's exit end.
Conveyors are conventionally used to convey or transport items such as parcels of product in warehouses, manufacturing facilities and other locations. Typically, such facilities employ a conveyor distribution system that receives the parcels in a random flow for transport to a different location within the facility or location. However, it is desirable at some point during the conveyor distribution system to align the parcels into a single file for individual handling. Such alignment often is done by hand by workers at the facility, standing alongside at a convenient location or locations adjacent one or more conveyors.
Singulating conveyors have therefore been introduced into the marketplace in order to reduce the necessity for or number of workers to place the parcels in a desirable single file. One singulating conveyor has been marketed by Roach Manufacturing Corporation of Trumann, Arkansas (hereinafter “Roach”) under the trademark “Gator”. A copy of the Roach brochure directed to its “Gator” conveyor was submitted as part of the aforesaid U.S. Provisional Application for Patent No. 63/281,283, filed Nov. 19, 2021; the disclosure of the brochure is incorporated by reference herein as if fully set forth. Roach is the applicant and assignee of the present application and the invention disclosed herein.
The Roach “Gator” conveyor is able to reasonably singulate the transported parcels using increasing longitudinal speed zones in a herringbone pattern to drive two lanes of transporting rollers steered towards the center line of the conveyor. A top plan view drawing illustrating the rollers and images of the underneath dual motors and pulley systems for operating the four longitudinal speed zones of the Roach “Gator” conveyor is shown in
Another singulating conveyor has been marketed by Lewco Inc., of Sandusky, Ohio, some features of which are disclosed in U.S. Pat. Nos. 9,981,804, 10,556,745 and 10,988,314.
Accordingly, a need exists for a singulating conveyor which is better able to organize random parcels into a single file order with a minimum of congregation as the parcels exit at the exit end of the conveyor.
In order to improve the “congregation” problem described above, it has been surprisingly found that providing different speeds to the opposite sides of the lateral complementary left (“L”) and right (“R”) zones (looking from the entry end) of each of the longitudinal zones of the Roach “Gator” conveyor causes the parcels to form to a better straight-line configuration. The speed differential between the L and R lateral zones work in conjunction with increasing speeds of the longitudinal zones, from the first zone at the entry end of the conveyor toward the last zone near the exit end of the conveyor. In first preferred embodiments of the present invention (herein described as the Conveyor A embodiment, the Conveyor B embodiment, and the Conveyor C embodiment), there are four longitudinal zones 1, 2, 3 and 4 which, while working in conjunction with the L and R lateral zones, more effectively singulate the transported parcels. Each of the lateral zones L and R is preferably operated by utilizing a separate motor to each lateral zone, eight (8) motors in all counting each of the four longitudinal zones. Each motor can be controlled by its own separate variable speed controller, if desired by the user. Hence, each separate group or zone of conveying rollers, eight (8) in all, have speeds which vary both laterally and longitudinally along the conveyor. Alternatively, a pair of side-by-side motors, one for each of the L and R lateral sides, along with different ratio gearing assemblies, could be used to provide each of the eight respective longitudinal and lateral zones with the desired speed differentials.
The above-described singulating conveyors of the present invention include four longitudinal zones; however, a plurality of longitudinal zones could be used starting with only two and including more than four, so long as the longitudinal zones provide increasing speeds to the respective roller zones starting with the first zone adjacent the entry end of the conveyor and continuing toward the final zone at the exit end of the conveyor.
Additionally, the speed of the final longitudinal zone is increased or decreased from the speed of its next preceding longitudinal zone based on the speed desired for the singulated parcels to exit the conveyor.
More recently, it has been found that by increasing the number of longitudinal zones in the forward or herringbone portion of the conveyors of the present invention from the four (4) zones of the first preferred embodiments, further customization of the speeds ratios between zones allows for even better singulation. Further, it has also been found that splitting the discharge or skew portion of the conveyors into a plurality of separate longitudinal zones allows for variation in speeds between the discharge zones for even better singulation.
Accordingly, in second preferred embodiments of the present invention, the singulating conveyors include more than four (4) longitudinal zones in the forward or herringbone portion of the conveyor, preferably six (6) or eight (8) longitudinal zones, each of the six (6) or eight (8) longitudinal zones having a pair of L and R lateral zones. These two preferred singulating conveyors are described herein as the Conveyor D embodiment and the Conveyor E embodiment, respectively. The discharge or skew portion of the Conveyor D embodiment and the discharge or skew portion of the Conveyor E embodiment are preferably the same and are preferably divided into seven (7) additional separate longitudinal zones.
Each of the six (6) lateral zones L and R of the herringbone portion of the Conveyor D embodiment is operated by utilizing a separate motor for each lateral zone, twelve (12) motors in all counting each of the six (6) longitudinal zones. Each of the eight (8) lateral zones L and R of the herringbone portion of the Conveyor E embodiment is also operated by utilizing a separate motor for each lateral zone, sixteen (16) motors in all counting each of the eight (8) longitudinal zones.
Each of the seven (7) separate additional longitudinal zones of the skew portion of these conveyors is also operated by utilizing a separate motor for each separate longitudinal zone, seven (7) motors in all. Thus, there are nineteen (19) motors in all for the Conveyor D embodiment and twenty-three (23) motors in all for the Conveyor E embodiment, and each motor can be controlled by its own separate variable speed controller, if desired by the user.
Hence, each separate group of rollers or zone in the herringbone portion of the Conveyor D embodiment, twelve (12) in all, has speeds which vary both laterally and longitudinally along the conveyor. Similarly, each separate group of rollers or zone in the herringbone portion of the Conveyor E embodiment, sixteen (16) in all, has speeds which vary both laterally and longitudinally along the conveyor. In both the Conveyor D embodiment and Conveyor E embodiment, each of the seven (7) separate groups of rollers or zones in the skew portion also have speeds which vary longitudinally along the conveyors.
Further, it has also been found that in the Conveyor D embodiment and the Conveyor E embodiment, with all zones having different speed capabilities in both the herringbone portion and the skew portion, it is not always necessary or desirable that the speed of the rollers in each longitudinal zone increase sequentially from the entrance end and toward the exit end of the conveyor. As will be described in more detail hereinafter, rather, it may be desirable to have some adjacent longitudinal zones operate at the same speed while other adjacent zones can be operated at a higher speed or a lower speed as may be helpful in singulating the parcels in a single file as they approach the end or exit end of the conveyor.
As will be described in more detail hereinafter, the position of the motors in the second preferred embodiments is different from the positioning of the motors in the first preferred embodiments, and the second preferred embodiments also utilize a different drive mechanism whereby the torque created by of the motors is transferred to their respective conveyor rollers.
The singulating conveyors of the present invention include a horizontal framework which supports each group of conveying rollers, as well as the motors and drive systems underneath. The lateral L and R rollers are skewed toward the center in a herringbone fashion and divided into the series of longitudinal zones, which are driven in increasing speeds from the entrance end toward the exit end of the conveyor. As is conventional, the framework and rollers are supported from the floor at a desired height by reinforced stanchions.
More specifically, the singulating conveyors of the present invention include two sets of lateral rollers at the feed end, or entrance, of the conveyor. The rollers in each zone of the conveyor are in parallel alignment, but skewed at an angle with the outer end of the rollers being forward compared to the inner end of the rollers. This skewing causes the parcels to be driven towards the center line of the conveyor. The group of rollers on the R side of the conveyor continues to the exit end, i.e., the discharge rollers, of the conveyor while maintaining the angle of the rollers. This angling of the discharge rollers at the exit end moves the parcels from the center or center line of the conveyor to the left side (when looking down the conveyor entry or feed end). Alternatively, the conveyor can be arranged in order to move the parcels to the other side of the exit, by having the L side rollers continue to the exit, rather than the R side rollers. Generally, the lateral side of the rollers (R side or L side) which includes the discharge rollers is considered to represent the “outside” lateral zones and the other side, the “inside” lateral zones.
Preferably, the rollers in each outside lateral zone operate at a selected higher speed than the rollers in its corresponding and adjacent inside lateral zone, except perhaps the last outside lateral zone that includes the discharge rollers. Further, a portion of the rollers of some outside lateral zones preferably have a higher coefficient of friction than the rollers of the corresponding and adjacent inside lateral zones. The higher coefficient of friction of the rollers in the outside lateral zones can conventionally be achieved by utilizing standard friction coverings known in the art and available commercially. A preferred conventional friction covering is ⅛ inch thick polyurethane.
The rollers in the first preferred embodiments of the present invention are driven by a V-Belt drive system mounted underneath the rollers and supported from the horizontal framework. Each group of rollers, preferably eight (8) zones in total including two lateral zones in each of four longitudinal zones, has its own V-Belt drive system. Each of the V-Belt drive systems are set in motion by each respective separate motor (8 in total), and a gear reducer turns a drive shaft which in turn drives a drive sheave at one end of the V-belt. The V-Belt drive system includes a supporting sheave horizontally spaced from the drive sheave to support the outer end of the V-belt and intermediate pulleys underneath the drive section of the V-belt. These sheaves and pulleys provide sufficient pressure so that the upper course of the V-belt presses against the bottom of the transporting rollers to thus drive the rollers in each zone of the conveyor. The rollers are located longitudinally using vertically elongated hex holes, which allow the bottom of the transporting rollers to more easily match the upper course of the V-belt, and vertically by specially designed brackets, which limit how high the rollers can travel in the vertically elongated hex holes. Since each V-Belt drive system has a separate motor, the speed of the transporting rollers in each of the eight zones can be selected and controlled independently of each other.
Alternatively, a single pair of motors could be utilized similar to the Roach “Gator” conveyor. However, in such an arrangement, the two sheaves in each V-Belt drive system have to be individually sized in order to secure the desired speeds for each of the eight zones in a four longitudinal zone conveyor. However, once established with separately sized sheaves, the speeds established for each zone can only be somewhat varied in that a variable speed drive controller can be connected to each motor. The zone speeds on the R side will increase or decrease together by the ratios established by their corresponding sheaves. Similarly, the zone speeds on the L side will increase or decrease together by the ratios established by their corresponding sheaves. The only way to achieve greater variance is by substituting sheaves.
In the second preferred embodiments of the present invention, the Conveyor D embodiment and the Conveyor E embodiment, each separate group of rollers or zones is driven by a separate motor, nineteen (19) or twenty-three (23) motors in all, respectively.
The motors are preferably mounted underneath the rollers of their respective zones and supported from the horizontal framework adjacent the outer edge on each side of the framework and positioned at an angle similar to the skewed angle of the rollers. A drive sheave is mounted on each motor shaft and includes two side-by-side grooves, each of which engages a complementary drive band. Each drive band is tensioned around a complementary groove towards the outer end of adjacent drive rollers. The remaining rollers of each conveyor group or zone, the driven rollers, are interconnected to the drive rollers and to each other by a series of power roller belts, which engage complementary grooves also on the outer ends of adjacent rollers.
Accordingly, it is an object of the present invention to provide a singulating conveyor which better addresses the problem of congregation of the conveyed parcels so that the parcels form a better single-file configuration at the exit end of the conveyer.
It is another object of the present invention to provide a singulating conveyor having a plurality of longitudinal zones in a herringbone pattern with the speed of the rollers in each longitudinal zone increasing from the entrance end toward the exit end of the conveyor, while simultaneously providing different speeds to the complementary lateral L and R zones of each of the longitudinal zones.
It is a further object of the present invention to provide a singulating conveyor in accordance with the preceding object in which there are preferably four longitudinal zones of increasing speeds, thus with the different speeds of the lateral L and R zones making a total of eight different roller groups potentially having different variable speeds.
It is a further object of the present invention to provide a singulating conveyor in accordance with the preceding object in which the last longitudinal zone speed is increased or decreased to achieve the desired exit speed of the parcels.
It is a still further object of the present invention to provide a singulating conveyor in accordance with the preceding object in which each of the eight groups of rollers is driven by a separate motor and respective V-Belt drive system.
Yet another object of the present invention is to provide a singulating conveyor having six (6) or eight (8) longitudinal zones in the forward or herringbone portion of the conveyor, with the speed of the rollers in each longitudinal zone varying from the entrance end and toward the exit end of the conveyor, while simultaneously providing different speeds to the complementary lateral L and R zones of each of the longitudinal zones.
Still another object of the present invention is to provide a singulating conveyor in accordance with the preceding object in which the discharge or skew portion of the conveyor includes seven (7) separate groups of rollers or zones to exit the conveyed parcels on either side of the conveyor.
Still a further object of the present invention is to provide a singulating conveyor in accordance with the two preceding objects in which each of the nineteen (19) or twenty-three (23) groups of rollers or zones is driven by a separate motor and respective drive sheave and complementary drive bands and drive belts.
A further object of the present invention is to provide a method of manufacturing multiple singulating conveyors in a modular fashion to improve inventory control, simplification of the manufacturing process, and operational flexibility.
Another object of the present invention is to provide a method for operating a singulating conveyor having a plurality of longitudinal zones in a herringbone pattern in which the speed of the rollers in each longitudinal zone can vary from the entrance end toward the exit end of the conveyor, while at the same time simultaneously operating the rollers in the outside lateral zones at a higher speed than the rollers in the corresponding and adjacent inside lateral zones, except perhaps the last outside lateral zone that includes the discharge rollers.
Another object of the present invention is to provide a method for operating a singulating conveyor in accordance with the preceding object in which there are preferably four longitudinal zones operated at increasing speeds, thus with different speeds of the outside and inside lateral zones making a total of eight different roller groups potentially operated at different variable speeds.
Yet another object of the present invention is to provide a method for operating a singulating conveyor in accordance with the preceding object in which the outside lateral zone which includes the discharge rollers is operated at an increased or decreased speed to achieve the desired exit speed of the parcels from the conveyor.
Still another object of the present invention is to provide a method for operating a singulating conveyor having preferably six (6) or eight (8) longitudinal zones in the forward or herringbone portion of the conveyor, in which the speed of the rollers in each longitudinal zone can vary from the entrance end toward the exit end of the conveyor, while at the same time simultaneously operating the rollers in the outside lateral zones at a higher or equal speed than the rollers in the corresponding and adjacent inside lateral zones.
Yet a further object of the present invention is to provide a method for operating a singulating conveyor in accordance with the preceding object in which the six (6) or eight (8) longitudinal zones together with the respective lateral zones are capable of operating at different speeds making a total of twelve (12) or sixteen (16) different lateral groups in the herringbone portion of the conveyor potentially operated at different variable speeds.
Still a further object of the present invention is to provide a method for operating a singulating conveyor in accordance with the preceding two objects, in which the skew portion of the conveyor includes a plurality, preferably seven (7), longitudinal zones operated at different speeds, increasing or decreasing in order to achieve a desired singulation and exit speed of the parcels from the conveyor.
Other objects, features, and advantages of the present invention will become apparent to those skilled in the art based upon the disclosure provided herein.
Turning first to the prior art Roach “Gator” conveyor shown in
Each of the eight zones 110 L, 110 R, 120 L, 120 R, 130 L, 130 R, 140 L and 140 R include a series of conveying or transporting rollers 112 L, 112 R, 122 L, 122 R, 132 L, 132 R, 142 L and 142 R, respectively. These rollers are in parallel alignment, but skewed at an angle with the outer end of the rollers being forward compared to the inner ends of the rollers. As shown, the rollers 142 R continue beyond the end of zone 140 L, at 145 and continue to the exit end 146 of the conveyor 100. This continuation of rollers 142 R causes the parcels to move from the center or center line of the conveyor to the left side at the conveyor exit end.
As shown in
As will be seen, there are herein disclosed first and second preferred embodiments of singulating conveyors in accordance with the present invention: the first preferred embodiments include the Conveyor A embodiment, the Conveyor B embodiment, and the Conveyor C embodiment; and the second preferred embodiments include the Conveyor D embodiment and the Conveyor E embodiment.
Turning now to
Turning now to
Each of the longitudinal zones includes a pair of side-by-side lateral zones designated left (L) and right (R), thus forming four outside lateral zones 210R, 220R, 230R and 240R, and four inside lateral zones 210L, 220L, 230L and 240L. Each lateral zone of each longitudinal zone, eight (8) in total, includes a series of transporting rollers 212 L, 212 R, 222 L, 222 R, 232 L, 232 R, 242 L and 242 R. The rollers in each zone of conveyor 200 are in parallel alignment, but skewed at an angle with the outer end of the rollers being forward compared to the inner end of the rollers. The skewing causes the transported parcels to be driven towards the center line 260 of the conveyor. In a preferred configuration, the parallel rollers in each lateral zone are skewed forwardly at an angle of about 76 degrees from the center line of the conveyor, but the skewed angle can vary as much as +/−ten percent (10%). As shown
As shown in
In the embodiment shown in
In accordance with the present invention, the conveyor 200 is designed so that the transporting rollers in each of the eight lateral and longitudinal zones can be driven independently and separately at variable and different speeds. Surprisingly, if the opposite sides of the lateral complementary left (L) and right (R) zones of each longitudinal zone is provided with different speeds, the parcels conveyed by the conveyor 200 form a better straight-line configuration at the exit end 246. To this end, each of the eight zones is provided with separate motors 260 L and 260 R for zone 210, 262 L and 262 R for zone 220, 264 L and 264 R for zone 230 and 266 L and 266 R for zone 240. Each of the motors 260 L and R, 262 L and R, 264 L and R, and 266 L and R drive separate and individual V-Belt drive systems 270 L and R, 272 L and R, 274 L and R and 276 L and R, respectively. Each of the eight motors are the same and seven of the V-Belt drive systems 270 L and R, 272 L and R, 274 L and R, 276 L and R are the same. Drive system 276 R is extended beyond zone 240 L and continues to the exit end 246 of the conveyor 200, as shown by discharge rollers 245, so that the parcels exit on the left side (or inner side) of conveyor 200.
Preferably, the rollers 212 R, 222 R, 232 R and 242 R of each of the outside lateral zones are driven at a selected faster speed than the corresponding rollers 212 L, 222 L, 232 L and 242 L of each of the adjacent inside lateral zones. Further, the coefficient of friction for a portion of the rollers in a plurality of the outside lateral zones is greater than that for the rollers in the corresponding and adjacent inside lateral zones. This higher coefficient of friction can be achieved by covering at least some of the rollers in the outside lateral zones with standard ⅛ inch thick friction polyurethane coverings which are available commercially from Spiratex of Romulus, Michigan. Similar polyurethane roller sleeves are available from Kastalon Polyurethane Products of Alsip, Illinois, and conveyor roller covers and coatings are available from C & M Coatings, Inc of Grand Haven, Michigan.
Further, there are a few of the transporting rollers in each zone where the V-Belt drive system cannot contact the rollers. In such circumstances, the rollers are connected by bands 261 to provide for their rolling action. The bands (dark lines) can be seen in
The transporting rollers and motors 260L, 262L, 264L and 266L are mounted on a horizontal framework 280 as shown in
Turning next to
As shown in
The motor 266 R and associated drive system 276 R for zone 240 R are shown separately in
Next, turning to
Turning now to the singulating conveyor shown in
The differences between the Conveyor B embodiment and the Conveyor A are as follows:
The frictional coverings in the Conveyor B embodiment are shown as shaded rollers in
As can be seen from
As shown in
The representative motor 260R and associated V-Belt 270R for the seven zones 210L and 210R, 220L and 220R, 230L and 230R and 240L of the Conveyor B embodiment are shown in
As shown in
As shown in
As will be appreciated by those skilled in art, the elongation of the hex holes 550 allows the surface of the transporting rollers in each zone to lay on top of the respective V-belt. The axle shaft 211 of the roller, and the roller itself, is limited vertically in the down direction by the roller being in contact with the V-belt and vertically in the up direction by the notches 554 in the bracket 552.
The following description of roller speeds and roller speed ratios applies equally with respect to conveyor 200 of both the Conveyor A embodiment and the Conveyor B embodiment.
It has been found that the speed of the conveyor 200, and each of the individual eight zones, can be varied depending on the particular application and the parcels to be conveyed and singulated thereby. The zone with the lowest roller speed is zone 210 L and can range from as low as 50 ft. per minute to as high as 150 ft. per minute. Preferably, the speed of the rollers 212 L in zone 210 L is typically set at 131 ft. per minute. Once the speed of the rollers 212 L in zone 210 L is established, there has been success in setting the rollers in the other zones to have speeds according to the following sets of ratios:
In addition to the above, the average speed for each of the 4 longitudinal zones change in ratios and should be in accordance with the following:
In addition to the foregoing preferred speed ratios for the various zones, it is contemplated that the speed ratios can vary +/−twenty percent (20%).
Again, the above description and data for roller speed and ratios is set forth for conveyor 200 and applies equally to the Conveyor A embodiment, and the Conveyor B embodiment.
While two preferred embodiments of the present invention have been described in detail in connection with conveyor 200, i.e., the Conveyor A embodiment and the Conveyor B embodiment, it is also possible to achieve the same variable speeds of the eight lateral and longitudinal zones by varying the size of the sheaves which support the V-belts that drive the transporting rollers in each of the eight zones. This alternate preferred embodiment is illustrated in
As shown in
In order to accomplish the speed ratios outlined above for conveyors 200, it is believed that the sheave diameters for conveyor 400 should be arranged in the following ratios:
In addition to the foregoing preferred sheave diameter ratios for the various V-Belt drive systems, it is contemplated that the diameter ratios can vary +/−ten percent (10%).
The first preferred embodiments of the present invention have been described in detail in connection with conveyors 200 and 400 having the parcels exit on the left hand side of the conveyor. If it is desired to have the parcels exit to the right hand side of the conveyors, the speed ratios mentioned before should be swapped between L and R.
The method for operating a singulating conveyor in accordance with the first preferred embodiments of the present invention should be evident to those skilled in the art based upon the foregoing descriptions and related drawing figures. For example, the Conveyor B embodiment illustrated in
Turning now to the singulating conveyors of the second preferred embodiments, the Conveyor D embodiment and the Conveyor E embodiment, as shown in
Each of the longitudinal zones 605, 610, 615, 620, 635, and 640, includes a pair of side-by-side lateral zones designated left (L) and right (R), thus forming six (6) outside lateral zones 605R, 610R, 615R, 620R, 635R, and 640R, designated zones R1-R6, inclusive, on
The discharge or skew portion, generally designated by reference numeral 604 of the conveyor 600 includes discharge rollers 645, preferably divided into seven (7) separate longitudinal zones 650, 655, 660, 665, 670, 675, and 680, designated zones 7-13, inclusive, on
Each of the six (6) lateral zones L and R in the herringbone portion 602 of the Conveyor D embodiment is preferably operated by utilizing a separate motor for each lateral zone, motors 608R, 613R, 618R, 623R, 638R, and 643R on the right hand side of the conveyor and motors 608L, 613L, 618L, 623L, 638L, and 643L, on the left hand side of the conveyor, twelve (12) motors in all. See
As shown
As shown in
The drive system described in the two preceding paragraphs is the same for driving the discharge rollers 645 in each of the seven (7) separate discharge zones 650, 655, 660, 665, 670, 675, and 680 by their respective separate motors 652, 657, 662, 667, 672, 677, and 682. As shown in
Hence, the rollers 607L and 607R, 612L and 612R, 617L and 617R, 622L and 622R, 637L and 637R, and 642L and 642R of the forward portion 602 of the conveyor and the rollers 645 of the discharge portion 604 of the conveyor can be individually operated at selected speeds.
As shown in
The photoeyes 654 are installed to detect when there is a large number of parcels moving in a zone in small intervals of time, so that the speed of the transporting rollers can be adjusted, as necessary. The optional photoeyes 654 are preferably installed along the outer lateral zones of the conveyor 600, but can be installed on the inner lateral zones if necessary.
As shown in various drawings including
Turning now to the Conveyor E embodiment, as shown in top plan view in
Each of the longitudinal zones 705, 710, 715, 720, 725, 730, 735, and 740 includes a pair of side-by-side lateral zones designated left (L) and (R), thus forming eight (8) outside lateral zones 705R, 710R, 715R, 720R, 725R, 730R, 735R, and 740R, designated zones R1-R8, inclusive, on
As with the Conveyor D embodiment, the rollers in each complementary lateral zone in the herringbone portion 702 of the conveyor 700 in the Conveyor E embodiment are in parallel alignment, but skewed at an angle with the outer end of the rollers being forward compared to the inner end of the rollers. In a preferred configuration, the parallel rollers in each lateral zone are skewed forwardly also at an angle of 75.5% from the center line 703 of the conveyor, but the skewed angle can vary as much as plus or minus five percent (5%).
The rollers of the Conveyor E embodiment have the same conventional supporting hexagonal (hex) axles as previously described in connection with the Conveyor D embodiment and are located in corresponding main hex holes in inside channels and center ribs, except the shortened rollers have their inside axle supported by L brackets, all as previously described in connection with the Conveyor A embodiment and the Conveyor D embodiment.
The discharge or skew portion 704 of the conveyor 700 includes discharge rollers 745, again preferably divided into seven (7) separate longitudinal zones 750, 755, 760, 765, 770, 775, and 780, designated as zones 9-15, inclusive, on
As previously described with respect to the Conveyor D embodiment, each of the eight (8) lateral zones L and R in the forward portion 702 of the Conveyor E embodiment is preferably operated by utilizing a separate motor 708L and 708R, 713L and 713R, 718L and 718R, 723L and 723R, 728L and 728R, 733L and 733R, 738L and 738R, and 743L and 743R, for each lateral zone, sixteen (16) motors in all, as illustrated in
The drive system between each of the twenty-three (23) motors of the Conveyor E embodiment and the respective rollers of each of the sixteen (16) lateral zones in the forward portion 702 and the seven (7) longitudinal zones of the discharge portion 704 is the same as previously described in connection with the Conveyor D embodiment and illustrated in
As will be evident to those skilled in the art, the features previously described with respect to conveyor 600 of the Conveyor D embodiment relating to the band guards 651 and the optional side panels 653, photoeyes 654, and parcel guide 658, apply equally to conveyor 700 of the Conveyor E embodiment.
A desirable feature of the second preferred embodiments of the present invention is a simplification of the manufacturing process, which provides for better inventory control and operational flexibility. By using a first modular conveyor section as part of the herringbone portions 602 and 702 of conveyors 600 and 700 and a second modular conveyor section having the same skew portions 604 and 704, the Conveyor D embodiment can be expanded into the Conveyor E embodiment by simply combining a third modular conveyor section between the first two modular conveyor sections. This relationship is illustrated in
As shown in
As will be readily understood by those skilled in the art, the above described modular manufacturing process can be applied to a variety of sizes for singulating conveyors. More specifically, the first modular conveyor section can consist of two or more longitudinal zones for the entry end of the conveyor. The second modular conveyor section can consist of one or more of the last longitudinal zones of the herringbone portion of the conveyor together with the skew portion of the conveyor. The third modular conveyor section can then include one or more longitudinal zones of the herringbone portion. The make-up of the three modular zones can obviously be varied depending upon the size and variety of singulating conveyors to be manufactured.
As has been previously described, each of the inner and outer lateral zones of the herringbone portion 602 of conveyor 600 and each of the seven longitudinal zones of the skew portion 604 is operated by a separate motor, and therefore the speed of the rollers can be established as desired by the user. As with the first preferred embodiments, it has been found that the speed of the rollers in the outer lateral zones of the herringbone portion should be greater than the speed of the rollers in their complementary inner lateral zones, and the speed in each progressive longitudinal zone should increase sequentially from Zone 1 to Zone 6. On the other hand, it has been found preferable to vary the speed sequentially in the zones of the skew portion for better singulation.
The method for operating a singulating conveyor in accordance with the second preferred embodiments of the present invention should also be evident to those skilled in the art based upon the forgoing descriptions and related drawing figures. Below is a chart showing representative speeds for each zone of the Conveyor D embodiment.
The above numbers in the left hand column correspond to the numbers appearing in the drawings for each of the longitudinal Zones 1-13, respectively, of the Conveyor D embodiment. The R and L columns represent speeds in the outer lateral zone (R) and inner lateral zone (L) in the herringbone portion 602 of the conveyor 600, and the numbers in the middle column for Zones 7-13 are the representative speeds for the zones in the skew portion. The information provided in the Avg, Ratio and Avg Ratio columns are simple calculations based upon the speeds provided.
As can be seen from the above chart, Zones 1-10 of the conveyor 600 preferably operate at speeds as previously described in connection with the first preferred embodiments and sequentially increase, while having a higher speed in the outer lateral zones compared to their complementary inner lateral zones in order to cause a swirling action of the parcels being transported. Zones 11 and 12 slow down to stack parcels together end to end, and Zone 13 then speeds up to put a gap between parcels for sorting at the exit end of the conveyor.
It should be appreciated that the speeds provided in the above chart are representative and can be determined by the user as best suits operation and use of the conveyor 600. However, it is considered preferable that the speed ratio should not vary more than +/−twenty percent (20%) from the speed ratios listed in the above chart.
Turning now to the Conveyor E embodiment, the chart below shows representative speeds for each zone of the conveyor 700.
Again, the above numbers in the left hand column correspond to the numbers appearing in the drawings for each of the longitudinal Zones 1-15, respectively, of the Conveyor E embodiment. The R and L columns represent speeds in the outer lateral zone (R) and the inner lateral zone (L) in the herringbone portion 702, and the numbers in the middle column for Zones 9-15 are representative speeds for the zones in the skew portion. The information provided in the Avg, Ratio and Avg Ratio columns again are simple calculations based upon the speeds provided.
As can be seen from the above chart, the speeds in Zone 1-4 remain constant, although the speed of the outer lateral zones are greater than the speeds of their complementary inner lateral zones in order to create the desired swirling action. The speed increases in Zones 5 and 6, and thereafter decreases in Zones 7 and 8 in the outer lateral zones, while the speed in the inner lateral zones increases to be equal to that in the outer lateral zones. This arrangement of the speed in Zones 7 and 8 allows the parcels to align in a single row in the center of the conveyor.
As the parcels move into the skew portion 704 of conveyor 700, the speed in Zone 9 is decreased from the speed in Zones 7 and 8, which allows the parcels to stack together end-to-end. The substantially increased but equal speed in Zones 10-12, pulls a gap between parcels while they are stacked in line against the diverter 658. Zones 13 and 14 slow down the parcel speed to stack the parcels together end-to-end, and Zone 15 then speeds up to pull a gap between parcels before the parcels exit the conveyor.
Again, it should be appreciated that the speeds provided in the above chart are representative and can be determined by the user as best suits operations and use of the conveyor 700. However, it is considered preferable that the speed ratio should not vary more than +/twenty percent (20%) from the speed ratios listed in the above chart.
The foregoing is considered as illustrative of the principles of the invention. Further, numerous modifications and changes will readily occur to those skilled in the art. As such, it is not desired to limit the invention to the exact construction and operation shown and described; all suitable modifications and equivalents may be resorted to falling within the scope of the invention.
This application is a Continuation-In-Part of pending application Ser. No. 17/982,884, filed Nov. 8, 2022, and also claims priority back to U.S. Provisional Application for Patent No. 63/281,283, filed Nov. 19, 2021.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 17982884 | Nov 2022 | US |
| Child | 18458501 | US |
