Patent Application
20110139582
The presently-disclosed embodiments generally relate to material handling transportation, and more particularly, to transporting media in material handling systems.
Typically, material handling systems transport media (envelopes, boxes, cards, sheet material including paper, corrugated cardboard, mail or the like or stacks of sheet material) from input station(s) to output station(s), often consisting of multiple stations. A conveyor system, for example, may transport any number of media items between an inlet station(s) and a delivery station(s). Stacks of media are placed on the belts of the conveyor system between two successive pushers (an elongated member, attached to a belt at a predetermined location, separating two sections of the belt and being capable of pushing media on the conveyor system).
Many processing applications work with variable-sized media, requiring variation in the distance between two pushers. If the belt has detachable pushers, as is usually the case, manual adjustment of these pushers will be required. Alternatively, operators may add additional flight bars (bars used to vary the distance between adjacent pushers) or pushers leading to loss in productivity. In the event that variable-sized media transportation proceeds without the pusher adjustment, the media may scatter, curl, or shingle during transportation.
It would be highly desirable to have a relatively simple and cost-effective system for combining high production on a material handling line with the ability to automatically vary the distance between successive pushers.
An aspect of the disclosure provides an apparatus for transporting variable-sized media. The apparatus employs multiple parallel beltsets and a control module. Multiple parallel beltsets, having one or more parallel belts each, lie between an inlet station and a delivery station. Each beltset includes a motor, connected to the beltset, for driving the beltset. The apparatus also includes multiple pushers, attached to one or more belts of the beltset, such that the distance between two successive pushers is greater than the size of the largest media that can be transported. Further, the pushers of one beltset lie between the successive pushers of the adjacent beltset. A control module, coupled to all the motors, adjusts the distance between the pushers of adjacent beltsets, based on the size of the media to be transported.
Another embodiment disclosed here is a method for transporting variable-sized media. Multiple parallel beltsets, having one or more parallel belts each, lie between an inlet station and a delivery station. Each beltset includes a motor, connected to the beltset, for driving the beltset. Multiple pushers are attached to one or more belts of the beltset, such that the distance between two successive pushers is greater than the size of the largest media to be transported. Further, the pushers of one beltset lie between the successive pushers of the adjacent beltset. The method involves determining the size of the media to be transported between the inlet and the delivery station and using a control module for adjusting the distance between two successive pushers on the system. The control module is coupled to all the motors, allowing adjustment of the distance between the pushers. Having adjusted the pushers, the beltsets move, transporting the media from the inlet station to the delivery station.
The following detailed description is made with reference to the figures. Preferred embodiments are described to illustrate the claimed invention, not to limit its scope, which is defined by the claims. Those of skill in the art will recognize a variety of equivalent variations for the embodiments described.
As used throughout this disclosure, the term “media” refers to envelopes, boxes, cards, sheet material including paper, corrugated cardboard, mail or the like or stacks of sheet material or other suitable items. It should be understood that the concepts set out here could be employed both in devices handling relatively small sized media, such as paper sheets, as well as apparatus handling large sheets of material, such as corrugated cardboard material. A “pusher” is an elongated member protruding from a conveyor belt, separating two sections of the belt. The design of the pushers is such that they can push the media on the belt. Further, the pusher location can be changed if they are detachable from the conveyor belt. The term “bin size” refers to the distance between two successive pushers. The pushers may be designed either to be individual pushers on each belt or to span the width of a belt. The pushers may even extend across the entire width of a single beltset. Alternatively, the pushers can span all belts of a beltset but may not cover the entire width of the beltset. Further, in some embodiments, the pushers may not be present on all belts of a beltset. The term “media size” refers to the size of media that can be transported. The term “TE pushers” (trailing edge pushers) refers to pushers facing the trailing edge of the media during transportation, while the term “LE pushers” (leading edge pushers) refers to pushers facing the leading edge of the media being transported.
According to aspects of the disclosure illustrated here, a system for transporting variable-sized media is described. The system employs multiple parallel beltsets, having one or more parallel belts each, extending between an inlet station and a delivery station. A control module directs the system, controlling motors connected to each beltset to drive the beltsets. Multiple pushers are attached to one or more belts in the beltset, such that the distance between the two successive pushers on the beltset is greater than the size of the largest media to be transported. Further, the pushers of one beltset lie between successive pushers of the adjacent beltset. The control module adjusts the distance between the pushers of the adjacent beltsets, based on the size of the media to be transported, without any operator intervention.
In the present embodiment, the apparatus 200 transports media between an inlet station (not shown) and a delivery station (not shown), and can be implemented in any suitable material handling application, which involves handling variable-sized media. The inlet and the delivery stations may be printers, storage or collection areas, or processing units or the inlet and delivery stations can be part of a material handling system. Additionally, there can be multiple inlet and delivery stations within the apparatus 200.
The apparatus 200 includes a first beltset 202 and a second beltset 204 that is parallel to the first beltset 202, both having one belt each. A first motor 206 drives the first beltset 202, while a second motor 208 drives the second beltset 204. As depicted here, the apparatus 200 transports media from left to right. Pushers 210 and 212, attached to the first beltset 202, are LE pushers and pushers 214, 216, and 218, attached to the second beltset 204, are TE pushers. Although, the LE pushers 210 and 212 are attached only to the first beltset 202, these pushers span both the first beltset 202 and the second beltset 204, without making contact with the second beltset 204. Part of a pusher may protrude from the lower part of the pusher, as shown in
Further, a sensor device (not illustrated) determines the media size automatically. For example, the sensor device can be a RFID (Radio-Frequency Identification) reader. Accordingly, the media would carry a machine-readable marker, such as a barcode, which includes information related to the media size. The position of the sensor can be in close proximity with the inlet station or the control module 220, such that the sensor can read the marker present on the media. Those of skill in the art will recognize that the sensor system may employ a variety of equivalent electronic detectors, readers, or scanners to serve the same purpose, such as an infrared sensor, a laser sensor or the like. Further, after determining the media size, the sensor device transmits that information to the control module 220. On receiving the media size, the control module 220 actuates one or more motors to adjust the pushers, forming a bin of the desired size. For example, if the bin size is greater than the media size, the control module 220 moves the pushers closer to each other to reduce the bin size.
In another embodiment, the media size specification takes place manually. The control module 220 can have an interface that accepts the media size through user instructions. The interface may have an input device, such as a keyboard or a touch-screen and a display device, so that the user can key-in the media size and can view information related to the ongoing operation.
The belts, as described in relation with the apparatus 200, can be urethane or co-polyester belts. Alternatively, the belts can be metallic or may further be chains with attached pushers, as commonly used in a mail handling equipment. Moreover, the belts or chains can be mounted below a baffle so that only the pushers project through the baffle. Thus, the media being transported only makes contact with the pushers and not the upper surface of the belts. Further, the structure of the belts can be rough, smooth, or may include ridges depending upon the media. For example, the belt may have a rough surface for better transportation of relatively smooth items, such as glossy photo paper. It will be evident to those skilled in the art that the belts may be manufactured using any other suitable material, such as rubber or other similar plastic compounds and may further vary in surface texture.
Joining the TE pushers 214, 216, and 218 and the LE pushers 210, and 212 to the belts involves various mechanical coupling methods, such as welding, bolting, groove & pulley, and chemical melting. In one implementation, integral and sequential formation of the belt teeth 222 with the belt involves molding the belt teeth 222 with the belt. In a further implementation, the belt teeth 222 can be urethane teeth.
As shown in
In an exemplary embodiment, the apparatus 200 can operate in a high-speed mailing system for transporting envelopes, letters, inserts, boxes, or other similar items. The inlet station, which can be another conveyor belt, printer, storage area, mail-processing station, and so on, includes a laser scanner. A barcode is present on the transported items, holding information related to item size. The laser scanner reads the barcode to determine the item size. The transmission of the determined item size to the control module 220 results in the actuation of the first motor 206, the second motor 208, or both (the first motor 206 and the second motor 208), to adjust the bin size according to the determined item size. The bin size adjustment involves changing the relative distance between the TE pushers 214, 216, and 218 and the LE pushers 210, and 212 by actuating the motors (the first motor 206, the second motor 208, or both), responsible for the belt movement. The bin size adjustment takes place in the same manner as described earlier for the apparatus 200. Then, the items being transported are positioned within the bins and transported to the delivery station, which can be another conveyor belt, printer, another storage area, or any other mail-processing station (for example, envelope insertion station). Additionally, the apparatus 200 can be used in the transportation of various parts of machinery in an industrial conveyor application. It will be apparent to those skilled in the art that the apparatus 200 can be implemented in any industrial, mechanical, or electrical set-up for the transportation of different parts, items, boxes, or packages between an inlet station(s) and a delivery station(s).
The apparatus 200 overcomes the disadvantages of conventional systems as the adjustment of the LE pushers 210, and 212 and the TE pushers 214, 216, and 218 according to the media size to attain optimum bin size prevents media scatter. In addition, the optimum bin size prevents curling, shingling and un-stacking of media 302 during transportation.
The pushers of the pusher-set 420 span a fraction of the width of the first belt 406 and the second belt 408 of the first beltset 402; alternatively, the pusher-set 420 may span the complete width of the beltsets. The same is true for the pushers of the pusher-set 422 on the first belt 410 and the second belt 412 of the second beltset 404. This pusher structure also forms a bin for carrying media satisfactorily, preventing media scatter. For instance, while transporting huge boxes, the small pushers will prevent box toppling. Similarly, when transporting a stack of sheets, relatively taller pushers will avoid non-alignment of a stack of sheets. As will be recognized by those of skill in the art, several conceivable pusher structures may be employed for forming bins of varying sizes, thus preventing media scatter. The operation of the exemplary apparatus 400 is as described for the apparatus 200 in
A pusher may be attached to each belt in a beltset. In this case, more than two belts in a beltset results in multiple attachment points for a pusher, which strengthens the pusher structure and prevents the pusher from being deformed. The likelihood of pusher deflection reduces, as this pusher structure is far more robust as compared to a pusher attached to only one belt.
It will be obvious to those skilled in the art that several conceivable pusher and beltset structures may be employed for forming bins of varying sizes, preventing media scatter, without departing from the scope and intended functions of the claimed invention.
A sensor device, as explained in relation with the apparatus 200 in
The disclosed method 700 eliminates the need for addition of pushers, flight bars, manually or mechanically, to the belt for bin size adjustment. Moreover, the method 700 allows bin size variation without operator intervention, reducing the operating time.
The method 700 can be associated with any suitable material handling application, allowing variable bin size and enabling transport of different sized media between an inlet station and a delivery station, and thus ensuring higher productivity for the material handling application. Those of skill in the art will comprehend that the disclosed systems and methods can also be used to transport various parts of machinery in an industrial conveyor application or any other similar set-up.
While this specification contains many specific implementation details, these should not be construed as limitations on the scope of any invention or of what may be claimed, but rather as descriptions of features, that may be specific to particular embodiments of particular inventions. Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable sub-combination. Similarly, while operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.
