Abstract:
A conveyor system and method is described for conveying articles between different levels of a structure. The conveyor system utilizes stacked helical shaped conveyors to move articles up from a first level and down from a third level to a common second level. The conveyor system may also move articles down from the second level to the first level or up from the second level to the third level. The stacked helical conveyors eliminate the need for gated lifts or ramps and also minimize the footprint required to convey articles between levels.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     Not Applicable 
     FEDERAL SPONSORSHIP 
     Not Applicable 
     JOINT RESEARCH AGREEMENT 
     Not Applicable 
     TECHNICAL FIELD 
     This invention pertains generally to an article or package conveyor systems, and more particularly, to multi level article or package conveyance systems that convey articles between multiple levels to or from a point of convergence. 
     BACKGROUND 
     Generally, conveying systems have been utilized in many business operations including assembly plants, packaging facilities, food processing, shipping, distribution centers, and other operations that have a need to effectively convey goods from one location to another. Prior conveyors have, for example, transported goods from one location to another location within a building along a belt or other continuous conveyor. Additionally, some buildings have multiple floors requiring a lift, ramp or other elevator to transport goods from one floor to another. 
     In the past, attempts have been made to bypass lifts and ramps by conveying goods up or down a continuous spiral conveyor. While spiral conveyor arrangements have attempted to transport goods from one level or floor to another, the present invention provides a merging or diverging among a plurality of distinct conveyors that are stacked and aligned vertically. In this manner, multiple distinct feed lines servicing multiple floors of a building may be combined into a single elevated delivery line. Conversely, a single feed line positioned on the second floor of a building, for example, may be diverged into a plurality of distinct delivery lines servicing multiple floors. 
     SUMMARY 
     Embodiments according to aspects of the invention include a helical conveyor system having a first helical conveyance path for conveyance in a first helical direction and a second helical conveyance path for conveyance in a second helical conveyance direction, where the first and second helical rotational conveyance directions are opposite one another. The second helical conveyance path is elevated above the first helical conveyance path and the paths share a common center axis and intersect at a convergence or intersection. Articles may be conveyed up the first helical conveyance path at the same time articles are conveyed down the second helical conveyance path. 
     Also described herein is a conveyor system for conveying articles along helical tracks having a common helical center axis. The tracks join together at a juncture and convey articles from stations at multiple levels. The helical tracks include drive mechanisms that convey articles along the track. A first drive mechanism drives articles up a lower portion of the track and a second drive mechanism drives articles down an upper portion of the helical track. In this manner, articles may be moved up from a first level to a second while simultaneously moving other articles down from a third level to the second level. An additional track may intersect the helical tracks at the second level. 
     Also described herein is a conveyor system for conveying articles that includes a first conveyor for conveying articles about a central transport axis in a first helical direction, wherein a portion of the first conveyor extends to a first station. The conveyor system also includes a second conveyor for conveying articles about a center axis in a second helical direction, where the central transport axis is linearly aligned with the center axis. In this conveyor system the first helical direction and second helical direction are diametrically opposed. A portion of the second conveyor extends to a second station and the second station is elevated above the first station. The conveyor system also includes a third station of a third conveyor for conveying to or from the first and second conveyors. 
     In an embodiment of the invention the first conveyor, second conveyor and third conveyor join at a juncture. The conveyor system may also include a fourth conveyor for conveying articles, wherein the fourth conveyor joins the first, second and third conveyors at the juncture. In an embodiment of the invention the first conveyor and the second conveyor have helical symmetry. The conveyor system of the invention may also include a first drive mechanism to convey articles from the first station towards the third station and the second conveyor includes a second drive mechanism to convey articles from the second station towards the third station. 
     The accompanying drawings, which are incorporated in and constitute a portion of this specification, illustrate embodiments of the invention and, together with the detailed description, serve to further explain the invention. The embodiments illustrated herein are presently preferred; however, it should be understood, that the invention is not limited to the precise arrangements and instrumentalities shown. For a fuller understanding of the nature and advantages of the invention, reference should be made to the detailed description in conjunction with the accompanying drawings. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
       In the various figures, which are not necessarily drawn to scale, like numerals throughout the figures identify substantially similar components. 
         FIG. 1  is a front perspective view of a conveyor system in accordance with an embodiment of the invention; 
         FIG. 2  is a top plan view of conveyor system of the type shown in  FIG. 1 ; 
         FIG. 3  is a front perspective view of a conveyor system in accordance with an embodiment of the invention; 
         FIG. 4  is a top plan view of conveyor system of the type shown in  FIG. 3 ; 
         FIG. 5  is a front perspective view of a conveyor system in accordance with an embodiment of the invention; 
         FIG. 6  is a top plan view of conveyor system of the type shown in  FIG. 5 ; 
         FIG. 7  is a front perspective view of a conveyor system in accordance with an embodiment of the invention; 
         FIG. 8  is a top plan view of conveyor system of the type shown in  FIG. 7 ; 
         FIG. 9  is a front perspective view of a conveyor system in accordance with an embodiment of the invention; 
         FIG. 10  is a top plan view of conveyor system of the type shown in  FIG. 9 ; 
       and 
         FIG. 11  is a partial sectional perspective view of a juncture within a conveyor system in accordance with an embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION 
     The following description provides detail of various embodiments of the invention, one or more examples of which are set forth below. Each of these embodiments are provided by way of explanation of the invention, and not intended to be a limitation of the invention. Further, those skilled in the art will appreciate that various modifications and variations may be made in the present invention without departing from the scope or spirit of the invention. By way of example, those skilled in the art will recognize that features illustrated or described as part of one embodiment, may be used in another embodiment to yield a still further embodiment. Thus, it is intended that the present invention also cover such modifications and variations that come within the scope of the appended claims and their equivalents. 
     Turning attention now to the Figures, embodiments of the conveyor system will now be described in more detail. With Reference to  FIGS. 1 and 2  conveyor system  10  is shown having a first conveyor or track  12 , second conveyor or track  14 , and third conveyor or track  16 . The first and second conveyors  12  and  14  converge or join together at juncture  20 . Each conveyor  12 - 16  is formed from modular, linear or curved, track subsections of suitable known construction. A portion of conveyors  12  and  14  include sub sections that wrap around or wind about an axis  22 . The windings about axis  22  are sufficiently spaced apart to allow the transport of goods along a continuous arc. The continuous arc of the first conveyor forms a first helical path about the axis  22  and the continuous arc of the second conveyor forms a second helical path about the axis  22 . The helical windings are held in a spaced apart relation by frame  22 . The helix formed by the continuous arc may be arranged to form a helix having helical symmetry. Third conveyor  16  extends from the intersection or juncture  20  of conveyors  12  and  14 . Goods may be positioned onto the conveyors or removed from the conveyors at corresponding first, second, and third stations  30 - 34 . Thus, the goods may be conveyed along conveyors  12  or  14  to the intersection  20  and merging onto third conveyor  16 . Alternatively, goods may convey along third conveyor  16  to the juncture  20  where the goods diverge onto first and second conveyor tracks  12  and  14 . 
     With Reference to  FIGS. 3 and 4  conveyor system  10  is shown having a first conveyor or track  12 , second conveyor or track  14 , third conveyor or track  16 , and fourth conveyor or track  18 . The first, second, third and fourth conveyors  12 - 18  converge or join together at juncture  20 . Each conveyor  12 - 18  is formed from modular, linear or curved, track subsections of suitable known construction. A portion of conveyors  12  and  14  include sub sections that wrap around or wind about an axis  22 . The windings about axis  22  are sufficiently spaced apart to allow the transport of goods along a continuous arc. The continuous arc of the first conveyor forms a first helical path about the axis  22  and the continuous arc of the second conveyor forms a second helical path about the axis  22 . The helical windings are held in a spaced apart relation by frame  22 . The helix formed by the continuous arc may be arranged to form a helix having helical symmetry. As shown in  FIG. 1  the helical conveyance paths of the first and second conveyors  12  and  14  intersect at intersection or juncture  20 . Third conveyor  16  extends from the intersection or juncture  20  of conveyors  12  and  14 . Goods may be conveyed along conveyors  12 ,  14  or  16  to the intersection  20  and the goods merge onto third conveyor  16 . Alternatively, goods may convey along third conveyor  16  to the juncture  20  where the goods diverge onto first, second or third conveyor tracks  12 ,  14  and  18 . Goods may be positioned onto the conveyors or removed from the conveyors at corresponding first, second, third, and fourth stations  30 - 36 . 
       FIGS. 5 and 6  illustrate an alternative embodiment of the conveyor system  10 . First conveyor or track  12 , second conveyor or track  14 , third conveyor or track  16 , and fourth conveyor or track  18  are constructed similar to the embodiment described in conjunction with  FIGS. 3 and 4 . The first, second, third and fourth conveyors  12 - 18  converge or join together at juncture  20 . However, the first conveyor  12  intersects with fourth conveyor  18  on a first side of the fourth conveyor  18  and the second conveyor  14  intersects with the fourth conveyor  18  on a second side of the fourth conveyor  18 . 
       FIGS. 7 and 8  illustrate an alternative embodiment of the conveyor system. Conveyor system  10  is shown having a first conveyor or track  12 , second conveyor or track  14 , and fourth conveyor or track  18 . The first, second, and fourth conveyors  12 ,  14  and  18  converge or join together at juncture  20 . First conveyor  12  and intersects with fourth conveyor  18  and fourth conveyor further intersects with second conveyor  14 . Each conveyor  12 ,  14  and  18  is formed from modular, linear or curved, track subsections of suitable known construction. Similar to other embodiments, conveyors  12  and  14  include sub sections that wrap around or wind about an axis  22  to form helical paths about the axis  22 . 
       FIGS. 9 and 10  illustrate an alternative embodiment of the conveyor system. Conveyor system  10  is shown having a first conveyor or track  12 , second conveyor or track  14 , and third conveyor or track  16 . The first, second, and third conveyors  12 ,  14  and  16  converge or join together at juncture  20 . First conveyor  12  and intersects with third conveyor  16  and third conveyor  16  further intersects with second conveyor  14 . Each conveyor  12 - 16  is formed from modular, linear or curved, track subsections of suitable known construction. Similar to other embodiments, conveyors  12  and  14  include sub sections that wrap around or wind about an axis  22  to form helical paths about the axis  22 . 
     Exemplary flows of the goods or articles along the conveyors are depicted in the Figures with directional arrows. With reference to  FIGS. 1 and 2  goods may be positioned on the first conveyor at first station  30 . Arrow  24  depicts that the goods or articles are conveyed up the helix to intersection  20 . The articles then travel out of the helix along third conveyor  16  to the third station  34  in a direction represented by arrow  28 . Goods or articles positioned on the second conveyor at second station  32  are conveyed down the helix to intersection  20  as depicted by arrow  26 . The articles travel down the helical path and out the helix along third conveyor  16  to the third station  34 . 
     With reference to  FIGS. 3-6  goods may be positioned on the first conveyor at first station  30 . Arrow  24  depicts that the goods or articles are conveyed up the helix to intersection  20 . The articles then travel out of the helix along third conveyor  16  to the third station  34  in a direction represented by arrow  28 . Goods or articles positioned on the second conveyor at second station  32  are conveyed down the helix to intersection  20  as depicted by arrow  26 . The articles travel down the helical path and out the helix along third conveyor  16  to the third station  34 . Goods or articles positioned on the fourth conveyor at fourth station  36  are intersect the helix formed by first and second conveyors and then travel out the helical path along the third conveyor  16  to the third station  34 . 
     With reference to  FIGS. 7 and 8 , goods may be positioned on the first conveyor at first station  30 . Arrow  24  depicts that the goods or articles are conveyed up the helix to intersection  20 . The articles then continue to travel up the helix along second conveyor  14  to the second station  32  in a direction represented by arrow  26 . Goods or articles positioned on the fourth conveyor at fourth station  36  are conveyed to the helix intersection  20  as depicted by arrow  27 . The articles then continue to travel up the helical path and out the helix along second conveyor  14  to the second station  32 . 
     With reference to  FIGS. 9 and 10  goods may be positioned on the second conveyor at second station  32 . Arrow  26  depicts that the goods or articles are conveyed down the helix to intersection  20 . The articles then continue to travel down the helix along first conveyor  12  to the first station  30  in a direction represented by arrow  24 . Goods or articles positioned on the third conveyor at third station  34  are conveyed along conveyor  16  to the helix intersection  20  as depicted by arrow  28 . The articles then travel down the helical path and out the helix along first conveyor  12  to the first station  30 . 
     Referring now to  FIG. 11  a portion of the junction of first conveyor  14  and second conveyor  16  is shown. Each section of the conveyor includes a plurality of spaced apart rollers. Select rollers  50  are linked together with linkages  52 , and one or more motors (not shown) are coupled to one or more corresponding drive rollers. When the motors rotate the drive rollers all of the linked rollers will likewise rotate. A controller of suitable known construction (not shown) is used to activate and deactivate the motors. Each conveyor  12 - 18  has independent motors and controllers that serve as a drive mechanism to convey articles along the track in a desired direction. As seen in  FIGS. 1-8 , the motorized drive rollers of first conveyor  12 , conveys articles along the first conveyor up the helical path towards junction  20 . The motorized drive rollers of second conveyor  14 , conveys articles along the second conveyor down the helical path toward juncture  20  in  FIGS. 1-6  and  9 - 10  and conveys articles up the second conveyor  14  from the juncture  20  in  FIGS. 7-8 . Those skilled in the art will appreciate that the direction of rotation of the motorized drive rollers may be reversed so that the motorized drive rollers of conveyors will convey articles in an opposite direction, if desired. 
     These and various other aspects and features of the invention are described with the intent to be illustrative, and not restrictive. This invention has been described herein with detail in order to comply with the patent statutes and to provide those skilled in the art with information needed to apply the novel principles and to construct and use such specialized components as are required. It is to be understood, however, that the invention can be carried out by specifically different constructions, and that various modifications, both as to the construction and operating procedures, can be accomplished without departing from the scope of the invention. Further, in the appended claims, the transitional terms comprising and including are used in the open ended sense in that elements in addition to those enumerated may also be present. Other examples will be apparent to those of skill in the art upon reviewing this document.