Abstract:
A guide rail system for guiding containers moved by a conveyor defining a path with a straight or curved segment. The guide rail system is adjustable such that by engaging a single mechanism, the distance between a pair of rails (one rail on each side of the conveyor) is changed across multiple conveyor segments (straight and/or curved). The invention provides an adjustable guide rail system for use in connection with a conveying surface capable of moving with respect to the guide rail system.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Patent Application Ser. No. 62/037,717, filed on Aug. 15, 2014. All information disclosed in that application is incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates generally to the field of conveyors, and specifically to guide rail systems for guiding items moved by a conveyor defining a path with a straight or curved segment, and including equipment connected to such conveyors, as found in modern assembly, such as rinsers, fillers, cartoners, and case packers, to guide product into and out of such machines. 
     It is common for conveyors to need some type of guide rails alongside the conveying surface, so as to keep the items being conveyed from falling off the conveyor, or even just to keep the items upright and not falling over on the conveying surface, which could cause not only damage to the items being conveyed, but also jamming of the conveyor or the items being conveyed. It is desirable to be able to adjust the spacing between the guides, so as to accommodate different types and sizes of items to be conveyed. There have been prior systems where the spacing of the guides has been adjustable. But there is a need for simpler and quicker adjustments of the spacing. 
     The present invention relates to improvements over the apparatus described above and to solutions to some of the problems raised or not solved thereby. 
     SUMMARY OF THE INVENTION 
     The invention provides a guide rail system that is adjustable such that by engaging a single mechanism, the distance between a pair of rails (one rail on each side of the conveyor) is changed across multiple conveyor segments (straight and/or curved). The adjustable guide rail system is for use in connection with a conveying surface capable of moving with respect to the guide rail system. The guide rail system includes a guide rail positioned alongside the conveying surface. A guide rail support system is connected to the guide rail, the guide rail support system including a plurality of guide rail adjustment assemblies. Each guide rail adjustment assembly has a guide rail arm, to which the guide rail is mounted. The guide rail arm has an adjustment rack, and a guide rail pinion engaged with the adjustment rack and positioned such that a rotation of the guide rail pinion causes the adjustment rack, and consequently the guide rail arm and in turn the guide rail itself, to move generally linearly, closer to and further away from the center of the conveying surface. The guide rail support system further includes a synchronizing connector connected to the guide rail pinions of two guide rail adjustment assemblies. A rotator is connected to the synchronizing connector for rotating the synchronizing connector and thereby rotating the connected guide rail pinions. 
     Other objects and advantages of the invention will become apparent hereinafter. 
    
    
     
       DESCRIPTION OF THE DRAWING 
         FIG. 1  is a perspective view of a conveyor having an adjustable guide rail according to one embodiment of the invention. 
         FIG. 2  is an enlarged perspective view of a straight section of the conveyor shown in  FIG. 1 . 
         FIG. 3  is an enlarged perspective view of a section of the conveyor shown in  FIG. 2 , showing detail of the adjusters opposite each other. 
         FIG. 4  is an enlarged perspective view of a section of the conveyor shown in  FIG. 3 , showing further detail of one of the adjusters. 
         FIG. 5  is a cross sectional view of the conveyor shown in  FIG. 3 , taken along line  5 - 5 . 
         FIG. 5A  is a cross sectional view of the conveyor shown in  FIG. 2 , taken along line  5 A- 5 A. 
         FIG. 6  is an enlarged perspective view of a curved portion of the conveyor shown in  FIG. 1 . 
         FIG. 7  is a perspective view of the curved portion of the conveyor shown in  FIG. 6 , from the opposite side. 
         FIG. 8  is a cross sectional view of a portion of the conveyor shown in  FIG. 8 , taking along line  8 - 8 . 
         FIGS. 9A and 9B  are enlarged perspective views of an area of the curved portion of the conveyor and an adjacent area of the straight portion of the conveyor, showing the detail of the sliding support. 
         FIG. 10  is a perspective view of a portion of a conveyor constructed according to an alternative embodiment of the invention. 
         FIG. 11  is a perspective view of a portion of a conveyor constructed according to another alternative embodiment of the invention. 
         FIG. 12  is an enlarged perspective view of a section of the conveyor shown in  FIG. 11 . 
         FIG. 13  is a cross sectional view of a conveyor constructed according to another alternative embodiment of the invention, wherein only one side of the guide rail is adjustable. 
         FIG. 14  is a cross sectional view of a conveyor constructed according to another alternative embodiment of the invention, wherein the guide rail is adjustable directly over the conveyor. 
         FIG. 15  is a cross sectional view of a conveyor constructed according to another alternative embodiment of the invention, including multiple adjustable guide rails on each side of the conveyor. 
         FIG. 16  is a cross sectional view of a conveyor constructed according to yet another alternative embodiment of the invention, including multiple adjustable guide rails sufficient to form multiple lanes on the conveyor. 
     
    
    
     DETAILED DESCRIPTION 
     Referring now to  FIG. 1 , a conveyor  10  is generally shown, having a conveying surface  12  for conveying various items (not shown). The conveying surface  12  is supported on a frame  14 , and is capable of moving along the frame, by means of a conveyor motor (not shown) as is conventional and well known. 
     According to the invention, as shown in  FIGS. 1-4 , a guide rail  16  is positioned along at least one side of the conveying surface  12 . In the embodiment shown there, there are two guide rails  16 , one positioned along each side of the conveying surface  12 , substantially along the entire length of the conveyor  10 . The invention provides for a guide rail support system, for supporting the guide rail  16  with respect to the conveying surface  12 . As will be explained below with respect to different embodiments of the invention, the guide rails  16  may be positioned at the side of the conveying surface, or over the conveying surface  12 , so as to guide the items with respect to a portion of the conveying surface, such as the center of the conveying surface. 
     As part of the guide rail support system, at certain spaced-apart locations along the conveyor  10  are positioned guide rail adjustment assemblies  18 . Each guide rail adjustment assembly  18  includes a guide rail arm  20  which is attached to and supports the portion of the guide rail  16  in the vicinity of the guide rail arm. Each guide rail arm  20  also has an adjustment rack  22 , which is shown integrally formed with the respective guide rail arm  20 , but which could also be formed as a separate item and assembled to the guide rail arm. Each adjustment rack  22  passes into a respective pinion block  24  to engage with a pinion gear or pinion  26 , shown in  FIG. 5 . Each pinion block  24  is mounted to the frame  14  by means of pinion block mounting brackets  18   a . While the means of engagement between the pinion  26  and the adjustment rack  22  is shown to be pinion teeth  26   a  engaging with openings  22   a  formed for that purpose in the adjustment rack, any other suitably accurate and repeatable engagement between those two elements is also contemplated by the invention, including for example other gearing such as bevel gearing. The pinion block  24  and adjustment rack  22  are positioned and arranged so that, when pinion  26  is rotated in one direction, the guide rail arm  20 , and the respective portion of the guide rail  16 , is moved closer to the selected or desired area of conveying surface  12 , whereas when pinion  26  is rotated in the opposite direction, the guide rail arm  20 , and the respective portion of the guide rail  16  in the vicinity of the guide rail arm, is moved further away from the desired area of conveying surface  12 . 
     The invention further provides a synchronizing connector  28  connecting the respective pinions  26  of each pair of adjacent pinion blocks  24  on one side of the conveyor  10 , such that when one synchronizing connector  28  is rotated, the pinions  26  of each pair of adjacent pinion blocks  24  is rotated. Thus, when one synchronizing connector  28  is rotated, all the pinions  26  in all the pinion blocks  24  are rotated, thereby moving all the guide rail arms  20 , in turn moving the entire guide rail  16  on that side of the conveyor  10 . The synchronizing connector  28  shown in the drawing figures has a substantially square cross section. Synchronizing connectors with other cross sections could also be used, including rectangular, or oval. Even a round cross section could be used, but that would require the inclusion of a set collar or some other structure to connect the synchronizing connector to the respective pinions so as to pass on the torsional forces supplied by the synchronizing connectors. 
     The invention further provides a rotator  30  for rotating the synchronizing connectors  28  and pinions  26 , so as to move the guide rail a desired amount. In  FIGS. 1 and 2 , the rotator  30  includes a crank handle  32  connected to a crankshaft  34 . As shown most clearly in  FIG. 2 , in this embodiment the crankshaft  34  is oriented transverse to the synchronizing connectors  28 , and so this embodiment includes a gear box or other transfer case  36 , wherein the crankshaft  34  is the input shaft, and with the transfer case translating the rotational motion, the output shaft is connected to the nearest synchronizing connector(s)  28 . The rotator  30  may take other forms as well, as will be explained below. 
     It is common, though not required, for a conveyor  10  to have guide rails  16  on both sides. The present invention provides that the two guide rails  16  on the two opposite sides of the conveyor may have separate guide rail support systems, which could be separately adjustable, in the manner described above for a single side. The invention also provides for synchronizing the guide rail support systems of the two sides, if desired. According to the invention, as shown best in  FIGS. 2 and 5A , the sides-synchronized version of the invention provides for an opposite transfer case  36   a  on the side of the conveying surface  12  opposite the transfer case  36 . For this arrangement, transfer case  36  includes a second output shaft  38 , which acts as, or connects to, the input shaft  34   a  of opposite transfer case  36   a . In  FIG. 5A , this connection is made by extender shaft  39 , but other suitable connections may be supplied. As with transfer case  36 , the output shaft of opposite transfer case  36   a  is connected to the synchronizing connectors  28  on that side of the conveyor  10 . Thus, when the rotator  30  rotates the crankshaft  34  of the transfer case  36 , the second output shaft  38  rotates the input shaft  34   a  of the opposite transfer case  36   a , which causes the output shaft of opposite transfer case  36   a  to rotate the synchronizing connectors  28  on that side of the conveyor  10 . In this fashion, both sides of guide rails  16  are moved at the same time. 
     As shown in  FIG. 1 , conveyor  10  may include a straight portion  10   a , but it may also include a curved portion  10   b . As shown in  FIGS. 6, 7, 8, 9A and 9B , the invention also provides for supporting and adjusting the guide rail  16  in the curved portion  10   b  of the conveyor  10 . As shown in those figures, at the center of the curve, the guide rail arm  20  is affixed to the guide rail  16  as described above. However, at each end of the curved section, the respective guide rail arm  20  is connected to the respective portion of the guide rail  16  by means of a slider assembly  40 , which allows relative sliding lateral movement between the guide rail and the guide rail arm. As shown best in  FIGS. 8, 9A and 9B , in this embodiment slider assembly  40  is formed of a rail portion  40   a , connected to the guide rail  16 , and an arm portion  40   b  connected to the guide rail arm  20 . Rail portion  40   a  and arm portion  40   b  are connected together in a manner that permits them to slide with respect to each other, laterally, along the lengthwise direction of the guide rail  16 . 
     Thus, when guide rail arm  20  on the outside of the curve is moved away from the conveying surface  12  by the action of the synchronizing connectors  28  and pinion  26 , the rail portion  40   a  slides along the arm portion  40   b  away toward the center point of the curve, as shown in  FIG. 9A , whereas when guide rail arm  20  on the outside of the curve is moved toward the conveying surface  12  by the action of the synchronizing connectors  28  and pinion  26 , the rail portion  40   a  slides along the arm portion  40   b  away from the center point of the curve, as shown in  FIG. 9B . Conversely, when guide rail arm  20  on the inside of the curve is moved away from the conveying surface  12  by the action of the synchronizing connectors  28  and pinion  26 , the rail portion  40   a  slides along the arm portion  40   b  away from the center point of the curve, again as shown in  FIG. 9A , whereas when guide rail arm  20  on the inside of the curve is moved toward the conveying surface  12  by the action of the synchronizing connectors  28  and pinion  26 , the rail portion  40   a  slides along the arm portion  40   b  toward the center point of the curve, again as shown in  FIG. 9B . 
     In general,  FIG. 9A  shows the guide rails  16  and  16   a  in their widest position, and it can be seen that the guide rails  16  and  16   a  forming the outer side of the curve do not overlap each other, whereas the guide rails  16  and  16   a  forming the inner side of the curve do overlap to an extent. Conversely,  FIG. 9B  shows the guide rail  16  and  16   a  in their narrowed position, and it can be seen that the guide rails  16  and  16   a  forming the outer side of the curve do overlap each other to some extent, whereas the guide rails  16  and  16   a  forming the inner side of the curve do not overlap. The overlap described herein is permitted or accommodated in the embodiment shown, by the fact that the straight portion guide rail  16  is a single rail, at a level a bit lower (closer to the level of the conveying surface  12 ) than the curved portion guide rail  16   a , so that the same distance from the opposing guide rail  16  or  16   a  is maintained by both straight guide rail  16  and curved guide rail  16   a.    
     In connection with the curved portion  10   b  of the conveyor  10 , the synchronizing connectors are provided with universal joints  44 , or other suitable connectors, or flexible members may be used, to permit rotational forces to be transmitted to pinion blocks  24  around the curvature of the curved portion. 
       FIG. 10  shows an alternative embodiment of the invention. Where the embodiment shown in  FIGS. 1 and 2  showed the rotator  30  to include a crank handle  32 , the embodiment shown in  FIG. 10  illustrates a rotator  30  that includes a motor  42 . Operation of a motor to bring about a desired number of rotations, or a desired portion of a single rotation, is well known by persons of ordinary skill in the art. The motor  42  may be controlled locally, such as by an operator in the presence of the motor, or may be controlled remotely through a distributed control system. 
       FIGS. 11 and 12  show another alternative embodiment of the invention wherein the pinion blocks  24  are mounted in a guide support frame  46  above the conveyor surface  12 , and wherein the guide rail adjustment rack  22  is mounted vertically within the pinion blocks, so that the adjustment permitted is vertical adjustment of the guide rail  16 , higher or lower along the length of the conveyor surface  12 . 
       FIG. 13  shows another alternative embodiment of the invention wherein, as alluded to above, the guide rail  16  may be mounted adjustably on one side of the conveying surface  12 . On the opposite side of the conveying surface  12 , the guide rail  16  is mounted by attaching a fixed position mount  48  directly to the frame  14 . Fixed position mounts vary in design and shape, but in general are well known to persons of ordinary skill in the art. 
       FIG. 14  shows an embodiment of the invention similar to that shown in  FIGS. 11 and 12 , in that the guide rail  16  is vertically adjustable. In this embodiment the guide rail  16  is positioned directly above the conveying surface  12 , and can apply pressure downwardly onto items on the conveying surface. 
       FIG. 15  shows an embodiment of the invention having multiple guide rails  16  on each side of the conveying surface  12 . As can be seen, the upper and lower guide rails may be controlled separately from each other, and the respective opposing guide rails may be controlled together as described above. 
       FIG. 16  shows an embodiment of the invention having multiple adjustable guide rails  16  sufficient to form multiple lanes  50  on the conveying surface  12 . 
     This invention has a number of advantages over prior art. First, the single piece turn rail minimizes catch points and is cleaner without overlapping multiple pieces. Second, there is a linear bearing/slide mechanism in the turn section to facilitate the change in radius and circumferential distance, while maintaining the desired rail gap. This invention permits the use of fewer actuation points per length of conveyor. The design is modular, and thus does not require custom engineering for turns. Some prior art conveyors require all turns to be specially engineered and designed by the manufacturer. In general, the design is cleaner. The housing can be flushed with water to clean the pinion and rack. The fact that the rack can be manufactured of multiple different materials, including steel, facilitates custom lengths and is less expensive to produce. Finally, the implementation of the non-round shaft eliminates need for set collars. 
     While the apparatus hereinbefore described is effectively adapted to fulfill its intended objects, it is to be understood that the invention is not intended to be limited to the specific preferred embodiments set forth above. Rather, it is to be taken as including all reasonable equivalents to the subject matter described.