Abstract:
Mounting apparatus is used for supporting an accessory device, e.g., a sensor, in a manner permitting adjustment. An accessory device-receiving mount is fixable to the accessory device and has at least one surface forming a cross-section permitting adjustment in at least one degree of freedom. A clamp ring engages the device-receiving mount at the surface, so that the cross-section permitting adjustment. A clamping mechanism selectively clamps the clamp ring and includes a manually threaded fastener and a lever-operated clamp tightener. The lever-operated clamp tightener acts on the manually threaded fastener to releasably tighten the clamping mechanism beyond that achieved by manually threading the manually threaded fastener, permitting manually threading the clamping arrangement at a maximum tension less than a full tension applied by the lever-operated clamp tightener.

Description:
BACKGROUND 
     Field 
       [0001]    The present disclosure relates to toolless and minimum tool mounting of accessories in industrial environments such as conveyers and assembly lines. The present disclosure also relates to the mounting of cameras and similar equipment in industrial environments, in which positional alignment of the camera or other equipment is desired. 
       Background 
       [0002]    In industrial environments, accessory devices such as sensors are often mounted for alignment with a conveyer or other equipment providing positioning or movement of items. The sensors can be, by way of non-limiting example, cameras and similar equipment. The purpose of the accessory device is to detect or otherwise engage with items or workpieces on the conveyer or equipment providing movement. In order to perform such tasks, the accessory device is positioned in its alignment in a manner which locks the accessory device in place. 
         [0003]    In many cases, positioning or repositioning and alignment of the accessory device is frequently performed, such as with changes in the production run or type of accessory device being detected. Additionally, it is also possible that the configuration of the conveyer or other equipment is changed, which could affect the alignment of the accessory device with respect to the sensed items. Even if the type of accessory device is not changed, frequent adjustments in positioning or alignment are desired. While there are many instances in which the accessory device is adjusted at a time when a technician is performing other assembly or adjustment tasks, and would therefore have a toolbox available, there are other instances in which adjustment is not coincident with other operations, requiring that tools be retrieved specifically for the purpose of adjustment. 
         [0004]    It is also desired that the positioning be stable, regardless of whether the type of accessory device is changed. Further, it is desired that the adjustments not require tools or require a minimum amount of tooling. In addition, it is desirable to be able to remove and replace or re-install the accessory device without a requirement that the alignment of the accessory device be performed. 
       SUMMARY 
       [0005]    Mounting apparatus is provided for supporting an accessory device in a manner permitting adjustment. A device-receiving mount is fixable to the accessory device and comprising at least one surface forming a cross-section permitting adjustment in at least one degree of freedom. A clamp ring is used to engage the device receiving mount at the surface forming the cross section. The engagement of the device at the cross-section permits adjustment of the device-receiving mount with the accessory device. A clamping mechanism is configured to selectively clamp the clamp ring, using a manually threaded fastener and a lever-operated clamp tightener. The lever-operated clamp tightener acts on the manually threaded fastener to releasably tighten the clamping mechanism beyond that achieved by manually threading the manually threaded fastener. The operation of the manually threaded fastener and the lever-operated clamp tightener permits manually threading the clamping arrangement at a maximum tension less than a full tension applied by the lever-operated clamp tightener. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]      FIG. 1  is a diagram showing a roller conveyer system. 
           [0007]      FIG. 2  is a diagram showing a belt conveyer system. 
           [0008]      FIGS. 3A-3E  are schematic diagrams showing a sensor assembly.  FIG. 3A  shows the sensor mount and sensor.  FIG. 3B  shows a cover member lifted to loosen the sensor within the mount and to allow finger tightening or loosening of a clamping mechanism.  FIG. 3C  shows a sensor attachment used to directly hold the sensor.  FIG. 3D  shows the sensor attachment aligned for being received by the clamping mechanism.  FIG. 3E  shows a tapered surface arrangement used to effect tightening of the clamping mechanism when the cover member is closed against a base member. 
       
    
    
     DETAILED DESCRIPTION 
       [0009]      FIGS. 1 and 2  are diagrams respectively showing roller and belt conveyer systems, which are configured on-site to allow a particular operation. In the non-limiting example shown, the particular operation is diverting items on the conveyers, it being understood that the particular operation of the conveyer and the diversion are not part of the disclosed technique. In  FIG. 1 , conveyer system  101  has rollers  111  which cause items  123  to move along the conveyer system  101 . Diverter dogs  127  are used to cause items to move onto selected ones of side conveyers  131 ,  132 ,  133 . One or more camera sensors  151  are fixed to camera mounts  153 . 
         [0010]    In  FIG. 2 , conveyer system  201  has conveyer belts  211 - 214  which cause items  123  to move along the conveyer. Diverter rollers  227  are used to cause items to move onto selected ones of side conveyers  231 ,  232 ,  233 . If it is desired to sequence the movement of the items  123  to the side conveyers  131 - 133  or  231 - 233 , the presence of the item approaching the side conveyers  131 - 133  or  231 - 233  must be taken into account, typically by sensing or detecting the presence of the items  123 . If changes are made to the system, this could affect the sensing or detecting. 
         [0011]    One way to detect the presence of items  123  is to use a camera sensor  151 , mounted on a camera mount  153 . While timing can be used to estimate further movement, additional camera sensors (not shown) can be used at each individual side conveyor location. (Co-aligned locations, e.g., side conveyers  131 ,  132 , can use a single camera sensor.) These camera sensors  151  can be adjusted and can be removed and replaced as required. 
         [0012]      FIGS. 3A-3E  are schematic diagrams showing an example sensor assembly  301 . While a specific configuration is shown, this is given as a non-limiting example in order to demonstrate the disclosed techniques. 
         [0013]      FIG. 3A  shows sensor assembly  301 , comprising sensor mount  311  and sensor  313 . Sensor mount  311  comprises base  321  and sensor receiving portion  323 . Base  321  is configured for vertical attachment to an accessory attachment point (not shown) at an appropriate location which is generally present on the conveyor system  101  or  201 , in an alignment as depicted by horizontal lines  331 ,  332 , using a fastener and alignment pin ( FIGS. 3B  and D). The attachment location of base  321  would correspond to the locations of camera mount  153  in  FIGS. 1 and 2 . Sensor  313  is received by sensor receiving portion  323  and can be removed and rotationally adjusted at sensor receiving portion  323 . 
         [0014]    The description of sensor assembly with sensor mount  311  and sensor  313  is given by way of non-limiting example, as any accessory device can be supported using the disclosed technology. Likewise, conveyer systems  101 ,  201  are given by way of non-limiting examples, as the technology can be used for any of a wide variety of applications requiring adjustable mounting of one device at a mounting location. 
         [0015]      FIG. 3B  is a schematic diagram showing sensor mount  311 , and depicting base mounting portion  341  and cover member  343 .  FIG. 3B  shows cover member  343  lifted. The lifting of cover member  343  results in sensor receiving portion loosening the sensor within sensor mount  311 , as will be described. Sensor receiving portion  323  comprises clamp ring  345 , which extends from base  321  and supports sensor attachment  353 . Clamp ring  345  extends from base mounting portion  341  as part of sensor receiving portion  323 . Bolt hole  331 A and alignment pin  332 A are used to position sensor mount  311  in alignment with the accessory attach points on the conveyer system  101  or  201 . 
         [0016]    Sensor attachment  353  functions as a device carrier, to directly support sensor  313  or another accessory device in sensor mount  311 . Sensor attachment  353  has an outer contour which allows movement. By way of non-limiting example, sensor attachment  353  has a spherical outer contour, as shown in  FIGS. 3C  and D. The spherical outer contour extends along a surface area where sensor attachment is engaged by clamp ring  345 , as shown in  FIGS. 3A  and B. The example shown in  FIGS. 3C  and D show sensor attachment  353  as a sphere section; however, it is possible to construct sensor attachment  353  with parts of its outer contour not conforming to the spherical shape and still provide the spherical outer contour where sensor attachment  353  is engaged by clamp ring. While the example shown in  FIGS. 3A-D  use a spherical contour to allow rotational movement in up to 3 degrees of freedom, other contours, such as cylindrical contours or linear contours can be used to achieve different types of movement. 
         [0017]    Sensor attachment  353  in turn receives sensor  313  and allows rotation of sensor  313  by virtue of sensor attachment  353  being able to rotate within clamp ring  345  until clamp ring  345  is tightened. Knurled knob and bolt assembly  367 ,  368  are used to secure sensor attachment  353  within clamp ring  345 . When base  321  is mounted to the accessory attachment point, freedom of adjustment is at sensor attachment  353 . Sensor attachment  353  forms a cross-section permitting adjustment in 3 degrees of freedom when supported by clamp ring  345 . 
         [0018]    It is noted that sensor attachment  353  is formed as a sphere section and not as a complete ball or sphere, with threaded sensor receiving opening  371  transecting sensor attachment  353 . This precludes full 360° movement of sensor  313 ; however, full 360° movement of sensor  313  is not a sensor adjustment criterion. While sensor attachment  353  allows 3 degrees of freedom of adjustment, it is alternatively possible to provide an attachment device which permits 1 or 2 degrees of freedom, and to provide an attachment device which also permits extension or lateral movement of the item being supported by the attachment device. 
         [0019]    Knurled knob and bolt assembly  367 ,  368  allow tightening and loosening adjustment of clamp ring  345  by manual threading. As used herein, “manual threading” refers to manually rotating the threaded parts (i.e., screwing or rotating the parts on the threads; not fabricating the threads). 
         [0020]    In this non-limiting example, clamp ring  345  and base mounting portion  341  are formed as a single unit, with the extension of clamp ring  345  from base mounting portion  341  at a fixed end  355  of clamp ring  345 . Clamp ring  345  has sufficient elastic movement to permit insertion and removal of sensor attachment  353 . In that arrangement, clamp ring  345  is fixed to base mounting portion  341 , but is able to flex sufficiently to receive sensor attachment  353 . This arrangement also makes it easier to assemble the sensor mount, as the movement between base mounting portion  341  and clamp ring  345  is limited to the flexibility of clamp ring  345 . 
         [0021]    Cover member  343  is attached to clamp ring  345  where clamp ring  345  joins base mounting portion, and extends around clamp ring  345  where knurled knob and bolt assembly  367 ,  368  pass through clamp ring  345 . When knurled knob and bolt assembly  367 ,  368  are loose, cover member  343  can pivot freely, and if knurled knob and bolt assembly  367 ,  368  are removed, cover member  343  can be removed entirely. When knurled knob and bolt assembly  367 ,  368  are tightened, cover member  343  functions as outer washer elements and clamps clamp ring  345  tight under the tensile force of the tightened knurled knob and bolt assembly  367 ,  368 . 
         [0022]    The configuration of the base mounting portion  341  and clamp ring  345 , in combination with cover member  343  and knurled knob and bolt assembly  367 ,  368  is such that knurled knob and bolt assembly  367 ,  368  form a hinge pivot for cover member  345  to rotate with respect to base mounting portion  341  and clamp ring  345 . Thus, cover member  343  is able to be rotated about an axis of knurled knob and bolt assembly  367 ,  368 , and the combination of base mounting portion  341  and clamp ring  345 , cover member  343  and knurled knob and bolt assembly  367 ,  368  form part of a hinge arrangement. 
         [0023]    Therefore, knurled knob and bolt assembly  367 ,  368 , when tightened, secure sensor attachment  353  by tightening clamp ring  345 . Knurled knob and bolt assembly  367 ,  368  can be loosened as necessary to allow sensor attachment  353  to be moved either easily, or against frictional resistance of clamp ring  345  when partially-tightened. 
         [0024]      FIG. 3E  shows a tapered surface arrangement comprising tapered or ramped surfaces  375  forming mating surfaces of clamp ring  345 , and raised contacting followers  377  on cover member  343 . Ramped surfaces  375  are recessed in a rotational direction, as circularly ramping surfaces, which increases clamping of clamp ring  345  when cover member  343  is closed against base mounting portion  341 . (Contacting followers  377  are formed on both legs of clamp ring  345  and ramped surfaces  375  are formed on both legs of cover member  343 .) Ramped surfaces  375  and contacting followers  377  cause the legs of cover member  343  to separate with respect to each other, thereby separating thrust bushing surfaces  378 ,  379  against which knurled knob and bolt assembly  367 ,  368  seat. As a result of the movement of contacting followers  377  against ramped surfaces  375 , the lifting of cover member  343  results in sensor receiving portion loosening the sensor within sensor mount  311  to allow finger tightening or loosening of a clamping mechanism and allows directional adjustment of sensor attachment  353 . When cover member  343  is closed against base mounting portion  341 , the increased clamping pressure prevents or inhibits movement of sensor attachment  353 . 
         [0025]    Latch mechanism  381 ,  382  at the bottom of cover member  343  and base mounting portion  341  ( FIGS. 3A  and B) retain cover member  343  in the closed position unless deliberately released. 
         [0026]    Thrust bushing surfaces  378 ,  379  provide seating surfaces for knurled knob and bolt assembly  367 ,  368  to tighten against, and can accept knurled knob and bolt assembly  367 ,  368  directly or with washers, as desired. While thrust bushing surfaces  378 ,  379  are described, it is understood that thrust bushing surfaces  378 ,  379  need not be separate components from cover member  343 . 
         [0027]    The action of ramped surfaces  375  and raised contacting followers  377  allows securing clamp ring  345  with knurled knob and bolt assembly  367 ,  368  as finger-tight, and then closing cover member  343  over base mounting portion  341  to achieve a separation force on thrust bushing surfaces  378 ,  379 , thereby increasing the clamping effect of knurled knob and bolt assembly  367 ,  368 . The difference in clamping pressure with cover member  343  in the open ( FIG. 3B ) and closed ( FIG. 3A ) positions may, by way of non-limiting example, be sufficient to allow forced movement of sensor  313  mounted in sensor attachment  353  when cover member  343  is open, but prevent movement of sensor  313  mounted in sensor attachment  353  when cover member  343  is closed. Thus ramped surfaces  375  and raised contacting followers  377 , as operated by cover member  343 , function as a lever-operated clamp tightener. 
         [0028]    The arrangement of the cover member  343  and latch mechanism  381 ,  382  as a technique for increasing clamping also provides a visual cue or visual indication that clamp ring  345  is tightened, provided that knurled knob and bolt assembly  367 ,  368  are properly adjusted and not loosened. This allows final tightening of sensor  313  in its adjusted position in a visually observable manner. Additionally, the final tightening of sensor  313  is achieved in a manner which is unlikely to affect the adjusted alignment of sensor  313  in sensor mount  311  because the clamping motion of clamp ring  345  is at a different location from the movement of cover member  343 . 
         [0029]    While it is possible that removal of sensor  313  can be accomplished by threadably removing sensor  313  from sensor attachment  353  while sensor attachment  353  is secured by clamp ring  345 , it is also possible to threadably assemble sensor attachment  353  onto sensor  313  while sensor attachment  353  is removed from clamp ring  345 . As shown in  FIGS. 3C  and E, sensor attachment  353  has one or more grooves  385  on its surface that can be used for gripping sensor attachment  353  with a spanner wrench or ring pliers; however, by clamping sensor attachment  353  with clamp ring  345 , a technician can tighten sensor  313  inside sensor attachment  353  or remove sensor attachment  353  from sensor  313 . This tightening operation may cause sensor  313  to be rotationally out of alignment, but clamp ring  345  can then be loosened to allow for alignment of sensor  313 . 
         [0030]    If the threaded sensor receiving opening  371  and sensor  313  are fabricated so that the rotational alignment of sensor attachment  353  on sensor  313  is predicable, groove  385  (or grooves  385 ) can be received by a corresponding pin (not shown) in clamp ring  345  to maintain alignment in at least one degree of freedom. 
         [0031]    Nevertheless, with sensor attachment  353  secured against movement by knurled knob and bolt assembly  367 ,  368 , sensor  313  can be removed or installed by threadably removing or attaching sensor  313  from or to sensor attachment  353 . Sensor  313  can be removed by unscrewing from within sensor attachment  353 . If sensor attachment remains clamped, the alignment of sensor  313  will not change because sensor attachment  353  remains in its clamped position. Therefore, if a sensor  313  is removed and a different sensor having the same focal or sensing geometry is attached, the alignment of the new sensor would remain the same as the original sensor  313 . 
       OPERATION AND INDUSTRIAL APPLICATION 
       [0032]    The configuration provides a technique for mounting a sensor or other accessory device to machinery or other equipment, in which some or all of the final assembly can be achieved without tools. This further allows positional adjustment of the accessory device (e.g., sensor  313 ) without tools, and can also allow the adjustment to achieved in a friction mount in order to achieve stability while making the adjustment, followed by securing the accessory device in its adjusted position. As a result of the operation of cover member  343  and latch mechanism  381 ,  382 , the securing of the accessory device, can be achieved with minimal disturbance in the positional adjustment of the accessory device. If the lifting of cover member  343  does not substantially loosen clamp ring  345 , the accessory device remains in its positional adjustment as a starting point for further adjustment. 
       Conclusion 
       [0033]    It will be understood that many additional changes in the details, materials, steps and arrangement of parts, which have been herein described and illustrated to explain the nature of the subject matter, may be made by those skilled in the art within the principle and scope of the invention as expressed in the appended claims. 
         [0034]    In particular, it is noted that, while a sensor mounted to production line equipment is described, the technology described can be used for many other types of mounting arrangements, and can be used in multiple environments in which adjustment and positioning is desired. The technology is particularly useful in environments in which field adjustment is desired without a requirement that tools be retrieved for purposes of achieving the adjustment. While positioning and alignment of a sensor is described, the technology can be used for positioning or alignment of a wide variety of devices. 
       LIST OF REFERENCES 
       [0035]    conveyer system  101   
         [0036]    rollers  111   
         [0037]    items  123   
         [0038]    diverter dogs  127   
         [0039]    side conveyers  131 ,  132 ,  133   
         [0040]    camera sensor  151   
         [0041]    camera mount  153   
         [0042]    conveyer system  201   
         [0043]    conveyer belts  211 - 214   
         [0044]    diverter rollers  227   
         [0045]    side conveyers  231 ,  232 ,  233   
         [0046]    sensor assembly  301   
         [0047]    sensor mount  311   
         [0048]    and sensor  313   
         [0049]    base  321   
         [0050]    sensor receiving portion  323   
         [0051]    horizontal lines  331 ,  332   
         [0052]    bolt hole and alignment pin  331 A,  332 A 
         [0053]    base mounting portion  341   
         [0054]    cover member  343   
         [0055]    clamp ring  345   
         [0056]    sensor attachment  353   
         [0057]    fixed end of clamp ring  355   
         [0058]    knurled knob and bolt assembly  367 ,  368   
         [0059]    threaded sensor receiving opening  371   
         [0060]    tapered or ramped surfaces  375   
         [0061]    raised contacting followers  377   
         [0062]    thrust bushing surfaces  378 ,  379   
         [0063]    latch mechanism  381 ,  382   
         [0064]    groove  385