Abstract:
A method for repairing a side rail of a roller type conveyer, includes installing a clip on the side rail. The clip has an aperture which replaces a worn or distorted roller aperture on the side rail. The clip is driven onto the side rail at the location of the distorted roller aperture, and grips the side rail so as to maintain the desired location. The end of the roller axle of the roller is then installed into the aperture of the clip to restore proper operation of the conveyer. The repair can be made in a short time, and requires no modification to the side rail.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims the filing benefit under 35 U.S.C. §119(e) of U.S. Provisional Application No. 60/363,478, filed Mar. 11, 2002, which is included herein by reference. 
    
    
     TECHNICAL FIELD 
     The present invention pertains generally to roller type conveyors, and more particularly to a method and apparatus for repairing the side rails of such a conveyor. 
     BACKGROUND OF THE INVENTION 
     Roller type conveyors are utilized to move items from one location to another. These conveyors comprise a plurality of spaced apart rollers which are mounted between two elongated side rails. Each end of the roller axle engages a roller aperture in one of the side rails, and the roller then rotates about the axle. The items are then placed on the rollers and are conveniently moved from roller-to-roller along the conveyor either by gravity or an urging force. 
     With time however, the vibration of the rollers causes the roller apertures to wear and distort so that they no longer properly receive the ends of the roller axle, thereby degrading the operation of the conveyor. In extreme cases, the roller can even fall out of the roller aperture. When distortion occurs, even to only one or two roller apertures, repair needs to be made. One common repair method is to replace one or both of the side rails. This is a time consuming and costly process. Another repair method is to add a plurality of reinforcing strips to the side rails. This technique is illustrated in U.S. Pat. No. 6,112,875 which includes a conveyor frame roller shaft alignment strip and method. The invention includes a multi-layer reinforcement strip having a layer of sheet metal and at least one layer of high density plastic material is affixed to the worn frame rails. The reinforcement strip is provided with a plurality of openings formed therein, corresponding in size and spacing to the series of openings in the frame rail prior to being worn for supporting a series of roller support shafts. The multi-layer re-aligns the rollers and reduces conveyor vibration. However, even this procedure is time consuming and expensive. 
     A method is needed to quickly and inexpensively repair a conveyor side rail. The method should require nether replacement nor modification of the side rail. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to a method and apparatus for effecting quick and inexpensive repair of a conveyor side rail. The method and apparatus of the present invention allow repair of the side rail to be made in less than one minute, with no required drilling or other modification to the side rail. Additionally, the present invention allows a roller to be removed, a single new roller aperture installed, and the roller reinstalled without necessitating the removal of adjacent rollers. 
     The present invention is particularly useful in a field environment where time is of the essence, and where the conveyor users do not have access to repair facilities. For example, if a single conveyer roller is non-operational, that roller may be removed, a new aperture added, and the roller replaced, thereby returning the conveyor to an operating condition. 
     The present invention is primarily targeted at temporary side rail repair, however the present repair method can last for an extended time period. 
     In accordance with a preferred embodiment of the invention, a method for repairing a side rail of a conveyer, includes: 
     (a) providing a conveyor having: 
     two spaced apart side rails, the side rails each having a plurality of spaced roller apertures, wherein at least one of the roller apertures is distorted; 
     a plurality of rollers, each roller including an axle about which a cylindrical body freely rotates, the rollers being perpendicularly installed between the two side rails, wherein one end of the roller engages a roller aperture in one side rail and the other end of the roller engages a roller aperture in the other side rail; 
     (b) providing a clip for repairing the side rail(s) which has a distorted roller aperture, the clip including: 
     a first side connected to an opposite second side; 
     an opening disposed between the first and second sides, the opening shaped and dimensioned for receiving the side rail, wherein the clip may be installed onto the side rail and grip the side rail without requiring attachment hardware; 
     the first side of the clip having an aperture which has the shape of an undistorted roller aperture; 
     (c) removing the roller which engages the distorted roller aperture; 
     (d) installing the clip onto the side rail at the location of the distorted roller aperture so that the aperture aligns with the distorted roller aperture; and, 
     (e) installing one of (1) the roller that was removed in step (c), and (2) a new roller, in the aperture of the clip installed in step (d). 
     In accordance with an aspect of the method; 
     prior to step (d), providing a hammer; and, 
     in step (d), the installation of the clip onto the side rail including using the hammer to drive the clip onto the side rail. 
     In accordance with an aspect of the method: 
     steps (c), (d), and (e) are performed in less than one minute. 
     In accordance with an aspect of the method: 
     steps (c), (d), and (e) are performed without having to remove any rollers other than the roller which engages the distorted roller aperture. 
     In accordance with an aspect of the method: 
     in step (d), the installation of the clip onto the side rail requiring no modification to the side rail. 
     In accordance with an aspect of the method: 
     in step (a), the side rail having a plurality of distorted roller apertures; and, repeating steps (c) through (e) until clips have been installed at all side rail locations having a distorted roller aperture. 
     Other aspects of the present invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a reduced top plan view of a prior art roller type conveyor; 
     FIG. 2 is a reduced side elevation view of the prior art conveyor; 
     FIG. 3 is a fragmented perspective view of a side rail and roller; 
     FIG. 4 is a fragmented perspective view of a second side rail embodiment; 
     FIG. 5 is a perspective view of a worn side rail; 
     FIG. 6 is a perspective view of a second worn side rail embodiment; 
     FIG. 7 is a front elevation view of a clip for repairing the side rail of a conveyor in accordance with the present invention; 
     FIG. 8 is a side elevation view of the clip; 
     FIG. 9 is a rear elevation view of the clip; 
     FIG. 10 is a perspective view of the clip being installed on a side rail; 
     FIG. 11 is a perspective view of the clip installed on the side rail; 
     FIG. 12 is a cross sectional view along the line  12 — 12  of FIG. 11; 
     FIG. 13 is a front elevation view of a second embodiment of the clip; 
     FIG. 14 is a side elevation view of the second embodiment clip; 
     FIG. 15 is a rear elevation view of the second embodiment clip; 
     FIG. 16 is a perspective view of the second embodiment clip being installed on a side rail; 
     FIG. 17 is a perspective view of the second embodiment clip installed on the side rail; 
     FIG. 18 is a cross sectional view along the line  18 — 18  of FIG. 17; 
     FIG. 19 is a perspective view of another embodiment of the clip; 
     FIG. 20 is a perspective view of another embodiment of the clip; and, 
     FIG. 21 is a perspective view of the clip being installed on another side rail embodiment; 
     FIG. 22 is a cross sectional view of the clip installed on the side rail embodiment of FIG. 21; and, 
     FIG. 23 is a perspective view of another embodiment of the clip. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring initially to FIGS. 1 and 2, there are illustrated reduced top plan and side elevation views respectively of a roller type conveyer, generally designated as  500 . Conveyor  500  includes two spaced apart side rails  502 , side rails  502  each having a plurality of spaced roller apertures  504 . Conveyer  500  further includes, a plurality of rollers  506 , each roller  506  includes an axle  508  (refer to FIG. 3) about which a cylindrical body  510  freely rotates. Rollers  506  are installed between the two side rails  502 , wherein axle  508  of roller  506  engages one roller aperture  504  in each of the side rails  502 . Conveyor  500  moves item  600  from one end of the conveyor to the opposite end. 
     FIG. 3 is a fragmented perspective view of side rail  502  and roller  506 , showing roller apertures  504 , roller axle  508 , and cylindrical body  510 . Side rail  502  has a width W 1 . In the shown embodiment, roller apertures  504  have a hexagonal shape to accept the hexagonal end of roller axle  508 . When axle  508  is installed in roller aperture  504 , body freely rotates about axle  508 . Also in the shown embodiment, roller  506  may be longitudinally compressed in direction  512  (similar to a toilet paper roller) so that it may be installed between the roller apertures  504  of the two side rails  502 . 
     FIG. 4 is a fragmented perspective view of a second prior art side rail  502  embodiment. In this embodiment roller aperture  504  comprises a slot which receives the end of axle  508  of roller  506 . It may be appreciated that in this design, rollers  506  may be installed from the top of side rail  502 , with no need to compress roller  506  during the installation process. 
     FIGS. 5 and 6 are perspective views of worn side rails  502 . Due to vibration an other mechanical stresses, roller aperture  504  has distorted becoming both enlarged and rounded. As such, these distorted roller apertures  504  do not properly receive the end of axle  508  of roller  506 . 
     Referring not to FIGS. 7-9, there are illustrated front elevation, side elevation, and rear elevation views respectively of a clip for repairing a side rail  502  of a conveyor  500  in accordance with the present invention, the clip generally designated as  20 . Clip  20  includes a first side  22  connected to an opposite second side  24 . An opening  26  is disposed between first  22  and second side  24 . Opening  26  is shaped and dimensioned for receiving side rail  502  (refer to FIGS.  12  and  18 ), so that clip  20  may be installed onto side rail  502  and grip side rail  502  without requiring attachment hardware (such as screws or bolts and nuts). In an aspect of the invention, clip  20  is hammered onto side rail  502 , and remains fixedly in place thereon. In an aspect of the invention, opening  26  has a second width W 2  which is slightly less than first width W 1  of side rail  502 . This ensures that when clip  20  is installed it will tightly grip side rail  502 . In another aspect of the invention, first  22  and second  24  sides are biased toward one another to effect the gripping of side rail  502 . 
     First side  22  of clip  20  has an aperture  28  which has the shape of an undistorted roller aperture  504  (refer to FIG.  3 ). That is, a new roller aperture  504  which has not been subjected to vibration or wear. In the shown embodiment, first side  22  has exactly one aperture  28 , so that one clip  20  is used to repair each distorted roller aperture  504 . In the shown embodiment, second side  24  of clip  20  also has an aperture  28  having the shape of an undistorted roller aperture  504 . The aperture  28  in second side  24  is aligned with the aperture  28  in first side  22  so that axle  508  of roller  506  can engage both apertures  28 . 
     In an aspect of the invention, clip  20  is fabricated from sheet metal which will resiliently bend slightly to accept side rail  502 . 
     FIGS. 10 and 11 are perspective views of clip  20  being installed on side rail  502 . Clip  20  is installed onto side rail  502  at the location of distorted roller aperture  504  so that aperture  28  aligns with distorted roller aperture  504  and thereby functionally replaces the distorted roller aperture  504 . That is, when clip  20  is installed onto side rail  502 , aperture  28  is located at the site of the original undistorted roller aperture  504 , thereby providing a new undistorted aperture  28  to receive the end of axle  508  of roller  506  (refer to FIG.  11 ). Clip  20  is installed on side rail  502  by driving clip  20  downward in direction  30  onto side rail  502  with a hammer. As defined herein, a hammer may be any device which is sufficiently massive to drive clip  20  onto side rail  502 . In the installed position, first side  22  is disposed on the side of side rail  502  which faces rollers  506 , and second side  24  is disposed on the opposite side of side rail  502 . The two sides of clip  20  therefore grip side rail  502 . It is important to note that the installation of clip  20  onto the side rail  502  requires no modification (such as drilling) to side rail  502 . 
     FIG. 12 is a cross sectional view along the line  12 — 12  of FIG. 11, showing clip  20  grip side rail  502 . The gripping action of clip  20  keeps clip  20  from moving either up or down or longitudinally along side rail  502 . 
     FIGS. 13-15 are front elevation, side elevation, and rear elevation views respectively of a second embodiment of clip  20 . This embodiment is utilized with the slotted side rail  502  shown in FIG.  4 . Again clip  20  has a first side  22 , a second side  24 , an aperture  28  for receiving the end of roller axle  508 , and an opening  26  for receiving side rail  502 . 
     FIGS. 16 and 17 are perspective views of the second embodiment clip  20  being installed on side rail  502 . As with the embodiment shown in FIGS. 10 and 11, clip  20  is driven down in direction  30  onto side rail  502  at the location of the distorted roller aperture  504  thereby forming a new aperture  28  for receiving the end of axle  508  of roller  506 . 
     FIG. 18 is a cross sectional view along the line  18 — 18  of FIG. 17, showing clip  20  grip side rail  502 . 
     FIG. 19 is a perspective view of another embodiment of clip  20 . In this embodiment, the aperture  28  of FIGS. 7-9 is used with the clip design of FIGS. 13-15. 
     FIG. 20 is a perspective view of another embodiment of clip  20 . In this embodiment, the aperture  28  of FIGS. 13-15 is used with the clip design of FIGS. 7-9. 
     FIG. 21 is a perspective view of clip  20  being installed on another side rail  502  embodiment. In this embodiment, side rail  502  is not solid, but is rather “L” shaped (refer also to FIG.  22 ). Clip  20  is installed so that second side  24  surrounds the edge or side rail  502 . 
     FIG. 22 is a cross sectional view of clip  20  installed on the side rail  502  embodiment of FIG.  21 . Second side  24  of clip  20  is hooked so that it can surround and capture the edge of side rail  502 . 
     FIG. 23 is a perspective view of another embodiment of clip  20 . In this embodiment clip  20  includes a plurality of apertures  28  (two in the shown embodiment, however a larger number could also be used). By using a clip  20  with multiple apertures  28 , the repair of more than one distorted roller aperture  504  may be made simultaneously. 
     In terms of use, a method for repairing a side rail  502  of a conveyer  500 , includes: 
     (a) providing a conveyor  500  having: 
     a side rail  502 , the side rail  502  having a plurality of spaced roller apertures  504 , wherein at least one of the roller apertures  504  is distorted; 
     a plurality of rollers  506 , each roller  506  including an axle  508  about which a cylindrical body  510  freely rotates, wherein axle  508  of roller  506  engages roller aperture  504 ; 
     (b) providing a clip  20  for repairing the side rail  502 , clip  20  including: 
     a first side  22  connected to an opposite second side  24 ; 
     an opening  26  disposed between first  22  and second side  24 , opening  26  shaped and dimensioned for receiving side rail  502 , wherein the clip  20  may be installed onto the side rail  502  and grip the side rail  502  without requiring attachment hardware; 
     first side  22  of clip  20  having an aperture  28  having the shape of an undistorted roller aperture  504 ; 
     (c) removing roller  506  which engages the distorted roller aperture  504 ; 
     (d) installing clip  20  onto side rail  502  at the location of the distorted roller aperture  504  so that aperture  28  aligns with the distorted roller aperture  504 ; and, 
     (e) installing one of (1) the roller  506  removed in step (c), and (2) a new roller  506 , in aperture  28  of the clip  20  installed in step (d). That is, either the same roller or a new roller  506  may be used. 
     The method further including: 
     prior to step (d), providing a hammer; and, 
     in step (d), the installation of clip  20  onto side rail  502  including using the hammer to drive clip  20  onto side rail  20 . 
     The method further including: 
     steps (c), (d), and (e) being performed in less than one minute. 
     The method further including: 
     steps (c), (d), and (e) performed without having to remove any rollers  506  other than the roller  506  which engages the distorted roller aperture  506 . 
     The method further including: 
     in step (d), the installation of clip  20  onto side rail  502  requiring no modification to side rail  502 . 
     The method further including: 
     in step (a), side rail  502  having a first width W 1 ; 
     in step (b), opening  26  in clip  20  having a second width W 2  which is slightly less than first width W 1  of side rail  502 . 
     The method further including: 
     in step (b), first  22  and second  24  sides biased toward one another to effect the gripping of side rail  502 . 
     The method further including: 
     in step (b), first side  22  of clip  20  having one of (1) exactly one aperture  28 , and (2) a plurality of apertures  28 . 
     The method further including: 
     in step (a), said side rail having a plurality of said distorted roller apertures; and, 
     repeating steps (c) through (e) until said clips have been installed at all said side rail locations having a said distorted roller aperture. 
     The method further including: 
     the method implementing a temporary repair of side rail  502 , wherein at a later time the entire side rail  502  is replaced. 
     The preferred embodiments of the invention described herein are exemplary and numerous modifications, variations, and rearrangements can be readily envisioned to achieve an equivalent result, all of which are intended to be embraced within the scope of the appended claims.