Dual conveyor for autonomous guided vehicle

A conveyor assembly is provided for use with a mobile vehicle. The conveyor assembly includes a conveyor module. The conveyor module includes a first roller assembly. The first roller assembly includes a first rotatable roller body and a second rotatable roller body. The first and second roller bodies are interconnected to each other in such a manner as to share a first rotational axis yet be at least substantially rotationally independent of each other, such that each of the first and second roller bodies can rotate without causing or interfering with rotation of the other of the first and second roller bodies.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to a motor-driven conveyor assembly.

2. Discussion of the Prior Art

Conveyor assemblies with motor-driven conveyor belts are often used in the materials handling industry for transport and/or distribution of goods in a workspace such as a commercial warehouse. Some known conveyor systems include a scrolling belt supported by a pair of rollers, with one of the rollers being rotatably powered by a motor via indirect attachment thereto (e.g., via a transmission such as a pulley drive).

SUMMARY

According to one aspect of the present invention, a conveyor assembly is provided for use with a mobile vehicle. The conveyor assembly includes a conveyor module. The conveyor module includes a first roller assembly. The first roller assembly includes a first rotatable roller body and a second rotatable roller body. The first and second roller bodies are interconnected to each other in such a manner as to share a first rotational axis yet be at least substantially rotationally independent of each other, such that each of the first and second roller bodies can rotate without causing or interfering with rotation of the other of the first and second roller bodies.

The drawing figures do not limit the present invention to the specific embodiments disclosed and described herein. While the drawings do not necessarily provide exact dimensions or tolerances for the illustrated structures or components, the drawings are to scale with respect to the relationships between the components of the structures illustrated in the drawings.

DETAILED DESCRIPTION

The present invention is susceptible of embodiment in many different forms. While the drawings illustrate, and the specification describes, certain preferred embodiments of the invention, it is to be understood that such disclosure is by way of example only. There is no intent to limit the principles of the present invention to the particular disclosed embodiments.

Furthermore, unless specified or made clear, the directional references made herein with regard to the present invention and/or associated components (e.g., top, bottom, upper, lower, inner, outer, etc.) are used solely for the sake of convenience and should be understood only in relation to each other. For instance, a component might in practice be oriented such that faces referred to as “top” and “bottom” are sideways, angled, inverted, etc. relative to the chosen frame of reference.

With initial reference toFIGS.1and2, a mobile conveyor system10is provided. The mobile conveyor system10preferably comprises a conveyor assembly12and a vehicle14(shown schematically in hidden line). The conveyor assembly12is preferably mounted on and supported by the vehicle14in any manner providing suitable stability. More particularly, the conveyor assembly12preferably is fixed to a top surface14aof the vehicle14.

The vehicle14is preferably moveable to facilitate positioning/repositioning of the conveyor system10as a whole and, consequently, of the conveyor assembly12. In the illustrated embodiment, for instance, the vehicle14includes a plurality of wheels15.

Most preferably, the vehicle14is powered, such that selective movement of the vehicle14may be accomplished through use of one or more vehicle motors (not shown) or other power sources. In a preferred embodiment, for instance, each of the wheels15is a drive wheel powered by a respective motor.

Movement of the vehicle14is most preferably automated, with the vehicle14being an autonomous guided vehicle (AGV) or robot. Detailed descriptions of suitable embodiments of the vehicle14may be found in U.S. patent application Ser. No. 14/960,138, U.S. patent application Ser. No. 15/047,244, U.S. patent application Ser. No. 15,331,560, and U.S. patent application Ser. No. 15/433,923, each of which is incorporated in its entirety by reference herein.

Although a vehicle of the type described above is preferred, it is noted that movement may be controlled in any one or more of a variety of manners without departing from the scope of the present invention. For instance, vehicle movement might be controlled through an onboard user interface, be controlled remotely, or be manually controlled.

Still further, movement of the vehicle may be facilitated in a manner other than or in addition to wheeled rolling. For instance, the vehicle might additionally or alternatively be slidable, tracked, etc.

It is also permissible according to some aspects of the present invention for the conveyor assembly to be intended for stationary placement or have a limited range of motion. In such an instance, the vehicle might be omitted and replaced with a framework or other supporting structure fulfilling the particular positioning needs of the given application.

In a preferred embodiment, the conveyor assembly12broadly includes a conveyor module16, a chassis18, and a power module20. As will be discussed in greater detail below, the conveyor assembly12is configured to facilitate the advancement of one or more items (not shown) supported thereon.

Conveyor Module

The conveyor module16preferably includes a conveyor belt22, a drive or powered roller24, and a driven or following/passive roller26. The conveyor belt22preferably extends in fore and aft directions along a fore-aft or longitudinal axis of the conveyor module16. The drive roller24and the driven roller26preferably extend parallel to one another and orthogonal to the longitudinal axis, in lateral or side-to-side directions. The rollers24and26are furthermore spaced from one another in the fore and aft direction (i.e., along the longitudinal axis).

The conveyor belt22preferably extends along the longitudinal or fore-aft axis to form a single, continuous (i.e., endless) loop around the rollers24and26. More particularly, the conveyor belt22presents discrete lateral sides28and30but has no fore or aft edges. As will be discussed in greater detail below, rotation of the rollers24and26results in corresponding circulation of the conveyor belt22such that a given portion of the conveyor belt22presents an upper belt surface22athereof at one moment but later, upon sufficient rotation of the rollers24and26, presents a lower belt surface22bthe conveyor belt22. Furthermore, at any given moment, the conveyor belt22presents an upper run23aextending between and above the rollers24and26, as well as a lower run23bextending between and below the rollers24and26.

Most preferably, the conveyor belt22is entirely continuous, although it is permissible according to some aspects of the present invention for one or more discontinuities such as slots or openings to be formed therein. However, at least some degree of longitudinal continuity is most preferable to ensure efficient scrolling operability as described above.

It is also noted that it is permissible according to some aspects of the present invention for the belt itself to include a plurality of mini-belts, roller segments, or other components that collectively or collaboratively present an item-supporting surface and function in a scrolling manner as noted above. Furthermore, the conveyor assembly or conveyor module described herein might be sub-components of a larger system.

The items supported by the conveyor belt22(i.e., disposed on the upper belt surface22athereof) may be of any one or more of a variety of types. For instance, one or more of the items might be a package or container such as a box, envelope, mailer, tube, carton, bag, tub, tote, can, drum, or crate. One or more of the items might instead or additionally be an unpackaged good or a bulk material (e.g., a particulate matter, etc.)

Chassis

The chassis18preferably comprises a pair of laterally spaced apart first and second side rails32and34disposed adjacent respective ones of the sides28and30of the conveyor belt22. The first and second side rails32and34each preferably broadly extend both along and orthogonally to the longitudinal axis so as to be parallel to each other. Skewed rails or portions of the rails are permissible according to some aspects of the present invention, however.

The chassis18and, more particularly, the side rails32and34, preferably rest on the vehicle14in such a manner as to elevate the conveyor belt22relative to the vehicle14. That is, a gap36is formed between the vehicle14and the bottom surface22bor lower run23bof the conveyor belt22.

The first and second side rails32and34are structurally similar in many regards but diverge with regard to structure associated with the aforementioned power module20. For clarity, the first side rail32will therefore be referred to herein as the drive side rail32. In contrast, the second side rail34will continue to be referred to herein simply as the second side rail34. Key distinctions between the side rails32and34will be discussed in greater detail below.

With regard to common features, however, each of the side rails32and34includes a respective sidewall38or40extending upwardly and downwardly relative to the conveyor belt22such than a exposed upper portion38aor40aextends upwardly relative to the upper belt surface22aor upper run23a, and a lower portion38bor40bextends downwardly relative to the lower belt surface22bor lower run23b.

The drive side rail32further preferably includes a flange42including upper, lower, fore, and aft sections42a,42b,42c, and42d. The second side rail34similarly preferably includes a flange44including upper, lower, fore, and aft sections44a,44b,44c, and44d. The flanges24and44each extend laterally outwardly from the corresponding one of the sidewalls38and40. The lower sections42band44bof the flanges42and44, respectively, are preferably configured to directly abut (i.e., rest on) the vehicle14, although other configurations fall within the scope of the present invention.

In a broad sense, the side rails32and34provide lateral guidance to the conveyor belt22, offer structural support to the conveyor module16, protect and support various components of the conveyor assembly12, and to at least some extent protect personnel from inadvertent contact with components of the conveyor assembly12.

In addition to the side rails32and34, the chassis18further preferably includes a subframe46that extends between and interconnects the side rails32and34. Still further, the chassis18preferably includes a slider bed48(seeFIG.4) extending between the side rails32and34and below at least a portion of the upper run23aof the conveyor belt22to support the upper run23a.

The drive or powered roller24preferably includes a tubular roller body50presenting lateral ends50a,50band a pair of bearing adapters or roller inserts56and58in part received within and secured to respective ones of the ends50a,50b. As will be discussed in more details below, the roller insert56is a drive insert56and varies slightly in structure from the other insert58.

The driven or following/passive roller26is preferably similarly constructed to the drive roller24, including a tubular roller body (not shown) and a pair of bearing adapters or roller inserts60and62most preferably constructed similarly or identically to the insert58. Alternative configurations fall within the scope of the present invention, however.

The drive roller24is preferably rotatably supported on the chassis18by a pair of roller-supporting bearings64and66. Similarly, the driven roller26is preferably supported on the chassis18by a pair of roller-supporting bearings68and70. More particularly, in a preferred embodiment, each of the bearings64,66,68, and70is supported in a respective seat64a,66a,68a,70aformed by the chassis18.

The drive insert56is shown in detail inFIGS.8and9. As illustrated, the drive insert56preferably includes a circumferentially constricted inboard connector portion72, a circumferentially enlarged intermediate or crown portion74outboard of the connector portion72, and a bearing support portion76outboard of the crown portion74and circumferentially constricted relative thereto.

The connector portion72is preferably received within the corresponding end52of the roller body50such that the connector portion72and the roller body50rotate in unison.

The crown portion74preferably presents an inner shoulder74athat engages the end52of the roller body50and an outer shoulder74bthat engages the roller-supporting bearing64. The crown portion74further presents an upper face74cthat engages and guides the conveyor belt22. Tapered faces74dand74epreferably extend from each lateral edge of the upper face74c.

The roller-supporting bearing64is preferably disposed on the bearing support portion76. More particularly, the roller-supporting bearing64preferably encircles the bearing support portion76.

The drive insert56preferably further includes a pulley support portion78outboard of the bearing support portion76. A slot78aand a circumferential notch or groove78bare preferably formed in the pulley support portion78. The pulley support portion78will be discussed in greater detail below.

In a preferred embodiment, the inserts58,60, and62are identical to or very nearly identical to the drive insert56except in that they are devoid of a pulley support portion. However, it is permissible according to some aspects of the present invention for fully identical or more divergent inserts to be provided.

Power Module

The power module20preferably includes a power assembly in the form of a motor assembly80. The power module20further preferably includes a drive in the form of a pulley drive82. The pulley drive82is operable to transmit driving power from the motor assembly80to the drive insert56, rotating the drive roller24and advancing the conveyor belt22.

In a preferred embodiment, the motor assembly80includes a motor84, a housing86, and a bearing assembly88. The motor84is preferably an electric motor, although other motor types fall within the scope of the present invention. Non-motor power sources (for instance, batteries) might additionally or alternatively be provided without departing from the scope of some aspects of the present invention.

Most preferably, the motor84includes a stator90and a rotor92. The rotor92is rotatable about a motor axis. The motor axis preferably extends laterally (i.e. perpendicularly to the longitudinal axis), although other axis orientations fall within the scope of certain aspects of the present invention.

The stator90preferably at least substantially circumscribes the rotor92, such that the motor84is an inner rotor motor. Outer rotor motors or dual rotor motors fall within the scope of some aspects of the present invention, however.

The stator90preferably includes a stator core94and a plurality of electrically conductive coils96wound about the stator core94.

Preferably, the rotor92includes a rotor core98, a plurality of magnets100, and a rotatable output shaft102(which may also be referred to as a motor or rotor shaft102). The output shaft102preferably extends laterally outwardly beyond the rotor core98and the stator90for purposes to be discussed in greater detail below. It is noted that a variety of additional rotor configurations, including but not limited to spoked rotor configurations, fall within the scope of the present invention.

The motor housing86preferably in part defines a motor chamber104in which the motor84is at least substantially disposed. That is, in a preferred embodiment, the housing86at least substantially encloses the motor84. In the illustrated embodiment, for instance, the housing86includes a cylindrical shell106and an inner end wall108. The shell106preferably circumscribes the stator90, the rotor core98, the magnets100, and a portion of the output shaft102. The inner end wall108is preferably secured by any means known in the art (e.g., welding, adhesives, latches, threaded fasteners, bolts, and/or integral formation) to an inner end of the shell106, such that the housing86is closed at an inboard end thereof.

Mounting and Support of Motor

The motor84is preferably integrally mounted to the chassis18, with the drive side rail32of the chassis18forming part of the housing86. More particularly, the drive side rail32defines an outer endshield110that is preferably integrally formed by the sidewall38. The outer endshield110preferably includes a disc-shaped, vertically oriented end wall112, a circumferentially extending outer mounting lip114, and a bearing support structure116. The shell106of the housing86preferably circumscribes and abuts the mounting lip114.

Preferably, the shell106and, more broadly, the motor assembly80is removably mountable to the drive side rail32. More particularly, the motor assembly80is preferably removably mounted to the outer endshield110formed by the drive side rail32. For instance, the mounting lip114preferably fits securely (e.g., via a friction fit or close slip fit) into the shell106such that the shell106and, in turn, the inner end wall108, are supported thereon. Furthermore, it is permissible for the shell to be secured to the lip and/or the end wall via removable fasteners (such as screws or bolts), latches, or other shiftable or reconfigurable means.

However, permanent or semi-permanent connection means, including but not limited to welding, adhesives, extremely tight fits (such as friction fits or thermal fits), and integral formation fall within the scope of some aspects of the present invention. It is also permissible according to some aspects of the present invention for the shell to instead be integrally formed with the chassis or, more particularly, the sidewall of the drive side rail.

Provision of an integrated outer endshield110formed by the chassis18as described above eliminates the need for a separate endshield component, resulting in advantageous reductions in cost, complexity, and weight. Various of the features described above, including but not limited to the mounting lip114, also facilitate reduced usage of fasteners, resulting in advantageous reductions in cost, complexity, and weight. It is noted that, although weight reduction is often deemed advantageous in motor system design, reduced weight is particularly desirable in the present invention due to mounting of the conveyor assembly12on the vehicle14. That is, reducing the load that must be supported by the vehicle14is highly preferred.

It is also permissible according to some aspects of the present invention for the motor assembly to be devoid of the shell and/or the inner endshield. In such an embodiment, the stator might be secured directly to the chassis via threaded fasteners extending axially through the stator core and into engagement with corresponding threaded openings in the chassis. Such openings might be formed in an integral receiving pad or other suitable region of the chassis, or instead in a discrete component mounted to the chassis.

In a preferred embodiment, the bearing support structure116comprises a cylindrical or tube-like main body118and a disc-like end120defining a shaft aperture122. The main body118, the aperture122, and the motor shaft102are preferably coaxial, such that the motor shaft102extends centrally through the aperture122and into a bearing pocket124defined internally by the main body118and the end120.

The aforementioned motor bearing assembly88preferably includes inner and outer motor bearings126and128disposed in the bearing pocket124and supported by the main body118of the bearing support structure116. The motor bearings126and128in turn preferably rotatably support the rotor shaft102and, more broadly, the motor84relative to the outer endshield110and drive side rail32. Thus, in a preferred embodiment, the motor84is supported directly on the chassis18in a simple, efficient, removable, and lightweight manner.

It is noted that the bearing126and128preferably support the shaft102and, in turn, the motor84in a cantilevered manner. However, it is permissible according to some aspects of the present invention for the bearings to be alternatively positioned (e.g., on opposite axial ends of the rotor or shaft).

In a preferred embodiment, appropriate lateral positioning of the motor bearings126and128is effected by a spacer sleeve130disposed between the motor bearings126and128, a retaining ring132secured in a groove134in the main body118adjacent the outer bearing128, and a wavy washer136disposed between the inner bearing126and the end120. An additional spacer sleeve138is disposed outboard of the outer bearing128to facilitate positioning of the outer bearing128relative to the pulley drive82.

The motor bearings126and128are each preferably unit bearings. That is, the components of the motor bearings126and128are preferably pre-packed and fully enclosed. Such a configuration is advantageous in, among other things, preventing contaminant ingress. Other types of bearings are permissible according to some aspects of the present invention, however.

Pulley Configuration and Positioning

As noted previously, the pulley drive82is preferably operable to transmit rotational power from the rotor92to the drive insert56and drive or powered roller24, resulting in fore or aft travel of the conveyor belt22. As will be discussed in greater detail below, the pulley drive82preferably broadly includes a drive or powered pulley140, a driven or passive/following pulley142, and an endless or continuously extending drive belt144.

More particularly, the drive or powered pulley140is preferably mounted to an outermost end102aof the motor shaft102and spaced outwardly from the outer bearing128by means of the spacer sleeve138.

Preferably, the drive pulley140is secured to rotate with the motor shaft102by means of a key146received in corresponding shaft and pulley slots148and150, respectively. That is, the key146preferably ensures that rotation of the output shaft102corresponds directly to rotation of the drive pulley140. However, other interconnection means facilitating cooperative rotation of the motor shaft and the drive pulley may additionally or alternatively be used.

The driven or passive/following pulley142is preferably disposed above and at least in part in lateral alignment with the drive or powered pulley140. That is, the drive pulley140and the driven pulley142are at least in part coplanar in a vertical and fore-aft plane. Most preferably, such plane extends parallel to the longitudinal axis.

The driven pulley142is preferably mounted to the pulley support portion78of the drive insert56. Most preferably, the driven pulley142is secured to rotate with the drive insert56.

The drive belt144preferably extends in a loop about both of the pulleys140and142and is also at least in part co-planar therewith.

It is noted that correct positioning of the drive belt and pulleys140and142via co-planarity, appropriate pulley spacing, etc. is essential to efficient operation of the pulley drive82. As will be discussed in greater detail below, the present invention advantageously facilitates correct positioning of these components.

For instance, outward lateral shifting of the drive or powered pulley140(along with attached structures including the motor84) is restricted primarily via engagement of the outer motor bearing128against the retaining ring132and engagement of the drive pulley140against a retaining ring152disposed about the motor shaft102. Laterally inward shifting of the drive pulley140is restricted primarily via engagement of the of the inner motor bearing126relative to the end120of the bearing support structure116, as modulated by the wavy washer136. The spacer sleeves130and138also play a role in positioning of the drive pulley140.

Outward lateral shifting of the driven or passive/following pulley142is restricted primarily via engagement of the driven pulley142against a retaining ring154disposed about the insert56so as to received in the notch or groove78b, and engagement of the bearing64against an inner side of a shoulder156of the sidewall40of the chassis side rail32(seeFIG.5). Laterally inward shifting of the driven pulley142is restricted primarily by engagement of the driven pulley142with an outer side of the shoulder156of the sidewall40. Additional spacing control is preferably provided by a spacer158disposed between the driven pulley142and the bearing64.

Appropriate vertical and fore-aft positioning of the drive pulley140is facilitated primarily by secure fitment of the motor bearings126and128within the main body118of the bearing support structure116.

Appropriate vertical and fore-aft positioning of the driven pulley142is facilitated primarily by the positioning of the roller bearing64in the bearing seat64a.

Thus, the chassis18, the motor bearings126and128, the roller bearing64, and other components cooperate to precisely locate the drive pulley140and the driven pulley142relative to one another. Such carefully controlled positioning enables the conveyor assembly12and, more specifically, the pulley drive82thereof, to be efficiently operable without the use of a tensioning device such as an idler pulley.

Although the illustrated pulley drive configuration is preferred, it is noted that is it permissible according to some aspects of the present invention for a tensioning device (including but not limited to an idler pulley) to be provided. Furthermore, an alternative or additional device or mechanism might be provided (i.e., in lieu of or in addition to the previously described pulley drive) to transmit power from the electric motor to the drive roller. For instance, a chain and sprocket drive might be utilized

Further still, although it is preferred that the motor shaft102directly drive the drive pulley140, as illustrated, it is permissible according to some aspects of the present invention for the motor to be configured or mounted in such a manner as to require an intermediate transmission to transfer power from the output shaft to the drive pulley.

A second preferred conveyor system is illustrated inFIG.10. It is initially noted that, with certain exceptions to be discussed in detail below, many of the elements of the conveyor system210of the second embodiment are the same as or very similar to those described in detail above in relation to the conveyor system10of the first embodiment. Therefore, for the sake of brevity and clarity, redundant descriptions and numbering will be generally avoided here. Unless otherwise specified, the detailed descriptions of the elements presented above with respect to the first embodiment should therefore be understood to apply at least generally to the second embodiment, as well.

Similarly to the conveyor system10, the conveyor system210of the second preferred embodiment preferably comprises a conveyor assembly212and a vehicle214(shown schematically in hidden line).

The vehicle214is preferably moveable to facilitate positioning/repositioning of the conveyor system210as a whole and, consequently, of the conveyor assembly212. In the illustrated embodiment, for instance, the vehicle214has positioned the conveyor assembly212adjacent a chute216in a package distribution center218to enable transfer of a package220from the conveyor assembly212to the chute216.

As discussed above with regard to the first preferred embodiment, movement of the vehicle214is most preferably automated, with the vehicle214being an autonomous guided vehicle (AGV) or robot. However, as also discussed above, the vehicle might in alternate embodiments be differently configured or omitted entirely.

In a preferred embodiment, the conveyor assembly212broadly includes a conveyor module222, a chassis224, a power module226, a stiffening assembly228, and a tensioning system230.

Conveyor Module

The conveyor module222preferably includes a conveyor belt232, a drive or powered roller assembly234, and a driven or following/passive roller assembly236. The roller assemblies234and236are preferably spaced from one another in a fore-aft direction or, alternatively stated, along a longitudinal/fore-aft axis of the conveyor module222. The conveyor belt232preferably extends along the longitudinal or fore-aft axis to form a single, continuous (i.e., endless) loop around the roller assemblies234and236.

The drive or powered roller assembly234includes a drive or powered roller body238rotatable about a first or drive roller axis. The driven or following/passive roller assembly236includes a driven or following/passive roller body240rotatable about a second or passive roller axis. Rotation of the roller bodies238and240results in corresponding shifting and circulation of the conveyor belt232such that a given portion of the conveyor belt232presents an upper belt surface232athereof at one moment but later, upon sufficient rotation of the roller bodies238and240, presents a lower belt surface232bof the conveyor belt232. Furthermore, at any given moment, the conveyor belt232presents an upper run233aextending between and above the roller assemblies234and236, as well as a lower run233bextending between and below the roller assemblies234and236.

The tensioning system230, in cooperation with the chassis224, facilitates the application, adjustment, setting, and maintenance of appropriate tension of the conveyor belt232via the setting and maintenance of appropriate longitudinal spacing between the drive and passive roller assemblies234and236, respectively. The tensioning system230and the chassis224will each be discussed in greater detail below.

The drive roller body238is preferably tubular or cylindrical in form and presents lateral ends238aand238b. The drive roller assembly234further preferably includes a pair of bearing adapters or roller inserts242and244in part received within and secured to respective ones of the ends238aand238b. A intermediate insert246is also provided in an intermediate position between the ends238aand238b.

The passive roller body240is also preferably tubular or cylindrical in form and presents lateral ends240aand240b. The passive roller assembly236further preferably includes a pair of bearing adapters or roller inserts248and250in part received within and secured to respective ones of the ends240aand240b.

Chassis

The chassis224preferably comprises a pair of laterally spaced apart drive and second side rails252and254. The side rails252and254each preferably extend in the fore-aft direction and parallel to each other to present respective fore and aft ends252a,band254a,b.

In contrast to those of the first preferred embodiment, the side rails252and254of the conveyor module222each preferably include a respective sidewall256or258disposed at least substantially laterally outward of the conveyor belt232and vertically between the upper and lower runs233aand233b, respectively, thereof. Extension of either or both of the sidewalls upward of the upper run and downward of the lower run is permissible without departing from the scope of some aspects of the present invention, however.

In addition to the side rails252and254, the chassis224further preferably includes a slider bed260extending between and interconnecting the side rails252and254. The slider bed260is preferably disposed below at least a portion of the upper run233aof the conveyor belt232to underlie and support the upper run233a.

The chassis224is preferably unitarily and integrally formed. More particularly, the slider bed260and the side rails252and254are preferably formed unitarily and integrally with each other by means of a stamping process. That is, the slider bed260and the side rails252and254are preferably formed by a single piece of material, most preferably via a stamping process. It is permissible according to some aspects of the present invention, however, for the chassis to be formed by an alternative process or processes and/or to be non-integrally or non-unitarily constructed.

Most preferably, the chassis224comprises steel. Even more preferably, the chassis224comprises thin gauge steel. For instance, in a preferred embodiment of the present invention, steel having a gauge between ten (10) gauge and twenty (20) gauge is used. More preferably, steel having a gauge between twelve (12) gauge and sixteen (16) gauge is used. Most preferably, fourteen (14) gauge steel is used. However, alternative materials (including but not limited to metals such as aluminum) and/or thinner or thicker gauges fall within the scope of some aspects of the present invention.

Power Module

The power module226preferably provides power to the drive roller assembly234and more particularly, the drive roller body238.

The power module226most preferably includes a power assembly in the form of a motor assembly262. The power module226further preferably includes a bearing assembly264and one or more sensors266.

In a preferred embodiment, the motor assembly262includes a motor268and a motor housing270. The motor268is preferably an electric motor, although other motor types fall within the scope of some aspects of the present invention.

Most preferably, the motor268includes a stator272and a rotor274. The rotor274is rotatable about a motor (or rotor) axis. The motor axis preferably extends laterally (i.e. perpendicularly to the longitudinal axis of the conveyor assembly212in a broad sense), although other axis orientations fall within the scope of certain aspects of the present invention. In the illustrated embodiment, the motor axis is coincident with the drive roller axis. That is, in a preferred embodiment, the rotor274and drive roller body238share a rotational axis.

The stator272preferably at least substantially circumscribes the rotor274, such that the motor268is an inner rotor motor. Outer rotor motors or dual rotor motors fall within the scope of some aspects of the present invention, however.

The stator272preferably includes a stator core276and a plurality of electrically conductive coils278wound about the stator core276.

Preferably, the rotor274includes a rotor body280and a rotatable output shaft282(which may also be referred to as a motor or rotor shaft282). The rotor body280preferably comprises a rotor core284and a plurality of rotor magnets286arranged arcuately about the rotor core284. The rotor magnets286preferably cooperate with the stator272(more specifically, the coils278thereof) to impart rotation to the rotor274.

The rotor body280preferably defines axially spaced apart inner and outer rotor body margins280aand280b, respectively. As will be discussed in greater detail below, the output shaft282preferably projects axially from the rotor body280beyond the inner rotor body margin280abut does not extend beyond the outer rotor body margin280b. Rather, a controller288(e.g., a printed circuit board, as illustrated) is preferably mounted laterally outward of and immediately adjacent the outer rotor body margin280b.

The bearing assembly264preferably includes a first bearing290, a second bearing294, and a bearing housing294in which the bearings290and292are seated. The bearings290and292are most preferably components of a unit bearing, as illustrated. However, a variety of bearing configurations fall within the scope of some aspects of the present invention.

Preferably the bearings290and292and, even more preferably, the entire bearing assembly264, is disposed laterally inward of the inner rotor body margin280a. More particularly, the rotor shaft282includes a bearing portion296. The bearings290and292engage the bearing portion296and rotatably support the rotor274. The motor268can thus be described as cantilevered (with the rotor core284and magnets286being located on a cantilevered portion of the shaft282—i.e., these rotor components are not located between a pair of bearings).

The motor housing270preferably in part defines a motor chamber298in which the motor268is at least substantially disposed. In the illustrated embodiment, for instance, the housing270includes a cylindrical shell300that circumscribes the stator272, the rotor core284, the magnets286, and a portion of the output shaft282. The insert244preferably defines a laterally outer end of the motor chamber298, while the intermediate insert246preferably defines an inner end of the motor chamber. The bearing housing294also preferably in part constitutes the motor housing270via a flange302disposed between the shell and the intermediate insert246.

The output shaft282preferably includes a keyed end304disposed at least in part laterally inward of the bearing assembly264. That is, the keyed end304is laterally inward of the bearing portion296. The keyed end304is preferably received within the intermediate insert246so as to rotatably drive the intermediate insert246. The intermediate insert246in turn drives rotation of the drive roller body238in a broad sense.

In a preferred embodiment, the controller288includes the aforementioned sensors266. The sensors266are preferably operably connected to the controller288and each positioned near and slightly radially outward of the rotor magnets286. The sensors266are preferably configured to detect a magnetic field and, more particularly, to detect the rotor magnets286. Most preferably, the sensors266are Hall effect sensors.

It is particularly noted that provision of a unit bearing assembly264disposed on a single axial side of the stator272and the rotor body280, in contrast to one or more bearings being disposed on each side of the stator and the rotor body, facilitates convenient positioning of the controller288and the sensors266thereof in near proximity to the rotor body280. This positioning in turn enables the use of the rotor magnets286as the sensed elements for the sensors266. Provision of a separate magnetic ring or other sensed element(s) is unnecessary. Alternatively stated, the same rotor magnets286are used both as sensor pickups or sensed elements and to power the motor268.

Stiffening Assembly

As noted previously, the chassis224preferably includes a stiffening assembly228. The stiffening assembly228comprises a bracket308and an insert310. The insert310is preferably discrete from the bracket308but, as will be discussed in detail below, disposed thereon. The bracket308extends between and interconnects the side rails252and254and is most preferably disposed at least substantially equidistantly between the fore and aft ends252aand252bof the side rail252and the fore and aft ends254aand254bof the side rail254. The bracket308also preferably extends perpendicularly to each of the side rails252and254. However, offset positioning and/or non-perpendicular extension falls within the scope of some aspects of the present invention.

Most preferably, each side rail252and254defines a respective laterally inwardly extending lip312or314. The lips312and314cooperatively support the bracket308. More particularly, in the illustrated embodiment, the bracket308is bolted to the underside of the lips312and314. Other mounting methods fall within the scope of some aspects of the present invention, however. For instance, screws, latches, adhesives, welds and/or other means of securement might be additionally or alternatively used.

The bracket308preferably includes a base316and a pair of sidewalls318and320. The base316is spaced vertically below and extends planarly parallel to the to the slider bed260such that a vertical gap322is formed between the slider bed260and the bracket308. The bracket308also preferably includes a pair of sidewalls318and320extending upwardly from the base316toward (but not in contact with) the slider bed260. The sidewalls318and320might be alternatively configured or omitted in some embodiments of the present invention, however.

The bracket308preferably comprises aluminum, although one or more other materials might alternatively or additionally be used. Ideally, any material used for the bracket should be substantially strong and rigid while also being substantially light weight.

A plurality of perforations or openings324are preferably formed in the base316, although the base might alternatively be devoid of openings therethrough. Such perforations324aid in weight reduction without substantial losses in strength or rigidity.

The insert310is disposed on the bracket308and extends upward across at least a portion of the gap322. Most preferably, the insert310fills the entirety or almost the entirety of the vertical dimension of the gap322so as to contact or nearly contact the slider bed260when no vertically downward load is applied to the slider bed260(e.g., when no package220or similar is supported thereon). For instance, the insert310preferably fills at least seventy-five percent (75%) of the vertical dimension of the gap322, more preferably at least ninety percent (90%) of the vertical dimension of the gap322, and most preferably at least ninety-five percent (95%) of the vertical dimension of the gap322when the conveyor module222is not loaded.

The insert310preferably includes lateral sides310aand310band fore and aft sides310cand310d, respectively. In a preferred embodiment, the bracket308defines a pair of laterally spaced apart lips326and328disposed adjacent respective ones of the lateral sides310aand310b. Most preferably, the lips326and328abut the lateral sides310aand310band aid in securement of the insert310relative to the bracket308. In contrast, the fore and aft sides310cand310dare preferably spaced from the sidewalls318and320, although contact is permissible according to some aspects of the present invention. Additional securement of the insert310to the bracket308is most preferably not necessary, although other means, including but not limited to adhesives, latches, fasteners, etc. might additionally or alternatively be used without departing from the scope of some aspects of the present invention.

Preferably, the insert310comprises foam. The foam is most preferably a closed cell foam. Most preferably, the foam is a high density closed cell foam such as six (6) lb/ft3polyethylene foam. Certain variations in density, type of closed cell foam (e.g., an elastomeric foam rather than a polyethylene foam), or type of foam in a broad sense (e.g., open cell foam rather than closed cell foam) fall within the scope of some aspects of the present invention. Most preferably, however, a selected foam will provide sufficient cushioning and support; have a relatively low weight; resist dirt and moisture accumulation and absorption; be substantially tough, resilient, and puncture resistant; have an advantageous thermal insulating capacity and maintain or at least substantially maintain such capacity when subject to expected compressive forces; and be sufficiently low cost.

The bracket308and the insert310cooperatively stiffen the chassis224and, most preferably, resist undesirable bending, flexing, and/or other forms of deflection of the slider bed260as a result of vertically downward loading thereof (e.g., due to large packages220being disposed on the conveyor belt232). This stiffening effect is achieved without excessive increases to the overall weight of the conveyor module222and in such as manner as to reduce or at least not increase operational noise. In summary, it is preferred in a broad sense that the conveyor module222be lightweight yet sufficiently rigid to support substantial packages220without excessive distortion, be economical to produce (e.g., terms of material costs, labor, etc.), and operate quietly. The present conveyor module222achieves these objectives through an economical and lightweight thin gauge chassis in combination with a lightweight, easy to produce, and easy to assemble stiffening assembly. A thickened chassis, one or more supplemental roller assemblies, and other conventional modifications are avoided.

Tensioning System

As noted previously, the conveyor system210preferably includes a tensioning system230. More particularly, the tensioning system230includes a pair of tensioning devices330and332each coupled to the passive roller assembly236and selectively shiftably mounted to the chassis224such that shifting of the tensioning system230(and, more particularly, each of the tensioning devices330and332) in the fore-aft direction along the chassis224results in corresponding fore-aft shifting of the passive roller body240relative to the drive roller body238. The tensioning system230thus facilitates adjustment of the tension in the conveyor belt232.

As will be discussed in greater detail below, each tensioning device330and332preferably includes a respective sliding bracket334or336shiftably mounted to the chassis224. More particularly, each sliding bracket334or336is preferably mounted to a respective one of the side rails252and254.

Each bracket334and336preferably includes a plate-like body338or340, respectively, although other forms fall within the scope of some aspects of the present invention. The body338preferably defines threaded fore and aft fastener-receiving openings338aand338b, respectively, as well as a roller shaft opening (not shown). Similarly, the body340preferably defines threaded fore and aft fastener-receiving openings340aand340b, respectively, as well as a roller shaft opening340c.

Each side rail252and254and, more particularly, each respective sidewall256or258thereof, preferably defines a respective positioning slot256aor258aextending in the fore-aft direction. The sidewall256defines a fore-aft extending roller shaft slot256b. Likewise, the sidewall258defines a roller shaft slot258b, also extending in the fore-aft direction.

Each tensioning device330and332further preferably includes a respective positioning fastener assembly342or344, each including a pair of positioning fasteners346.

As best shown inFIG.16, each positioning fastener346is most preferably in the form of a threaded bolt, including a positioning head346aand a threaded positioning shaft346b. The positioning heads346aare preferably at least in part cross-sectionally larger than the corresponding positioning shafts346b, for reasons that will be discussed in greater detail below. Most preferably, the shafts346bare generally cylindrical to present a shaft diameter. The heads346aare preferably frustoconical to present a maximum head diameter adjacent the corresponding shafts346b.

The positioning slots256aand258apreferably have heights corresponding to the diameters of the positioning shafts346bsuch that vertical shifting of the positioning shafts346bwithin the positioning slots256aand258ais at least substantially prohibited.

Each positioning head346apreferably presents a tool-receiving recess350configured to receive a hex key (as illustrated), screw driver, or other tool used to rotate the positioning fastener346.

The positioning shafts346bof each pair of positioning fasteners346are configured to extend through the positioning slot256aand258ain the corresponding side rail252or254and threadably into respective ones of the fastener-receiving openings338a,338b,340a, and340bof the bracket bodies338and340. As is conventional for such threaded engagement, rotation of the positioning shafts346bresults in lateral shifting thereof through the corresponding fastener-receiving openings338a,338b,340a, and340bsuch that each heads346amoves laterally nearer to or farther from the corresponding sliding bracket334or336.

More particularly, each head346apresents a mating surface352extending perpendicularly relative to the corresponding side rail252or254. Each sidewall256and258presents an inner face256cor258c, respectively, and an outer face256dor258d, respectively. Each sliding bracket334or336presents an inner face334aor336a, respectively, and an outer face334bor336b, respectively. Rotation of the positioning fasteners346of a given pair in a “tightening direction” (conventionally but not necessarily clockwise) when the threads of the positioning shafts346bare engaged with those of the corresponding fastener-receiving openings338a,338b,340a, and340bresults in lateral shifting of the mating surfaces352toward the corresponding outer faces334band336bof the sliding brackets334and336until (1) the mating surfaces352of the heads346aengage the outer faces256dand258dof the corresponding sidewalls256and258, respectively, of the side rails252and254and (2) the outer faces334band336bof the sliding brackets334and336, respectively, engage the corresponding inner faces256cand258cof the sidewalls256and258, respectively, of the side rails252and254. That is, the side rail252is squeezed between the corresponding heads346aand the sliding bracket334. The side rail254is squeezed between the corresponding head346aand the sliding bracket336. In this secured or fixed state of the tensioning system230, fore-aft shifting of the positioning fasteners346in the corresponding positioning slots256aand258aand, in turn, fore-aft shifting of the sliding brackets334and336relative to the corresponding side rails252and254, is restricted or at least substantially prohibited.

In contrast, rotation of the positioning fasteners346of a given pair in a “loosening direction” (conventionally but not necessarily counterclockwise) when the threads of the positioning shafts346bare engaged with those of the corresponding fastener-receiving openings338a,338b,340a, and340bresults in lateral shifting of the mating surfaces352away from the corresponding outer faces334band336bof the sliding brackets334and336to disengage and/or further shift the mating surfaces352of the heads346aaway from the outer faces256dand258dof the corresponding side rails252and254, respectively. Any compression of the side rails252and254between the heads346aand the sliding brackets334and336, respectively, is thus decreased or eliminated. Sufficient decrease or elimination of compressive forces, such that the tensioning system230is in a shiftable state, facilities at least substantially unrestricted fore-aft shifting of the positioning fasteners346in the corresponding positioning slots256aand258aand, in turn, at least substantially unrestricted fore-aft shifting of the sliding brackets334and336relative to the corresponding side rails252and254.

Alternatively stated, shifting of each sliding bracket334or336relative to the corresponding side rail252or254adjusts the position of the fastener-receiving openings338a,338band340a,340brelative to the corresponding positioning slot256aor258b.

Stated yet another way, the positioning fastener assemblies342and344are operable to selectively secure the respective brackets334and336to the respective side rails252and254.

In a preferred embodiment, each of the positioning fasteners346is coated with an anti-loosening material such as a nylon thread locker patch. This coating restricts inadvertent loosening of the positioning fasteners346due to, for instance, vibration. It is noted that, at least in part due to such coating, provision of nuts, lock washers, or other auxiliary pieces to secure the positioning fasteners is unnecessary, further contributing to the advantageous simplicity of the present invention.

As noted previously, each sliding bracket334or336includes a respective one of the roller shaft openings (e.g., the roller shaft opening340cof the bracket336, with the corresponding roller shaft opening of the bracket334not being illustrated herein). Each sidewall256and258includes a respective one of the roller shaft slots256band258b. The passive roller assembly236preferably includes roller shafts354and356extending laterally outwardly from corresponding ones of the inserts248and250. Each roller shaft354and356extends through a corresponding one of the roller shaft openings (such as the opening340c) to restrict fore-aft shifting of the passive roller assembly236relative to the sliding brackets334and336. Furthermore, as will be discussed in greater detail below, the roller shafts354and356extend through corresponding ones of the roller shaft slots256band258bso as to be selectively shiftable therein in the fore-aft direction.

More particularly, in a preferred embodiment and as illustrated, the roller shafts354and356are hexagonal in cross-section. The roller shaft openings (such as the roller shaft opening340cof the bracket336) are likewise hexagonal and sized and shaped to facilitate a close or tight fit about the roller shafts354and356. Most preferably, reliefs358are provided at the corners of the openings (such as opening340c) to facilitate proper fit. The roller shaft slots256band258bpreferably have heights corresponding to those of the corresponding roller shafts354and356such that vertical shifting of the roller shafts354and356within the roller shaft slots256band258bis at least substantially prohibited.

As will be discussed in greater detail below, each roller shaft354and356includes an adjustment end354aor356a, respectively, projecting laterally outward beyond the corresponding side rail252or254.

In view of the above, it will be apparent to those of ordinary skill in the art that the present invention facilitates efficient and secure adjustment of the tension of the conveyor belt232. In a preferred method, for instance, the positioning fasteners346are initially loosened to enable sliding of the sliding brackets334and336relative to the side rails252and254. An operator then grips at least one of the adjustment ends354aor356a(e.g., using a wrench) and shifts the passive roller assembly236in a fore or aft direction relative to the drive roller assembly234to, in turn, increase or decrease the tension of the conveyor belt232until the desired tension is achieved. (As discussed above, fore-aft shifting of the passive roller assembly236is accompanied by fore-aft shifting of the sliding brackets334and336, which slide relative to the corresponding ones of the side rails252and254.) The positioning fasteners346are then tightened such that the side rails252and254are secured between the corresponding mating surfaces352and sliding brackets334and336. Fore-aft slipping of the passive roller assembly236is thereby restricted and conveyor belt tension is maintained, except as resulting from stretching of the conveyor belt232itself, if applicable. In some methods, for instance, it may be desirable to set the conveyor belt232to an over-high tension initially so as to achieve an acceptable tension after relaxation of the belt232has occurred.

It is particularly noted that the conveyor belt tension firmly holds the roller shafts354and356against the corresponding brackets334and336, eliminating the need for any external clamps to hold the brackets334and336.

Although the above described configuration of the tensioning system230is preferred, it is noted that a variety of modifications may be made without departing from the scope of some aspects of the present invention. For instance, either or both of the fastener-receiving slot and shaft slot might instead be defined by the sliding bracket. Similarly, either or both of the fastener-receiving openings and the shaft-receiving opening might be formed instead in the corresponding side rails. Alternative shapes of the roller shaft are permissible according to some aspects of the present invention, as are modified forms of the adjustment end thereof. The heads of the positioning fasteners might also be alternatively shaped.

Conveyor System—Third Embodiment—Dual Conveyor with Dually Powered and Dually Passive Roller Assemblies

A third preferred conveyor system is illustrated inFIGS.22-28. It is initially noted that, with certain exceptions to be discussed in detail below, many of the elements of the conveyor system410of the third embodiment are the same as or very similar to those described in detail above in relation to the conveyor system10of the first embodiment and the conveyor system210of the second embodiment. Therefore, for the sake of brevity and clarity, redundant descriptions and numbering will be generally avoided here. Unless otherwise specified, the detailed descriptions of the elements presented above with respect to the first and second embodiments should therefore be understood to apply at least generally to the third embodiment, as well.

Similarly to the conveyor system10and the conveyor system210, the conveyor system410of the third preferred embodiment preferably comprises a conveyor assembly412and a vehicle414(shown schematically in hidden line).

The vehicle414is preferably moveable to facilitate positioning/repositioning of the conveyor system410as a whole and, consequently, of the conveyor assembly412. In the illustrated embodiment, for instance, the vehicle414has positioned the conveyor assembly412adjacent a first chute416in a package distribution center418to enable transfer of a first package420from the conveyor assembly412to the first chute416. A second package422, also supported on the conveyor assembly412, is not transferred to the first chute416and might instead be subsequently offloaded into a second, separate chute424.

As discussed above with regard to the first and second preferred embodiments, movement of the vehicle414is most preferably automated, with the vehicle414being an autonomous guided vehicle (AGV) or robot. However, as also discussed above, the vehicle might in alternate embodiments be differently configured or omitted entirely. For instance, the conveyor system might alternatively be mounted to a manually rollable cart, used in a fixed position, etc.

In a preferred embodiment, the conveyor assembly412broadly includes a conveyor module426, a chassis428, and a power module430.

The conveyor module426preferably includes a pair of independent conveyor belts432and434, a dually powered roller assembly436, and a passive roller assembly438. The roller assemblies436and438are preferably spaced from one another in a fore-aft direction or, alternatively stated, along a longitudinal/fore-aft axis of the conveyor module426.

As will be discussed in greater detail below, the dually powered roller assembly436preferably includes first and second axial sections440aand440b. Similarly, the passive roller assembly438preferably includes first and second axial sections442aand442b.

The conveyor belt432preferably extends along the longitudinal or fore-aft axis to form a single, continuous (i.e., endless) loop around the first axial sections440aand442aof the roller assemblies436and438, respectively. Similarly, the conveyor belt434preferably extends along the longitudinal or fore-aft axis to form a single, continuous (i.e., endless) loop around the second axial sections440band442bof the roller assemblies436and438, respectively.

Although continuously extending, unitarily belts432and434are illustrated, it is noted that it is permissible according to some aspects of the present invention for each belt to itself include a plurality of mini-belts, roller segments, ball bearings, plates, slats, chains, lines, or other components that collectively or collaboratively present an item-supporting surface and function in a scrolling manner as noted above. It is also noted that it is permissible according to some aspects of the present invention for scrolling belts to be omitted in a conventional sense, with transport of goods being achieved in part through use of components positioned between the fore and aft roller assemblies (and not looping thereabout). Although the above examples are not exhaustive, the wide variety of applicable material handling/transport technologies to which the present invention may be applied will be readily apparent to those of ordinary skill in the art.

The dually powered roller assembly436includes a pair of drive or powered roller bodies444aand444brotatable about a first or drive roller axis. The passive roller assembly438includes a pair of passive roller bodies446aand446brotatable about a second or passive roller axis.

Each of the drive roller bodies444aand444bis preferably tubular or cylindrical in form. The drive roller bodies444aand444bpresent respective laterally outer ends448aand448b, The drive roller bodies444aand444bfurther present respective laterally inner ends450aand450b.

Respective pairs of bearing adapters or roller inserts452aand452bare preferably in part received within and secured relative to respective ones of the laterally outer ends448aand448b.

Respective couplers454aand454bof a dually powered roller coupling assembly456, which will be described in greater detail below, are cooperatively received at least in part within and secured relative to each of the laterally inner ends450aand450bso as to extend axially from the respective roller bodies444aand444b.

The power module430preferably includes a pair of motor assemblies458aand458b, each of which is at least substantially disposed within a respective one of the drive roller bodies444aand444b, between the lateral ends448aand450aor448band450b, respectively. The motor assembly458apreferably provides power to the drive roller body444a. The motor assembly458bpreferably provides power to the drive roller body444b.

The motor assembly458apreferably broadly includes a motor459a, a bearing assembly460a, a gear assembly461a, and a motor output shaft462a. The motor assembly458bpreferably broadly includes a motor459b, a bearing assembly460b, a gear assembly461b, and a motor output shaft462b.

As noted previously, the passive roller assembly438preferably includes the pair of passive roller bodies446aand446brotatable about the second or passive roller axis. Each of the passive roller bodies446aand446bis preferably tubular or cylindrical in form. The passive roller bodies446aand446bpresent respective laterally outer ends463aand463b. The passive roller bodies446aand446bfurther present respective laterally inner ends464aand464b.

Respective pairs of bearing adapters or roller inserts465aand465bare preferably in part received within and secured relative to respective ones of the laterally outer ends463aand463b.

Respective couplers466aand466bof a passive roller coupling assembly468, which will be described in greater detail below, are cooperatively received at least in part within and secured relative to each of the laterally inner ends464aand464b.

In contrast to the dually powered roller assembly436, no motor assembly or assemblies are provided within or directly associated with the passive roller bodies446aand446b. That is, the power module430is associated only with the dually powered roller assembly436.

The chassis428preferably includes only a single, unitary slider bed and only a single pair of laterally spaced apart sidewalls extending upward from the slider bed. That is, a first sidewall is disposed laterally outward of the conveyor belt432, and a second sidewall is disposed laterally outward of the conveyor belt434. No sidewall or sidewalls are formed by the chassis428between the belts432and434. (Alternatively stated, the first and second sidewalls are disposed laterally outward of respective ones of the laterally outer ends463aand463b. No sidewall or sidewalls are formed by the chassis428adjacent the laterally inner ends464aand464b.)

The slider bed and the sidewalls are most preferably integrally formed, although discrete formation falls within the scope of some aspects of the present invention.

Preferably, the chassis428further includes a spaced apart pair of fore and aft stiffening brackets, each of which laterally spans both lateral halves of the conveyor assembly412. Still further, each of the stiffening brackets is preferably fitted with a pair of laterally spaced apart foam inserts, each of which provides support to components of one lateral half of the conveyor assembly412. Alternative stiffening and/or dampening approaches fall within the scope of some aspects of the present invention, however.

The chassis428also preferably includes a fore-aft extending, laterally centrally positioned support bracket428a.

It is noted that alternative chassis configurations, including but not limited to modifications to the bed, sidewalls, and brackets described above, are within the ambit of some aspects of the present invention.

A divider470including an upwardly projecting divider plate474is preferably secured to the chassis428to extend longitudinally in a fore-aft direction. The divider470is disposed laterally between the conveyor belts432and434such that the conveyor belts432and434preferably do not contact each other. The divider470is also configured to help separate items carried on the respective conveyor belts432and434.

The divider470may be secured by a variety of means, including but not limited to threaded fasteners, latches, or pegs. Most preferably, the selected securement means facilitate efficient removal and reinstallation of the divider470to respectively enable or restrict packages or other goods being conveyed from resting on both belts432and434. However, it also permissible for the connection means to be permanent or semi-permanent in nature (i.e., designed to be removable but not rapidly so). It also is permissible according to some aspects of the present invention for the divider to be omitted entirely or alternatively configured in some other manner.

In view of the above, the conveyor assembly412can be understood to include two side-by-side subassemblies476aand476b. The first subassembly476aincludes the powered roller body444a, the passive roller body446a, the conveyor belt432, the motor assembly458a, the bearing inserts452aand465a, and the couplers454aand466a. The second subassembly476bincludes the powered roller body444b, the passive roller body446b, the conveyor belt434, the motor assembly458b, the bearing inserts452band465b, and the couplers454band466b.

In a preferred embodiment, and as will be discussed in greater detail below, each of the couplers454aand454bof the dually powered roller coupling assembly456and each of the couplers466aand466bof the passive roller coupling assembly468functions as a combined torque transmission coupler and bearing cartridge.

It is noted that the couplers454a,454b,466a, and466b(and more broadly, the coupling assemblies456and468) are preferably identical to one another. Thus, for the sake of simplicity and clarity, only the coupler454a, illustrated in detail inFIGS.27and28, will be described in depth herein. However, it should be understood that the details provided herein with regard to the coupler454apreferably apply to the remaining couplers454b,466a, and466b, as well.

Turning now toFIGS.27and28, the coupler454aincludes a respective laterally outermost torque transmission portion478and a laterally inner bearing portion480. It is permissible according to some aspects of the present invention, however, for separate torque transmission couplers and bearing portions to be used, or for coupling to be achieved by one or more of a variety of other techniques.

The torque transmission portion478preferably includes a plurality of arcuately spaced apart stub shafts or pins478aconfigured to be received in corresponding ones of a first set of openings479aformed in a torque ring479.

The bearing portion480preferably includes pair of bearings480a. The bearings480aare preferably ball bearing assemblies, but alternative bearings (e.g., journal, roller, etc.) are permissible. Furthermore, although two bearings480aare illustrated, more or fewer bearings may be provided without departing from the scope of some aspects of the present invention.

The coupling assembly456also includes a connector shaft482extending between and interconnecting the couplers454aand454b. Likewise, the coupling assembly468includes a connector shaft484extending between and interconnecting the couplers466aand466b. As will be discussed in greater detail below, the connector shafts482and484are not intended to rotate, instead providing a stationary or at least substantially stationary link between the rotatable couplers454aand454band the rotatable couplers466aand466b, respectively.

Each shaft482and484includes a polygonal portion482aor484a, respectively. The support bracket428aof the chassis428preferably defines fore and aft seats486corresponding to the polygonal portions482aand484a. More particularly, each polygonal portion482aor484ais configured to be in part received in, rest on, or “float” above a corresponding one of the seats486. It is noted that the polygonal portions482aand484aare preferably hexagonal in form but permissibly any one of a variety of polygonal or rotation resistant shapes, including but not limited to eccentric shapes or keyed shapes.

A motor shaft connector488is also provided. The motor shaft connector488includes an opening488afor receiving a laterally inner end of the motor shaft462aprojecting from the gear assembly461aof the motor assembly458a. The motor shaft connector488further preferably includes a plurality of arcuately spaced apart stub shafts or pins488bconfigured to be received in corresponding ones of a second set of openings479bformed in the torque ring479. (As illustrated, the first set of openings479ais preferably arcuately offset from the second set of openings479b, such that the openings of the sets479aand479balternate arcuately with one another.)

The torque ring479is disposed laterally between the motor shaft connector488and the coupler454a. Most preferably, the torque ring479comprises an elastomeric material, although any one or more of a variety of materials fall within the scope of some aspects of the present invention.

As will be apparent to those of ordinary skill in the art, rotation of the motor shaft of the motor assembly458ais transferred from the motor shaft to the motor shaft connector488, and thereafter through the torque ring479to the torque transmission portion478of the coupler454a.

Preferably, a portion of the coupler454ais inserted into the inner end450aof the roller body444avia a press fit with the aid of a tolerance ring490. The tolerance ring490preferably presents arcuately spaced apart ends to facilitate installment of the tolerance ring490about the body of the coupler454a. The tolerance ring490further preferably includes a plurality of radially outwardly projecting, deformable ribs for engaging an inner surface of the roller body444aat the inner end450a. Engagement of the coupler454awith the roller body444aultimately results in transfer of rotation of the motor shaft to the roller body444a.

It is noted that other fitment approaches such as welding, fasteners connected between the roller body and the coupler, etc. fall within the scope of some aspects of the present invention, as well, and may be used instead of or in addition to tolerance rings.

It is also permissible according to some aspects of the present invention for the coupler to be received in its entirety within the respective roller body or to be located in its entirety external to or outside the respective roller body.

In view of the above, it will be apparent to those of ordinary skill in the art that, provided that any bearing friction is reasonably low, torque generated by each of the subassemblies476aand476bis not transmitted to the other of the subassemblies476aand476b, or such transmission is negligible. That is, movement of parts of one subassembly476aor476bdoes not influence or affect movement of parts of the other subassembly476aor476b. Thus, as will be discussed in greater detail below, the conveyor belts432and434are fully independently driven and therefore can shift independently of one another.

As will also be apparent to those of ordinary skill in the art, it is intended that the shaft482be rotationally isolated from and therefore not transfer rotation between the roller bodies444aand444b(or the couplers454aand454b) by merit of the previously described design of the couplers454aand454b, in which the bearings480asupport the shaft482. Likewise, it is intended that the shaft484be rotationally isolated from and therefore not transfer rotation between the roller bodies446aand446b(or the couplers466aand466b) by merit of the design of the couplers466aand466b, in which the bearings thereof support the shaft484.

Alternatively stated, the powered roller bodies444aand444bare interconnected to each other in such a manner as to share a first rotational axis yet be at least substantially rotationally independent of each other, such that each of the powered roller bodies444aand444bcan rotate without causing or interfering with rotation of the other of the powered roller bodies444aand444b. The passive roller bodes446aand446bare likewise rotational independent of one another.

Preferably, the coupler454aincludes a belt guide492defined by the bearing portion480. The belt guide492is preferably in the form of a groove492acorresponding to a projection494on the conveyor belt432. (A projection496is similarly formed on the conveyor belt434.) The belt guide492preferably facilitates enhanced tracking of the belt432, as well as enabling an increased belt width.

The groove492ais preferably cast in the bearing portion480, although other methods of formation fall within the scope of some aspects of the present invention. The groove might also be omitted without departing from the scope of some aspects of the present invention.

As noted previously, the couplers454a,454b,466a, and466bare all preferably identical to one another. However, it is noted that only the couplers454aand454bare associated with respective torque rings (such as the torque ring479) and motor shaft connectors (such as the motor shaft connector488). The couplers466aand466b, as a result of their placement in the fully passive roller assembly438, are not associated with such motor-related components. Thus, the couplers of the passive roller assembly might, without departing from the scope of the present invention, be designed differently than those associated with the fully powered roller assembly. Among other things, for instance, the (nonfunctional) pins of the torque transmission portions might be omitted. However, despite the “over-design” of the couplers466aand466bof the fully passive roller assembly438of the illustrated embodiment, use of a single coupler design in all four (4) instances provides advantages including but not limited to manufacturing or sourcing simplicity and assembly simplicity (e.g., by reducing the types of different parts required for assembly).

The conveyor system410described above is highly advantageous. In a distribution center, for instance, a conventional single-belt conveyor assembly supported by an automated vehicle might typically only transport a single package per trip from a loading area to a distribution zone in which the package is dispatched at an appropriate location (e.g., a pre-specified chute). In contrast, with reference toFIG.22, the automated vehicle414might be loaded at the loading area with the first package420on the belt432and the second package422on the belt434. The automated vehicle414might then transport the conveyor assembly412to the first chute416, at which time operation of only the first conveyor subassembly476a(and thus movement of only the first belt432) might occur into order to offload the first package420into the first chute416. After the vehicle414repositions itself adjacent the second chute424, operation of the second conveyor subassembly474b, in order to rotate the second belt434and thus shift the second package422, might occur to offload the second package422into the second chute424.

Furthermore, as shown inFIG.26, the conveyor assembly412can, if desired, additionally function much like a conventional single-belt conveyor to facilitate transport and shifting of larger packages that cannot be or preferably are not shifted by a single one of the belts432and434. In such an instance, removal of the divider470(if previously present) enables a package to rest simultaneously on both belts432and434. Concurrent operation of the motor assemblies458aand458bso as to move the belts432and434in a single direction and at equal speed then facilitates shifting of the package as desired.

Still further, it is noted that provision of two (2) “combination” couplers454aand454b, each integrating both a torque transmission portion and a bearing portion (as illustrated with regard to the coupler454avia provision of a torque transmission portion478and a bearing portion480), decreases the axial length required to achieve the same functionality that might otherwise be achieved in a dually powered roller using two (2) sets of separate torque transmission couplers and bearing cartridges. Thus, such “combination” couplers454aand454benable an equivalent functional conveyor belt total width (i.e., a sum of the widths of the belts432and434) to be achieved in a smaller total conveyor assembly width.

It is also noted that, in contrast with two (2) independent conveyor systems, the conveyor system410of the present invention achieves reduced weight due to reduced mounting complexity. More particularly, two (2) independent conveyor systems would require four (4) sets of mounting hardware, whereas the conveyor system410requires only two (2) sets of mounting hardware. This reduction in mounting hardware needs also advantageously reduces the associated bill of materials (BOM).

Finally, it is noted that expansion of the conveyor system410to include additional subassemblies (i.e., additional conveyor belts, etc.) falls within the scope of some aspects of the present invention.

A fourth preferred conveyor system is illustrated inFIGS.29and30. It is initially noted that, with certain exceptions to be discussed in detail below, many of the elements of the conveyor system510of the fourth embodiment are the same as or very similar to those described in detail above in relation to the conveyor system10of the first embodiment, the conveyor system210of the second embodiment, and the conveyor system410of the third embodiment. Therefore, for the sake of brevity and clarity, redundant descriptions and numbering will be generally avoided here. Unless otherwise specified, the detailed descriptions of the elements presented above with respect to the first through third embodiments should therefore be understood to apply at least generally to the fourth embodiment, as well.

Similarly to the conveyor systems10,210, and410, the conveyor system510of the fourth preferred embodiment preferably comprises a conveyor assembly512and a vehicle (not shown). The vehicle is preferably moveable to facilitate positioning/repositioning of the conveyor system510as a whole and, consequently, of the conveyor assembly512.

In a preferred embodiment, the conveyor assembly512broadly includes a conveyor module514, a chassis516, and a power module518.

The conveyor module514preferably includes a pair of independent conveyor belts520and522and a pair of structurally identical but oppositely oriented partially powered roller assemblies524and526. The roller assemblies524and526are preferably spaced from one another in a fore-aft direction or, alternatively stated, along a longitudinal/fore-aft axis of the conveyor module514.

Furthermore, the roller assemblies524and526are preferably oppositely oriented. More particularly, the partially powered roller assembly524preferably includes powered and passive axial sections524aand524b. Similarly, the partially powered roller assembly526preferably includes powered and passive axial sections526aand526b. The conveyor belt520preferably extends along the longitudinal or fore-aft axis to form a single, continuous (i.e., endless) loop around the powered axial section524aand the passive axial section526b. Similarly, the conveyor belt522preferably extends along the longitudinal or fore-aft axis to form a single, continuous (i.e., endless) loop around the passive axial section524band the powered axial section526a.

For conciseness and clarity, only the partially powered roller assembly524is illustrated and described in detail herein. However, as noted above, the partially powered roller assembly526is preferably identical (but oppositely oriented) to the partially powered roller assembly524. Thus, descriptions provided herein with reference to the partially powered roller assembly524should be understood to apply to the partially powered roller assembly526, as well.

Turning now toFIG.28, similarly to the corresponding components of the previously described embodiments, each of the axial sections524aand524bof the partially powered roller assembly524includes a corresponding roller body528aor528b. Furthermore, each roller body528aand528breceives a corresponding bearing adapter or roller insert530aor530b. Still further, a coupling assembly532, including couplers534aand534band a connector shaft536, preferably connects the powered and passive axial sections524aand524b.

The couplers534aand534bare preferably each configured as described above with regard to the coupler454a(and are thus likewise configured at least substantially identically to the couplers454b,466a, and466b). Furthermore, the coupler534aof the powered axial section524ais preferably associated with a torque ring579(configured as described above with respect to the torque ring479) and a motor shaft connector581(configured as described above with respect to the motor shaft connector488). In contrast, the coupler534b, associated with the passive axial section524b, is not associated with a torque ring or motor shaft connector. Thus, certain of the features of the illustrated coupler534b, such as the pins of the torque transmission portion thereof, are not strictly necessary to its functionality and may be omitted without departing from the scope of some aspects of the present invention.

The power module518preferably includes a motor assembly538at least substantially disposed within the roller body528a(as well as corresponding motor assembly associated with the partially powered roller assembly526).

A divider540is preferably provided, as discussed above with respect to the conveyor system410of the third embodiment.

In view of the above, the conveyor assembly512can be understood to include two identical but oppositely oriented side-by-side subassemblies542aand542b. The first subassembly542aincludes the powered roller body528a, the passive roller body (not labeled) of the roller assembly526, the conveyor belt520, the motor assembly538, the bearing insert530aand the bearing insert (not labeled) of the passive section526broller assembly526, and the coupler534aand the coupler (not labeled) of the passive section526bof the roller assembly526. The second subassembly542bincludes the passive roller body528b, the powered roller body (not labeled) of the roller assembly526, the conveyor belt522, the motor assembly (not labeled) of the roller assembly526, the bearing insert530band the bearing insert (not labeled) of the powered section526aof the roller assembly526, and the coupler534band the coupler (not labeled) of the powered section526aroller assembly526.

Furthermore, as discussed above with regard to the conveyor system410of the third preferred embodiment, provided that any bearing friction is reasonably low, torque generated by each of the subassemblies542aand542bis not transmitted to the other of the subassemblies542aand542b, or such transmission is negligible. That is, movement of parts of one subassembly542aor542bdoes not influence or affect movement of parts of the other subassembly542aor542b.

The conveyor system510described above is highly advantageous, including each of the advantages discussed above with regard to the conveyor system410of the third embodiment. However, the conveyor system510is additionally advantageous in that the two roller assemblies524and526are identical to each other and are simply “flipped” relative to one another for assembly of the conveyor assembly512. That is, whereas the conveyor system510of the third embodiment requires manufacture or purchase of two completely differently configured (i.e., one dually powered and one fully passive) roller assemblies436and438, the conveyor system510of the fourth embodiment simply requires manufacture or purchase of two identical roller assemblies524and526.

A roller assembly for a fifth preferred conveyor system is illustrated inFIGS.31and32. It is initially noted that, with certain exceptions to be discussed in detail below, many of the elements of the conveyor system610of the fourth embodiment are the same as or very similar to those described in detail above in relation to the conveyor system10of the first embodiment, the conveyor system210of the second embodiment, the conveyor system410of the third embodiment, and the conveyor system510of the fourth embodiment. As will be apparent from the below description, the conveyor system610of the fifth embodiment is particularly similar in many regards to the conveyor system510of the fourth embodiment. Therefore, for the sake of brevity and clarity, redundant descriptions and numbering will be generally avoided here. Unless otherwise specified, the detailed descriptions of the elements presented above with respect to the first through fourth embodiments should therefore be understood to apply at least generally to the fifth embodiment, as well.

Similarly to the conveyor systems10,210,410, and510, the conveyor system610of the fifth preferred embodiment preferably comprises a conveyor assembly612and a vehicle (not shown). Furthermore, in a preferred embodiment, the conveyor assembly612broadly includes a conveyor module614, a chassis616, and a power module618.

The conveyor module614preferably includes a pair of independent conveyor belts620and622and a pair of identical but oppositely oriented partially powered roller assemblies (only a first roller assembly624is shown). As shown with respect to the conveyor system510of the fourth preferred embodiment, the first roller assembly624and the second roller assembly (not shown) of the fifth preferred embodiment are preferably spaced from one another in a fore-aft direction or, alternatively stated, along a longitudinal/fore-aft axis of the conveyor module614.

Furthermore, as also shown with respect to the conveyor system510of the fourth embodiment, the first roller assembly624and the second roller assembly (not shown) are preferably oppositely oriented. More particularly, the first partially powered roller assembly624preferably includes first powered and passive axial sections624aand624b. Similarly, the second partially powered roller assembly preferably includes second powered and passive axial sections (not shown). The conveyor belt620preferably extends along the longitudinal or fore-aft axis to form a single, continuous (i.e., endless) loop around the powered axial section624aof the first partially powered roller assembly624and the passive axial section (not shown) of the second partially powered roller assembly (not shown). Similarly, the conveyor belt622preferably extends along the longitudinal or fore-aft axis to form a single, continuous (i.e., endless) loop around the passive axial section624bof the first partially powered roller assembly624and the powered axial section (not shown) of the second partially powered roller assembly (not shown).

For conciseness and clarity, only the first partially powered roller assembly624is illustrated and described in detail herein. However, as noted above, the second partially powered roller assembly (not shown) is preferably identical (but oppositely oriented) to the first partially powered roller assembly624. Thus, descriptions provided herein with reference to the first partially powered roller assembly624should be understood to apply to the second partially powered roller assembly (not shown), as well.

Turning now toFIGS.30and31, similarly to the corresponding components of the previously described embodiments, each of the axial sections624aand624bof the partially powered roller assembly624includes a corresponding roller body628aor628b. Furthermore, each roller body628aand628breceives a corresponding bearing adapter or roller insert630aor630b. Still further, a coupling assembly632, including couplers634aand634band a connector shaft636, preferably connects the powered and passive axial sections624aand624b.

The coupler634aand of the first powered axial section624ais preferably associated with a torque ring679(configured as described above with respect to the torque rings479and579) and a motor shaft connector681(configured as described above with respect to the motor shaft connectors488and581). Such associations are preferably in the manner described above with regard to the conveyor system510.

In contrast, the coupler634b, associated with the first passive axial section524b, is not associated with a torque ring or motor shaft connector. This is also in keeping with the configuration described above with regard to the conveyor system510.

The couplers634aand634bare preferably similar in many regards to the previously described couplers454a,454b,466a,466b,534a, and534b. For instance, the coupler634aincludes both a torque transmission portion678and a bearing cartridge portion680. The coupler634bis preferably identical to the coupler634band thus likewise includes these portions. A key distinction between the couplers634aand634bof the fifth preferred embodiment and those of the previously described embodiments will be discussed in greater detail below.

First however, it is noted that similarly to previously discussed embodiments, the power module618preferably includes a motor assembly638at least substantially disposed within the roller body628a, as well as corresponding motor assembly (not shown) associated with the second partially powered roller assembly (not shown). A divider640is also preferably provided.

In view of the above, the conveyor assembly612can be understood to include two identical but oppositely oriented side-by-side subassemblies642aand642b. The first subassembly642aincludes the powered roller body628a, the passive roller body of the passive section of the second roller assembly (not shown), the conveyor belt620, the motor assembly638, the bearing insert630a, the bearing insert of the passive section of the second roller assembly (not shown), the coupler634a, and the coupler of the passive section of the second roller assembly (not shown). The second subassembly642bincludes the passive roller body628b, the powered roller body of the powered section of the second roller assembly (not shown), the conveyor belt622, the motor assembly of the powered section of the second roller assembly (not shown), the bearing insert630b, the bearing insert of the powered section of the second roller assembly (not shown), the coupler634b, and the coupler of the powered section of the second roller assembly (not shown).

Turning now to key distinctions, as will be readily apparent fromFIGS.30and31, the couplers634aand634bof the fifth preferred embodiment present significantly longer axial (i.e., lateral) lengths, both nominally and relative to other components of the conveyor system610, than the couplers454a,454b,466a,466b,534a, and534of the third and fourth embodiments.

For instance, the couplers634aand634bpresent respective axial lengths that are between about twenty-five (25) percent and about seventy-five (75) percent of the lateral width of the corresponding ones of the belts620and622. More specifically, the couplers634aand634bpresent respective axial lengths that are between about thirty-three (33) percent and about sixty-six (66) percent of the lateral width of the corresponding ones of the belts620and622. Most specifically, the couplers634aand634bpresent respective axial lengths that are about fifty (50) percent of the lateral width of the corresponding ones of the belts620and622.

It is also noted that the belts620and622and, in a broad sense, the conveyor module614as a whole, are each laterally wider than the corresponding elements of the conveyor systems10,210,310,410, and510. Among other things, such increased width enables transport of larger packages/cargo.

Still further, it is noted that the extended length of the coupler634aresults in a general centralization within the powered axial section624aof the various power-generating and power-transferring elements (e.g., the motor assembly638, the motor shaft connector681, the torque ring679, and the torque transmission portion478of the coupler634a).

The coupler634aalso provides substantial structural support to the belt620(with additional support provided by the powered roller body628a).

The design of the coupler634is also highly advantageous to the conveyor system610in a broad sense in that lateral expansion and contraction of the system610as a whole may be achieved simply through a change in the lateral extent of the coupler634aand a corresponding change in the width of the associated belt620and chassis616(and/or similar adjustments to the coupler634band belt622). That is, modifications to the motor assembly638, the motor shaft connector681, the torque ring679, the roller body628aand so on are unnecessary to revise the lateral width of an existing conveyor system610.

Alternatively, considered from an initial production perspective rather than the above-described post-production modification perspective, it will be readily apparent to those of ordinary skill in the art that the remaining components such as the motor assembly638, the motor shaft connector681, the torque ring679, the roller body628a, and so on may be manufactured for initial use in conveyor systems of any of a variety of lateral widths. That is, the parts of the system excluding the couplers, belts, and chassis may be produced and to at least some extent assembled without regard for final use.

Finally, it is noted that the advantages described above with regard to the conveyor system410of the third embodiment and the conveyor system510of the fourth embodiment also apply to the conveyor system610of the fifth embodiment.

CONCLUSION

Features of one or more embodiments described above may be used in various combinations with each other and/or may be used independently of one another. For instance, although a single disclosed embodiment may include a preferred combination of features, it is within the scope of certain aspects of the present invention for the embodiment to include only one or fewer than all of the disclosed features, and one or more features of another embodiment, unless the specification expressly states otherwise or as might be understood by one of ordinary skill in the art. Therefore, embodiments of the present invention are not necessarily limited to the combination(s) of features described above.

Although the above description presents features of preferred embodiments of the present invention, other preferred embodiments may also be created in keeping with the principles of the invention. Furthermore, as noted previously, these other preferred embodiments may in some instances be realized through a combination of features compatible for use together despite having been presented independently as part of separate embodiments in the above description.

The inventors hereby state their intent to rely on the Doctrine of Equivalents to determine and access the reasonably fair scope of the present invention as pertains to any apparatus not materially departing from but outside the literal scope of the invention set forth in the following claims.