Modular conveyor system

A conveyor system providing for convertibility of existing and new conveyor equipment, incorporating use of a double “T” slot for mounting the conveyor beam to existing equipment and/or connecting existing accessories to the new conveyor beam and for ease of conveyor chain interchangeability while providing for a robust conveyor chain assembly.

FIELD OF THE INVENTION

This invention relates to conveyor systems and, more specifically, to conveyor systems comprising conveyor beams, conveyor chain pieces and mounting means for conveyor accessories.

BACKGROUND OF THE INVENTION

Efforts to improve industrial plant efficiency have generated interest in making industrial plants relatively quickly and easily convertible from one industrial process to another. Convertibility of industrial plants permits plant managers to stay abreast of and provide for the demands of the marketplace. A very important component of virtually every industrial plant is conveyor systems. Therefore, the convertibility of conveyor systems is very important to the convertibility of industrial plants. In the conveyor system art, convertibility relates to accommodating articles having various sizes, shapes and physical characteristics.

One particular feature of convertibility is the ease by which a conveyor chain is removable from a conveyor beam. The easier and quicker it is to remove and change out a conveyor chain, the more convertible the industrial plant is.

Another important aspect of conveyor systems is interchangeability. As a conveyor line is converted from one configuration to another, it may be advantageous to utilize accessories supplied by various manufacturers depending on the article of manufacture to be run. Therefore, having a conveyor beam that is able to accommodate many varying accessories is critical to interchangeability and convertibility. It is also critical to provide a conveyor beam that is easy to retrofit with, for instance, existing conveyor equipment.

Extruded conveyor beams have been utilized for many years. Typically these beams have had, when viewed in longitudinal cross-section, sidewalls extending above and below a center section and flanges extending inwardly from the upper and lower ends of the sidewalls to carry conveyor chains. Typically, the conveyor chain will ride on top of the upper flanges while transporting an article to a selected destination, and is then inverted, riding on the lower flanges on the return trip, the lower flanges keeping the conveyor chain from falling out of the beam.

Generally, these beams have presented a symmetrical longitudinal cross section. This means that the sidewalls and flanges that extend upwardly from the center section have mirrored counter parts that extend downwardly from the center section such that the upper and lower sidewalls and flanges have exactly the same measurements.

This presents the disadvantage that, to remove the conveyor chain in order to retool the conveyor system, the beam must be dismantled at a selected location and the chain removed at that point, typically from an end section. Further, the replacement conveyor chain must then be inserted at the removal point and the beam reconnected. This process is difficult and time consuming, greatly increasing the costs associated with retooling a line.

A number of patents have attempted to deal with this problem with limited success. For instance, U.S. Pat. No. 4,961,492 to Wiseman et al. (“the '492 patent”) discloses the use of differing wearstrips, one that will permit the conveyor chain to freely be lifted out of the beam and the other that will securely hold the conveyor chain to the beam. The beam is designed such that the conveyor chain may freely be lifted out at any point, while the placement of the wearstrips determines where the conveyor chain will be freely removable. However, a disadvantage of the '492 patent is that the beam is taught to be symmetrical in cross-section from top to bottom such that the wearstrips must retain the conveyor chain in the beam when, for instance, inverted, and the wearstrips must structurally bear the weight of the inverted conveyor chain rather than the flange itself which typically comprises an extruded material such as aluminum ('492 patent, FIGS. 2, 5, col. 4, 42-55). Any subsequent failure of the conveyor equipment that causes a shutdown of the line can be very expensive, both in terms of repair costs and shutdown time. The '492 patent further teaches that the conveyor chain used has plastic protrusions designed to engage with the specially designed wearstrips to hold the conveyor chain to the beam ('492 patent, FIGS. 2, 5, col. 5, lines 26-33 and 62-68, and col. 7, lines 2-9). This is also undesirable because the conveyor chain is only maintained in the beam by plastic tabs rather than by a more robust means. In addition, the specially designed wearstrips add complexity and cost to the system, as do the specially designed conveyor chain pieces with the small plastic tabs. Still further, the '492 patent fails to teach or disclose the use of mounting recess capable of receiving many varying accessories or retrofitting to existing equipment (such as a double-T slot recess), located in the sides of the outer walls of the beam. Instead, the '492 patent only teaches the use of a single slot which will limit interchangeability and the ability to retrofit the beam to, for instance, existing equipment ('492 patent, FIG. 2, col. 4, lines 53-57).

U.S. Pat. No. 5,316,134 to Donohue (“the '134 patent”) has further tried to address this issue with limited success. The '134 patent discloses a conveyor system where the conveyor chain may be lifted out of the top of the beam while still holding the conveyor chain to the beam on the bottom of the beam. This method, like the '492 patent, discloses that the conveyor chain utilized has plastic protrusions designed to engage with the lower flanges ('134 patent, FIG. 1, col. 3, lines 15-21). However, as previously stated, it is undesirable to have the conveyor chain structurally maintained in the beam only by small plastic tabs. This conveyor chain also adds cost and complexity to the system. In addition, the '134 patent fails to provide any means by which to attach to the side of the beam, excluding the use of many standard accessories thereby severely limiting interchangeability, convertibility and the ability to retrofit the system. In fact, the '134 patent specifically teaches that no cavities or recesses may be located in the outer walls ('134 patent, FIG. 1, col. 1, lines 61-68). Further, the lower run of the conveyor chain is not freely accessible as it is enclosed on both sides by the downwardly extending sidewalls. ('134 patent, FIG. 1, col. 1, lines 67-68, col. 2, lines 1-4 and 7-13). This lack of accessibility can greatly increase the difficulty in servicing or repairing the system, for instance, if the conveyor chain is damaged.

U.S. Pat. No. 6,374,989 to van Dyke, Jr. et al. (“the '989 patent”) discloses the use of a double-T slot recess located on the outer wall of the conveyor beam. ('989 patent, FIGS. 4, 7, 8, 21 and 24). However, the '989 patent teaches away from having flanges that extend inward such that the conveyor chain may freely be lifted out of the beam from the top. ('989 patent, FIGS. 4, 7, 8, 21 and 24). For instance, the '989 patent teaches that the “edge walls 68 and 70 include ledge portions 76 and 78 (FIG. 4) located at a predetermined height above the conveyor belt 60 and projecting over the conveyor belt 60″ and that the “ledge portions 76 and 78 cooperate with the conveyor belt60to form a vertical confinement . . . and hold a sample tube.” ('989 patent, col. 5, lines 54-60.) This confinement is critical to the proper functioning of delivering tubes of “different heights and diameter.” ('989 patent, col. 5, line 61.) The '989 patent then, specifically teaches against removability of the conveyor chain from the top of the beam. In addition, although flanges are provided on the bottom of the beam, the conveyor chain disclosed in the '989 patent is never inverted such that the lower flanges of the beam are not utilized. Therefore, the '989 patent fails teach use of differing flanges from top to bottom such that the lower flanges engagingly hold the conveyor chain to the beam while the top flanges facilitate removal of the conveyor chain. Therefore, this configuration severely limits convertibility and interchangeability of the conveyor system.

What is desired is a conveyor system that allows easy removal of a conveyor chain while at the same time facilitates attachment of many various accessories and/or attachments to the side of the beam.

It is further desired to provide a conveyor system that provides a means of removeably engaging the conveyor chain to a beam that is simple, cost effective and structurally robust.

It is still further desired to provide a conveyor system that allows easy removal of a simple conveyor chain that is accessible on both the top and bottom run.

It is yet further desired to provide a conveyor system that minimizes the costs and time associated with repair and/or replacement of the various conveyor components.

It is still further desired to provide a conveyor system that facilitates retrofitting of newer and older conveyor equipment.

SUMMARY OF THE INVENTION

These and other objectives are achieved in one advantageous embodiment of the present invention, by providing a conveyor beam having upper and lower flanges such that the conveyor chain may easily be lifted out of the top of the beam. In addition, when inverted, the conveyor chain is securely held to the conveyor beam by the lower flanges, which engage protrusions located on the conveyor chain pieces. The conveyor chain pieces further have an opening located at the front of each conveyor chain piece for receiving a pin. The protrusions also each have an opening for receiving a pin, such that the individual conveyor chain pieces are securely held to one another in an end-to-end fashion. The pin extends through the protrusions and beyond the lower flanges such that the pin adds structural support for maintaining the conveyor chain in the conveyor beam when the chain engages the lower flanges.

A further advantageous aspect of the present invention is the provision of a double-T slot recess provided in the outer walls and running along at least a portion of the length of the conveyor beam. What is meant by a double-T slot is, when viewed in cross-section, the beam presents two adjacent rectangular cavities, an inner cavity and an outer cavity, where the inner cavity has an opening that opens into the outer cavity and the outer cavity has an opening that opens to the environment. The two cavities are of differing sizes to accommodate attachment of a variety of differing equipment and retrofitting to existing equipment. Generally the inner cavity presents a larger cross-section than the outer cavity, but this is not required.

In one advantageous embodiment of the present invention, a conveyor system is provided comprising a conveyor beam having a pair of integrally formed upper flanges defining an upper channel having a width (W1) and a pair of integrally formed lower flanges defining a lower channel having a width (W2), the width (W2) being smaller than the width (W1) of the upper channel. The system further comprises a conveyor chain having a retaining portion which has a width (W3) larger than the width (W2) of the lower channel, but smaller than the width (W1) of the upper channel, the retaining portion being positioned on said chain such that the chain is restrained in the lower channel, but is adapted to be freely lifted out of the upper channel. The retaining portion further has an opening extending therethrough for receipt of a pin to connect various chain sections together, the pin having a width (W4) larger than the width (W2) of the lower channel, but smaller than the width (W1) of the upper channel.

In another advantageous embodiment of the present invention, a conveyor system is provided comprising a conveyor beam having a pair of integrally formed upper flanges defining an upper channel having a width (W1), a pair of integrally formed lower flanges defining a lower channel having a width (W2), the width (W2) being smaller than the width (W1) of the upper channel, and a double-T slot cavity located in outer walls of said conveyor beam and extending longitudinally along at least a portion of the length of said conveyor beam. The system is also provided so that the conveyor beam is adapted to receive a conveyor chain having a retaining portion which has a width (W3) larger than the width (W2) of the lower channel, but smaller than the width (W1) of the upper channel such that the chain is restrained in the lower channel, but is adapted to be freely lifted out of the upper channel.

In still another advantageous embodiment of the present invention, a conveyor system is provided comprising a conveyor beam having a pair of integrally formed upper flanges defining an upper channel having a width (W1), a pair of integrally formed lower flanges defining a lower channel having a width (W2), the width (W2) being smaller than the width (W1) of the upper channel, and a double-T slot cavity located in outer walls of said conveyor beam and extending longitudinally along at least a portion of the length of said conveyor beam. The system further comprises a conveyor chain having a retaining portion which has a width (W3) larger than the width (W2) of the lower channel, but smaller than the width (W1) of the upper channel, the retaining portion being positioned on said chain such that the chain is restrained in the lower channel, but is adapted to be freely lifted out of the upper channel. The retaining portion further has an opening extending therethrough for receipt of a pin to connect various chain sections together, the pin having a width (W4) larger than the width (W2) of the lower channel, but smaller than the width (W1) of the upper channel.

The invention and its particular features and advantages will become more apparent from the following detailed description considered with reference to the accompanying drawings.

DETAILED DESCRIPTION OF THE DRAWINGS

FIGS. 1 and 2generally illustrate the conveyor beam10according to one advantageous embodiment of the present invention and will be discussed together.FIG. 1is a perspective drawing of conveyor beam10, whileFIG. 2is a cross-sectional drawing of conveyor beam10.

Generally, conveyor beam10presents an “H” shape configuration, having upper exterior walls12,16and lower exterior walls14,18. Upper and lower exterior walls12,16, and14,18are joined by a web generally comprising an upper web section20and a lower web section22. Upper web section20joins upper exterior walls12,16, while lower web section22joins lower exterior walls14,18. Upper exterior walls12,16and upper web section20generally define an upper cavity24, which is generally rectangular in shape, while lower exterior walls14,18and lower web section22generally define a lower cavity26, which is also generally rectangular in shape. It can be seen fromFIGS. 1 and 2that upper and lower exterior walls12,16, and14,18are provided along the length of conveyor beam10and generally extend perpendicular to the length of the conveyor beam10.

Again referring toFIGS. 1 and 2, upper exterior walls12,16further comprise upper flanges28,30located at upper ends of upper exterior walls12,16. Upper flanges28,30generally extend inwardly from upper exterior walls12,16, respectively, and each is substantially perpendicular to upper exterior walls12,16. The distance between upper flanges28,30is indicated as width (W1).

Lower exterior walls14,18also comprise lower flanges32,34located at lower ends of lower exterior walls14,18. Lower flanges32,34also generally extend inwardly from lower exterior wall14,18and each is substantially perpendicular to lower exterior walls14,18. The distance between lower flanges32,34is indicated as width (W2).

It can be seen fromFIGS. 1 and 2that width (W1) is generally larger than width (W2). While these widths may individually vary, width (W1) should always be provided such that it is larger than width (W2).

Also provided on upper flanges28,30is a ridge36and a channel38for engaging with an upper wearstrip (not shown in FIGS.1and2). In like manner, lower flanges32,34are provided with a ridge40and a channel42, which are also provided for engaging with a lower wearstrip (not shown in FIGS.1and2).

A double “T” slot cavity is provided in the upper and lower exterior walls12,16, and14,18. The double “T” slots run along at least a portion of the length of the conveyor beam10as illustrated in FIG.1. The double “T” slot comprises an inner cavity44and an outer cavity46. Inner cavity44is defined by an inner wall48, which extends between upper web section20and lower web section22. Upper web section20and lower web section22generally extend outwardly to engage upper and lower exterior walls12,16, and14,18, with a slight doglegging around inner cavity44. In this particular embodiment, inner cavity44is larger than outer cavity46. Inner cavity walls50define an opening from inner cavity44to outer cavity46. Likewise, the ends of upper and lower exterior walls12,16, and14,18define an opening from outer cavity46to the environment.

Inner cavity44and outer cavity46are generally illustrated as rectangular, with inner cavity44being larger than outer cavity46, however, this is not necessary. For instance, outer cavity46could be larger than inner cavity44. In addition, both or either cavity could be square-shaped or be elongated. Having differing sized cavities will provide greater interchangeability as many differing devices can be variously attached to the side of the conveyor beam10. Typically, the cavities receive, for instance, a nut or engaging device that can be inserted into the cavity (inner or outer depending upon the size of the nut or engaging device) when positioned in one direction and when rotated, for instance, 90 degrees, engages with the cavity walls to securely hold to the exterior of the convey beam10.

Conveyor beam10may be formed of any suitable rigid material, such as, for instance, aluminum or plastic. The conveyor beam10may also be formed via, for instance, an extruding process. In one advantageous embodiment, conveyor beam10is provided in discrete sections that may be connected to one another in an end-to-end fashion through connector plates (not shown) that are located in the double “T” slot cavities and span the joint formed between the two conveyor beams10. Individual sections are also provided such that they can be formed or bent as desired according to the installation.

FIG. 3illustrates a bottom view of an individual conveyor chain piece100, whileFIG. 4illustrates a side of the individual conveyor chain piece100. As such,FIGS. 3 and 4will be discussed together.

Conveyor chain piece100comprises a lower portion102that is generally circular and having arms104,106extending generally tangentially from lower portion102. Arms104,106extend generally rearward from lower portion102, based upon a path of travel of conveyor chain piece100. In addition, the distance between arms104,106expands slightly as the arms104,106extend rearward from lower portion102. The distance between arms104,106will increase such that the diameter of the lower portion102can fit between arms104,106. Protrusions108,110are located at the rearward ends of arms104,106and extend generally perpendicular to arms104,106.

As can be seen inFIG. 4, protrusions108,110present a generally round cross-section with a flat section located on the top of the protrusion. The distance between the end of protrusion108and protrusion110is defined as width (W3) depicted in FIG.3. Width (W3) is provided such that it is smaller than width (W1) shown inFIGS. 1 and 2, but larger than width (W2), also illustrated inFIGS. 1 and 2. Protrusions108,110are also each provided with a hole116designed to receive a pin (not shown in FIGS.3and4), which extend therethrough and are each substantially axially aligned with each other.

Lower portion102further comprises a front section112that comprises tapered sections (both top and bottom) as can generally be seen in FIG.4. Lower portion also comprises a hole114, extending laterally through lower portion102and designed to receive a pin (not shown in FIGS.3and4). Also provided in lower portion102is a knuckle joint122. Knuckle joint122has a hole114extending laterally therethrough and is provided to rotate clockwise and counterclockwise as desired to facilitate lateral articulation of chain pieces when a pin (not shown inFIGS. 3 and 4) extends laterally therethrough to connect individual conveyor chain pieces together in an end-to-end fashion. Hole114presents a constant circular diameter through knuckle joint122, but presents an expanding ellipse cross-section front-to-back as one travels outwardly from knuckle joint122.

Conveyor chain piece100further comprises a top plate118and a transitional section120(seen in FIG.4), which connects top plate118with lower portion102. Top plate118may comprise any number of varying shapes and sizes depending upon the article that is to be transported, such that top plate118can be selected and rigidly attached to lower portion102depending upon the intended application. In addition, conveyor chain piece100generally comprises a lightweight rigid material, such as cast or molded plastic, but may also comprise any suitable material.

FIGS. 5 and 6generally depict multiple conveyor chain pieces200,300shown connected to each other in an end-to-end fashion. Conveyor chain pieces200,300generally correspond to conveyor chain piece100previously described in connection withFIGS. 3 and 4such that the individual features of conveyor chain pieces200,300will not be re-described here.

Conveyor chain pieces200,300are engagingly secured to one another in an end-to-end fashion by means of pin224(illustrated inFIG. 6as a dashed line). Conveyor chain piece200is provided such that the distance between arms204,206is slightly larger than the diameter of lower portion302. Pin224passes through hole216in protrusion208, hole314in knuckle joint322located in lower section302and hole216in protrusion210, thereby securing conveyor chain piece200to conveyor chain piece300. Pin224is frictionally fit and maintained in holes216. Conveyor chain pieces200,300are provided such that lateral articulation via knuckle joint322and vertical articulation via rotation of the pin in knuckle joint322are possible.

Pin224may comprise any durable rigid material such as, for instance, steel or stainless steel. The width of pin224is illustrated inFIG. 6as width (W4), which, in the illustrated embodiment, is slightly less than width (W3) as illustrated in FIG.3. Width (W4) can be less than that illustrated inFIG. 6; however, it is advantageous to have pin224extend well into holes216located in protrusions208,210.

Referring now toFIG. 7, a wearstrip60is provided for attachment to upper flanges28,30and is shown in an engaged position with upper flanges28,30in FIG.8. Wearstrip60comprises an upper wear surface62that connects at an inside end with a vertical wear surface64. Also connected to vertical wear surface64is an engaging portion66. On an upper side of engaging portion66a ridge68and a channel70are provided. Ridge68and channel70are designed to engagingly mate with ridge36and channel38provided on upper flanges28,30(see FIG.2). Once wearstrip60is attached to upper flanges28,30, ridge68interacts with channel38and ridge36interacts with channel70such that wearstrip60is engagingly held to upper flanges28,30. Wearstrip60may comprise any suitable rigid or semi-rigid material.

FIG. 8illustrates conveyor beam10with wearstrip60attached to upper flanges28,30, and conveyor chain piece100seated thereon. As can be seen inFIG. 8, top plate118of conveyor chain piece100rides along upper wear surface62. As can also be seen, protrusions108,110engage vertical wear surface64, which prevents lateral displacement of conveyor chain piece100as it travels along a path of movement. Notably, width (W3) of protrusions108,110is less than width (W1) between upper flanges28,30such that conveyor chain piece100may freely be lifted out of upper cavity24of conveyor beam10.

Also illustrated inFIG. 8is inverted conveyor chain piece100, shown inverted when, for instance, on a return path opposite a path of travel for the items to be transported. It can be seen from the drawing that lower flanges32,34have wearstrips72mounted thereon, which engage with protrusions108,110. It can readily be seen that width (W3) of protrusions108,110is greater than width (W2) between lower flanges32,34such that conveyor chain piece100is engagingly held to lower flanges32,34of conveyor beam10when inverted. It should also be noted that since width (W4) of pin224is slightly smaller than width (W3) of protrusions108,110, width (W4) is greater than width (W2) between lower flanges32,34. This is highly desireable because pin224, which is made of a rugged material such as steel or stainless steel, will be part of the structure that engages with lower lower flanges32,34holding chain piece100to conveyor beam10.

Utilizing protrusions108,110as a retaining portion to keep conveyor chain piece100engaged with conveyor beam10is desirable because it provides for a more robust engaging means due to pin224and for a simplified design of chain piece100. In addition, both wearstrip60and wearstrip72comprise simple structures that are easy and cost effective to manufacture and install.