Conveyor system with passive roller transfer assembly

A conveyor system with an improved roller transfer assembly is provided for transferring articles from the end of a first conveyor to the start of a second, in-line conveyor. A conveying surface is formed by a plurality of rollers that span substantially the entire space across the transfer zone. The conveyor transfer assembly includes a plurality of shafts extending transversely across the zone, a mounting block at each end for supporting the shafts, which blocks are secured within a holding pan. The support for the assembly includes a pair of tabs on each end of the pan that cooperate with a respective pair of open notches on a pair of frame plates. In turn, the plates are secured at the ends of the transfer zone to the frame of the conveyor system. A pair of angular slots in the plates allows adjustment of the transfer assembly to allow movement of the articles from one level on the first conveyor to a second level on the second conveyor.

BACKGROUND OF THE INVENTION 
The present invention relates generally to conveyors, and more particularly 
to a conveyor system having a transfer zone between the end of a first 
conveyor and the start of a second conveyor. 
It is common in conveyor systems to have two or more conveyors that are 
positioned in end to end relationship that are adapted to feed articles 
along a feed path, such as in food processing or packaging lines. In the 
transfer zone where the two conveyors come together, it has always been a 
problem to provide an efficient passage of the articles from the feeding 
portion of the first conveyor to the receiving portion of the second 
conveyor. One of the most prevalent problems is to provide a conveyor 
transfer assembly for this purpose that not only provides for a smooth 
transition along the transfer zone, but also can be released in the event 
that a jam occurs. For example, a jam can occur at the transfer zone due 
to the lodging of a foreign object within a recess of the modular 
conveyor, or simply from an object that is out of place carried along by 
the article being conveyed. In either case, there is a problem in 
preventing damage to the articles and/or the conveyor in the event of this 
type of jam. 
In the past, there have been attempts to solve this problem, but insofar as 
I am aware a truly acceptable solution has not been found prior to the 
present invention. For example, in the Chance U.S. Pat. No. 5,009,307, to 
et al. issued Apr. 23, 1991, there is a provision for a plate that is held 
in position by the frame on one end of a conveyor. In order to hold the 
plate in position, spring loaded detents are required at both sides. 
Depending on the strength of the spring for each detent, the plate is 
designed to be released in the event of a foreign object being lodged 
between the end of the conveyor and the plate. The unreliability of this 
type of article transfer means plays a key role in the limited 
acceptability that it has. For example, when the conveyor system is new, 
and the springs have a high compression rate, then the release of the 
transfer section requires a substantial force in order to be operative. On 
the other hand, over the years, and assuming multiple release episodes of 
the transfer section, the springs weaken and the surfaces of the detent 
are changed so that the release becomes easier. In such an event, the 
transfer section can literally fall out of the conveyor system of its own 
accord. This is especially true in an instance where the spring force is 
overcome when heavy articles are being conveyed. 
Furthermore, in an arrangement such as shown in the '307 patent, the cost 
of the transfer section is unduly high. Also, there is no provision made 
for anti-friction transfer, such as by the inclusion of rollers. As a 
result, the speed of the articles being transferred must be increased in 
order to make certain that enough momentum remains in the articles to 
cause them to successfully cross the exit zone, as taught by the patent. 
Accordingly, the need exists for a new type of conveyor transfer assembly 
for articles feeding along a feed path or transfer zone between two 
conveyors. A prerequisite is that the transfer assembly be simple and 
inexpensive to manufacture and substantially fool proof in operation. The 
transfer assembly should also be lightweight and supported freely on the 
conveyor support, preferably resting only by gravity, for easy and quick 
pop-up release in the event of a foreign object causing an article jam or 
the like. 
Other arrangements prevalent in the prior art usually take the form of 
permanently mounted roller sections, wherein individual rollers are 
mounted on pairs of arms that are mechanically held in position for 
pivoting action. Again, this arrangement is such that the consistent 
avoidance of damage in the event that a jam occurs is very inconsistent. 
An example of this type of prior art arrangement is shown in the earlier 
U.S. Pat. No. 2,624,444, to Casabona issued Jan. 6, 1953. Thus, this line 
of technology also indicates that improvement is necessary to allow for a 
freer and more predictable release of the conveyor transfer section in the 
event of an article jam or the like. 
SUMMARY OF THE INVENTION 
Accordingly, in order to provide a more efficient manner of transferring 
articles in a conveyor system, I am proposing an improved conveyor 
transfer assembly to be positioned downstream of a feeding portion of a 
first conveyor and upstream of the receiving portion of a second conveyor. 
The transfer conveyor assembly of my invention allows more efficient 
feeding of articles, such as cartons, along the conveyor system. The 
concept is such that the smooth transfer of articles is assured, 
especially in a conveyor system utilizing modular link conveyors that are 
so popular in the food processing and packaging industry. The transfer 
assembly is adaptable to virtually any system wherein belt-type conveyors 
are used in an end to end relationship. 
The conveyor transfer assembly includes a conveying surface on the top for 
moving the articles between the two conveyers. In the preferred embodiment 
of the present invention, the support means of the transfer section is 
freely resting by gravity on side plates of the frame of the conveyor 
system. It will be realized that in the event of an article jam, such as 
when any other foreign object becomes lodged on the upstream conveyor, the 
transfer assembly is easily lifted in a pop-up fashion and thereby 
released before any appreciable damage to the conveyor or the articles 
being transferred can occur. 
Preferably, the conveying surface includes a plurality of rollers to assist 
the article in making the transition across the transfer zone. The rollers 
are mounted on a plurality of shafts extending transversely across the 
transfer zone and with a mounting block at each end of the shafts to 
secure the same in position. Furthermore, the preferred embodiment of the 
transfer assembly includes a recessed pan for holding the mounting blocks 
and positioning the rollers at the proper level. Advantageously, the pan 
is fabricated of lightweight metal in order to provide the necessary 
strength, but at the same time to be relatively easily lifted in the event 
that a jam occurs. Similarly, the mounting blocks and the rollers are made 
of lightweight plastic material. Preferably, the rollers are freely 
rotatable discs to allow easy feeding of the articles across the full 
width of the transfer zone. 
The support means of the conveyor transfer assembly of the present 
invention advantageously includes a pair of tabs on each end of the 
support pan. The tabs in turn fit in a pair of open notches formed in the 
upper surface of the pair of upstanding side plates. Since the tabs rest 
in the notches only by gravity, in the event that a foreign object is 
present on the in-feed conveyor, the entire assembly is lifted and damage 
is prevented. Of course, the positioning of the tabs in the notches 
maintains the transfer assembly in its intended longitudinal position 
along the feed path defined by the conveyor during normal operation. 
In order to allow a change in elevation in the transfer zone, the side 
plates include a means for allowing angular adjustment with respect to the 
frame of the conveyor system. In the preferred embodiment, the adjustments 
are made by simply loosening and tightening fasteners that are mounted in 
angular slots formed in the plates. 
Additional objects, advantages and other novel features of the invention 
will be set forth in part in the description that follows and in part will 
become apparent to those skilled in the art upon examination of the 
following or may be learned with the practice of the invention. The 
objects and advantages of the invention may be realized and obtained by 
means of the instrumentalities and combinations particularly pointed out 
in the appended claims.

Reference will now be made in detail to the present preferred embodiment of 
the invention, an example of which is illustrated in the accompanying 
drawings. 
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
With reference now to FIG. 1 of the drawings, there is shown an area in a 
conveyor system 10 where a first conveyor 11 meets a second conveyor 12; 
the conveyor system 10 serving (as an example) as a continuous food 
handling or packaging line. For example, in a packaging line, the conveyor 
system 10 may be operating on a plurality of cartons C (only one shown in 
FIG. 1). The first and second conveyors 12 are preferably modular link 
conveyors which have been found over the years to be very efficient in 
this field of technology. The first conveyor 11 includes a belt 13 trained 
around a sprocket 14 at the end of its run (see flow arrows in FIG. 1). 
The conveyor 11 thus represents a feeding portion for the cartons C, or 
other articles, along the packaging line. Similarly, the conveyor 12 
includes a modular link belt 15 operating about a sprocket 16 and 
representing in FIG. 1 a receiving portion of the belt 15 to pick-up the 
carton C after passing the transfer zone in between. The modular link 
conveyors 11, 12 are preferably of the type shown in U.S. Pat. No. 
4,953,693, issued Sep. 4, 1990 and owned by the present assignee. 
As disclosed in the '693 patent, the sprocket 14 for the first conveyor 11 
may be driven by a shaft 20, the sprocket 16 being driven in a similar 
fashion by a shaft 21, and both shafts 20, 21 operating in a clockwise 
direction, as illustrated. The conveyor system 10 includes a frame, 
represented in the drawings by frame arms F.sub.1, F.sub.2, which in turn 
support the conveyor shafts 20, 21, respectively. For more detail with 
regard to the frame arms of a typical conveyor system of the type shown 
herein, reference can be made to the '693 patent. The frame of the 
conveyor system 10 also includes a pair of side plates, designated by the 
reference numerals 25, 25' (see FIGS. 1 and 2). As illustrated in FIG. 2, 
the shaft 20 is preferably driven by an electric motor M.sub.1 and the 
shaft 21 is driven by a similar electric motor M.sub.2. The two motors are 
controlled from a power source and controller P/C. 
According to the improvement of the present invention, a conveyor transfer 
assembly, generally designated by the reference numeral 30, as illustrated 
in FIGS. 1-3, is provided. The purpose, as indicated above, is to allow a 
smooth and efficient transfer of the cartons C across the transfer zone 
from the feeding portion of the belt 13 of the first conveyor 11 to the 
receiving portion of the belt 15 of the second conveyor 12 (see in 
particular, FIG. 1). As illustrated, the carton C is, in effect, 
continuously conveyed, as represented by the dashed outline in FIG. 1, 
with substantially no loss of speed or control. As represented by the 
carton C, the driving force, represented by the action arrows, pushes each 
carton forward until the carton has fully passed the transfer zone and is 
picked up for positive feed by the belt 15 of the second conveyor 12. Of 
course, depending on the size of the carton C, or other article, momentum 
is sufficient to assure proper transfer. 
However, as will be seen below, it is possible in accordance with the 
purposes of the present invention to tilt the conveyor transfer assembly 
30 so as to supplement the feeding by gravity transfer. Furthermore, in 
accordance with the broadest aspects of the present invention, the 
transfer assembly 30 can include live or driven rollers so that continuous 
feeding is provided across the entire transfer zone. 
As best shown in FIGS. 1 and 3, in the preferred embodiment the transfer 
assembly 30 includes a plurality of passive rollers 35, each roller 
including a plurality of short segments 35a, 35b . . . 35n. In effect, the 
rollers 35 forming the conveyor surface on the top of the transfer 
assembly 30 allow the carton C to readily make the transition from the 
first conveyor 11 to the second conveyor 12. 
As best shown in FIG. 3, the rollers 35 of the transfer assembly 30 include 
a support means, generally designated by the reference numeral 40. As 
illustrated, the support means includes a pair of mounting blocks 41, 42 
in which the ends of shafts 43 for the rollers 35 are held (see FIG. 3). 
In addition, the support means 40 includes a recessed pan 44 in which the 
mounting blocks 41, 42 are fixed by suitable fasteners 45. 
At the ends of the recessed pan 44, in which the mounting blocks 41, 42 are 
fastened, there is provided a pair of support tabs 50, 51. Matched with 
the tabs 50, 51 are a pair of notches 52, 53 on the upstanding side plates 
25, 25' of the frame of the conveyor system. 
As will now be apparent, and in accordance with the advantageous feature of 
the present invention, the entire conveyor transfer assembly 30 is 
positioned in the transfer zone between the first conveyor 11 and the 
second conveyor 12 by simply engaging the tabs 50, 51 in the respective 
notches 52, 53. The tabs hold the transfer assembly 30 in position in the 
direction of flow from the cartons C, C', C" but in the event of a jam, 
the transfer assembly is available to be lifted in a pop-up fashion to 
prevent damage. Forwardly and rearwardly directed stripper fingers 44a, 
44b assist in this function (see FIGS. 4a, 4b). 
Also as shown in FIG. 3, the frame of the conveyor system (only frame arm 
F.sub.2 being shown) is adjustable attached for support of the side plates 
25, 25' by fasteners 55 that thread into fixed nuts 56. As illustrated, 
the side plates 25, 25' include curved slots 57 to receive the fasteners 
55. In this manner, the plates 25, 25' can be adjusted with respect to the 
two conveyors 11, 12 (see FIG. 4a). Once the fasteners 55 are tightened, 
the plates 25, 26 are secured in place and the transfer assembly 30 is 
positioned at the desired angle so that the cartons C continue to be 
transferred efficiently. 
In operation, the cartons C, C', C" representing articles being transferred 
between the first conveyor 11 and the second conveyor 12 flow in a regular 
spacing, as shown in FIG. 4a. When the plates 25, 26 are positioned at an 
angle where the two conveyors come together at different levels, the 
cartons C, C', C" are illustrated as shown in the dashed line outline. 
With reference to FIG. 4a, there is shown a foreign object F caught within 
a recess or pocket of the modular conveyor belt 13 under the carton C. As 
illustrated, the foreign object F engages one or more of the stripper 
fingers 44a, causing a jam but easily allowing the edge of the transfer 
assembly 30 to be lifted. As will be understood, the leading cartons C', 
C" are already passed the transfer zone and being supported in total or in 
part by the belt 15 of the second conveyor 12. Since the transfer assembly 
30 is lifted upon engagement with the foreign object F, there can be no 
damage to the conveyors 11, 12 or to the cartons C or other articles being 
conveyed. Furthermore, once the transfer assembly 11 is lifted, in 
accordance with another feature of the present invention, a microswitch 60 
that is placed in the circuit with the motors M.sub.1, M.sub.2 and the 
power/controller P/C, controls both conveyors 11, 12 causing a feed 
interruption. One microswitch 60 is shown mounted on each upstanding side 
plate 25, 25' (see FIGS. 2 and 3). In both instances, the feeler arm (not 
numbered) of each microswitch 60 is depressed by the tabs 50, 51 during 
normal operation, and then when the transfer assembly 30 pops-up, one of 
the switches 60 is opened, and the power to the motors M.sub.1, M.sub.2 is 
interrupted through the power/controller P/C (FIG. 2). 
In summary, it will be realized that an improved conveyor system for 
articles, such as cartons C, is provided. A simplified and low cost 
conveyor transfer assembly 30 allows articles to be fed along the system 
in a smooth and efficient manner spanning between first and second 
conveyors 11, 12. The rollers 35 provide an efficient conveying surface 
for allowing the articles to move directly from the feeding portion of the 
first conveyor 11 to the receiving portion of the second conveyor 12. The 
30 support means 40, including the tabs 50, 51 resting within notches 52, 
53 of the side plates 25, 25' allow the entire assembly 30 to pop-up in 
the event there is an article jam or the like. Furthermore, as an extra 
feature, microswitches 60 can be positioned to sense when the tabs 50, 51 
are displaced by upward movement of the assembly 30 so that the conveyor 
system is interrupted. 
The foregoing description of a preferred embodiment of the invention has 
been presented for purposes of illustration and description. It is not 
intended to be exhaustive or to limit the invention to the precise form 
disclosed. Obvious modifications or variations are possible in light of 
the above teachings. The embodiment was chosen and described to provide 
the best illustration of the principles of the invention and its practical 
application to thereby enable one of ordinary skill in the art to utilize 
the invention in various embodiments and with various modifications as is 
suited to the particular use contemplated. All such modifications and 
variations are within the scope of the invention as determined by the 
appended claims when interpreted in accordance with breadth to which they 
are fairly, legally and equitably entitled.