Conveyor apparatus

A conveyor apparatus for diverting product from a single lane to one of a plurality of lanes includes a wall having an upstream portion positioned proximate the single lane and a downstream portion positioned proximate the plurality of lanes. The upstream portion is stationary relative to the single lane and the downstream portion is configured to be movable relative to the plurality of lanes. A length of the wall is configured to vary in response to movement of the downstream portion.

BACKGROUND

The present invention relates to a conveyor apparatus, and in particular a laner for diverting articles along a conveyor path from a single conveyor to one of a plurality of downstream lanes.

Diverters are used in product processing or conveying systems to divide a single file flow of products into multiple rows, or lanes, of products. Some diverters divide product flow into multiple lanes without stopping or slowing down the product flow rate along an infeed path; however, such diverters do not maintain product stability during lane changes, make lane changes while stopping product flow or allowing products to move out of lane limits (i.e., directing products to between lane points along the flow path), and require complicated electro-mechanical devices to accomplish lane changes. These diverters decrease product flow through the conveying system and result in product contact, damage, and jams during lane changes.

SUMMARY

In one embodiment, the invention provides a conveyor apparatus for diverting product from a single lane to one of a plurality of lanes. The conveyor apparatus includes a wall having an upstream portion positioned proximate the single lane and a downstream portion positioned proximate the plurality of lanes. The upstream portion is stationary relative to the single lane and the downstream portion is configured to be movable relative to the plurality of lanes. A length of the wall is configured to vary in response to movement of the downstream portion.

In another embodiment, the invention provides a conveyor apparatus for diverting product from a single lane to one of a plurality of lanes, whereby the product in the single lane is moving on a conveyor along a travel path. The conveyor apparatus includes a wall provided above the conveyor. The wall has an upstream portion and a downstream portion. The downstream portion is configured to be movable in a direction substantially parallel to the travel path and is configured to be selectively movable in a non-parallel direction to the travel path in order to selectively direct the product to one of the plurality of lanes. While the wall is moving relative to the travel path, the wall is configured to selectively vary a wall length between the upstream portion and the downstream portion.

In yet another embodiment, the conveyor apparatus includes a wall having an upstream portion positioned proximate the single lane and a downstream portion positioned proximate the plurality of lanes. The wall is configured to direct the product from the single lane toward the plurality of lanes. The conveyor apparatus also includes a carriage system configured to move relative to the plurality of lanes in a first direction and in a second direction non-parallel to the first direction. The downstream portion of the wall is coupled to the carriage system for movement therewith. The carriage system moves the downstream portion of the wall adjacent to one of the plurality of lanes to direct the product toward the one of the plurality of lanes. The conveyor apparatus also includes a take-up system coupled to the wall and configured to take-up and release a portion of the wall in response to movement of the downstream portion of the wall.

In still another embodiment, the conveyor apparatus includes a first wall having a first upstream portion positioned proximate the single lane and a first downstream portion positioned proximate the plurality of lanes. The conveyor apparatus also includes a second wall generally parallel to the first wall and defining a channel therebetween. The second wall has a second upstream portion positioned proximate the single lane and a second downstream portion positioned proximate the plurality of lanes. The first and second upstream portions are stationary relative to the single lane, and the first and second downstream portions are movable relative to the plurality of lanes. A length of each of the first and second walls is configured to vary in response to movement of the first and second downstream portions. The conveyor apparatus further includes a carriage system having a yoke configured to be movable relative to the plurality of lanes in a first direction and a second direction non-parallel to the first direction. The first downstream portion and the second downstream portion are coupled to the yoke for movement therewith.

Other aspects of the invention will become apparent by consideration of the description below and accompanying drawings.

DETAILED DESCRIPTION

The present invention relates to a conveyor apparatus10, or laner or diverter system, used in a product processing or conveying system14to divide a single file product flow into multiple rows, or lanes, of products. The conveying system14includes an infeed conveyor18defining an upstream flow path and an outfeed conveyor22formed by a plurality of lanes22A,22B,22C, each defining a downstream flow path. Each lane22A,22B,22C feeds one or more downstream channels26A,26B,26C, each of which is defined by the outfeed conveyor lanes22A,22B,22C and dividers30. In the illustrated embodiments, three lanes are shown although it should be readily apparent to those of skill in the art that fewer or more lanes may be used.

The diverter system10is used to divide product flow from the infeed conveyor18to one of the lanes22A,22B,22C without stopping or slowing down product flow rate along the infeed conveyor18. The diverter system10also maintains stability of product and keeps product within lane limits during lane changes. Therefore, the diverter system10allows for increased process flows through the conveying system14, and reduces or eliminates product contact and damage during lane changes.

FIGS. 1 and 2illustrate one embodiment of the diverter system10used in the conveying system14. The infeed conveyor18is formed by a conveyor having a movable carrying surface, and the outfeed conveyor22and the lanes22A,22B,22C are formed by a series of side-by-side conveyors. Examples of the types of conveyors used in the diverter system10include a chain, a belt, or other known conveyors. In the illustrated embodiment, the outfeed conveyor22and the lanes22A,22B,22C are formed by three separate side-by-side chains, generally referred to as table top chains. In another embodiment, a single wide chain may be used, generally referred to as mat top chain.

The diverter system10includes a pair of guide walls34that extend a length of the outfeed conveyor22. The guide walls34are spaced apart to define a channel38through which conveyed articles42, or product, pass. In the illustrated embodiment, each guide wall34is formed of modular plastic belting and includes a stainless steel backing plate46to provide additional support to the guide wall34. It should be readily apparent to those of skill in the art that in a further embodiment, the guide wall34may be formed from a bead rail, a flexible rail, a driven rail belt, a gripper-type chain, soft textured belting, a belt with a band of memory foam attached thereto, or another known material for stabilizing conveyed product. In an embodiment with a driven rail belt, speed of the rail belt may be varied with respect to the speed of the outfeed lanes. Each guide wall34includes a downstream portion34A coupled to a yoke member50extending from a carriage system54of the diverter system10and an upstream portion34B coupled to a coil assembly58. A portion of the wall34is selectively taken up by and fed out from the coil assembly58to shorten and lengthen an exposed portion of the wall34, and thereby, the channel38.

The carriage system54selectively moves a portion of the guide walls34proximate the downstream portion34A across the outfeed conveyor22and the lanes22A,22B,22C to divert products from the first lane22A, which is aligned with the infeed conveyor18, to the second lane22B or the third lane22C. The carriage system54also selectively moves the guide walls34along the outfeed conveyor22. Thus, the walls34effectively move in a diagonal direction to divert articles to the selected lane. A length of the walls34is released by the respective coil assembly58as the downstream portion34A moves away from the infeed conveyor18to extend the walls34and the channel38. Likewise, a length of the walls34is taken up by the respective coil assembly58as the downstream portion34A moves toward the infeed conveyor18to shorten the walls34and the channel38.

Movement of the walls34is coordinated by a controller (not shown), such as a PLC, and product quantity sensors (not shown) positioned downstream of the infeed conveyor18. In the illustrated embodiments the guide walls34are moved and positioned at the downstream portion34A by a linear servo slide assembly of the carriage system54. In further embodiments, other known actuator assemblies may be used, such as a pneumatic cylinder (with preset stop positions or position feedback capability), a linear actuator, a gear rack assembly, or the like. The product quantity sensors may be a photo eye or photocell, a sonic sensor, a vision sensor, a photoelectric sensor, an encoder, a proximity sensor, or any other known position quantity sensor.

Referring toFIGS. 3A-3C, the carriage system54includes a linear servo system mounted above the outfeed conveyor22to facilitate movement of the guide walls34along a length of the outfeed conveyor22(i.e., in a first direction generally parallel to a travel direction of articles42) and across a width of the outfeed conveyor22(i.e., in a second direction generally perpendicular to a travel direction of the articles42). In the illustrated embodiment, the linear servo system is mounted to a frame62(FIG. 1) of the conveyor system14. The downstream portion34A of each guide wall34includes a bracket66that is coupled to the yoke member50, which is coupled to the carriage system54.

The carriage system54includes a first carriage assembly70aligned generally parallel to the outfeed conveyor22travel path for the conveyed product (i.e., in the first direction) to define a first axis, and a second carriage assembly74aligned generally perpendicular to the travel path (i.e., in the second direction) to define a second axis. The first carriage assembly70includes a support plate78, a track82coupled to the support plate78, a mount plate86slidably coupled to the track82such that the plate86slides back and forth along the track82in the first direction, and a linear bearing90for effecting movement of the plate86. As shown inFIGS. 3A-3C, the yoke members50are coupled to the mount plate86such that movement of the mount plate86in the first direction translates to linear movement of the guide walls34along the outfeed conveyor22.

The second carriage assembly74includes a support plate94coupled to the frame62, a track98coupled to the support plate94, a mount plate102slidably coupled to the track98such that the plate102slides side to side across the outfeed conveyor22in the second direction, and a linear bearing106for effecting movement of the plate102. As shown inFIGS. 3A-3C, the mount plate102of the second carriage assembly74is coupled to the support plate78of the first carriage assembly70(e.g., by screws of other known fasteners) such that movement of the mount plate102in the second direction translates to linear movement of the first carriage assembly70and thereby the downstream portion34A of the guide walls34across the outfeed conveyor22.

Each carriage assembly70,74includes a servo motor110,114and the linear bearing90,106for sliding the mount plates86,102along the respective tracks82,98. The servo motors110,114allow for instant speed changes to match upstream or downstream product requirements. Movement of the plates86,102, and thereby the guide walls34, is controlled by a controller (not shown) based upon preset parameters and user commands. The controller commands the carriage assemblies70,74to move the guide walls34to specific positions along the outfeed conveyor22. An example of a linear positioning system used with the carriage assemblies70,74in the diverter system10is provided by LinTech (Monrovia, Calif.). It should be readily apparent to those of skill in the art that in further embodiments other systems may be used for moving the guide walls in the first direction and the second direction, such as rodless, pneumatic or electric cylinders, a linear actuator, a gear rack assembly, a ball screw, or other known actuator assemblies.

InFIG. 3A, the first carriage assembly70is at a central position on the second carriage assembly74and the yoke members50are at an upstream, or rearward, position on the first carriage assembly70. Such a configuration represents a first, or “home”, position of the carriage system54. InFIG. 3B, the carriage system54is moved to a second position, whereby the yoke members50are at a downstream, or forward, position on the first carriage assembly70. InFIG. 3C, the carriage system54is moved to a third position, whereby the first carriage assembly70is at an end of the second carriage assembly74such that the guide walls34direct the product toward a different channel than when in the first position (FIG. 3A). In addition, the yoke members50are at a central position on the first carriage assembly70.

Referring toFIGS. 1 and 2, the plurality of lane dividers30are positioned downstream of the carriage system54to define the channels26A,26B,26C. A pair of U-shaped frame members118A,118B are coupled to opposite sides of a conveyor bed122such that a central portion of each frame member118A,118B is spaced above the outfeed conveyor22. Each divider30is coupled to the frame members118A,118B and extends downwardly therefrom to define the channels26A,26B,26C. Spacing between the adjacent dividers30may be varied depending on the conveyed product size. In the illustrated embodiment, four dividers are shown to define three channels, although fewer or more dividers may be used depending on the number of outfeed lanes and channels for the conveyor system14.

Referring toFIG. 4A, the upstream portion34B of each guide wall34is attached to the respective coil assembly58, or take-up system. A portion of the wall34coils about the coil assembly58for storage. A length of each wall34is selectively released and taken up by the respective coil assembly58during operation of the diverter system10. In the illustrated embodiment, the coil assemblies58are positioned at the interface between the infeed conveyor18and the outfeed conveyor22, and are supported by a plate126positioned above the infeed conveyor18.

As shown inFIGS. 5 and 6, each coil assembly58includes a spring housing130, a torsion spring134, a pair of clamping collars138A,138B, and a pair of tensioners142A,142B. The guide wall34is coupled to the coil assembly58between the pair of clamping collars138A,138B. The clamping collars138A,138B guide or position the guide walls34about the housing130, and are adjustable to accommodate different sized walls or to adjust the height (i.e., distance) of the walls34from the infeed conveyor18and the outfeed conveyor22.

The spring housing130, or bushing, is rotatable relative to the plate126to take-up (i.e., coil) the wall34about the spring housing130and to release (i.e., uncoil) the wall34from the coil assembly58. The torsion spring134is contained within the spring housing130and is supported between the tensioners142A,142B. Each of the tensioners142A,142B includes inwardly extending flanges146that engage opposite ends of the torsion spring134. The upper tensioner142A is exposed through the plate126such that a user may turn the tensioner142A to thereby adjust the tension of the torsion spring134. A spacer150is positioned between the upper tensioner142A and the spring housing130to reduce friction and facilitate relative rotation of the tensioner142A. In the illustrated embodiment, the torsion spring134is biased to a first position, or coiled position, whereby the guide wall34is taken up by the coil assembly58and coiled about the spring housing130. However, the torsion spring134is rotatable to a second position against the bias of the torsion spring134(e.g., when the wall34is pulled from the coil assembly58) such that the spring134and the wall34are under tension.

In operation, as the carriage system54moves the yoke members50away from the infeed conveyor18in the first direction, the guide wall34is pulled from the coil assembly58, which causes the torsion spring134and the spring housing130to rotate and release the wall34. As the carriage system54moves the yoke members50back toward the infeed conveyor18, tension is released by the torsion spring134and the spring134rotates back to the first position. The guide wall34then coils about the spring housing130. In a further embodiment, the guide walls34may be moved and positioned by a rotary servo motor, a rotary air cylinder, a rotary actuator, or another known actuator assembly.

In the illustrated embodiment, a first adjustment assembly154(FIGS. 3A-3C) is coupled to the downstream portion34A of the guide walls34by the yoke members50, and a second adjustment assembly158(FIG. 4B) is coupled to the upstream portion34B of the guide walls34by roller assemblies162A,162B. The adjustment assemblies154,158allow a user to adjust the width of the channel38to accommodate different sized products. Typically, both the first and second adjustment assemblies154,158are adjusted such that the width of the channel38is the same at both the downstream portion34A and upstream portion34B of the guide walls34. Each adjustment assembly154,158operates in a similar manner and, as such, only the second adjustment assembly158will be described in detail herein.

Referring toFIG. 4B, the adjustment assembly158includes a crank handle166(FIG. 4A) and first and second dovetail slides170A,170B. First and second rollers172A,172B of the roller assemblies162A,162B are coupled to the slides170A,170B through posts174A,174B and mount brackets178A,178B to engage the guide walls34and define the width of the channel38. In the first adjustment assembly154, the yoke members50are coupled to the slides170A,170B directly to engage the guide walls34and define the width of the channel38. The slides170A,170B are supported for movement along a track182on the plate126. Rotating the crank handle166in one direction (e.g., counterclockwise) causes the slides170A,170B, and thereby the rollers172A,172B, to separate, increasing the width of the channel38. Rotating the crank handle166in an opposite direction (e.g., clockwise) causes the slides170A,170B, and thereby the rollers172A,172B, to come together, decreasing the width of the channel38. In some embodiments, the crank handles166of the first and second adjustment assemblies154,158may be coupled such that rotation of one crank handle166also causes the other crank handle166to rotate. Additionally or alternatively, the adjustment assemblies154,158may be automatically actuated by a servo motor or other suitable device.

In operation, a single file of products enters the diverter system10on the infeed conveyor18, which in the illustrated embodiment aligns with or forms the center, first lane22A. When product flows from the infeed conveyor18to the first lane22A, the guide walls34are positioned between the first lane22A and the second lane22B and between the first lane22A and the third lane22C (i.e., the first position), respectively. The product maintains positioning on the first lane22A for as long as required or desired. In the first position (FIG. 3A), the second carriage assembly74is centered about the first carriage assembly70and the yoke members50are at an upstream position on the first carriage assembly70such that a portion of the guide walls34is coiled up within the coil assemblies58. In another embodiment, the guide walls34are extended from the coil assemblies58.

When the first lane22A has reached capacity or a pre-determined value, a sensor signals the controller to move the guide walls34to another lane, either the second lane22B or the third lane22C. The yoke members50are moved to the upstream position on the first carriage assembly70(FIG. 3A), if not already located at the upstream position, such that a portion of the guide walls34is coiled up within the coil assemblies58. The yoke members50coupled to the mount plate86then move away from the infeed conveyor18(i.e., forward) along the first carriage assembly70to the downstream position (FIG. 3B). Simultaneously, the first carriage assembly70moves sideways toward the desired lane along the second carriage assembly74(FIG. 3C). The combination of downstream (i.e., forward) movement in the first direction and movement in the second direction by the yoke members50aligns the product flow through the channel38with a new lane. It should be readily apparent to those of skill in the art that simultaneous movement of the first and second carriage assemblies70,74will result in effective diagonal movement of the guide walls34to the desired lane.

During extension and retraction of the guide walls34, the walls34are kept under constant tension between the yoke members50and the coil assemblies58. When the downstream portions34A of the walls34move in the second direction (FIG. 3C), some bowing of the walls34may occur to absorb product. In the illustrated embodiment, the walls34do not follow a serpentine path. Once the lane alignment is complete, the yoke members50move to the upstream position on the first carriage assembly70, while the first carriage assembly70remains stationary, in preparation for a new cycle. The cycle is then repeated depending upon which lane is signaled by the controller.

Movement of the guide walls34may also be coordinated based upon sensed gaps between conveyed product on the infeed conveyor18or within the outfeed channels26A,26B,26C downstream of the diverter system10. In one embodiment, if no gap is detected by the sensors, the walls34stop during lane change to prevent product from catching between the outfeed channels26A,26B,26C. The walls34will move again once the lane change is complete. In one embodiment, the guide walls34are mounted such that the walls34automatically move in and out of relationship to any product width.

FIG. 7illustrates another embodiment of a conveyor apparatus210, or diverting system, used in a conveying system214. The diverting system210is similar to the diverting system10discussed above with reference toFIGS. 1-6and like parts have been given the same reference number plus 200. Reference is hereby made to the description accompanyingFIGS. 1-6for explanation of the various features and elements of the diverting system210not specifically discussed herein.

Referring toFIG. 8, each coil assembly258, or take-up system, includes an outer housing386, an inner spring housing390, a compression spring394, a compression spring housing398, a torsion spring402, and a compression spring retainer406. The inner spring housing390is contained within the outer housing386and includes an anchor flange410extending radially outward from an exterior wall of the spring housing390. The outer housing386includes an opening communicating with an inner chamber of the housing386. The guide wall234enters the opening of the outer housing386and is coupled to the anchor flange410of the inner spring housing390to anchor the wall234to the coil assembly258.

The inner spring housing390is rotatable relative to the outer housing386to take-up (i.e., coil) the wall234about the spring housing390and to release (i.e., uncoil) the wall234from the coil assembly258. The torsion spring402is contained within an inner chamber390A of the inner spring housing390and is supported by the compression spring housing398. The compression spring394is contained within the compression spring housing398and is biased in an upward position against the torsion spring402. The spring retainer406covers the compression spring housing398to contain the compression spring394within the housing398. An upper flanged portion406A of the retainer406is coupled to the torsion spring402to allow the torsion spring402to rotate relative to the compression spring housing398. A first end402A of the torsion spring402is coupled to the spring retainer406and has a smaller diameter than a remaining portion of the torsion spring402. The first end402A of the torsion spring402fits into an opening of the compression spring housing398. The compression spring394maintains the torsion spring402in a centered position as the spring402rotates.

Similar to the coil assembly58discussed above with reference toFIGS. 5 and 6, the torsion spring402is biased to a first position, or coiled position, whereby the guide wall234is taken up within the coil assembly258and coiled about the inner spring housing390. The torsion spring402is also rotatable to a second position against the bias of the spring402such that the spring402and the wall234are under tension. As the carriage system254moves the yoke members back toward the infeed conveyor218, tension is released by the torsion spring402and the spring402rotates back to the first position. The guide wall234then coils about the inner spring housing390.

Although particular embodiments of the present invention have been shown and described, other alternative embodiments will be apparent to those skilled in the art and are within the intended scope of the present invention. The foregoing description of the present invention has been presented for purposes of illustration and description. Furthermore, the description is not intended to limit the invention to the form disclosed herein. Consequently, variations and modifications commensurate with the above teachings, and the skill or knowledge of the relevant art, are within the scope of the present invention. The embodiments described herein are further intended to explain best modes known for practicing the invention and to enable others skilled in the art to utilize the invention in such, or other, embodiments and with various modifications required by the particular applications or uses of the present invention.

Various features and advantages are set forth in the following claims.