Self-aligning pallets and a system for automated conveying of components through an assembly line

The disclosure is directed at a system for conveying apparatus over a conveyor belt assembly. The system includes a set of pallets which support the apparatus and travel within parallel driving conveyors of the conveyor belt assembly. While the pallets in both driving conveyors are capable of rotation, only the pallets in one of the driving conveyors may move in a direction perpendicular to the direction of travel so that the apparatus may be centred over the conveyor belt assembly when the pallets are in motion.

FIELD OF THE DISCLOSURE

The present disclosure relates generally to self-aligning pallets and more specifically, to a method and system for automated conveying of components through an assembly line.

BACKGROUND OF THE DISCLOSURE

In a conveyor system, conveyor pallets are used to transport goods or products that are not suitable to be transported directly on the conveyor system itself by reason of the nature of the goods or the need to access the goods for processing, such as a plurality of goods in a magazine. In addition, the goods may require a pallet because of their shape and/or size, or due to their sensitivity, fragility or inability to be positionally stable.

Conveyor systems may have curved sections, diverts, merging mechanisms and the like and may operate at varying speeds. Accordingly, the pallet may be subject to sudden acceleration, deceleration or radial forces. Further, in conveying around curved sections, the pallets may become jammed due to mis-alignment in the conveyor tracks. If conveying an unstable, off-centered, or top heavy product, forces may cause the product to topple off of the pallet or become dislodged from the pallet, which could result in damage to the product or conveyor system. This may result in the need to shut down the conveyor system or may reduce the ability to be able to orient the product in a controlled manner on the conveyor system.

Conventional pallets are generally simple platforms that may have some fixtures or mechanisms for supporting a product thereon but can still be quite unstable, particularly when undergoing acceleration, deceleration or radial forces.

Thus, there is a need for a pallet or adapter having features address at least some of the challenges of alignment and stability while supporting a product, for example, a top heavy or an off-center product during travel over a conveyor system.

SUMMARY OF THE DISCLOSURE

It is desirable to provide a pallet and system for the conveyance of products into, through and out of an automated assembly line in an uncomplicated, reliable, repeatable and cost-effective manner. It is also desirable to have such a system which carries magazines which are easily accessible from underneath.

It is an aspect of the present disclosure to obviate or mitigate at least one disadvantage of previous conveyor systems and pallets for use with such conveyor systems.

In a first aspect, the present disclosure provides a conveyor system pallet comprising: a body having an upper surface with a rotatable post positioned generally orthogonal to the upper surface, the rotatable post being connectable to a support plate, magazine base, sub plate, chassis, frame, carrier, or the like.

In another aspect, the present disclosure provides a conveyor system pallet comprising: a body having an upper surface with a rotatable post positioned generally orthogonal to the upper surface, the rotatable post being connectable to a carrier.

In a preferred case, the post is rotatably connected to the upper surface using a cylindrical bearing.

In another preferred case, the rotatable post has a cap attachable thereto.

In another preferred case, the pallet upper surface has a wear surface.

In another preferred case, the wear surface is an annular ring.

In another preferred case, the wear surface is self lubricating.

In another aspect, the present disclosure provides a system for conveying a support rack, the system comprising: a conveyor system having a first track and a second track, the first track spaced horizontally from the second parallel track; a first pallet positioned on the first track, and a second pallet and a third pallet positioned on the second track and each of the pallets being rotatably attached to the support rack, such that the pallets are freely rotatable along a generally vertical axis through the pallets.

In a preferred case, each of the pallets have a rotatable post positioned generally orthogonal to an upper surface of the pallets.

In another preferred case, the rotatable post has a cap attachable thereto.

In another preferred case, the pallet upper surface has a wear surface.

In another preferred case, the wear surface is an annular ring.

In another preferred case, the wear surface is self lubricating.

DETAILED DESCRIPTION

The present disclosure is directed at methods and system for conveying components through an assembly line or conveyor system. The system includes a set of pallets, preferably self-aligning, which may be controlled on the friction driven conveyor system. In operation, different components of the self-aligning pallets are controlled so that the movement of the pallets through the conveyor assembly is improved.

FIG. 1is a front perspective view of a portion of a conveyor system or assembly line with a magazine on top. The conveyor system10includes two parallel flexible link friction driving conveyors12which are spaced apart with a distance therebetween. Within the individual driving conveyors12are a set of pallets14which travel within the driving conveyors12but operate with each of the other pallets to assist in conveying a magazine16over the conveyor system. The number of pallets in the set of pallets is selected such that there is at least one pallet14in each of the driving conveyors12supporting the magazine16. Preferably, the conveyors12provide for the conveyance of pallets14in a friction drive manner through the conveyor system10.

The pallets14are shown inFIG. 1as supporting the magazine16which stores a plurality of products or components18. In the current embodiment, the products18are identical and are to be conveyed for processing. As shown, the magazine14is accessible from underneath within the space between the driving conveyors12such that access to the magazine16and products18is possible when the conveyor system10is stopped.

Turning back to the driving conveyors12, each of the conveyors12include guide rails20. The guide rails20assist to limit vertical movement of the individual pallets14and prevent tipping of the magazine16as will be described below.

FIG. 2is a close-up view of a pallet located within a driving conveyor supporting a magazine. For ease of view, the guide rail20is shown as see-through so that features of the pallet14may be viewed. The pallet14is located within the driving conveyor12and shown as supporting the magazine16and the product18within the magazine16.

The conveyor guide rail20is supported by brackets22mounted to a conveyor support structure24and includes channels26for assisting in the movement and containment of the pallet14. In one embodiment, pallet direction guide and anti-tip bearings or rollers28interact with the channels26of the conveyor guide rail20to provide more stable transport of the pallet14over the conveyor system10.

As shown in the embodiment ofFIG. 2, two lower rollers28aare positioned to abut a lower ledge of the conveyor guide rail20, or channels26, thereby limiting vertical travel of the pallet14from the surface of the driving conveyor12while two upper rollers28bare provided to abut a side of the conveyor guide rail20as the pallet14travels along the driving conveyor12in a direction of travel along the conveyor system10. The direction of travel is identified as arrow30. Although only two lower rollers and two upper rollers are shown, any number of rollers may be used depending on the characteristics of the conveyor system such as, but not limited to, the radius of curvature of turns within the conveyor system. For small radius of curvatures, more rollers may be included.

The pallet14further includes an adapter, such as plate32attached thereto which is preferably mounted or attached to the pallet. In one embodiment, the adapter plate32is bolted to the pallet14, however it is contemplated that the adapter plate32may be attached via other methods such as, but not limited to, mechanical fasteners, adhesive, and the like.

The pallet14further includes a wear plate34and a sensor register36. The sensor register36is used to track the location of the pallet14while it is moving within the conveyor system10. Corresponding sensing apparatus for detecting the presence of the sensor registers36may be mounted throughout the conveyor system, such as along the channels26of the drive guide20or as individual mounted apparatus in proximity to the driving conveyors12. The sensor registers36may include identification information to identify the magazine16or the products18that are being transported by the pallets14or may simply include an identification of the pallet14.

The pallet14may also include a bumper portion38. A second bumper may be mounted on an end opposite the bumper portion38so that there is protection for the pallet14in the direction of travel30. In a preferred embodiment, the pallet14is one such as is described in U.S. Provisional Patent Application No. 61/318,938, filed Mar. 30, 2010, titled “Conveyor Pallet and Guiding System”, the contents of which are incorporated herein by reference.

FIG. 3shows a rear view of the conveyor system shown inFIG. 1. As can be seen, the magazine16, or pair of magazines, rest atop the pallets14which are located within the driving conveyors20.

FIG. 4is a perspective view of a pallet. As described above, the pallet14includes the adapter plate32which, in the current embodiment, is fixed thereto via a set of fasteners, such as bolts42. The adapter plate32is shown as a plate having an upper surface44with an annular wear surface46, preferably self-lubricating, circumscribing an area of the upper surface44of the adapter plate32. Proximate a middle of the annular wear surface44is a rotatable post47which rotates through an axis approximately orthogonal to a plane of the upper surface44. A retaining cap48is shown positioned on a top of the rotatable post46for keeping the post in place, such as against the magazine, when the pallet14is in use. The post46is preferably fixed to a bearing (not shown) within the adapter plate32. Although shown as a plate32, the adapter may be any other apparatus which performs similar functionality. As can be seen fromFIG. 3, the adapter plate32is attached to the magazine16by positioning the rotatable post46against a base of the magazine16, and then fixing the cap48to the post46such that a thickness of the base of the magazine16is between the cap48and the upper surface44. Alternatively, the rotatable post46can be fitted through a hole in the base of the magazine18and held in place by affixing the cap48to the top of the post46. Other methods of mounting or connecting the magazine16to the pallet14may be contemplated.

FIG. 5is a underside view of a set of pallets. The driving conveyors have been removed in this Figure so that a clearer representation of a three pallet embodiment and their relationship may be shown and described. Depending on the set up of the system, any number of pallets may be used. The interaction and cooperative movement of the set of pallets when the conveyor system is in operation assist in providing an improved system and method for conveying components through the conveyor system. In the current embodiment, three pallets14a,14band14care shown.

The pallets14rotate through individuals arcs, identified as50a,50band50c, respectively. Rotation of each of the pallets14is via the individual rotatable posts46which have a predetermined amount of rotation and assists to reduce or prevent the pallets14from “jamming” when they are moving within the driving conveyors12. Directional arrow30represents the direction of travel of the combination of the magazine16and pallets14within the conveyor system10.

As shown, a single pallet14ais positioned at one side of the magazine16within one driving conveyor12, while two pallets14band14care positioned within the other driving conveyor12on opposite sides of the magazine16from pallet14a. In operation, pallet14ais capable of linear movement along the line, identified as bidirectional arrow52, which is generally transverse to the direction of travel30. In one embodiment, this is achieved either by fixing the pallet14bthrough a slot54in the magazine16, or by attachment of the post46(associated with pallet14a) to the adapter plate32(associated with pallet14a) such that the post is movable in the direction52.

In operation, as the pallets traverse around a corner of the conveyor system, the two pallets14band14ccontrol the arc of rotation for the magazine16. The three pallets14a,14band14cform a triangular pattern, which would require the single pallet14aon the opposite side to move away from the two pallets14band14c. This is compensated for with a generated curve for the radial section of the larger conveyor turn of the “outside” conveyor, but the flexible belt will not track around this variable geometry, therefore allowing the single pallet14ato “float” in one direction (perpendicular to the direction of motion) so that it is able to find its own position relative to the opposite pair of pallets.

FIG. 6is a top view of a conveyor system showing a sequential progression of pallets moving around a curve of the conveyor system. As with the example ofFIG. 5, the magazine16is supported by a set of three pallets14a,14band14cin this example. As pallet14amoves along its driving conveyor12aand pallets14band14cmove along driving conveyor12b, the pallets14a,14band14cfind their own neutral orientation to the magazine16, in particular through the corner by rotation on their respective axes. This is achieved by the rotation of the individual rotatable posts46and the ability for pallet14ato move in the direction of arrow52. Therefore, as the pallets14move along the conveyor system, and more specifically around a curve, pallets14band14care stationary with respect to travel in a direction perpendicular to the direction of travel, however, they may rotate about their rotatable posts. With pallet14a,as the magazine16and pallets14navigate the curve of the conveyor system, pallet14amay move in a direction perpendicular to the direction of travel to assist in centering the magazine over the conveyor system, thereby reducing the likelihood that the pallets, or magazine may stop moving. Therefore, by allowing pallet14ato move in a lateral direction, or direction perpendicular to the direction of travel, provides for an improved conveyance system.

For ease of understanding, the reference numbers without a prime designation is an initial position while the reference numbers with a prime designation, seen as including an apostrophe, is a position of the pallet or magazine at a different period of time. For example, pallets14a′,14b′ and14c′ and outline of magazine16′ are shown to represent a progression into the curve from the previous location shown as pallets14a,14band14cand outline of magazine16.

In operation, as can be seen, the relative distance between the pallet14aand the pallets14band14c, changes as the pallets progress around the curve. As discussed above, pallet14ais able to move in a lateral direction52, for example by sliding within a slot54which may be the hole within the magazine16through which the rotatable post46is located. This lateral movement of pallet14aadjusts the position of pallet14arelative to the other pallets14band14cand thus pallet14aremains “on center” with respect to driving conveyor12a. In the system shown inFIG. 6, the direction of travel of the magazine, carrier or such, is controlled in linear and radial directions by pallets14band14cas these only have rotational freedom of movement in a vertical axis as provided by the individual rotatable posts46.

In the preceding description, for purposes of explanation, numerous details are set forth in order to provide a thorough understanding of the embodiments. However, it will be apparent to one skilled in the art that these specific details are not required.