High speed baggage diverter

A diverter assembly according to the present invention includes a generally horizontal conveying surface, a pair of flipper assemblies, and an actuator for substantially concurrently actuating the flipper assemblies to an actuated position whereby the flipper assemblies are collinear. A driven diverting surface is defined on each flipper assembly wherein an article on the conveying surface is diverted when the article contacts one of the flipper assemblies when the flipper assembly is in its actuated position.

TECHNICAL FIELD AND BACKGROUND OF THE INVENTION

The present invention pertains to article diverters and, in particular, to high-speed diverters. Although the invention finds particular application to the diverting of baggage, such at airport baggage handling systems, or the like, the invention may find other applications.

Diverters for irregularly shaped articles, such as baggage, share many of the same goals and challenges that diverters for regularly shaped articles, such as boxes or containers, face. One goal is to sort the articles at a high rate so that the diverting or sorting function does not significantly slow the throughput of the articles. Another goal is to minimize damage to the articles being diverted. The faster the rate of the throughput, the greater the challenge this becomes.

Similar to boxes and containers, baggage can vary in their weight, size, and centroid location. In contrast to boxes or containers, baggage can vary greatly in their shape and composition. For example, baggage may include a relatively rigid suitcase, a duffle bag, a ski bag, a golf bag, or the like. Some baggage, such as duffel bags, is malleable. When pushed they may change shape or roll. This variation in shape and malleability of these irregularly shaped articles makes sortation even more challenging than sortation of regularly shaped articles. For example, baggage may be more susceptible to damage than articles, such as containers, because of the material forming the baggage, such as in the case of duffle bags, does not absorb any significant impact. Furthermore, given the variation in size and shape of baggage, larger articles, such as large trunks may topple over the diverter when diverted by many conventional diverters. Furthermore, baggage may include straps or loose handles, which can be easily snagged or caught up in a diverter assembly.

Consequently, there is a need for a diverter that can divert a variety of articles, including regularly shaped or irregularly shaped articles, at a high speed of sortation without the attendant problems associated with conventional diverters.

SUMMARY OF THE INVENTION

Accordingly, a diverter assembly of the present invention has a particular application as a high-speed diverter and may be used to divert articles, such as baggage or the like.

In one form of the invention, the diverter assembly includes a generally horizontal conveying surface, a pair of flipper assemblies on opposite sides of the conveying surface which are collinear when in an actuated position, and a driven diverting surface defined on each flipper assembly. The diverter assembly further includes an actuator for selectively and substantially concurrently actuating the flipper assemblies to their actuated positions, where an article on the conveying surface is diverted, and driving the diverting surface.

In one aspect, the diverting surface is defined by a driven surface, such as a drive belt.

In other aspects, the diverting surfaces of the flipper assemblies are at an angle with respect to the direction of travel of the articles on the horizontal conveying surface that is in a range from 20° to 60°. In a further aspect, the angle is approximately 45°.

According to yet another aspect, the actuator extends downwardly from the horizontal conveying surface no more that 18 inches. In a further aspect, the actuator extends downwardly from the horizontal conveying surface no more than 12 inches.

In yet another aspect, the diverter assembly is capable of diverting at least 60 articles per minute and, in some applications, is capable of diverting at least 80 articles per minute. In yet other applications, the diverter assembly is capable of diverting upwards of 140 articles per minute.

According to another form of the invention, a diverter assembly includes a conveying surface having a conveying direction, a pair of arms at opposed sides of the conveying surface, a driven diverting surface defined at both arms, and a drive assembly. The arms are mounted for pivotal movement between a non-diverting position wherein the arms are adjacent the conveying surface and a diverting position wherein the arms are pivoted across the conveying surface for diverting one or more articles conveyed on the conveying surface in a transfer direction. The drive assembly selectively and substantially currently moves the arms between their diverting position and their non-diverting position wherein an article on the conveying surface is diverted when the article contacts at least one of the arms when the arm is in its diverting position. In addition, the drive assembly drives the driven diverting surfaces at a speed that is approximately equal to the speed of the conveying surface divided by the cosine of the angle between the conveying direction of the conveying surface and the transfer direction of the diverter assembly.

In one aspect, the arms are generally collinear when the arms are pivoted to their diverting positions. In another aspect, at least one of the arms comprises a horizontal extent and a belt extending around the horizontal extent. The belt is driven about the horizontal extent and provides the diverting surface for that arm.

According to another aspect, the diverting surfaces comprise driven belts. For example, the driven belts are driven by rollers. In a further aspect, each roller includes a driven axis about which the respective roller is driven. The arms pivot about their respective pivot axis when pivoting between their non-diverting position and their diverting position. Optionally, the drive assembly may be adapted to decouple movement of the driven belts about their driven axis from movement of their respective arm about their pivot axis. For example, the drive assembly may include a clutch assembly.

In yet a further aspect, each driven axis is collinear with its respective pivot axis. In an alternate aspect, the driven axes and the pivot axes are spaced apart.

In another form of the invention, a diverter assembly includes a generally horizontal conveying surface, a pair of arms at opposed sides of the conveying surface, a driven diverting surface defined at each of the arms, and a drive assembly for selectively moving the arms between a diverting position and a non-diverting position. In the diverting position, the arms are pivoted with a portion of the arms extending across the conveying surface and another portion of the arms extending beyond the conveying surface, which continues to drive a diverted article when the diverted article is diverted off the conveying surface.

In one aspect, each of the arms includes a distal end, which are generally adjacent when the arms are pivoted to their diverting position. In another aspect, the distal ends of the arms are spaced apart when the arms are pivoted to the diverted position.

According to yet another form of the invention, a diverter assembly includes a generally horizontal conveying surface, a pair of arms which are mounted at opposed sides of the conveying surface, a driven diverting surface which is defined at each of the arms, and a drive assembly. The arms are mounted for pivotal movement between a non-diverting position wherein the arms are adjacent the conveying surface and a diverting position wherein at least a portion of the arms are pivoted across the conveying surface. The arms are spaced longitudinally along the conveying direction of the conveying surface wherein distal ends of the arms are offset and spaced apart when the arms are moved to their diverting position. The drive assembly selectively moves the arms between the diverting position and the non-diverting position.

In one aspect, the drive assembly drives the driven diverting surface and, further, drives the driven diverting surfaces at a speed approximately equal to the conveying speed of a conveying surface divided by a cosine of an angle between the conveying direction and the diverting direction. In this manner, when the article makes contact with the diverting surface, the forward vector component of the belt speed will approximately equal the forward speed of the article. As a result, the speed of the article will remain substantially unchanged.

In yet another form of the invention, a diverter assembly includes a conveyor section having a generally horizontal conveying surface, a pair of arms at opposed sides to the conveying surface, and a drive assembly. The arms are mounted for pivotal movement between a non-diverting position and a diverting position wherein at least a portion of the arms are pivoted across the conveying surface. The conveying surface is adapted to be selectively lowered at the arms when the arms are in their diverting position to release any articles caught between the conveying surface and the arms. The drive assembly selectively moves the arms between the diverting position and the non-diverting position.

In one aspect, the diverter assembly further includes a driven diverting surface defined at each of the arms; for example, the diverting surfaces may comprise driven belts. In a further aspect, the driven belts are driven at a speed equal to the conveying speed of the conveying surface divided by a cosine of an angle between the conveying direction and the diverting direction to thereby maintain the forward speed of the article being diverted generally constant.

According to yet another form of the invention, the diverter assembly includes a generally horizontal conveying surface, a pair of arms, and a driven diverting surface which is defined at each of the arms. The driven diverting surface has a vertical height of at least twelve inches whereby contact between an article and the arms will occur at or above the centroid of most articles. The diverter assembly further includes a drive assembly for selectively moving the arms between a non-diverting position wherein the arms are adjacent the conveying surface and diverting position wherein at least portion of the arms are pivoted across the conveying surface.

In one aspect, the driven diverting surfaces comprise driven belts. For example, each of the arms may include a horizontal extent, with the driven belts driven around the horizontal extents of the arms. In a further aspect, the driven belts are rotated about a pair of belt axes with the arms pivoting about a pivot axis spaced inwardly from one of the belt axes.

It can be appreciated from the foregoing that the diverter assembly of the present invention can divert articles that are conveyed at a relative high-speed without significantly, if at all, reducing the rate at which the articles are handled. Furthermore, since an article is redirected without significantly reducing the articles forward motion, the impact to the article being diverted is minimal.

These and other objects, advantages, purposes, and features of the invention will become more apparent from the study of the following description taken in conjunction with the drawings.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to the drawings and the illustrative embodiments depicted therein, the numeral10generally designates a high-speed diverter assembly of the present invention. High-speed diverter assembly10is particularly suitable for diverting articles, such as baggage, and is typically positioned between two conveyor sections C1and C2so that articles conveyed on, for example, C1may be diverted to a take-away conveyor section or chute C3(FIG.1), which is positioned adjacent diverter assembly10. High-speed diverter assembly10includes a horizontal conveying surface14, a pair of flipper assemblies16, and a flipper actuator or drive assembly18. Horizontal conveying surface14includes a bed or belt support surface20and a pair of guide pulleys or rollers22a,22b for supporting a driven belt (not shown), which typically would extend well beyond baggage diverter assembly10. It should be understood that other types of conveying surfaces, such as driven rollers, or the like, may be used to propel articles past or through baggage diverter assembly10. As will be more fully described below, flipper assemblies16are adapted so that they selectively and quickly divert articles conveyed on conveying surface14away from the conveying direction of conveyor sections C1and C2but with minimal impact on the articles being diverted.

Each flipper assembly16includes an arm19(FIG. 3) which comprises a flipper frame24and a diverting surface26supported by flipper frame24. In the illustrated assembly, diverting surface26is a driven belt but other surfaces are possible, such as driven or non-driven rollers, or the like. Flipper actuator assembly18selectively concurrently actuates flipper assemblies16between a retracted or non-diverting position, in which arms19are adjacent conveying surface14and are located beyond edges of conveying surface14, to an actuated or diverted position, shown in phantom inFIG. 2, in which diverting surfaces26of flipper assemblies16are generally collinear or coplanar and are aligned across conveying surface14to form a substantially continuous diverting surface. In the illustrated embodiment, diverting surfaces26are at an angle of approximately 45° with respect to the direction of travel of conveying surface14when arms19are pivoted to their diverting positions. However, they could extend anywhere from as low as 20° or less to up to 60° or more. The speed of belt26is related to the speed of conveying surface14according to the intercept angle of flippers16such that diverted articles maintain the same forward speed while being diverted. If this angle is 45°, then the speed of belt26is approximately 1.4 (forward speed divided by the cosine of 45°) times the speed of conveying surface14.

Flipper frame24includes a flipper weldment36made up of an arm37that supports a drive roller or pulley38and an idle roller or pulley40. Extending downwardly from driver roller38is a drive shaft42(FIG.6), which includes a sprocket or pulley44mounted thereon which engages or is engaged by a timing, or cog, belt (not shown) from a motor30and a gear reducer assembly32to thereby drive driver roller38and, in turn, belt26.

A flipper actuator lever28, when actuated, rotates flipper frame24between a retracted position and an actuated position. Flipper actuator lever28is selectively actuated by flipper actuator assembly18. Flipper actuator assembly18includes a pair of flipper drive pulleys46(FIG. 8) which are continuously driven by the same timing belt, which drives pulley38from motor30. A crank shaft assembly52,54is selectively connectable with a respective drive pulley46by an electromechanical clutch assembly48,50. When the clutch assemblies are actuated in order to initiate a divert, each crank shaft assembly52,54is rotated 180° from the rotation of its respective flipper drive pulley46. This causes a respective crank plate56,58to also rotate 180°. This motion is transferred to flipper actuation lever28by a respective connecting rod34. For each 180° rotation of crank shaft assembly, flipper assembly16is rotated 45°. When the clutch assemblies48,50are again actuated in order to retract the flipper assemblies, crank plates56,58are rotated another 180° in the same direction as before, which causes flipper assemblies to rotate 45° in the opposite direction. In the illustrated embodiment, clutch assemblies48,50are commercially available and marketed by Warner Spring Brake under Model CB7. The clutches are electrically actuated to extend flipper assemblies16by a control circuit (not shown) in response to an article to be diverted being detected in proximity to diverter assembly10and are, again, actuated by the control circuit to retract flipper assemblies16when the article is detected being received in the take-away conveyor or chute (not shown).

Advantageously, the present invention extends below the conveying surface by no more than 18 inches and preferably no more than 12 inches. This is desirable for overhead applications to provide maximum clearance under the diverter assembly. The present invention also provides for the majority of the actuation drive assembly to be located beneath the conveyor with minimal lateral extension beyond the width of the conveying surfaces. This reduces the footprint of the diverter assembly, which is especially desirable for floor level installations.

In the illustrated embodiment, divert speeds of up to 40 articles per minute, preferably 60 articles per minute, and most preferably 80 articles per minute are obtained when conveyor surface14is operated at 350 feet per minute. Although the invention is illustrated with separate clutches for each paddle assembly, which are electrically operated substantially in unison, it would be possible to mechanically link the paddle assemblies together and operate them from a single clutch assembly.

Referring toFIGS. 11-13, the numeral110generally designates a second embodiment of a diverter assembly of the present invention which is particularly suitable for high-speed applications. High-speed diverter assembly110includes a frame or bed112, which forms a generally horizontal conveying section114, a controller115, a pair of flipper assemblies116a and116b, and a drive assembly118, which is actuated by controller115similar to the previous embodiment. As best understood fromFIG. 1, high-speed diverter assembly110is typically positioned between inline conveyor sections C1and C2and is used to redirect the flow of articles from the conveying direction of conveyor sections C1and C2, which flows between conveyor sections C1and C2, to a take-away conveyor section C3. In the illustrated embodiments, take-away conveyor section C3is angled approximately 45° with respect to the conveying direction to define a transfer direction, which is approximately 45° with respect to the conveying direction. It should be understood that the transfer direction, however, may be varied and may be angled with respect to the conveying direction, for example, from an angle as low as 20° or less or up to 60° or more. However, for ease of reference, the remaining description will refer to the angular orientation of the transfer direction being approximately 45°.

In order to divert articles from the conveying direction to the transfer direction, flipper assemblies116a and116b are actuated to pivot arms117a and117b about their respective pivot axes116c and116d so that arms117a and117b are moved from their home or non-diverting position (shown inFIG. 12) adjacent conveying surface114to a diverting position in which at least a portion of the arms117a and117b of flipper assemblies116a and116b extend over conveying surface114and are preferably generally aligned (see FIG.13B), as will be more fully described below. As best seen inFIG. 14, frame or bed112is adapted so that its conveying surface will lower at arms117a and117b to permit an article caught between arms117a and117b and bed112to be released. For example, in the illustrated embodiment, frame112includes a detent or recess112a in the upper surface of bed112which is generally aligned under arms117a and117b when they are moved to their diverting positions. Detent112a will permit the conveying belt, which moves across the upper surface of bed112and which defines conveying surface114a, to drop down should an article get snagged under arm117a or117b. When the belt drops down, the article will be released.

When extended across conveying section114, arms117a and117b generally align such that their upstream facing surfaces117a′ and117b′ form a substantially continuous fence or diverting surface. In addition, the distal ends of arms117a and117b are substantially adjacent so that there is little or essentially no space between the ends of arms117a and117b. When in their home positions, arms117a and117b are aligned adjacent conveying section114and are positioned outboard of the conveyor section sides120a,120b so as to not interfere with the flow of articles along conveying section114.

As best understood fromFIGS. 13A and 14, arms117a and117b are moved between their home or non-diverting positions and diverting positions by drive assembly118, which is located generally beneath and adjacent one side of conveying section114. Drive assembly118includes a motor120and a clutch brake assembly121, with a plurality of linkages which together with clutch assembly121transform the drive motion of motor120into selective rotary motion of arms117a and117b and rotary motion of the belts of arms117a and117b, which will be more fully described below.

In the illustrated embodiment, motor120includes a reduction gear box122with a gear box drive shaft124, on which a timing belt sprocket126is mounted. Motor120may comprise a one horsepower motor, with gear box122comprising a 5:1 ratio gear box reducer. Sprocket126drives a belt128, such as a timing belt or cog belt. Belt128forms a closed path and is coupled to the respective flipper assemblies116a and116b by timing belt sprockets130and132. Belt128is directed around its path around timing belt sprockets126,130, and132by a belt idler timing belt sprocket134and a belt support sprocket136.

Referring now to FIGS.14and17-22, each arm117a and117b includes a frame138formed from an upper plate member140and a lower plate member142and a pair of intermediate belt support plate members144and146. Extending from upper plate member140through lower plate member142is a bearing housing148. Bearing housing148comprises a tubular or cylindrical body and includes a transverse passage150for receiving a drive shaft152, which is journaled in bearing housing148by a bearing170. As will be more fully described below, shaft152is driven by belt128to drive the belts of the respective flipper assemblies116a and116b.

Extending between upper plate140and lower plate142is a tubular member154. Tubular member154is mounted at its opposed ends to upper plate member140and lower plate member142, for example by welding. Intermediate plate members144and146are respectively welded to upper plate members140and142and, further, to tubular member154and bearing housing150to provide a bed or support for its respective belt. As best seen inFIG. 22, intermediate plate members144and146include a plurality of mounting flanges144a and146a which are welded to tubular member154and bearing housing148to thereby form a rigid flipper frame138. Frame138may be adjusted as needed but typically is at least 12 inches high for baggage diverting applications. In this manner, as best seen inFIG. 15, arms117a and117b will contact most baggage above their centroids or center-of-gravity (cg) or at least at or above the mid-height of the luggage (⅓H) thereby minimizing the risk of the baggage toppling over arms117a and117b. Optionally, frame138is formed from a lightweight but rigid material, such as a lightweight metal, including aluminum. In addition, plates144and146include grooves144a′,146a′ at their respective medial portions to help retain the driven belts on arms117a and117b.

Flipper assemblies116a and116b are mounted to the frame or bed112of conveying section114in mounting collars160and162. Mounting collars160and162comprise tubular members164and166, which are mounted to sides120a and120b of frame112, for example by welding. Lower portions168of bearing housings148extend into tubular members164and166and are journaled therein by bearings171to thereby pivotally mount arms117a and117b to frame112. In this manner, when actuated, arms117a and117b pivot about the central, vertical axes of mounting collars160and162which define their respective pivot axes116c and116d.

Referring again toFIG. 14, drive shaft152extends into bearing housing148and is journaled in upper plate member140by bearing170. Mounted to lower end of bearing housing148is a shaft stabilizer172through which drive shaft152extends and in which drive shaft152is journaled. Arms117a and117b are drivingly coupled to each other by a chain assembly190, with arm117b comprising a driver arm that is selectively drivingly coupled to drive assembly118by clutch assembly121, described more fully below. Chain assembly190is coupled to flipper assemblies116a and116b by sprockets192a and192b which are journaled on drive shafts152but mounted to shaft stabilizers172(which are mounted in bearing housing148) by fasteners193. Fasteners193extend through a plurality of mounting openings in sprockets192a and192b and into a corresponding plurality of threaded openings in shaft stabilizers172to thereby drivingly couple sprockets192a and192b to bearing housings148of arms117a and117b. In this manner, when sprockets192a and192b rotate, arms117a and117b pivot about their respective pivot axes116c and116d.

As noted above, drive assembly118includes clutch assembly121. Clutch assembly121is actuated to initiate the rotation of arms117a,117b or actuation of flipper assemblies116a,116b. Although belt128is continuously driven when motor120is running, arms117a,117b do not pivot until clutch assembly121is actuated. Clutch assembly121is electrically actuated by controller115, for example, in response to an article (that is to be diverted) being detected in proximity to diverter assembly110. Similarly, clutch assembly121is actuated to retract arms117a and117b when the article that is diverted is detected as being received by the take-away conveyor or chute C3. If more than one article is to be diverted, then clutch assembly121is actuated when the last article that is to be diverted is received by the take-away conveyor.

Referring again toFIG. 14, extending through belt sprocket136is a clutch shaft192which is drivingly coupled on one end to the clutch assembly121and on its other end to a drive transfer assembly194. Drive transfer assembly194includes a drive chain196and a plurality of sprockets198,200, and202around which drive chain196extends and forms a closed loop. Clutch shaft192is drivingly coupled to sprocket198. Therefore, when clutch assembly121is actuated, clutch shaft192rotates sprocket198, which in turn drives chain196around sprockets200and202. Sprocket202includes a cam member204, which couples to a tie rod206, which in turn couples to a second cam member208, which is mounted to sprocket192a. In this manner, when clutch assembly121is actuated, clutch shaft192will drive sprocket198, which in turn will drive sprocket202to rotate cam member204. As cam member204rotates, tie rod206pulls or pushes on cam member208to rotate sprocket192a. Since sprocket192a is mounted to bearing housing148of arm117a, arm117a will pivot about its pivot axis116c. As noted previously, sprocket192a is drivingly coupled to sprocket192b, which is similarly mounted to bearing housing148of flipper assembly116b. In this manner, when clutch assembly121is actuated, chain190will transform rotational movement of arm117a into rotational movement of arm117b such that arms117a and117b will move generally simultaneously and, further, both in a counter-clockwise direction (as viewed inFIG. 14) to thereby cause arms117a and117b to extend across conveying surface114a (FIG. 1) of conveyor section114. Further, arms117a and117b will be moved until they align along a transverse axis extending across conveying surface114a, which in the illustrated embodiment forms approximately a 45° angle with respect to the conveying direction of conveyor sections C1and C2.

Clutch assembly121preferably comprises a clutch brake unit Model CB10 available from Warner Spring Brake. In order to ease removal of articles jammed between arms117a and117b, the anti-backlash spring of clutch assembly121is optionally removed. In this manner, if an article is jammed between the arms, the flipper assemblies may be manually backed off the article to remove the article. In addition, controller115includes two detectors115a,115b, such as proximity detectors, for detecting whether there is a jam or a malfunction. Detectors115a,115b are mounted to cylindrical collar166by mounting plates166a and166b (FIG. 13A) and are positioned so that when arms117a and117b are in their home position, proximity detector115b will be aligned with an opening115d in sprocket192b. When arms117a and117b are moved to their diverting position, proximity detector115a aligns with a second opening115c in sprocket192b. In this manner, detectors115a and115b can be used to detect whether arms117a and117b are not properly rotated, for example because they are blocked or a malfunction has occurred. Controller115is in communication with detectors115a and115b and is adapted to shut down the drive assembly when it detects (through detectors115a or115b) that a jam or malfunction has occurred. The occurrence of a jam or malfunction is determined when the relevant proximities detector does not detect the opening. For example, when in the home position, proximity detector115b should detect opening115d. If controller115does not receive the appropriate signal from detector115b, the controller115will shut down the drive assembly. Similarly, when controller115has moved arms117a and117b to their diverting position and proximity detector115a does not detect second opening115c, then controller115detects that a jam or malfunction has occurred.

Each flipper assembly116a,116b includes driven diverting surfaces210a and210b. In this manner and as will be more fully described below, when an article makes contact with one or both arms, the articles forward motion will not be significantly, if at all, reduced and, instead, will be redirected in the transfer direction. In the illustrated embodiment, diverting surfaces210a and210b comprise closed loop belts212a and212b, respectively, which extend around the horizontal extents of arms117a and117b. Though it can be appreciated that other conveying surfaces may be used, such as provided by rollers or the like. In addition, belts210and210b extend over at least most, if not all, of the vertical extents of the respective arms117a and117b. As previously described, the vertical extents of arms117a and117b is preferably at least 12 inches.

Belts212a and212b comprise driven belts and are supported on arms117a and117b by a pair of rollers214a,214b,216a, and216b, respectively. Similar to belt support plates144and146, rollers214a,214b,216a, and216b, include grooves214a′,214b′,216a′, and216b′, respectively, which are used to assist in retaining belts210a and210b and arms117a and117b. As best seen inFIG. 16, belts210a and210b include a projecting rib or flange210a′ and210b′, respectively, which are guided in respective grooves144a′,146a′,214a′,216a′,214b′ and216b′ to thereby retain belts210a and210b on arms117a and117b.

Rollers214a,214b comprise idler rollers and are mounted between upper plate member140and lower plate member142of the respective flipper assembly. Idler rollers214a and214b are preferably provided at the distal end portion of the respective arm. Rollers216a,216b comprise belt drive rollers and are driven by driver assembly118about belt axes spaced outwardly from pivot axes116c and116d. In this manner, when arms117a and117b are pivoted about their respective axes116c and116d an end portion of each arm will project over the edge of conveyor section, with the end portion of arm117a providing a “bridge” between diverter assembly110and conveyor section C3. In this manner, when an article is diverted onto conveyor section C3, if there is a gap between conveyor section C3, arm117a will continue to provide a driven diverting surface until the article is deposited on conveyor section C3and its conveying surface takes over as the driving element for the article. In other words, the article will be under a substantially constant driving force which increases the flow of the article through the conveyor system. The remaining description of the belt drive assembly will be made in reference to flipper assembly116b; however, it should be understood that the corresponding component of flipper assembly116a are similarly numbered by with their numerals followed by an “a” rather than a “b”. As best seen inFIGS. 14 and 16, mounted to shaft217b of roller216b is a belt sprocket220b. As best seen inFIG. 14, belt sprocket220b is coupled to shaft152of flipper assembly116b by a belt222b and a sprocket224b, which is mounted on shaft152. In this manner, when shafts152rotate about their respective axes, belts222a and222b drive driver rollers216a and216b, which in turn drive belts210a and210b about the horizontal extents of arms117a and117b.

In order to retain belt222b on sprockets220b and224b, flipper assembly116b includes a belt cover226b which is releasably fastened to upper plate member140by a mounting plate228b. Mounting plate228b includes a cover support230b and a pair of openings through which shaft217b of roller216b extends and through which shaft152extends to thereby receive mounted thereon sprockets220b and224b. Cover226b also supports a cam follower232b which may be used to adjust the tension on belt222b. As would be understood by those skilled in the art, belts210a and210b are, therefore, continuously driven by motor120when motor120is energized. Similar to the previous embodiment, belts210a and210b are driven at a speed so that their forward speed vector matches the forward motion of the article being conveyed on conveying surface114a. Therefore, at the angular orientation shown in the illustrated embodiment, the speed of belts210a and210b is approximately 1.4 times the speed of the conveying surface (or the speed of the conveying surface divided by the cosine of the angle between the conveying direction and the transfer direction) so that the forward vector component of the belt equals the forward motion of the conveying surface.

Drive transfer assembly194is supported by a plate240, which mounts to frame120by a pair of rod members242and244(FIG.16). Plate240includes a slotted opening248on which sprocket134is mounted by a pin250(FIG. 14) which permits adjustment of the tension on belt128. Similarly, plate240includes a second slotted opening254on which sprocket200is mounted to provide adjustment for the tension on chain196. Adjustment for chain assembly190is provided by rod extensions190a and190b which include adjustable couplers191a and191b.

As best seen inFIG. 14, frame112comprises a boxed-shaped member which is formed by a plurality of side plates260a and260b and end plates260c and260d, which are interconnected, for example by welding. Frame112is typically supported by vertical supports or legs265so that is spaced above a support surface for aligning between conveyor section C1and C2and adjacent transfer conveyor section C3(as shown in FIG.1). In addition, frame120supports one or more belt rollers (not shown) for a closed loop belt (not shown) that provides a conveying surface and defines conveying surface114a. However, it should be understood that the conveying surface may be provided by rollers or the like. Frame120also provides a mounting surface for a number of components of assembly110. For example, clutch shaft192is journaled in a mounting bracket270, such as a pillow block bearing mounting, which secures to the side of frame112by a mounting block and fasteners. Furthermore, side plate member260b provides a mounting surface for a bearing member272, which forms part of a torsion limiter for clutch brake assembly121described below. In addition, side frame member260b provides a mounting surface for motor120. As best understood fromFIG. 14, mounted to side plate260b is a motor mounting plate261, which includes a plurality of mounting openings216a. Gear box122includes a corresponding plurality of mounting openings122a which receive fasteners262b that extend through openings261a to thereby secure motor120to frame112below flipper assembly116b and below conveying surface114a but to the side of frame112. In this manner, the components of drive assembly118that are more likely to need maintenance or service are mounted to the side of frame112, which provides easy access. In addition, the drive components are mounted to the side opposite from the transition side (the side which aligns with take-away conveyor). With the present configuration, therefore, the diverter assembly comprises a left-hand diverter. It should be understood that a right-hand diverter assembly would generally have a configuration that is a mirror-image of the configuration of the left-hand diverter assembly, though the same components may be used.

Clutch assembly121is preferably mounted so that it is free to rotate over a limited range of motion when actuated. In order to dampen or limit the torque on clutch brake assembly121, however, drive assembly118includes a clutch brake dampener280(FIG.15A). Dampener280comprises an L-shaped arm pivotally mounted to the clutch brake mounting plate282at one end280a and mounted at its elbow280b to plate282in a slotted opening (FIG.14). Free end286of dampener280includes a contact member286a, such as an aluminum tube, which bears against a stop or dampener272when clutch assembly121is actuated. Preferably, dampener272comprises a rubber or neoprene material to absorb the impact from contact with arm280, which dampens the rotation of the clutch assembly when clutch assembly121is actuated.

Similar to the previous embodiment, the power transfer components of drive assembly118are positioned below frame112, with motor120and clutch121provided at a side of the frame112to provide easy access for replacement, repair, or adjustments. Furthermore, drive assembly118is compact and extends below frame112no more than 18 inches and, preferably, no more than 12 inches. Again, this provides for maximum clearance under diverter assembly110.

Controller115preferably comprises a programmable logic controller (PLC) that is in communication, as noted above, with detectors115a and115b. In addition, controller115is in communication with at least one upstream detector, such as a proximity detector, which detects when an article that is to be diverted is approaching diverter assembly110. When such an article approaches diverter assembly110, the upstream detector generates a signal to controller115which in turn actuates clutch assembly121to pivot arms117a and117b to their diverting positions. When actuated, clutch assembly121performs a single 360° turn but through a 2:1 ratio so that cam or crank arm204rotates 180°, which translates into a 90° rotation of cam plate208. Thus, when controller115receives a signal from the upstream detector that an article is approaching, diverter assembly110, controller115transfers power to the solenoid clutch assembly121so that arms117a and117b will move simultaneously in a counter-clockwise direction to their diverting positions. In addition, controller115is in communication with a detector which detects when the article or articles to be diverted are diverted onto the take-away conveyor. In this manner, after the article or articles to be diverted is diverted on the take-away conveyor, controller115signals clutch assembly121to actuate a second single 360° turn that returns arms117a and117b to their home position. As a result, controller115actuates flipper assemblies116a and116b based on the gaps between the articles on conveying surface114a. Therefore, diverter assembly110(and also diverter assembly10) are unaffected by the sizes of the articles being diverted. The time of travel from start to finish (when arms117a and117b move from their home position to their diverting position), may be approximately 250 milliseconds. As would be appreciated by those skilled in the art, flipper assemblies116a and116b divert articles at a very high speed. As mentioned previously, with a main-line belt speed of 360 feet per minute diverter assembly110may achieve sortation rates of 60 articles or bags per minute, and in some cases 80 bags per minute. With smaller articles, such as articles having dimensions of less than one foot, the sortation speed can achieve upwards of 140 articles per minute.

Referring toFIG. 24, when an article is conveyed on conveying surface114a on the side close to arm117b, it can be appreciated, that if the speed of the article approaches the response time of flipper assemblies116a and116b, the article will make contact with arm117b at some point between rollers124b and126b, which will not adversely affect the diversion of the article. However, if an article is traveling down the middle of the conveying surface114a or the side close to arm117a, and the speed of the article exceeds the actuation time of flipper assemblies116a,116b, the article may contact the distal end of arm117a, which may result in damage to the article. For this given conveying speed, contact with the distal end of arm117a may be avoided by offsetting flipper assemblies116a and116b along the longitudinal axis of bed112. Although this will result in a gap between the ends of arms117a and117b, the momentum of the article, which is substantially unimpeded by contact with arm117b, will be sufficient so that the article will be transferred onto arm117a and without significantly slowing the forward motion of the article being diverted. When arms117a and117b are pivoted to their diverting position, the distal ends of respective arms are offset and spaced apart, for example in a range of about 2 inches to about 10 inches. As noted above, by offsetting the respecting arms117a,117b along the longitudinal axis of conveying section114, the distance the article has to travel before it would make contact with the distal end of arm117a is increased, thereby avoiding contact of the article with the distal end of arm117a when the article conveyance speed is increased. Or on other words, by offsetting flipper assemblies116a and116b, the rate of travel of the respective articles can be increased. Arms117a and117b may be actuated simultaneously by a common drive assembly similar to drive assembly118or may be individually driven by a respective assembly.

While several forms of the invention have been shown and described, other forms will now be apparent to those skilled in the art. For example, although illustrated as a symmetrical assembly, arms117a and117b may have different lengths with their ends generally meeting at a location offset from the center of the conveying surface or with their ends generally meeting at the center of the conveying surface but with the proximate end of the arm beyond the pivot axis which provides the extended diverting surface or “bridge” being reduced or eliminated. For example, the initial contact arm may have its diverting belt driven about the same axis that it is pivoted since the additional diverting surface which extends beyond the conveying surface may not be needed for that side of the diverter assembly. Therefore, it will be understood that the embodiments shown in the drawings and described above are merely for illustrative purposes, and are not intended to limit the scope of the invention, which is defined by the claims, which follow as interpreted under the principles of patent law including the doctrine of equivalents.