CONVEYOR ASSEMBLY

The conveyor assembly includes an elongate frame to which a looped conveyor track is mounted. The frame has a longitudinal direction, and the conveyor track is movable along the longitudinal direction. The conveyor track includes spaced engagement device. The conveyor assembly also includes a drive assembly with a drive shaft carrying a drive screw with a helical drive formation. The drive shaft and the drive screw are oriented parallel to the longitudinal direction of the frame, the helical drive formation being for engaging the spaced engagement device of the conveyor track.

CROSS-REFERENCE TO RELATED APPLICATIONS

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THE NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT

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BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a conveyor assembly.

The US patent describes a narrow independently-driven belt module which provides low-profile, space-efficient conveyorization. These modules can be placed side-by-side to create various configurations. The patent did not address any novel drive system and is subject to the limitations of currently available drive systems as described below.

Conveyors are typically coupled to a “parallel shaft drive system”, so named due to the direction of motion of the driving components being parallel to the direction of conveyor belt travel. These drive systems are usually located beside the conveyor and include the motor and different drive mechanisms like gears, chains, or timing belt drive trains. This limits the width of the main body's conveyor belt in order to provide the space needed to accommodate this drive system.

Another limitation is the bulkiness of these said “parallel shaft drive systems,” which require certain arrangements of drive sprockets and idler pulleys that dictate the minimum height profile of conveyors.

The transfer of rotational power from a driving source to a desired linear travel output is critical in many industrial and commercial applications. Traditionally, sprockets and pulleys have transferred rotational power through chains or belts. However, these systems have several limitations, including the need for continuous tension and alignment, belt stretch, difficulty accommodating direction changes, and a limited ability to absorb shock and vibrations. These bulky solutions are also restricted from using on any low-profile applications.

In recent years, there has been a growing demand for more flexible and efficient solutions for transferring rotational power. As a result, numerous attempts have been made to develop alternative drive systems to address these challenges, including using gear reducers to convert rotational torque into linear travel. However, these solutions often have limitations and inefficiencies, such as high costs, complexity, and decreased durability.

The present invention seeks to overcome or substantially ameliorate at least some of the deficiencies of the prior art, or to at least provide an alternative.

BRIEF SUMMARY OF THE INVENTION

According to a first aspect, the present invention provides a conveyor assembly comprising:an elongate frame to which a looped conveyor track is mounted, the frame having a longitudinal direction, the conveyor track movable along the longitudinal direction and comprising spaced engagement means,a drive assembly comprising a drive shaft carrying a drive screw with a helical drive formation, the drive shaft and the drive screw being oriented parallel to the longitudinal direction of the frame, the helical drive formation being for engaging the spaced engagement means of the conveyor track. In one embodiment, the lower engagement means comprises evenly spaced parallel rods.

In one embodiment, the track comprises an upper surface and the spaced engagement means comprises evenly spaced parallel rods disposed below the upper surface of the conveyor track.

In another embodiment, the track is formed by linked segments which are joined in series to form the looped track.

In another embodiment, each segment comprises an elongated body which extends laterally between side edges of the frame, the body including a flat upper surface, a leading edge, a trailing edge and side edges, the leading edge of including first coupling means, and the trailing edge including second coupling means to join with first coupling means of an adjacent trailing segment.

In another embodiment, the first coupling means comprises at least one rod which extends parallel to the lateral direction of the body.

In another embodiment, the first coupling means includes a central rod which defines the lower engagement means of the track.

In another embodiment, the first coupling means includes two side rods at either side of the central rod.

In another embodiment, the second coupling means comprises at least one trailing tab which corresponds and hingedly attaches with the rod of the leading edge.

In another embodiment, each segment comprises a central portion and wing portions extending laterally outwards from the central portion, the wing portions to rest on and slide along low friction side panels of the frame.

In another embodiment, the frame includes end plates with elongate shaped rail sections extending therebetween, the rail sections having upper low-friction side panels along side edges of the frame.

In another embodiment, the drive assembly comprises a motor driving a drive shaft, the drive shaft carrying at least one drive screw which has a helical groove formed at an outer surface, wherein the drive screw engages the spaced engagement means of the track.

In another embodiment, the spaced engagement means comprises angled spaced projections, portions of a gear formation, or portions of a helical thread to engage the helical drive formation of the drive assembly.

In another embodiment, the track comprises lateral edges, and the spaced engagement means comprises evenly spaced rollers or cam followers disposed adjacent at least one of the lateral edges.

In this embodiment, the track preferably includes spaced formations at its lower portion, the spaced formations being shaped to receive a respective connecting rod having the roller or cam follower at an outer end thereof.

In this embodiment, the drive shaft and the drive screw are preferably disposed above the spaced engagement means at an upper portion of the conveyor track.

The present invention provides a novel solution for transferring rotational power through a linked belt design. The linked belt design, driven with a spiral worm drive, offers significant advantages over traditional sprocket and pulley systems and alternative drive systems by providing a flexible and efficient means of transferring rotational power. This linked belt design is a versatile and innovative solution that has the potential to revolutionise the way rotational energy is transmitted in a variety of applications. Other aspects of the invention are also disclosed.

DETAILED DESCRIPTION OF THE INVENTION

It should be noted in the following description that like or the same reference numerals in different embodiments denote the same or similar features.

FIGS.1to5show a conveyor assembly10according to a preferred embodiment of the present invention. The conveyor assembly10comprises an elongate frame12having a longitudinal direction15to which a looped conveyor track14is mounted. The travel of the track14is along the longitudinal direction15between ends13of the elongate frame12. The track14is formed by linked segments24which are joined in series to form the looped track14. The conveyor assembly10also includes a drive assembly18for driving the track14.

Each segment24comprises an elongated body which extends laterally between side edges82of the frame12. The body32includes a flat upper surface34, a leading edge36, a trailing edge38and side edges40which are disposed adjacent to the side edges82of the frame12. The segment24comprises a central portion42and wing portions44extending laterally outwards from the central portion42. The wing portions44are generally flat extensions extending from the central portion42and which are to rest on and slide along low friction side panels74of the frame12. The central portion42and the wing portions44together define the flat upper surface34. As shown inFIG.5, the central portion42also includes retainer tabs45extending laterally outwards thereof, the retainer tabs45being spaced below the wing portions44.

The leading edge36of the central portion14includes spaced first coupling means47being spaced rods46which extend parallel to the lateral direction of the body32. The rods46include a central rod46aand two side rods46bat either side of the central rod46a. The rods46are held by spaced leading projections48of the central portion42. The rods46can be separate rod sections or can be a single piece rod held by the leading projections48.

The trailing edge38of the central portion14includes spaced second coupling means57being spaced trailing tabs58which are dimensioned and disposed to correspond and align with the rods46of the leading edge36. Thus, in the embodiment shown, the trailing tabs58include a central tab58aand two side tabs58b. Each tab58includes a lower channel (not shown) for receiving and engaging a corresponding rod46therein.

Recesses62are formed in the trailing edge38between the tabs58, and between the side tabs58band the wing portions44. The recesses62are aligned with the projections48of the leading edge36, and are dimensioned to receive the projections48of another segment24.

A plurality of the segments24are joined in series to form the looped track14. The central tab58aof a lead segment24receives and engages the central rod46aof a trailing segment24. Similarly, the two side tabs58bof the lead segment24receive and engage the respective two side rods46bof the trailing segment24. This linking arrangement follows along the series of segments24to form the looped track14.

As shown inFIG.5, the frame12includes end plates80with elongate shaped rail extrusion sections84extending therebetween. The rail sections84extend along lateral edges of the frame12and are shaped to retain upper low-friction side panels74aand lower low-friction side panels74b, along the side edges82of the frame12. The side panels74each include an outer surface76for engaging the wing portions44thereon. Each side panel74also includes a retaining channel78formed therein, parallel and spaced from the outer surface76. The retaining channels78receive therein the retainer tabs45of the segments24, thus retaining the segments24to the frame12.

The drive assembly18comprises a motor90driving a drive shaft94via a belt and pulley assembly92. The drive shaft94extends along the longitudinal direction15and is splined and carries spaced drive screws96. The rotational axis of the drive shaft94is thus parallel to the longitudinal direction15. The drive screws96each have a helical groove97formed at an outer surface thereof. The drive shaft94with the drive screws96extending along the longitudinal direction15are disposed such that the helical grooves97engage a lower portion of the central rods46aof the segments24at the upper running surface portion134of the track14. The central rods46athus define spaced lower engagement means49for the drive assembly18, in this embodiment the spaced lower engagement means49being evenly spaced parallel rods46adisposed below the upper surface34. In this manner, rotation of the drive shaft94with the drive screws96(via the motor90) is translated to movement of the segments24along the longitudinal direction15generally between the end plates80of the frame12. Alternatively, the drive screws96can be a single piece drive screw extending the length of the drive shaft94.

Each conveyor assembly10is a discrete independently driven unit with an upper portion (running surface102) of the conveyor track14in a planar orientation for conveying items thereon in use. A lower portion (return104) of the conveyor track14extends under the upper portion17.

The embodiments of the present invention provide a linked belt design for transferring rotational power from a driving source to a linear travel output. The belt comprises flexible links guided in a restrained track, engaged with a rotating spiral screw mechanism attached to a driving force. The linked belt offers a flexible and efficient solution for transferring rotational power and can be used in various applications such as conveyors, moving sidewalks, and automation drive systems. This patent application claims the linked belt design and its use in transferring rotational power and specific applications.

A linked belt design for transferring rotational power from a driving source to a desired linear travel output is disclosed in the embodiments described. The linked belt comprises a series of interconnected links, each equipped with a hinge body that allows for bending and flexibility. The hinge bodies are guided within a restrained track to ensure consistent engagement with the rotating spiral screw mechanism, which acts as the driven component that transfers rotational power to the screw.

In the embodiments shown, the spiral screw mechanism is attached to a driving force, such as a motor, generating the rotational motion necessary to drive the screw. The spiral screw mechanism can comprise one or multiple driving screws across the belt's width. Furthermore, a driving source can be at either end, both ends, or at an intermediary position along the length of the belt.

The flexible and dynamic nature of the belt links enables them to adjust and adapt to any changes in the belt travel direction based on the position of the screw, ensuring the consistent and accurate transmission of rotational power.

The linked belt design offers a flexible and efficient solution for transferring rotational power, offering advantages over traditional sprocket and pulley drive systems. The linked belt design can be used in automation for conveyor systems, moving sidewalks, or drive systems.

The preferred embodiments provide the linked belt design, a method of transfer of rotational power, and use in specific applications.

Advantages

The invention in a preferred embodiment provides a linked belt design for transferring rotational power from a driving source to a desired linear travel output, comprising:a. a series of interconnected links, each with a hinge body that allows for bending and flexibility;b. a restrained track for guiding the hinge bodies of the links;c. a rotating spiral screw mechanism attached to the hinge bodies of the links, acting as the driven component that transfers rotational power to the screw;d. a driving force such as a motor for rotating the belt and generating the rotational motion necessary to drive the screw.

In another preferred embodiment, the spiral screw mechanism comprises one or multiple driving screws across the belt's width.

In another preferred embodiment, the flexible and dynamic nature of the belt links enables them to adjust and adapt to any changes in the orientation or position of the screw, ensuring the consistent and accurate transmission of rotational power.

The embodiments also provide a method of transferring rotational power from a driving source to a desired linear travel output using the above linked belt design, comprising:a. connecting the driving source to the rotating spiral screw mechanism;b. rotating the belt using the driving source;c. transmitting rotational power from the rotating belt to the rotating spiral screw mechanism;d. generating linear travel output from the rotating spiral screw mechanism.

The linked belt design can be used in conveyor systems, moving sidewalks, or drive systems for automation.

The preferred embodiment provides a conveyor assembly comprising: a spiral worm drive configured to transfer rotational power, and a linked belt having a plurality of interconnected links, wherein the spiral worm drive engages with the linked belt to transfer rotational power.

In the preferred embodiment, the linked belt is configured to accommodate directional changes without requiring tensioning and alignment mechanisms.

In the preferred embodiment, the linked belt comprises a plurality of modular segments, each segment including at least one interlocking connection to a parallel segment.

In the preferred embodiment, the interlocking connection between adjacent segments comprises a male connection portion and a female connection portion that allows for easy assembly and disassembly of the linked belt.

In the preferred embodiment, the spiral worm drive can be configured to absorb vibrations during operation.

In the preferred embodiment, the conveyor assembly comprises a motor for providing rotational power to the spiral worm drive.

In the preferred embodiment, the motor in the embodiment is an electric motor, and the conveyor assembly further includes a control system configured to control the speed and direction of the motor. This allows the track to be moved in the opposite direction.

In the preferred embodiment, the linked belt includes a plurality of load-bearing members for carrying objects.

In the preferred embodiment, the linked belt in the embodiment is made of a low-friction material to minimize wear and energy loss during operation, such as a nylon material belt segment running over an Ultra-High Molecular Weight Polyethylene (UHMW-PE).

In the preferred embodiment, the conveyor assembly comprises a support frame for mounting the spiral worm drive and linked belt.

In the preferred embodiment, the support frame is adjustable in height to accommodate various applications.

In the preferred embodiment, the linked belt can be configured for low-profile applications.

In the preferred embodiment, the spiral worm drive is configured to provide a variable linear travel output depending on the input rotational speed of the motor.

In the preferred embodiment, the linked belt and the spiral worm drive are enclosed within a protective housing.

In the preferred embodiment, the protective housing comprises an ingress protection rating to prevent dust, debris, and moisture from entering the conveyor assembly, for use in outdoor or indoor operation.

In the preferred embodiment, the conveyor assembly preferably further comprises a tensioning mechanism to adjust the tension of the linked belt.

In the preferred embodiment, the spiral worm drive can be configured to operate in a range of environmental conditions, including extreme temperatures and high humidity levels due to the combination of hard-wearing industrial plastics and non-ferrous metal components.

In the preferred embodiment, the linked belt can be made of corrosion-resistant injection moulded plastic, which can also offer a non-slip surface in the design feature of the mould.

In the preferred embodiment, the linked belt can be configured for use in a vertical orientation.

The invention also provides a method of transferring rotational power to linear travel output, the method comprising: providing a conveyor assembly consisting of a spiral worm drive and a linked belt having a plurality of interconnected links; engaging the spiral worm drive with the linked belt; and transferring rotational power from the spiral worm drive to the linked belt to provide linear travel of the belt track assembly.

The present invention relates to an “Integrated Perpendicular Direct Drive System”, so named due to the direction of motion of the driving components being perpendicular to the direction of conveyor belt travel and driving the belt through direct contact. In this system all driving mechanisms are located inside the conveyor body area. This addresses the limitations of “parallel shaft drive systems” and can create a wider driving belt to the overall conveyor assembly width by eliminating the need for space to accommodate drive mechanisms. It can also reduce the overall height profile due to not needing drive sprockets and idler pulleys.

By incorporating this “Integrated Perpendicular Direct Drive System”, the conveyor belt can be broader than in conventional designs, thus giving a more significant percentage of traction area. Furthermore, eliminating driving rollers and idler pulleys can allow for a more compact profile, thus creating a conveyor nearly half the height of a conventional conveyor system, leading to space savings and greater operator safety in reducing step-up and step-down distance.

Whilst preferred embodiments of the present invention have been described, it will be apparent to skilled persons that modifications can be made to the embodiments described.

The track can be replaced by a belt having the spaced engagement means at the lower surface thereof for engaging the worm drive.

The lower engagement means in another embodiment can be angled spaced projections, portions of a gear formation, or portions of a helical thread. The rods in this embodiment can form part of the hinge for the segments and the projections/formations engage the helical thread of the drive mechanism.

In the embodiment shown inFIGS.6and7, the linked segments24bare joined in series to form the looped track14b.

Each segment24bcomprises a narrow body having first coupling means47at a leading end and corresponding second coupling means57at a trailing edge, the corresponding coupling means47,57being for receiving a connecting rod therebetween for joining adjacent segments24b.

The lower engagement means49for the drive assembly in this embodiment comprises spaced formations59being angled spaced projections, portions of a gear formation, or portions of a helical thread. In this manner, rotation of the drive shaft94with the drive screws96(via the motor90) engaging the formations59is translated to movement of the segments24bgenerally between the end plates80of the frame12. The upper surface134in this embodiment is curved and the track14bis narrow. This embodiment is useful for a moving handrail design, or other narrow profile conveyor.

FIGS.8to10show a section of another embodiment of the conveyor track14cwith an alternative drive assembly18placement. The track14cin this embodiment comprises a looped belt210with an engagement outer surface having spaced ribs212. The belt210includes spaced formations216at its lower portion, the spaced formations216being shaped to receive a respective connecting rod222having a roller224at an outer end thereof. The rollers224are disposed at one lateral edge, or both lateral edges of the belt210, in a spaced manner.

The drive screw96in this embodiment for the drive assembly18is disposed above the spaced rollers224at an upper portion230of the conveyor track14c. A drive screw96can be disposed at both sides of the conveyor track14cin the embodiment where both sides have the rollers224. Additional drive screws96can also be placed to engage the rollers224at a lower portion232of the conveyor track14cif desired.

The drive assembly18also comprises a motor90driving one or more drive shafts94for rotating the drive screws96. The helical grooves97of the drive screws96engage the spaced rollers224. The spaced rollers224thus define spaced engagement means49for the drive assembly, in this embodiment being evenly spaced rollers or cam followers for the groove97of the drive screw96. In this manner, rotation of the drive shaft94with the drive screws96(via the motor90) is translated to movement of the looped track14c.

This embodiment provides the advantage of the upper portion230and the lower portion232of the conveyor track14cbeing disposed close to each other, which provides a very low profile conveyor track.

This moves the drive to the edges of the belt, rather than in the middle, and still use the same screw drive that runs axially in the direction of belt travel.

The spaced engagement means can be roller bearings or cam follower, disposed off the lateral edges of the width of the belt. The screw drive mechanism will sit over the top of those bearing elements. Driven screws can be placed on each side of the belt link, allowing a much broader link/conveyor body to be driven with the low-profile drive mechanism.