Modular link conveyor with features for enhancing the efficient conveyance of articles

An apparatus for conveying an object in a conveying direction includes a conveyor comprised of a plurality of modular links adapted for interconnecting to form a chain. At least one of the links comprises a rounded upper portion forming an apical region for contacting and supporting the article for conveyance along at least a forward run in the conveying direction. The at least one link further including a forwardly projecting portion associated with a first transverse connector forming a part of the upper portion and a rearwardly projecting portion associated with a second transverse connector forming part of the upper portion. The first and second connectors may be staggered in the conveying direction and a direction transverse to the conveying direction. Further aspects pertain to a link with an apical engaging structure, and a sprocket with a removable tooth.

TECHNICAL FIELD

This disclosure relates to the conveyor arts and, more particularly, to an enhanced conveyor chain adapted for more efficiently conveying articles.

BACKGROUND

Modular link conveyor chains have enjoyed widespread use in the past several decades as an efficient and effective means of transporting articles. One particular common use of such conveyors is in an arrangement where the articles may adhere to the conveying surface, such as in the case of food products being frozen during conveyance or freshly baked, warm food products, such as breads, cookies, or tortillas. In this type of arrangement, or simply as a matter of a desire for conveyance over a long distance (such as for cooling, drying, etc.) without the need for wasting valuable floor space, it is also common to convey articles using a side-flexing conveyor chain in a spiral configuration (which typically involves driving the chain using sprocket teeth on a rotating central drum, but the drive arrangement may take different forms as well). Regardless of the form of drive, it can be appreciated that driving of the chain along the spiral path with an elevation change requires a significant input of energy, and thus improving efficiency is a matter of significant concern.

Accordingly, there is a need for an improved modular link conveyor that may address any one of these issues or perhaps other different issues that have yet to be identified. The arrangement should be readily adaptable to many different types of conveyors at minimal cost, and potentially applied in a retrofit situation without extensive effort. The arrangement would be especially adapted for use where the articles being conveyed are susceptible to adhering to a flat conveying surface, where there is a need for an efficient transfer of the articles from one conveyor to another, and also in the course of a spiral conveyance.

SUMMARY

According to a first aspect of the disclosure, an apparatus for conveying an object in a conveying direction is disclosed. The apparatus comprises a conveyor including a plurality of modular links adapted for interconnecting to form a chain. At least one of the links includes a rounded upper portion for contacting and supporting the object for conveyance along at least a forward run in the conveying direction. The at least one link further includes a forwardly projecting portion associated with a first transverse connector, a rearwardly projecting portion associated with a second transverse connector, the first and second transverse connectors being non-collinear.

In one embodiment, the first connector includes a first apical region and the second connector includes a third apical region. A third connector includes a third apical region, the third connector being collinear with either the first connector or the second connector.

At least one of the links includes a portion for engaging a drive structure, the portion comprising an apical or rounded surface. The portion may comprise a depending arm including the apical surface. The apical or rounded surface may be provided by a spherical cap.

The drive structure may comprises a tooth of a sprocket. The sprocket comprises a sprocket body including one or more removable teeth for forming the drive structure.

The at least one link may comprise a side link, and another link may form a row of the chain and connected to the side link by the connector. A connector rod is also provided for interconnecting adjacent rows of links to form the chain. The at least one link may further include an upstanding wall for confining objects being conveyed on the upper portion.

According to another aspect of the disclosure, an apparatus for conveying an object in a conveying direction is provided. The apparatus comprises a conveyor comprised of a plurality of modular links. At least one of the links includes an apical engagement surface for engaging a drive structure for driving the conveyor. In one embodiment, the link comprises a depending arm including the apical engagement surface. A member may also be provided for supporting the depending arm, the member including an upstanding projection extending above a conveying surface of the link. The apical engagement surface may be provided by a spherical cap, and may project rearwardly from the link.

A further aspect of the disclosure relates to a conveying apparatus, comprising a conveyor chain and a sprocket comprising a sprocket body including one or more removable teeth for forming a drive structure for driving the conveyor chain. The drive structure may comprise a tooth, and a sprocket body including a socket for receiving and capturing a portion of the one or more removable teeth. The sprocket may be mounted for rotation about a vertical axis, or may be mounted adjacent to an outer side of a curving conveyor chain (which may include at least one link having a rounded surface for engaging a tooth of the sprocket, and may be arranged to travel in a spiral path).

Yet another aspect of this disclosure pertains to an apparatus for conveying an object in a conveying direction. The apparatus comprises a conveyor comprised of a plurality of modular links for interconnecting to form a chain. At least one of the links comprises a substantially smooth, rounded conveying surface, the at least one link including a first connector with a first apical region forming a part of the conveying surface and a second connector with a second apical region also forming part of the conveying surface, the first and second connectors being spaced apart in the conveying direction and a direction transverse to the conveying direction. The first and second apical regions may have substantially the same height, and a third apical region may be aligned in the conveying direction with the first apical region.

Still a further aspect of the disclosure pertains to a conveyor link, comprising a body including a curved upper conveying surface including an S-shaped apical region. A conveyor chain formed of the links is also disclosed.

DETAILED DESCRIPTION

Reference is now made toFIGS. 1-4, which depict one embodiment of a conveyor system10adapted for the conveyance of articles, such as in a linear path or along a curved path (including possibly with an elevation change in either case). In this embodiment, the system10includes a belt or chain11adapted for supporting and conveying objects comprised of a plurality of interconnected modular links12. The links12forming the chain11are arranged in rows so as to define a pitch between adjacent rows (that is, the spacing from a location on a link of a first row to a point on a corresponding location on a link of a second row). Each row may include intermediate links sandwiched between specialized side links, which may be adapted (such as by including a depending arm12aand an inwardly projecting guide tab12b) to provide a guiding and hold-down function for the chain12along spaced guide rails G1, G2supported by a frame E. As shown inFIG. 3, each guide rail G1or G2may optionally include a wear strip W to reduce friction and increase durability.

Adjacent rows of links12are connected by transverse connectors14, which are typically stainless steel rods mounted through matching apertures (e.g., slots having flat lower surfaces and holes) in the adjacent rows and retained by locking tabs. As can be appreciated, this provides the resulting chain11with a degree of side-flexing to allow for the more effective negotiation of curves in the system10(such as would be present in a spiral conveying configuration). A more detailed description of various examples of such a modular link chain arrangement may be found in U.S. Pat. Nos. 4,953,693 and 5,031,757, the disclosures of which are incorporated herein by reference. However, the present arrangement is not limited to any particular design of modular link chain or conveyor system10, as the features described herein may find utility in various applications.

In this particular application, the chain11is shown as being arranged to travel in an endless conveying path with a conveying surface S for supporting objects (not shown) along a forward run F. In the illustrated embodiment, the conveyor chain11is guided between the forward run F and a return run R by end sprockets K mounted along and supported by a rotatable support shaft. The sprockets K are shown as being driven at one end by a motor M, which may be supported by the frame E. However, it is within the broadest aspects of the disclosure for the chain11to be driven in a continuous loop in a single (e.g., horizontal) plane, in which case the sprockets could be located anywhere along the path of conveyor travel. Alternatively, as discussed further below, the sprockets K could be arranged to rotate about a vertical axis and engage the side links12along an inner or outer side in order to drive the chain11.

Turning now toFIG. 5, one or more of the links12forming the chain11may be adapted in one of several ways to enhance the efficiency of the article conveyance. The illustrated link12is provided with a rounded upper portion20, which thus provides an apical region A for contacting and supporting an overlying article (see article L inFIG. 7). For purposes of this disclosure, the term “apical region” is a region including an apex, or highest point, of the upper surface of the link12in the conveying direction. Thus, as will be understood on reviewing the description that follows, a single link may have more than one apical region if the two are spaced apart, such as by a gap. The link12may also include a surface opposite the conveying surface S that is planar or flat, and thus contributes to added strength for purposes of transmitting power for driving the link.

Consequently, as shown inFIG. 7, when a plurality of the links12are arranged in tandem to form the endless chain11(which may comprise only a single link width in the direction transverse T to the conveying direction D) for conveying articles, the apical regions A (three identified for example only) of the consecutively arranged links12, thus serve to provide a discontinuous or undulating conveying surface S for the article L being conveyed (which may be considered a smooth surface with upper and lower regions formed on the same link12).

As can be appreciated, this apical region A minimizes the amount of contact between the article L and the conveying surface S along the upper portion20. This may help to prevent deleterious sticking that may otherwise result, especially when the article is, for example, a food product exposed to freezing temperatures during conveyance, or one that has been warmed or just baked (e.g., breads, cookies, tortillas). The minimal contact presented also tends to result in less friction, thus potentially making it easier to alter the path of conveyance, such as through lateral pushing, braking, or the like.

A further result of the rounded upper portion20can be understood from the illustration of the transition from the forward run F to the return run R inFIG. 7. At this transition (or the transition from the return to the forward run at the opposite end), the curvature of the upper portion20of the consecutive links12is such that a substantially smooth, arcuate conveying surface S is presented during travel along the rounded end section of the conveyor system10. This allows for a transfer T or like structure for transferring the article to an adjacent location (such as a downstream conveyor, not shown) to be positioned extremely close to the conveying surface along the transition. This can be done without the usual concern for irregularities created by “flat top” links making the transition, which would result in a larger gap that could potentially snag the articles and not only cause damage to the article, but potentially lead to a catastrophic failure.

As should be appreciated, the rounded portion20is shown as being applied to a link12having the depending arm12afor guiding the chain11along all or a portion of the endless path, but could also be applied to links without this structure, as outlined further in the description that follows. A feature of this link12is that it provides a substantially open or reticulated conveying surface S, as the result of openings formed in the body of each link. Likewise, there is no continuous central part extending across the surface, but rather connectors12bextending in the transverse direction T for interconnecting members12celongated in the conveying direction D, which together form the leading and trailing apexes12d,12eof the link12. In other words, at least two of the transverse connectors12bare not collinear (that is, they do not align on the same imaginary line extending in the transverse direction D).

As can be appreciated fromFIGS. 6 and 6A-6C, the connectors12bare discontinuous or, stated a different way, staggered in position in the conveying direction. For instance, in the illustrated embodiment, one connector12bincludes apical region A1, another connector includes apical region A2, which is spaced from apical region A1in the transverse direction T. Yet another connector includes apical region A3, which is aligned with the first apical region A1in the conveying direction, but spaced apart from it by a gap P.

The apical regions A1, A2, A3may be substantially the same height, or may be different heights, but as noted above, each includes the highest point or apex of the link in the conveying direction D (that is, there is no higher point when the link is viewed from front or rear (FIGS. 6D and 6E). The apical regions A1, A2, A3may all be of the same height when viewed from the side (although the heights could differ as well). The apical regions A1, A2, A3forming part of the curved upper portion of the link12thus may be considered to be S-shaped when viewed in a top plan view, with the actual highest points of the link being anywhere along the S-shape.

The foregoing features not only further reduce the amount of contact with articles being conveyed by spacing the apical regions A1, A2, A3, but also tend to allow air to reach the underside of the articles through the gap P, including when the links12are interdigitated and especially when the chain is expanded in the conveying direction D (FIG. 9). In situations where heat transfer is desirable during conveyance, such as in the case of warm baked goods, this can significantly contribute to the cooling provided, which may avoid the need for external cooling sources, such as fans or the like, or prolonged conveying runs to allow for suitable cooling time.

A further feature of these or any other links12may be to provide an apical contact surface22for engaging a drive structure, such as a sprocket26(FIG. 8) or the like. As can be understood from the bottom view ofFIG. 7, this surface22may be arranged on the depending arm12aso as to be rounded. For example, the surface make take the form of a rounded “button,” which may take the form of a spherical cap or a hemispherical structure. Alternatively, the surface22may comprise a generally pyramidial structure having rounded faces. The surface22may be molded as part of the link12and thus formed of the same material, or may be formed of a different material (such as an elastomer to provide for enhanced shock absorption and resilience), which may be done through co-molding techniques.

Thus, as can be understood with reference toFIG. 8, the link12is shown in engagement with a tooth24of a drive structure, such as a sprocket K (which may be a spiral drive arrangement as illustrated in U.S. Pat. No. 8,727,109 and U.S. Patent Application Publication No. 2014/0305774, the disclosures of which are incorporated herein by reference) arranged so as to have a vertical axis of rotation generally transverse to the conveying direction. As can be appreciated, as a result of the rounded surface22, the corresponding contact region with the engagement surface of the tooth24creates a tangent line at point B during both the initial contact and as the driving in the conveying direction D continues. Consequently, the arrangement provides for an efficient transfer of the motive force during the engagement (as compared to the situation where the contact would be between a sloping surface of the tooth24and a flat surface of the link12). As a result, efficiency is improved and wear is reduced, thus enhancing the service life of the arrangement.

A further possible feature of this arrangement is to provide the sprocket K with driving inserts removable from the body26thereof (such as in a direction transverse to the axis of rotation of the sprocket). Thus, in theFIG. 8arrangement, the insert is in the form of a generally triangular or pointed tooth24, which as shown includes oversized portions24areceived in and captured by a corresponding receiver26ain the sprocket body26. The nature of the capturing is such that the tooth24is fixed against movement in the radial direction, but can move in the axial direction (and may be held in place by a retainer applied to the sprocket body26, such as a removable cap). As can be appreciated, this allows for the tooth24to be made out of a resilient material, such as polyurethane, while the sprocket K is made of a different material to provide for an enhanced service life. For example, the sprocket body26could be made of a harder material, such as anodised aluminum.

Referring now toFIGS. 10-12, it can be seen that the link12may be provided with a raised portion30forming an upstanding wall or guard, which is optional. This raised portion30may be provided along a side link including depending arm12a, and thus help to confine the articles to the conveying surface S. Additionally, the raised portion may extend along the corresponding member12cto further strengthen the portion of the link12against the driving force transmitted by the engagement of a drive structure with the rounded surface22.

FIGS. 13-15illustrate a link12that is adapted for forming a middle or center link of a conveyor chain. Consequently, the link12does not include the depending arm12a, but does have the rounded or curved portion20forming the apical region and the lower planar portion21opposite the conveying surface S. The greatest width Y of the link12in the vertical direction V is at the apical region A, as indicated inFIG. 14. As can perhaps be best understood fromFIG. 15, the central portion of the link is discontinuous in the transverse direction T as a result of the staggering of the connectors12bconnecting members12cforming the leading and trailing apex12d,12e.

The foregoing description of several aspects of the embodiments disclosed herein is presented for purposes of illustration and description. The embodiments described are not intended to be exhaustive or to limit the invention to the precise form disclosed. Modifications or variations are possible in light of the above teachings. The embodiments described were chosen to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention when interpreted in accordance with the breadth to which it is fairly, legally, and equitably entitled.