Brake assembly for conveyor system

A brake assembly for a conveyor system includes a first bracket, a second bracket and a brake member. The first bracket is configured to receive a channel of the conveyor system. The second bracket is spaced from the first bracket and configured to receive the channel of the conveyor system. The brake member is pivotally connected to the second bracket. A pivot axis about which the brake member is configured to pivot is disposed outwardly of the second bracket. A biasing member is configured to bias the brake member inwardly.

BACKGROUND

Field of the Invention

The present invention generally relates to a brake assembly for a conveyor system. More specifically, the present invention relates to a brake assembly for a conveyor system in which a pivot pin and a brake member of the brake assembly are easily accessible.

Background Information

A conveyor system moves an item from one location to another. A power and free conveyor system, for example, allows the item to be moved when engaged to the power portion of the conveyor system, and allows the item to remain stationary when disengaged, that is, free, from the power portion of the conveyor system. A trolley is typically risen to transport the item, and is engaged and disengaged from the power portion of the conveyor system as necessary.

Brake assemblies are disposed throughout the conveyor system to facilitate controlling movement of the trolley through the conveyor system. A brake member is pivotally mounted by a pivot pin to a bracket to engage the trolley. However, the pivot pin and the brake member are disposed in locations that are not easily accessible when maintenance or repair of the brake assembly is required. Additionally, when the pivot pin breaks, the brake member can interfere with movement of the trolley, thereby disrupting operation of the conveyor system.

SUMMARY

One object of the present invention is to provide a brake assembly for a conveyor system in which a pivot pin and a brake member of the brake assembly are easily accessible to facilitate maintenance and repair of the brake assembly.

In view of the state of the known technology, one aspect of the present disclosure is to provide a brake assembly for a conveyor system. The brake assembly includes a first bracket, a second bracket and a brake member. The first bracket is configured to receive a channel of the conveyor system. The second bracket is spaced from the first bracket and configured to receive the channel of the conveyor system. The brake member is pivotally connected to the second bracket. A pivot axis about which the brake member is configured to pivot is disposed outwardly of the second bracket. A biasing member is configured to bias the brake member inwardly.

Another aspect of the present invention includes a conveyor system having an upper channel, and first and second lower channels. A chain is movably connected to the upper channel. The second lower channel is disposed opposite the first lower channel, and a first brake assembly is connected to the first lower channel. The first brake assembly includes a first bracket connected to the first lower channel. A second bracket is connected to the first lower channel. The second bracket is spaced from the first bracket in a direction of travel of the chain. A first brake member is pivotally connected to the second bracket. A first pivot axis about which the first brake member is configured to pivot is disposed outwardly of the second bracket. A first biasing member is configured to bias the first brake member toward the second lower channel.

Also other objects, features, aspects and advantages of the disclosed the brake assembly for the conveyor system will become apparent to those skilled in the art from the following detailed description, which, taken in conjunction with the annexed drawings, discloses exemplary embodiments of the electrostatic discharge assembly.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

Referring initially toFIG. 1, an overhead conveyor system10is illustrated in accordance with an exemplary embodiment of the present invention. The conveyor system10includes a power rail12and a free rail14. A chain16is movably connected to the power rail16to move in a direction D. A trolley18(FIGS. 11 and 12) is movably connected to the free rail14. A retractable dog (not shown) of the trolley18is selectively engaged with the chain16. When the retractable dog engages the chain16, the trolley18moves with the chain16(i.e., a power state). When the retractable dog is not engaged with the chain16, the trolley18does not move (i.e., a free state). The conveyor system10illustrated inFIG. 1is commonly referred to as a power and free conveyor system. Although the description refers to a power and free conveyor system, the brake assembly in accordance with exemplary embodiments of the present invention is not so limited and can be used with any suitable conveyor system.

The power rail12includes an upper channel20, as shown inFIG. 1. The chain16is connected to the upper channel20of the power rail12such that the chain16moves continuously in the direction D when the conveyor system10is in operation. The power rail12can alternatively be an H beam or an I beam. Alternatively, the power rail12can include a pair of upper channels that support the chain16for continuous movement.

The free rail14includes a first lower channel22and a second lower channel24, as shown inFIGS. 1-4. The second lower channel24is disposed opposite the first lower channel22. The first and second lower channels22and24of the free rail14movably support the trolley18(FIGS. 11 and 12) when the trolley18is engaged with the chain16. When the trolley18is not engaged with the chain16, the first and second lower channels22and24of the free rail14support the trolley in the free, or stationary, state.

The first lower channel22has a web member26connecting an upper flange28and a lower flange30. The upper and lower flanges28and30extend substantially perpendicularly in the same direction from opposite ends of the web member26.

The second lower channel24has a web member32connecting an upper flange34and a lower flange36. The upper and lower flanges34and36extend substantially perpendicularly in the same direction from opposite ends of the web member32. The second lower channel24is preferably substantially identical to the first lower channel22.

In the conveyor system10, the first and second lower channels22and24are disposed such that the upper flanges28and34extend toward one another and the lower flanges30and36extend toward one another, thereby forming gaps G1and G2between free ends of each of the upper and lower flanges, respectively. The gaps G1and G2allow the trolley to move between the first and second lower channels22and24of the free rail14. The gaps G1and G2are preferably substantially the same distance.

A first brake assembly38is connected to the first lower channel22, as shown inFIGS. 2-4. A second brake assembly40is connected to the second lower channel24. The second brake assembly40is preferably disposed directly opposite the first brake assembly38to facilitate braking a trolley18passing therebetween, as shown inFIGS. 11 and 12.

The first brake assembly38includes a first bracket42and a second bracket44connected to the first lower channel22. the second bracket44is spaced from the first bracket42in a direction of travel of the chain (indicated by the directional arrow D inFIG. 2). The second brake assembly40includes a third bracket46and a fourth bracket48connected to the second lower channel24. The fourth bracket48is spaced from the third bracket46in the direction of travel of the chain. The first bracket42is preferably disposed directly opposite the third bracket46, and the second bracket44is preferably disposed directly opposite the fourth bracket48.

The first brake assembly38, as shown inFIGS. 5-9, includes the first and second brackets42and44, a brake member50and a biasing member52. The first and second brackets42and44are configured to receive a channel of the conveyor system10, such as the first lower channel22(FIGS. 1-4). The first bracket42is preferably substantially C-shaped, and has an upper leg42A and a lower leg42B extending from opposite ends of a bracket leg42C. A first spacer54is preferably disposed on an inner surface of the bracket leg42C. A second spacer56is preferably disposed on an inner surface of the lower bracket leg42B.

The second bracket44is preferably substantially similar to the first bracket42, as shown inFIGS. 5-9. The second bracket44is preferably substantially C-shaped, and has an upper leg44A and a lower leg44B extending from opposite ends of a bracket leg44C. A first spacer58is preferably disposed on an inner surface of the bracket leg44C. A second spacer60is preferably disposed on an inner surface of the lower bracket leg44B.

As shown inFIGS. 5-9, a support member62extends between the first bracket42and the second bracket44. The support member62is connected to outer surfaces of the lower legs42B and44B of the first and second brackets42and44, respectively. The support member62is preferably rectangular, although the support member may be any suitable shape. The support member62spaces the first bracket42and the second bracket44in the travel direction D of the chain16(FIG. 1). The support member62is preferably made of steel.

A pivot hub64includes an upper hub member66and a lower hub member68, as shown inFIGS. 5-9. The upper hub member66is rigidly connected to the outer surface of the bracket leg44C of the second bracket44. The lower hub member68is rigidly connected to a lower surface62A of the support member62. Fastener openings66A and68A disposed in the upper and lower hub members66and68are aligned to receive a fastener, or pivot pin,70.

A brake member50is pivotally connected to the second bracket44, as shown inFIGS. 5-9 and 10. The brake member50preferably has a substantially rectangular shape, as shown inFIGS. 10-12. A trolley engaging edge50A preferably has rounded portions50B and50C proximal each end to facilitate engaging the trolley18. An edge50D opposite the trolley engaging edge50A is preferably linear. The brake member50is preferably made of steel.

A projection72extends outwardly proximal a first end of the brake member50. The projection72preferably extends perpendicularly from the edge50D. The projection72includes a flange member72A and a cylindrical member72B extending outwardly from a face of the flange member72A. A width of the cylindrical member72B is less than a width of the flange member72A, as shown inFIG. 10. The projection72is preferably integrally formed with the brake member50as a one-piece member.

A boss74is disposed at a first end of the brake member50, as shown inFIG. 10. Preferably, the boss74has an upper surface74A disposed above an upper surface50E of the brake member50and a lower surface74B disposed lower than a lower surface50F of the brake member50, as shown inFIGS. 8 and 10, thereby providing a strengthened pivot point for the brake member50and facilitating pivotal movement of the brake member50between the upper and lower huh members66and68. A fastener opening74C extends from the upper surface74A of the boss74to the lower surface74B of the boss74. The fastener opening74C extends in a direction substantially perpendicular to the direction in which the projection72extends. Alternatively, the boss has a thickness substantially equal to that of the brake member, such that the upper and lower surfaces of the boss are at the same height as the upper and lower surfaces of the brake member. The projection72and the boss74are disposed at opposite ends of the same side (that is, the edge50D) of the brake member50. Preferably, the boss74is integrally formed with the brake member50as a one-piece member.

The fastener70is inserted from an upper surface of the upper hub member66through the fastener opening66A in the upper hub member66, through the fastener opening74C in the brake member boss74, which is aligned with the fastener openings66A and68A in the upper and lower hub members66and68, and through the fastener opening68A in the lower hub member68. A washer76and a nut78are disposed on the fastener70, such that the washer76contacts a lower surface of the lower hub member68, as shown inFIG. 8. The brake member boss74allows the brake member50to pivot about the fastener70and between the upper hub member66and the lower hub member68. The nut76and washer78are easily removable from the pivot hub64, such that the fastener70can be easily accessed and replace to maintain operation of the brake assembly38.

The brake member50pivots about a first pivot axis A1passing through the fastener70. The first pivot axis A1is disposed outwardly of the second bracket44, as shown inFIGS. 5-9. In other words, as shown inFIG. 5, an outer surface44E is disposed between the first pivot axis A1and an inner surface44F of the bracket leg44C of the second bracket44. An inner surface44F of the bracket leg44C being the surface configured to receive the first lower channel22. The first pivot axis A1is preferably disposed between the first bracket42and the second bracket44in the travel direction D of the chain, as shown inFIGS. 8, 11 and 12. By providing the first pivot axis A1outwardly of the second bracket44, the fastener70is easily visible to determine the wear condition thereof, and is easily accessed for maintenance and replacement.

The biasing member52is configured to bias the brake member50inwardly, as shown inFIGS. 5-9. In other words, the biasing member52is configured to bias the brake member50in a direction away from the first bracket52. As shown inFIGS. 5 and 6, the biasing force pivots the brake member50in the counter-clockwise direction about the first pivot axis A1. The biasing member52is movably disposed in a housing80rigidly connected to the support member62. The biasing member52has a first end52A connected to the housing80and a second end52B receiving the projection72B of the brake member72. The biasing member52is preferably a helical spring.

The housing80has a first wall82and a second wall84extending outwardly from the support member62. The first wall82has a cutout portion82A to provide access to the biasing member52and the brake member50. The cutout portion82A allows the brake member50and the biasing member52to be easily removed when necessary for maintenance or replacement. The first wall82of the housing80is disposed closer to the first pivot axis A1then the second wall84. In other words, a first distance L1from the first wall82to the first pivot axis A1is less than a second distance L2from the second wall84to the first pivot axis A1, as shown inFIG. 5.

A third wall86extends between ends of the first and second walls82and84of the housing80, as shown inFIGS. 5-9, thereby defining an interior space of the housing80within which the biasing member52is disposed. The third wall86is preferably disposed substantially perpendicularly to each of the first and second walls82and84. A height of the second wall84is substantially constant from the third wall86to the support member62, as shown inFIG. 5. A first portion82B of the first wall82has a height larger than that of a height of the cut-out portion82A. A first housing support82C is disposed at a free end of the first wall82, and a second housing support84A is disposed at a free end of the second wall84. The first and second housing supports82C and84A are rigidly connected to a lower surface62A of the support member62in any suitable manner, such as by welding.

The first end52A of the biasing member52receives an adjusting member88, as shown inFIGS. 5-9, to adjust a tension of the biasing member52. The angle of the brake member50is controlled by adjusting the tension of the biasing member52, thereby controlling how far into the gap between the first and second lower channels the brake member extends. As shown inFIGS. 5-9, the adjusting member88is a threaded fastener88A passing through the third wall of the housing80and having a flange member88B connected thereto that engages the first end52A of the biasing member52. The threaded fastener88B is threadably rotated with respect to the third wall86of the housing80to adjust the tension of the biasing member52. The second end52B of the biasing member52receives the cylindrical member72B of the projection72such that the second end52B of the biasing member52abuts the flange member72A of the projection72.

As shown inFIGS. 2-4, the first brake assembly38is connected to the first lower channel22. Fastener holes42D in the upper leg42A of the first bracket42and fastener holes44D in the upper leg44A of the second bracket44can be used to connect the first and second brackets42and44to the first lower channel22. The first brake assembly40can then be rigidly connected to the first lower channel22by any suitable method, such as welding, if desired, to further secure the first brake assembly38to the first lower channel22.

As shown inFIGS. 2-4, 10 and 11, the second brake assembly40is substantially similar to the first brake assembly38except disposed as a mirror image thereof on the second lower channel24. The second brake assembly40includes a second brake member90pivotally connected to the fourth bracket48. The second brake member pivots about a second pivot axis A2, which is disposed outwardly of the fourth bracket48. The second brake member90pivots about the second pivot axis A2that passes through a second fastener, or pivot pin,112. The second pivot axis A2is disposed between the third and fourth brackets46and48in a travel direction of the chain16. The first and second lower channels22and24are disposed between the first and second pivot axes A1and A2in a direction perpendicular to the travel direction of the chain16(FIG. 1) when the first and second brake assemblies38and40are mounted to the first and second lower channels22and24. The second pivot axis A2is preferably substantially parallel to the first pivot axis A1.

A second support member92extends between the third and fourth brackets46and48, as shown inFIGS. 2-4. A second biasing member94is movably disposed in a second housing96connected to the second support member92. Similarly to the first housing80, the second housing96has a fourth wall98and a fifth wall100extending outwardly from the second support member92. A second cutout portion98A is disposed in the fourth wall98to facilitate accessing the second biasing member94and the second brake member90. The second cutout portion98A allows the second brake member90and the second biasing member94to be easily removed when necessary for maintenance or replacement. The fourth wall98of the second housing96is closer to the second pivot axis A2then the fifth wall100. In other words, a distance between the third wall98and the second pivot axis A2is less than a distance between the fifth wall100and the second pivot axis A2.

A second pivot hub102is substantially similar to the first pivot hub64. The second pivot axis A2passes through a second upper hub member104and a second lower hub member106. The second brake member90is pivotally connected to the fourth bracket48such that the second brake member90is configured to pivot between the second upper hub member104and the second lower hub member106.

The second brake member90is substantially similar to the first brake member50. The second brake member90has a second projection108extending outwardly from the second brake member90to engage the second biasing member94. The second projection108and the second pivot axis A2are disposed at opposite ends of the same side of the second brake member90. A second adjusting member110is rotatably connected to the second housing96to adjust the tension of the second biasing member94.

The first biasing member52is configured to bias the first brake member50toward the second lower channel24. The second biasing member94is configured to bias the second brake member90toward the first lower channel22. As shown inFIGS. 2-4, 10 and 11, the first and second biasing members52and94bias the first and second brake members38and40toward each other, thereby forming a gap G3between the first and second brake members52and94of the first and second assemblies38and40. The first and second adjusting members88and110can be used to control the gap G3between the first and second brake members50and90. By controlling the gap G3between the first and second brake members50and90, the amount of contact between the trolley18engaging edges of the first and second brake members50and90and the trolley18can be controlled, thereby controlling the amount of force applied to the trolley18as the trolley18passes between the first and second brake members50and90. As shown inFIG. 11, a trolley18is movably connected to the chain (FIG. 1) to move between the lower channels22and24of the conveyor system10. The trolley18engages the trolley engaging edges of the first and second brake members50and90, as shown inFIGS. 11 and 12, thereby slowing the trolley18to facilitate maintaining contact between the trolley18and the pusher. The trolley18has a width W greater than the gap G3between the first and second brake members, such that the trolley18pivots the first and second brake members50and90outwardly against the force applied by the first and second biasing members52and94. After the trolley18passes through the first and second brake assemblies38and40, the first and second biasing members52and94return the first and second brake members50and90to the rest positions shown inFIG. 11.

The first and second brake assemblies38and40facilitate maintaining proper positioning of the trolley. Preferably, the first and second brake assemblies38and40facilitate maintaining contact between the pusher and the retractable dog, which is disposed in front of the pusher in the direction of travel. The first and second brake assemblies38and40can be disposed at any desirable location along the first and second lower channels22and24of the conveyor system10, and preferably are disposed before an incline or decline on the first and second lower channels22and24of the conveyor system10in the direction of travel of the chain16.

GENERAL INTERPRETATION OF TERMS