Conveyor belt system with belt module drive surfaces mating with drive sprocket wheel in the hinging region

Abstract: Driving engagement is improved for variously shaped modular belt links (16,17,18,19) with drive surfaces extending from cylindrical structure about the pivot rod journalling aperture (27) to form drive surfaces for mating with sprocket teeth (44,45,46). Dynamically moving sprocket drive surfaces (55) interact between substantially radially disposed parallel drive planes on both the sprocket (41) and the belt modules (16-18), thereby to avoid radially directed forces that drive the belt (25) away from the drive sprocket (41) to cause wear and unreliability. Trapezoidal shaped mating drive teeth (55-56) upon the modules (16-18) extend from a generally cylindrical body about the pivot rod (14). Sprocket drive teeth (44-46) engage respective ones of such trapezoidal drive teeth on different end to end intercoupled modular links (16-19) so that the belt (25) may be driven in opposite directions. At the belt (25) edge, one of two different pivot rod retention cap embodiments (33) swivels elastically away from the normal pivot rod axis (28) position retaining a pivot rod (14) in place to permit pivot rods (14) to be inserted or removed.

Description: TECHNICAL FIELD: This invention relates to the structural characteristics of conveyor belt modules, and more particularly to interacting module and sprocket drive surfaces coacting at the hinging joints. BACKGROUND ART: Modularized conveyor belts and accompanying drive systems are well known in the art, and are found with modules of various characteristics that are coupled together and articulated by means of pivot rods so that they can be endlessly moved by means of rotatable sprockets. The trend in the art is to produce modules of various shapes and interactions for achieving various advantages in operation. EP-A-0 380 201 discloses a module having a top and bottom surface suitable for being pivotally connected with a multiplicity of similar modules by pivot rods to construct a conveyor belt which can move along a predetermined path, said module comprising: a plurality of elongated links extending the length of the module, each of said plurality of elongated links defining a first set of pivot holes aligned along a first pivot axis in the link ends at one end and a second set of pivot holes aligned along a second pivot axis in the link ends at the other end of said elongated link and also including a portion thereof which is not orthogonal to said pivot axes; the link ends of each link of said module suitable for being intermeshed and pivotally connected by pivot rods extending through said pivot holes with the link ends of similar module to form a conveyor belt; an integrally molded connecting structure extending transverse to said elongated links so as to join and maintain the other and having a bottom-most point which terminates substantially at said bottom surface; and driving surfaces defined by said connecting structure suitable for receiving a driving force to move said module and a conveyor belt constructed from a multiplicity of such modules in a selected direction. However, it suffers from insufficient operating characteristics particularly in the critical sprocket and module driving surface interface. Thus, one objective of this invention is to provide improved simplified modular elements and conveyor belt drive systems embodying modular elements. A critical operational region in conveyor belt systems driven by a sprocket at the hinged joints is caused by the hinging driving interface between the belt modules and the relatively moving rotating sprocket drive surfaces. The prior art has many different configurations of sprocket and belt structure with special driving surface features. However, the prior art hinge region drive surfaces present operational disadvantages. In consideration of the driving interface design of prior art conveyor belt systems, some of the critical operating conditions involved are the wear at interfacing drive surfaces, the ability of the belt to articulate smoothly over small diameter sprockets, the performance of the belt over the range of no-load to full-load conditions, the energy or friction losses of the drive system, the ability to run at various speeds, freedom from vibration and noise, and the ease of replacing worn surfaces or parts. In particular at the interface between sprocket and module surfaces tend to react frictionally during the hinging acting to urge the belt away from the sprocket. This, in turn introduces significant problems in controlling belt slack and tension and wear at the sprocket-hinge interface surfaces and visibly reacts in a manner similar to slack in the unloaded system. If the belt is tightened to remove slack, then the operating friction becomes excessive, without correcting the urging forces, thereby causing inefficient operation with more wear on the drive surfaces. Attempted solutions, such as counteracting forces applied to the belt or limiting guide brackets to limit belt movement away from the sprocket are not satisfactory. Accordingly a still further objective of this invention is to provide an improved conveyor belt system wherein interacting belt-sprocket drive forces that tend to drive the belt away from the sprocket are avoided. Other objects, features and advantages of the invention will become apparent from the following description taken with the accompanying drawings and claims. DISCLOSURE OF THE INVENTION: A modularized conveyor belt is formed from variously shaped modular members, illustrated for example in a wishbone-shaped embodiment defining modular elements with three fingers or link ends. The modular elements may be coupled together in one or more multiple element units disposed across the width of a belt. In the modular wishbone elements, a stem extends in one direction and two bifurcated fingers extend in the opposite direction. Spocket tooth drive surfaces are formed by the stem ends which surround journalled apertures for receiving pivot rods. The various modules for which this invention is directed have in common drive surfaces in the hinging region which move dynamically during articulation and thus produce an interface with mating sprocket drive surfaces. Modular members of one or more wishbone elements, when connected side by side and end to end into a belt by pivot rods thus have disposed about pivot rods side-by-side interfacing drive members extending alternately in opposite directions about pivot rods toward respective end to end articulating modules. Different configurations permit links to be articulated at opposite ends about a pivot rod, or groups of such links held together in modular units of predetermined width across the belt by means of integral interconnecting structure such as connecting crossbeams, usually centrally positioned along the length of the modular elements and disposed normally to the direction of belt travel. Typically the belt loading surface of one class of modular links or modular units terminates in a plane, which could be a suitably apertured flat sheet surface, for example, or alternatively an open gridwork arrangement. Another class of modular members may have non-planar belt loading surfaces. Spacings between adjacent parallel pivot rod axes (pitch) formed by the module member or modular sections may vary, but typically could be as little as about one-half inch (1.27 cm) for smaller modules. In such modules, drive tooth surfaces typically extend downward from the bottom belt surface about 0.1 inch (0.25 cm) for a 0.5 inch (1.3 cm) pitch. This invention is not pitch limited. A preferred wishbone pitch is 0.6 inch (1.5 cm). In any event, a typical drive surface afforded by this invention could comprise a generally trapezoidal drive tooth shape with planar sidewalls extending inwardly from the belt towards a drive sprocket and integrally formed on the generally cylindrical surfaces disposed about the pivot rod to form journalling apertures. Belt systems in general are driven by a rotary sprocket wheel with peripheral teeth entering mating apaertures defined in the belt assembly to interface with the interacting module drive surfaces surrounding the pivot rod. Thus, a drive force reacts on the pivot rod through generally cylindrical contact surfaces surrounding the pivot rods at opposite ends of the modular members. The entry angle of the sprocket drive tooth surfaces with respect to the module drive tooth surfaces requires the sprocket and module during the dynamic articulating motion to engage at two substantially parallel interacting drive surfaces accommodating entry of the module drive tooth into and exit from the sprocket wheel or drive contact without interference to impart tangential drive forces along the belt without tending to force the belt away from the sprocket wheel. Thus, two substantially planar surfaces are mated with substantially parallel dynamic movement for both entry and exit of sprocket driving teeth into and out of the belt configuration. The respective planar drive surfaces of the sprocket are disposed generally radially with respect to the sprocket wheel drive axis for mating in movement over a pre-determined sprocket arc. The module members form sprocket channels or notches for sprocket drive teeth to enter or leave the belt with the sprocket and module tooth surfaces disposed substantially parallel during articulation so that radial forces outwardly from the sprocket tending to drive the belt away from the sprocket are avoided. To facilitate better driving forces when the sprocket drive tooth surfaces enter and leave the sprocket drive notch of the belt without any interference or substantial surface wear, the link end pivot rod journalling surfaces at the drive interfaces forming a belt drive tooth may have a different radius center at leading and trailing tooth surfaces. Thus, the two walls formed about the pivot rod at the module link finger ends in a plane parallel to the belt to form the drive tooth have different thicknesses to produce a thinner inside edge surrounding cylindrical wall positioned inwardly in the driven link in the driving direction than the corresponding outside driven edge wall thickness directed away from the driven link ends. This avoids any interference, scrubbing or wear on the sprocket teeth from the adjacent interdigited link ends of the adjoining modular section during dynamic reaction with sprocket drive teeth at the articulation joint. Accordingly the modular belt conveyor system drive interface between the module links and the sprocket interengage in movement onto, about and away from the rotating sprocket wheel to produce substantially only circumferentially oriented drive forces tangential to the belt. The substantially tangential drive forces avoids interference and radial oscillation or flapping of the belt to keep noise, friction, vibration and wear at a minimum and maintains the belt in good circumferential contact with the sprocket wheel under all conditions from no-load to full-load. The invention will be hereinafter described in more detail with reference to the accompanying drawing. BRIEF DESCRIPTION OF THE DRAWING: In the drawing, wherein like reference characters represent similar features throughout the several views: Figures 1 and 2 are respectively top and left end views of a wishbone styled modular conveyor belt section embodiment of this invention, Figure 3 is a fragmental side view of a module showing drive surface interfacing with drive sprocket tooth surfaces with analysis lines of incremental interface surface confrontations over a movement arc of the conveyor belt in which the module link tooth shaped drive member enters the mating sprocket wheel notch; Figure 3A shows in greater detail the critical module driven member interacting configured surfaces for reducing interference, scrubbing action or frictional contact with sprocket tooth surfaces; Figures 3B and 3C are respective end views, partly in phantom of end to end modules in unarticulated and articulated postures, Figure 4 is a fragmental side view of a conveyor belt system illustrating the belt to sprocket wheel interfacing improvements afforded by this invention, Figure 5 is a fragmental plan view of a conveyor belt embodiment having wishbone shaped module links affixed together into modular units that are interfitted to form the belt, Figure 6 is a fragmental exploded sketch of a conveyor belt embodiment illustrating how the belt configuration features of the invention are bricklayered. THE PREFERRED EMBODIMENTS: Now with reference to Figure 1, it is seen that the belt module embodiment 15 is formed of four wishbone shaped basic modular links 16, 17, 18, 19, held in place by a substantially longitudinal transverse rod support structure 20 or connecting beam integrally joining the modular members 16, 17, 18 & 19 to provide a multi-linked modular unit. Typically the modular unit is molded from plastic and the connecting beam need not bear weight or act as a structural element such as drive member, but forms the individual links into a modular unit. As seen from the end view of Figure 2, the top of the belt 25 forming the working surface is generally flat or planar, and drive surfaces extend from the underside as teeth 26. Axial apertures 27 formed in the module fingers 30, 31, 32 receive and journal pivot rods in fixed alignment along two parallel pivot rod receiving axes (28). The belt edge wishbone link 19 of the module 15 forms a retaining cap 29 for preventing axial movement of the pivot rods out of the belt toward the right. The cap 29 is resiliently supported by elastic plastic arm 33 so that it may be flexed away from axis 28 to insert or remove a pivot rod along axis 28. Each wishbone module link 16, 17, etc. has a stem portion or finger 31 with the pivot rod journalling aperture 27 having an axis (28) normal to a first plane 35 passing through the stem portion 31. The stem portion is bifurcated at the location 36 near the connecting beam 20 to extend into two branches, link ends, or fingers 32, 30, which also define pivot rod journalling apertures 27, and which lie in planes 36, 37 parallel to and on opposite sides of plane 35. These wishbone module links 16, 17 are assembled with the alternating stems 31, 38 pointing in opposite directions and with appropriate spacings 39 between the fingers of slightly greater width than the width of the fingers for interdigitating link end fingers of like modular units 15 in place in end to end relationship. As seen from Figure 3, a peripheral arc 40 of a rotary sprocket drive wheel 41 has a plurality of notches or spaces 42, 43 formed between adjacent teeth 44, 45, 46 about the drive sprocket periphery. Thus, looking into the left end of Figure 1, the modular section 15 is viewed similar to the Figure 2 profile 25 existing at a sprocket wheel engagement position somewhere along the length of the modular section 15. The belt module tooth 26 thus mates into the sprocket notch 43 and the sprocket 41 drives the belt formed of end to end modules 25, etc. in the direction of arrow 48. The access notches 49 in the teeth (46) accommodate the transverse connecting beam 20 structure of the modular units 15 in a non-contact relationship to avoid interference, as seen from the incremental movement line segments 47. Driving surfaces 52, 53 on opposite sides of notches (43) in the sprocket wheel 41 are substantially radially disposed from the axis of rotation of the sprocket wheel 41, thereby presenting substantially planar surfaces. The sprocket teeth 44, 45, 46, etc. pass through access apertures on the bottom surface of the assembled belt end-to-end modular sections 15 in a manner later shown. Mating surfaces 55, 56 on the modular unit teeth 26 of the belt thus mate into the sprocket notches (43) between the teeth on the sprocket wheel 41 and only the surface 55 interacts as a driving surface. (The mating surfaces are not shown in touching contact in Fig. 3 to avoid clutter.) The particular parallel surface structure of the interengaging drive surfaces 52, 55 herein provided assures minimal frictional losses, quiet and vibrationless entry and exit of the belt teeth 26 into the sprocket notches 43, smooth transmission of power from the sprocket drive wheel to the belt, and optimal entry and exit behavior of the belt teeth 26 with the sprocket drive notches. The drive power is thus transferred without inducing any substantial radial drive forces tending to force the belt either toward or away from the sprocket wheel periphery. Thus the belt 60 is conveyed substantially tangentially to the periphery of the sprocket wheel 41, with all drive forces urging the belt in the direction 48, as seen better from the view of Figure 4. The belt module drive members 26 are substantially immersed in the notches 43, etc. up to, or just above, the diameter of the pivot rods and pivot rod journalling apertures 27. The incremental postures of the belt tooth interface surfaces during the critical entry (or exit) phases as the sprocket rotation progresses over the arc 40 is represented for a set of incremental positions by the sets of position lines 61. By means of the generally trapezoidally shaped region 66 formed by the belt module drive appendages extending away from each pivot rod journalling aperture 27 and surrounding cylindrical body to form the belt drive teeth 26, the belt presents substantially planar contact interaction surfaces 55, 56. Thus, as seen in sprocket notch 42, the drive surfaces interact upon belt tooth 26 entry so that the respective belt and sprocket drive surfaces are parallel and thus avoid any driving forces tending to move the belt radially from or towards the rotation axis of the sprocket wheel 41. As may be seen in Figure 3A, the opposite walls 57 and 58 of the body 54 about the pivot pin journalling aperture 27' are of different thickness. Thus, the cylindrical curvature of the wall 57 by the radial arrow to provide wall 57 to the left is generated from center 60 of the cylindrical aperture 27' lying on axis 59R as noted by the radial arrow extending to wall 57. The thinner wall 58 to the right is generated similarly from offset center 62 on axis 59L as noted by the radial arrow extending to wall 58. The pivot rod journalling aperture 27' is generated from center 60 as shown by the third radial arrow. This difference in wall thicknesses reduces the tendency of the surface 56 on the belt drive tooth 26 to scrub against the mating notch (43) surface 53 of the sprocket wheel during the dynamic movement of the interengaging belt and sprocket wheel. The trapezoidally shaped tooth appendages 26 on the belt modules extend outwardly from a substantially cylindrical integral structure 54' about the pivot pin journalling aperture 27, with the contact surface 55 entering the sprocket notches 42, 43, etc. with parallel contact surfaces. Because of the thinner wall 58, the non-drive surface 56 enters and leaves the sprocket notches 42, 43, etc. without scrubbing or interference that causes wear or radial forces urging the belt modules 25, etc. away from the sprocket. The wishbone module elements and sections 15 have a preferred pitch of the order of a 0.6 inch (1.3 cm) between the axes 28 of the pivot rods so that a belt can make very sharp turns about a sprocket of less than three inches (7.6 cm) in diameter and having sixteen sprocket teeth. Four and one-half inch (11.4 cm) diameter and six inch (15.2 cm) diameter sprockets having twenty-four or thirty-two sprocket teeth also are used where room is available for less sharp turns. Thus, the distinct advantages are attained by this invention of (1) less tendency for the belt to push away from the sprocket with corresponding advantage of simplicity in adjusting belt tension and reduced friction and energy, (2) long life because of reduced scrubbing and wear, and (3) low drive energy with very little vibration and noise caused in the drive mechanisms. The invention is characterized by hinge driven modular conveyor belt forming links. A preferred embodiment integrally carries drive tooth surfaces extending downwardly from the belt surface from a generally hollow cylindrical link end body defining a pivot rod journalling aperture. Thus, opposite drive and non-drive surfaces are presented for interacting with mating drive surfaces of sprocket wheels at opposite sides of notches formed between drive sprocket teeth. The belt teeth are preferably shaped as trapezoidal appendages integrally extending from the generally cylindrical link end body forming a pivot rod journalling aperture. The drive tooth surfaces on the belt and the drive surfaces on the sprocket are disposed so that the belt teeth enter and leave sprocket drive channels between adjacent teeth with the opposing belt and sprocket surfaces in substantially parallel relationship to produce tangential driving forces and to avoid any radial driving forces tending to push the belt away from the sprocket. In Fig 3A, a characterizing feature is illustrated, namely that opposite cylindrical sidewalls 57, 58 have differing thicknesses in the plane 68 passing parallel to the belt thereby to reduce the chances of frictional contact during articulation when sprocket drive teeth engage the sidewalls. In Figures 3B and 3C the operational relationships of the thinner wall adjoining surface 56 and thicker wall adjoining surface 55 are illustrated. The phantom view modules 25' illustrate a pivot rod at axis 63 with respect to the modules 25, 25'. Figure 3B shows non-articulated belt modules and Figure 3C shows the belt modules 25, 25' articulated. The end to end connected and interdigitized modules 25 and 25' are alternately positioned with thicker walls 58 and thinner walls 57 facing in opposite directions. Non-drive surfaces 67, by means of the thinner-thicker wall structure 58, 57 are offset from the drive surfaces (64L and 64R for module 25' and 65L, 65R for modules 25), and thus assure that no frictional contact or interference occurs from the sprocket drive teeth during the dynamic articulation cycle. To drive the belt to the right, the drive surfaces 64L and 65L would be contacted by the sprocket drive teeth. Conversely, when driving the belt to the left, drive surfaces 65R and 64R are contacted by the sprocket teeth. As seen in Figure 5, the modular sections 15 are held together end to end in a belt configuration by means of pivot rods 14. The sprocket drive teeth 46, which are notched to straddle the link connecting beams 20 (Fig. 3), are shown in their drive relationship so that drive forces are effected upon the pivot rod in the articulation joint region by means of the intervening wishbone member drive tooth structure described in Figures 3B and 3C. Thus, the non-contact surfaces 67 are distinguished from the drive surfaces 64, 65. From the exploded view of Figure 6, it is seen that the modular sections may form a belt of desired width in bricklayered fashion by means of an end-cap-less modular section 71. The belt edge modular sections 15' of this embodiment have male pivot rod retention posts 72 inserted into the adjacent wishbone journalling aperture 27 to abut the pivot rod 14. As in the previous embodiment of Figures 1 and 5, the flexible retention arm 33 permits the retention posts 72 to be moved aside for entry or removal of the pivot rods 14. The right end modular section 15'' may be different in length from the left end modular section 15' on a row of modules. With various module lengths, the bricklaying pattern can be realized. However identical modules can be used on either belt edge with 180 degree rotation to fit on the opposite ends. The end-cap-less modules 71 also can be made of various lengths to fill the space between the endcapped belt edge units 15', 15''. Thus, with only a few basic wishbone modular section configurations the belts may be bricklayered, and belts of various widths may be constructed of a minimum of only two basic modular section configurations.

Claims: A modularized conveyor belt system comprising at least one drive sprocket wheel (41) with drive teeth (44, 45, 46) access notches (49) in the teeth (46) and a transverse connecting beam (20) of a modular unit, said sprocket wheel drive teeth (44, 45, 46) for driving a belt comprising a plurality of modular units (16, 17, 18, 19) each having said transverse connecting beam (20) and adapted for articulated interconnection end to end in an endless belt configuration, defining an outer belt side as a belt load carrying surface for disposal across a width of a conveyor belt and an inner belt side with drive surfaces for engaging said sprocket wheel drive teeth, said articulated interconnection comprising generally cylindrical bodies (54) provided with an axial aperture (27') for receiving and journalling a cylindrical one-piece pivot rod (14) in fixed alignment to pivotably connect the modular units (16, 17, 18, 19), characterized in that said access notches (49) accommodate the transverse connecting beams (20) in a non-contact relationship, said inner belt with the drive surfaces comprises teeth (26) extending integrally from said cylindrical bodies (54) as appendages directed away from the opposite belt side and carrying planar drive tooth surfaces (55, 56) extending from diametrically opposite sides of the generally cylindrical bodies (54), said planar drive tooth surfaces (55, 56) being disposed for interacting with mating planar drive surfaces (52, 53) radially extending from a drive sprocket wheel between adjacent teeth (26) disposed on the inner belt side, the appendage of said tooth (26) being generally trapezoidal in shape for presenting the planar drive surfaces to enter and leave corresponding planar sprocket wheel notches drive surfaces (52, 53) with the interengaging drive surfaces substantially parallel as the modular units (16, 17, 18, 19) pivot when engaging the sprocket wheel (41) to ensure minimal frictional losses and quiet vibrationless entry and exit of the belt teeth (26) into the sprocket notches (43) for driving the belt. A modularized conveyor belt system in accordance to claim 1, characterized in that the generally cylindrical bodies (54) have cylindrical side walls of differing thickness (57, 58) disposed on opposite sides of the journalling aperture (27) in a plane parallel to the belt. A modularized conveyor belt system in accordance to claim 2, further characterized by: a plurality of the basic modular link elements (18, 19) with two bifurcated fingers (31, 38) each defining said pivot rod journalling apertures (27) at two link ends with one link end offset parallel to that of the first pivot rod axis at the other link end, said modular link elements thereby comprising an assembly of side by side elements forming a section of a conveyor belt with alternating stem portions (31, 38) extending in opposite directions in each of plurality of end to end rows of wishbone shaped members (18, 19) disposed transversely across the belt from one belt edge to an opposite belt edge with the generally hollow cylindrical portions in the link ends of adjacent end to end links disposed side by side and defining a series of said sprocket drive openings in the belt for positioning belt sprocket drive teeth (44, 45, 46) in contact with one of two side by side cylindrical portions in the link ends, thereby to comprise driving structure for conveying the belt along a pathway in response to an external driving force. A modularized conveyor belt system in accordance to claim 3, further characterized by support means integrally holding a plurality of the side-by-side modular link elements in place in a modular belt unit with the stems (31) and extension branches forming interdigitating fingers (31, 38) extending in two opposite directions in a plane passing through the fingers and their pivot rod journalling apertures (27). A modularized conveyor belt system in accordance to claim 1 in driving relationship with the sprocket with the trapezoidal appendages (66) shaped for entry of the appendages into an exit from the sprocket notches in a drive path relationship that substantially avoids forces pushing the belt away from the sprocket. A modularized conveyor belt system in accordance to claim 1 further characterized by pivot rod retention means (72) integrally retained on at least one end of said unit by a member permitting repeatable movement by elastic deformation of the pivot rod retention means (72) away from a normal position for preventing a pivot rod end from extending out of the unit to a flexed position preventing entry or exit of the pivot rod (14) into the pivot rod retaining apertures (27). A modularized conveyor belt system in accordance to claim 6, further characterized by structure on said pivot rod retention means (72) for normally extending into a pivot rod journalling aperture (27) in a modular element and movable out of the aperture (27) in a three dimensional movement path by said elastic deformation to permit access to the aperture (27) for entry or removal of a pivot rod. A modularized conveyor belt system in accordance to claim 7, wherein the pivot rod retention means (72) is further characterized by a belt edge member flexibly movable substantially in a planar motion between the normal and flexed positions.

Inventors: HORTON PAUL L, HORTON, PAUL L.
Applicants: LAITRAM CORP, THE LAITRAM CORPORATION
Application year: 1991
Main classification: B65G23
IPC codes: B65G17