Abstract:
The present disclosure relates to a conveyor frame assembly that includes a pair of spaced side rails joined by one or more cross supports. Each of the side rails includes a dedicated wire channel and self-contained air flow cavity that enhances the functionality of the conveyor frame assembly. The air flow cavity and the wire channel are formed as part of the side rails separate from typical attachment slots that receive T-shaped connectors. The cross supports utilized with the conveyor frame assembly are attached to the side rails by upper and lower connectors that are each accessible from the top of the conveyor frame assembly. Specifically, the cross support includes a center web and laterally offset attachment webs that allow for easy and convenient construction and field modification of the conveyor frame assembly.

Description:
CROSS REFERENCE TO RELATED APPLICATION(S) 
       [0001]    The present application is based on and claims priority to U.S. Provisional Patent Application Ser. No. 60/892,636 filed on Mar. 2, 2007. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The present invention generally relates to modular conveyor frame assemblies. More specifically, the present invention relates to a conveyor frame assembly that includes configurable cross supports and side rails having multiple passageways and connector slots formed in the side rails. 
         [0003]    Presently, moving belt conveyor systems are utilized in vastly different applications to move products/materials from one location to another in an automated fashion. Since conveyor assemblies are used in vastly different applications, the conveyor assemblies oftentimes include auxiliary devices that function in connection with the conveyor assembly to aid in moving products in a desired fashion. As an example, photo detector eyes and pusher devices are oftentimes mounted to the side rails of the conveyor frame assembly to act on the articles being moved by the conveyor frame. When these types of auxiliary devices are utilized with the conveyor frame assembly, the air hoses and electrical wires leading to the auxiliary devices are typically attached to the conveyor frame in a somewhat haphazard manner. Although the conveyor frame side rails may include attachment slots that receive T-shaped connectors to support the auxiliary devices, the T-shaped connectors interrupt the attachment slots, which prevents wires from being received within the attachment slots. 
         [0004]    Further, when pushing devices that operate upon pressurized air are utilized, an air pressure hose is typically hung from the side rail of the conveyor frame. The attachment of the electrical wires and the air supply hose to the side rails of the conveyor frame creates a cluttered appearance near the conveyor and may result in inadvertent disconnection of either the electrical wires or the air supply hose by personnel working near the conveyor frame assembly. 
         [0005]    Further, in many applications, the user of the conveyor assembly desires to change the length of the conveyor frame based upon the current application. Typically, the length of the conveyor assembly is adjusted by removing portions of the side rail and shortening the conveyor belt. During this process, the cross supports that provide rigidity to the conveyor frame are typically moved and reinstalled at the desired location along the modified length of the conveyor frame. In many conveyor frame assemblies, the reattachment of the cross support requires personnel to add holes to the conveyor side frame, which is oftentimes not practical in the operating environment. 
         [0006]    Therefore, a need exists for a conveyor frame assembly that includes side rails that provide a better method of directing both electrical wiring and an air supply hose, while allowing the conveyor length to be modified without requiring holes to be added to the conveyor side rails. 
       SUMMARY OF THE INVENTION 
       [0007]    The present invention relates to a conveyor frame assembly that can be assembled without any modification to the side rails of the conveyor frame assembly. The conveyor frame assembly includes a pair of spaced side rails and cross supports that receive self-threading fasteners in self-tapping slots along the interior side of the side rails. The geometry of the self-tapping slots and the actual side rail are designed to provide added strength to the joint between the cross supports and the side rails. Preferably, the self-tapping slots formed in the side rails are positioned at a 30° angle to drive the cross member into the support shoulder on the side rail extrusion, although angles between 30°-60° are contemplated as being within the scope of the present invention. All of the self-threading fasteners are inserted from above the cross support extrusion to aid in the speed of assembly. The physical configuration of the cross support allows all of the self-threading fasteners used to attach the cross support to the side rail to be visible and accessible from above the conveyor assembly, which provides improved access for assembly and disassembly. 
         [0008]    In addition to the method of attaching the cross support to the side rails, each of the side rails includes at least one integrated “light duty” self-tapping auxiliary slot. Each side rail features at least one of light duty auxiliary slots, which can be used for supporting or landing of electrical wires or other auxiliary devices. Self-threading fasteners are inserted into the auxiliary slot on the side rails, which eliminates the need for a T-nut, thus reducing cost and reducing the time it takes to land electrical wires along the entire conveyor. 
         [0009]    In accordance with the present invention, each side rail extrusion contains an air flow cavity that can be configured to receive a supply of pressurized air. The end of each extrusion will be blocked, providing a continuous air line for customer access. When multiple section conveyors are used, a connection device is used to bridge the pressurized air from one module to the next. Preferably, the side rail has a location groove along the outside of the side rail to provide a location to access the integrated air flow cavity. To access the air flow cavity, a simple drill and tap can be preformed anywhere along the rail at the location groove and a pneumatic fitting can be installed. 
         [0010]    In addition to the integrated air line, the side rail extrusion contains an open wire channel that will accommodate several low voltage wire lines. The wire channel is a continuous, uninterrupted partially enclosed channel that provides support and protection for low voltage wires running from their electronic device to the main junction box or control enclosure. The wire channel has a close fitting cover to seal off the wire channel. This cover can be cut to allow wires to enter and exit the wire channel. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]    The drawings illustrate the best mode presently contemplated of carrying out the invention. 
           [0012]    In the drawings: 
           [0013]      FIG. 1  is a perspective view illustrating a conveyor frame assembly constructed in accordance with the present invention; 
           [0014]      FIG. 2  is an end view of the conveyor frame assembly shown in  FIG. 1 ; 
           [0015]      FIG. 3  is an end view, similar to  FIG. 2 , illustrating the location of the upper and lower runs of a continuous conveyor belt; 
           [0016]      FIG. 4  is a top perspective view illustrating the mounting of a cross support between a pair of spaced side rails; 
           [0017]      FIG. 5  is a perspective view of the cross support machined for use with a plurality of self-tapping fasteners; 
           [0018]      FIG. 6  is an end view of the cross support shown in  FIG. 5 ; 
           [0019]      FIG. 7  is an end view illustrating the side rail; 
           [0020]      FIG. 8  is a perspective view of the conveyor frame assembly illustrating the attachment of an auxiliary support device mounted to one of the self-tapping auxiliary slots formed in the conveyor frame side rail; and 
           [0021]      FIG. 9  is an end view of the conveyor frame assembly shown in  FIG. 8 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0022]      FIG. 1  illustrates a conveyor frame assembly  10  constructed in accordance with the present invention. The conveyor frame assembly  10  generally includes a pair of side rails  12  spaced from each other by the width of the conveyor belt (not shown) to be utilized with the conveyor frame assembly. The pair of side rails  12  are supported in a spaced relationship by the pair of cross supports  14  illustrated in  FIG. 1 . Although the conveyor frame assembly  10  shown in  FIG. 1  includes only a pair of cross supports  14 , it should be understood that additional cross supports  14  could be utilized in conveyor frame assemblies having a significantly greater length and/or width. The cross supports  14  provide structural integrity for the conveyor frame assembly  10  and additional cross supports  14  may be needed for longer lengths of the conveyor frame assembly. 
         [0023]    In the embodiment of the invention illustrated in  FIG. 1 , both the side rails  12  and the cross supports  14  are formed from extruded aluminum, although other materials are contemplated as being within the scope of the present disclosure. 
         [0024]    Referring now to  FIG. 6 , thereshown is an end view of one of the cross supports  14 . As illustrated, the cross support  14  includes a center section  16  defined by a pair of outer sidewalls  18 . The sidewalls  18  define a generally open interior  20 . The cross support  14  includes a pair of lower attachment webs  22 ,  24 . Both of the attachment webs  22 ,  24  include an internal, lateral attachment slot  26 ,  27 , respectively. Each of the lateral attachment slots  26 ,  27  is defined by an outer wall  28  and an internal rib  30 . 
         [0025]    The pair of attachment webs  22 ,  24  are separated from each other by a central slot  32  defined by the center web  34 . The center web  34  extends upward into the open interior  20  to create the slot  32 . 
         [0026]    The cross support  14  further includes a first upper section  36  and a second upper section  38  that are separated from each other by an upper slot  40 . The upper slot  40  is defined by the center web  42  that also extends into the open interior  20 . The first upper section  36  includes a central attachment slot  44  while the second upper section  38  includes a similar central attachment slot  46 . 
         [0027]    As illustrated in  FIG. 6 , the lateral attachment slots  26 ,  27  are laterally offset a similar distance from the center line of the cross support  14 . Each of the lateral attachment slots  26 ,  27  is positioned slightly below a generally flat face surface  48 . The face surface  48  formed on each of the attachment webs  22 ,  24  extends laterally from one of the spaced sidewalls  18  of the center section  16 . The central attachment slot  44  is also formed slightly below the top face surface  50  while the central attachment slot  46  is formed slightly below the top face surface  52 . 
         [0028]    Referring now to  FIG. 5 , thereshown is the cross support  14  machined for use between the side rails of the conveyor frame assembly. The cross support  14  includes a relieved access area  54  formed near both of the first and second ends  56 ,  58  of the cross support  14 . Specifically, each of the relieved access areas  54  is formed by removing a portion of the top face surface  50 ,  52  using a circular milling cutter. The relieved access areas  54  create a pair of attachment face surfaces  60 , each in one of the upper sections  36 ,  38 . In the embodiment shown in  FIG. 5 , the attachment face surfaces  60  are formed at an angle relative to vertical. In the embodiment of  FIG. 5 , each of the attachment face surfaces  60  extends at an angle of approximately 30° relative to vertical. The attachment face surface  60  extends through each of the central attachment slots  44 ,  46  such that connectors can be used to secure the cross support  14  in the manner to be described in detail below. 
         [0029]    In addition to the relieved access areas  54 , the cross support  14  is formed with a pair of lower, relieved access areas  62  formed in each of the attachment webs  22  and  24 . As shown in  FIG. 5 , the lower relieved access areas  62  are formed near both the first end  56  and the second end  58  of the cross support  14 . The lower relieved access areas  62  are formed by a milling process and create an attachment face surface  64 . The attachment face surface  64  is formed at a similar angle relative to vertical as the attachment face surfaces  60 . In the preferred embodiment, the attachment face surface  64  extends at the same 30° angle relative to vertical. The lower relieved access area  62  provides access to the lateral attachment slot  26  formed in the attachment web  24 . Although not shown in  FIG. 5 , similar relieved access areas  62  are formed in the attachment web  24  near both the first and second ends  56 ,  58  to provide similar access to the lateral attachment slot  27 . 
         [0030]      FIG. 7  illustrates an end view of the side rail  12  used in constructing the conveyor frame assembly  10  shown in  FIG. 1 . The side rail  12  is preferably formed from extruded aluminum. As can be understood in  FIG. 1 , both of the side rails  12  are formed from the same extrusion. Referring back to  FIG. 7 , the side rail  12  includes an upper T-slot  66  and a lower T-slot  68  recessed from the outer wall  70 . Each of the T-slots  66 ,  68  include a reduced width entrance opening  72  and a receiving cavity  74 . Each of the upper and lower T-slots  66 ,  68  are sized to receive a T-slot connector to mount various components, such as sensors and pusher devices, along the length of the side rail  12  in a conventional manner. 
         [0031]    In addition to the upper and lower T-slots  66 ,  68 , the side rail  12  includes a first self-tapping auxiliary slot  76  and a second self-tapping auxiliary slot  78  that are each sized to receive a self-threading fastener. The auxiliary slots  76 ,  78  include an expanded outer portion  80  and a constant height channel  82 . The self-tapping auxiliary slots  76 ,  78  can each receive a screw or other similar self-threading connector that allows relatively small devices to be supported on the side rail  12 . 
         [0032]    The side rail  12  further includes integrated wire channel  84 . The wire channel  84  is formed by an outer wall  86  that defines an internal wire cavity  88  having an entrance opening  90 . The wire cavity  84  extends, uninterrupted, from a first end  92  to a second end  94  of the side rail  12 , as illustrated in  FIG. 1 . The uninterrupted wire channel  84  allows each of the side rails  12  to support a continuous low voltage wire or wires running from electronic devices mounted to the conveyor frame assembly  10  to a main junction box or control enclosure. The wire channel  84 , unlike the upper and lower T-slots  66 ,  68 , is not designed to receive T-slot connectors. Thus, during use of the conveyor assembly, the wire cavity  84  will extend, uninterrupted, along the entire length of each of the side rails  12 . 
         [0033]    Referring back to  FIG. 7 , the side rail  12  further includes an air flow cavity  96  that extends, uninterrupted, along the entire length of the side rail  12 . The air flow cavity  96  is completely contained within the side rail  12  and extends along the entire length of the side rail. Preferably, the air flow cavity  96  can receive a pressurized supply of air by tapping into the air flow cavity  97  at a location between the first end  92  and the second end  94  of the conveyor frame assembly. Both ends of the side rail receiving the pressurized air typically receive an end cap to prevent the leakage of the pressurized air from within the air flow cavity  96 . If a multiple section conveyor is constructed, a connection device (not shown) can be used to bridge the pressurized air from one side rail  12  to a similar side rail of the following conveyor section. 
         [0034]    As illustrated in  FIG. 7 , the outer wall  98  includes a location groove  100  that provides a guide to access the air flow cavity  96  through the outer wall  98 . As an example, if a device is attached to the side rail  12  that requires a supply of pressurized air, an air connection can be drilled through the outer wall  98  through the location groove  100 . 
         [0035]    Referring back to  FIG. 7 , the interior side of the side rail  12  includes an upper self-tapping slot  102  and a lower self-tapping slot  104  that each extend at an angle (30°) inward from an inner wall  106 . The inner wall  106  terminates with a lower support shoulder  108 . Positioned below the support shoulder  108  is a lower conveyor belt receiving cavity  110 . The conveyor belt receiving cavity  110  is defined by a horizontal top wall  112  and a horizontal bottom wall  114 . The top and bottom walls  112 ,  114  are each joined by a back wall  116 . The height of the conveyor belt receiving cavity  110  is defined by the distance between the top and bottom walls  112 ,  114  and is selected to be greater than the thickness of the conveyor belt. 
         [0036]    The side rail  12  further includes a bottom, T-slot  118 . The bottom T-slot  118  is formed at the bottom of the side rail  12  and is configured to receive a conventional T-slot connector. Preferably, the bottom T-slot  118  allows the side rail  12  to be mounted to a support stand using conventional connectors. 
         [0037]    Referring now to  FIGS. 1 and 2 , the method of assembling the conveyor frame assembly  10  will now be described. Initially, the pair of cross supports  14  are positioned at the desired location along the length of the side rail  12  between the first end  92  and the second end  94 . In the embodiment shown in  FIG. 1 , a pair of cross supports  14  are utilized. However, it should be understood that additional cross supports  14  could be utilized while operating within the scope of the present invention. 
         [0038]    Referring now to  FIG. 2 , when the cross support  14  is positioned between the side rails  12 , the bottom edge  120  of the cross support  14  rests upon the support shoulders  108  formed on each of the side rails  12 . The support shoulders  108  provide the vertical support necessary to hold the cross support  14  in the position shown in  FIG. 2 . 
         [0039]    Once the cross support  14  has been positioned as shown in  FIG. 2 , a pair of upper fasteners  122 , such as self-threading screws, are used to secure the first end  56  and the second end  58  of the cross support  14  to each of the spaced side rails  12 . As shown in  FIGS. 1 and 2 , each of the upper fasteners  122  are received within the relieved access areas  54  machined into the cross support  14  and are tightened into the upper self-tapping slot  102 . The fasteners  122  are tightened until the head  124  of the fastener  122  contacts the attachment face surface  60  formed as part of the relieved area  54 , as best shown in  FIG. 5 . 
         [0040]    In addition to the pair of upper fasteners  122 , the cross support  14  is attached between the pair of side rails  12  by a pair of lower fasteners  126 . In the embodiment shown in  FIG. 2 , the lower fasteners  126  are also self-threading screws. The self-threading fasteners  126  are each received within the lower self-tapping slots  104  formed in each of the side rails  12  until the head  128  of the self-threading fastener  126  contacts the attachment face surface  64  of the relieved access area  62 . In this manner, the upper and lower fasteners  122 ,  126  secure the cross support  14  between the pair of side rails  12 . 
         [0041]    Referring now to  FIG. 4 , the configuration of the cross support  14  allows both the upper fasteners  122  and the lower fasteners  126  to be installed between the cross support  14  and the pair of side rails  12  from above the cross support  14 . Specifically, the lower fastener  126  is received within the attachment web  22 , which is laterally offset from the center section  16 . The upper fastener  122  is received within the central attachment slot  46  which is accessible from above the conveyor frame assembly  10 , as best illustrated in  FIG. 4 . Thus, during the initial construction of the conveyor frame assembly  10 , each of the cross supports  14  can be secured to the pair of spaced side rails  12  from above the conveyor frame assembly. Further, the lateral offset of the attachment web  22  allows both the upper and lower fasteners  122 ,  126  to be visible and therefore accessible by a straight installation tool, such as a screwdriver, at the same time from above the conveyor assembly. 
         [0042]    Referring now to  FIG. 3 , thereshown is the entire conveyor assembly  10  constructed and being used with a conveyor belt having an upper run  130  and a lower run  132 . In the embodiment illustrated, each of the side rails  12  includes a pair of upper wear clips  134  each attached to the upper wall  136 . The wear clips  134  are preferably formed from a durable, wear-resistant material, such as UHMW, that contacts the first surface  138  of the conveyor belt. Likewise, a pair of lower wear clips  140  are attached to the lower attachment flange  142  and contact the second surface  144  of the conveyor belt. 
         [0043]    As illustrated in  FIG. 3 , the lower run  132  of the conveyor belt is received within the conveyor belt receiving cavity  110  to limit the lateral and vertical movement of the conveyor belt during operation. As illustrated, the height of the conveyor belt receiving cavity  110  is greater than the thickness of the lower run  132  such that the conveyor belt can move vertically within the conveyor belt receiving cavity  110 . 
         [0044]    In the embodiment shown in  FIG. 3 , a center support  146 , having a wear resistant outer guard  148 , is mounted between the cross support  14  to provide additional support for the center of the upper run  130  of the conveyor belt. In the embodiment shown in  FIG. 3 , a series of low voltage wires  150  are received within the wire channel  84  and extend along the entire length of the side frame  12 . 
         [0045]    Referring now to  FIGS. 8 and 9 , each of the side rails  12  includes a pair of self-tapping auxiliary slots  76  and  78 . The self-tapping auxiliary slots  76 ,  78  extend along the entire length of the side rails from the first end  92  to the second end  94 . The self-tapping auxiliary slots  76 ,  78  are each sized to receive a self-threading connector such as shown by reference numeral  152 . The self-threading connector  152  includes a head portion  154  and a threaded shaft. As the fastener  152  is turned within one of the self-tapping auxiliary slots  76 ,  78 , the threads contained on the shaft of the fastener  152  creates a series of threads within the side rail  12 . 
         [0046]    In the embodiment shown in  FIG. 8 , the fastener  152  secures an auxiliary attachment device  156  to the outer face surface of the side rail  12 . The auxiliary attachment device  156  can be selectively positioned anywhere along the length of the side rail between the first end  92  and the second end  94 . Once in position, the fastener  152  can be threaded into the self-tapping auxiliary slot  76 . In this manner, the attachment device  156  can be selectively positioned at any location along the length of the conveyor frame assembly. It is contemplated that the attachment device  156  may be used for conduit to guide electrical wires, cables or air hoses along the length of the conveyor assembly. Alternatively, various other types of lightweight auxiliary devices can be mounted at any position along the length of the conveyor assembly through the use of the pair of self-tapping slots  76 ,  78 . 
         [0047]    Although the side rails  12  are shown with a pair of self-tapping auxiliary slots  76 ,  78 , it is contemplated that either an additional number of slots could be incorporated into the side rails or that a single slot could be formed in the side rails. In either case, the self-tapping auxiliary slots  76 ,  78  extend along the entire length of the side rails and allow various different auxiliary devices, such as air line supports, wire harnesses, photo sensors or various other lightweight devices to be attached selectively along the length of the conveyor frame.