Abstract:
A method of moving and boxing packages, including positioning a conveyor belt assembly having distal and proximal ends to receive a package at the distal end, sending a signal when a first package is placed upon the distal end, generating an air pulse to reorient the first package into a predetermined orientation, moving the first package to a loading area, and removing the first package into a shipping container. Next, the first package is moved far enough to make room for a second package, a second package is placed onto the distal end, a signal is sent when the second package is placed upon the distal end, and an air pulse is generated to reorient the second package into a predetermined orientation.

Description:
TECHNICAL FIELD OF THE INVENTION 
     The novel technology relates generally to mechanical conveyance, and more particularly to a portable collating conveyor system for delivering packages from a packing machine to be loaded for transport. 
     BACKGROUND OF THE INVENTION 
     Preparing and boxing smaller packages for transport is a repetitive task; thus, any small inefficiencies in the process are multiplied over time to become substantial losses of productivity. In the food packaging industry, conveyor belt systems are commonly used to move small packages from packaging machines to be boxed for transport to warehouses or points of sale. As seen in  FIG. 1 , such conveyor systems are semi-permanently emplaced, require two motors to drive two endless belt systems, and are inefficient. In particular, the standard conveyor systems have a first endless belt that catches a product, such as a bag, which is encouraged to fall forward. The belt conveys the bag up an incline and onto and over a separate hump. The bag passes a sensor, such as an electric eye, which actuates a paddle or bumper to reorient the bag as the bag travels onto a second endless belt. The second belt carries the bag to its destination where it is packed into a box or the like for shipping. 
     This system, while virtually ubiquitous in the industry, is inherently inefficient. It is cumbersome to navigate, unnecessarily bulky, requires two motors to run two endless belts, and has an excessive number of moving parts, requiring frequent maintenance and even then making it unnecessarily prone to breakdown. Further, this system delivers bags or packages one at a time at a rate that is determined by the dimensions (length) of an individual bag. 
     Thus, there remains a need for an improved conveyance system for use in moving packed or packaged items to a final boxing destination, and, more generally, for a more efficient industrial conveyor system. The novel technology addresses this need. 
     SUMMARY OF THE INVENTION 
     The novel technology relates to a conveyor system for moving industrial packages. The novel technology includes a system described as follows:
         A conveyor system, specifically collating conveyor system that can be used as a “pack off” conveyor or as a “continuous feed” conveyor.   The conveyor system of the novel technology further comprises a human operable control comprising analog dials to select belt speed, spacing between conveyed items, and conveyed item size.   Electronic sensor means are provided with the novel technology to determine the presence or absence of an object to be conveyed along the belt, thus allowing the conveyor of the present system to automatically start and stop based on need as opposed to running constantly.   The present conveyor system further comprises means to raise and lower the conveyor system for ergonomic purposes.   The present conveyor system is also modular, in that the length of the conveyor system is infinitely adjustable by merely adding an additional “leaf”, and adding a longer belt while using the same belt motor and control device. The belt motor and control provide, as stated earlier, variable speed and spacing of the conveyed objects.   The novel technology further comprises a variable pressure “air knife” for automatically blowing onto conveyed items to re-orient the same relative to the conveyor belt.       

     One object of the novel technology is to provide an improved conveyor system. Related objects and advantages of the novel technology will be apparent from the following description. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a first embodiment conveyor assembly of the novel technology. 
         FIG. 2  is a first partial perspective view of the embodiment of  FIG. 1  showing the motor assembly. 
         FIG. 3  is a second enlarged partial perspective view of the embodiment of  FIG. 1 . 
         FIG. 4  is a partial perspective view of the assembly of  FIG. 1  showing the distal end and air jet assembly. 
         FIG. 5  is a partial perspective view of  FIG. 1  as loaded with bags. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     For the purposes of promoting an understanding of the principles of the invention and presenting its currently understood best mode of operation, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, with such alterations and further modifications in the illustrated device and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates. 
       FIGS. 1-5  relate to a first embodiment of the novel technology, a modular mobile conveyor system  10  including a wheeled chassis assembly  15 , a motor  20  mounted in the chassis assembly  15 , an electronic controller  25  operationally connected to the motor  20  and typically mounted in the chassis  15 , an endless belt assembly  30  mounted in the chassis  15 , and a pneumatic jet “air knife” assembly  35  operationally connected to the electronic controller  25 . 
     The chassis assembly  15  further includes a generally flat support platform  40 . The support platform  40  may be a solid generally flat member, or may be defined by a plurality of elongated members  41  connected to define a framework  43 . A plurality of wheels, castors, or like members  45  are connected to the support platform  40  to provide mobility. The wheels  45  extend in a downward direction from the support member  40  when positioned for normal use. The chassis assembly  15  further includes a first support member  50  connected to the support platform  40  and extending upwardly (in a direction opposite the first, downward direction) from the support platform  40 . The first support member  50  is typically of variable length, and may include an actuator  51 , such as a crank, pneumatic or hydraulic cylinder, electric motor, or the like, for manually or automatically varying the length of the member  50 . A second support member  55  likewise is connected to and extends upwardly from platform  40 . The second member  55  may likewise be of variable length, but more typically is a rigid structural member and includes motor mounting members  60  attached thereto. A power supply  65  is operationally connected to the chassis  15  for powering the motor  20  and the controller  25 . The power supply  65  may be self-contained, such as a battery pack, or may simply be line current connected to the chassis  15  by cable means or the like. A control interface  70  operationally connected to the controller  25  is also typically connected to the chassis  15 . 
     The belt assembly  30  includes first and second pulleys or cylindrical members  80 ,  85  operationally connected to the chassis  15 . The pulleys  80 ,  85  may be elongated cylindrical rods or the like, and optionally are oriented parallel to one another and are spaced to define the operational length of the conveyor system  10 . A motor pulley  87  is operationally connected to the motor  20  and directly engages the endless belt  90  to move the belt  90 . The endless belt  90  is looped about the pulleys  80 ,  85  and is operationally connected to the motor  20  via the motor pulley  87 , such that the motor  20  may be energized to urge the belt  90  to travel around the pulleys  80 ,  85 . The belt  90  may be made up of a plurality of generally identical leaves or sections  95 , each section  95  connected to another  95  section at either end to define an endless loop. Energization of the motor  20  urges any given leaf  95  to travel over the first pulley  80  to the second pulley  85 , over the second pulley  85  and back to the first pulley  80 , typically engaging additional pulleys or cylindrical members  91  along the way to define the path of the belt  90 . Each leaf  95  further typically includes one or more raised portions  100  for engaging packages or items placed on the belt  90 . Typically, at least one, and more typically a pair of parallel, spaced elongated frame members  105  is/are positioned adjacent and parallel to the endless belt  90  to reinforce and define an elongated belt housing portion  110 . More typically, the elongated belt housing portion  110  includes a generally horizontal portion  111  hingedly or pivotably coupled to a second portion  113  that extends away from the horizontal portion  111 . The second portion  113  may be pivoted at an angle such that the distal end  114  of the elongated belt housing portion  110  is positioned closer to the ground. The second portion  113  is typically supported by member  50 , and actuator  51  is more typically connected to controller  25 . 
     A package sensor  120 , typically an optical sensor or the like, is positioned adjacent the distal end  114 . The sensor  120  is operationally connected to the electronic controller  25 . An air jet or air knife  130  is positioned adjacent the sensor  120  and operationally connected to the electronic controller  25  and connected in pneumatic communication with a pneumatic source  135 . 
     Additional sensors  140  are typically positioned at predetermined locations along the elongated belt housing portion  110  and connected in electric communication with the electronic controller  25  to provide information about the presence or absence of load items on the belt assembly  30 . 
     In operation, the conveyor assembly  10  is positioned such that the distal end  114  of the elongated belt housing portion  110  is positioned to receive a package dispensed from a production unit, such as a bagging or packaging machine. Such a package dropping onto the elongated belt housing portion  110  triggers the sensor  120  to send a signal to the electronic controller, and likewise (either directly or relayed through the controller  25 ) to the air knife  130 . The air knife sends a short burst of pressurized air to position the package on the endless belt  30 . The duration and intensity of the air blast is typically configured to a specific package size and mass; such configuration may be predetermined and the air knife  130  be calibrated accordingly, or air knife  130  may be calibrated in response to input from the sensor  120  and/or manual input through the interface  70 . 
     Once the package is correctly oriented by the air knife  130 , the motor  20  is energized to engage the belt  30  to move the package away from the distal end  114  of the elongated belt housing portion  110 . The speed of the belt  30  is controlled by the controller  25 , and may be varied to control spacing and orientation of the conveyed items. 
     The controller  25  may be coupled to the actuator  51 , such that the controller  25  may energize actuator  51  to change the length of member  50  and move distal end  114  of second portion  113  into a new desired position or elevation. Likewise, member  55  may be coupled to an actuator  51  connected to the controller  25 , and controller  25  may likewise energize actuator  51  to change the length of member  55  and move first portion  111  into a new desired position or elevation. First portion  111  is typically oriented horizontally at all times, and changes in length of member  55  simply change the elevation (i.e., raise or lower) first portion  111 . More typically, specific lengths of member  55  corresponding to elevations of first portion  111  are stored in controller  25  and respectively paired with codes (such as operator codes), such that different elevations of first portion  111  may be easily actuated. 
     While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character. It is understood that the embodiments have been shown and described in the foregoing specification in satisfaction of the best mode and enablement requirements. It is understood that one of ordinary skill in the art could readily make a nigh-infinite number of insubstantial changes and modifications to the above-described embodiments and that it would be impractical to attempt to describe all such embodiment variations in the present specification. Accordingly, it is understood that all changes and modifications that come within the spirit of the invention are desired to be protected.