Abstract:
A breakaway conveyor discharge member received between first and second conveying surfaces is provided. The conveyor discharge member is received by a bracket mounted on a frame connected between the first and second conveying surfaces. The conveyor discharge member includes a generally planar surface between the first and second conveying surfaces. The conveyor discharge member can withstand a vertical load substantially greater than a particular longitudinal load on the planar surface. Under normal operating conditions, the conveyor discharge member conveys the object from the first conveyor surface onto the intake conveying surface. Under jam conditions, when the substantially longitudinal load is great enough, the conveyor discharge member dislodges from the brackets to protect the first and second conveying surfaces by eliminating the jam point.

Description:
CROSS REFERENCE TO RELATED APPLICATION  
       [0001]     This application claims priority from U.S. provisional patent application Ser. No. 60/703,269, filed on Jul. 28, 2005, the disclosure of which is hereby incorporated herein by reference in its entirety. 
     
    
     BACKGROUND OF THE PRESENT INVENTION  
       [0002]     The present invention pertains to a conveyor system and more particularly to a conveyor discharge, or transition section, received between a discharge conveying surface and an intake conveying surface.  
         [0003]     Conventional slat conveyor systems often consist of conveyor beds with large radius sprockets or wheel guides at the charge end and the discharge end. These large sprockets or wheel guides often impart a large radius of curvature to the slat web thereby forming rounded ends and producing a substantial gap between a discharge conveying surface and the adjacent charge conveying surface. Accordingly, a transition surface may be required to compensate for the large radius of curvature of the rounded ends between the two conveying surfaces. A transition plate is often placed in this transition gap to assist in the smooth transition of conveyed objects between the two conveying surfaces. Conventional transition plates are often mounted between two conveying surfaces to provide a stationary planar transition surface.  
         [0004]     However, even with transition plates placed between tandem conveying surfaces, jamming of packages may occur in the gap area between the transition plate and the discharge conveying surface. Jams may result from objects protruding from conveyed packages which may catch in this gap area. Moreover, the discharge conveying surface may move at a high rate of speed, for example as with a positive displacement sorter. Thus, when jams occur at such a high rate of speed, conveyed objects may be damaged, subsequent objects may slam into jammed objects, and the conveyors may also be damaged.  
         [0005]     Accordingly, there is a need for an improvement to conventional transition plates or gap plates between two conveying surfaces to help prevent jams and reduce the likelihood of damage to packages and conveyors.  
       SUMMARY OF THE INVENTION  
       [0006]     The present invention provides a breakaway conveyor discharge member which mitigates the above-discussed difficulties.  
         [0007]     According to one aspect of the present invention, a conveyor system is provided. The conveyor system includes first and second conveying surfaces conveying objects in a longitudinal direction and defining a gap at a transition between the conveying surfaces with a conveyor discharge member at the gap. The conveyor discharge includes a plate defining a generally planar surface between the conveying surfaces. The conveyor discharge member is movable in response to a particular longitudinal force to reduce jam locations between the conveyor discharge member and the conveying surfaces.  
         [0008]     According to another embodiment of the present invention, a conveyor system is provided. The conveyor system includes first and second conveying surfaces conveying objects in a longitudinal direction and defining a gap at a transition between the conveying surfaces with a conveyor discharge member at the gap. The conveyor discharge member provides a generally planar surface between the conveying surfaces. The conveyor discharge member supports up to a particular vertical force upon the conveyor discharge member. The conveyor discharge member breaks away in response to a particular longitudinal force upon the conveyor discharge member, where the particular vertical force is greater than the particular longitudinal force.  
         [0009]     In one form of the present invention, a conveyor system is provided. The conveyor system includes a discharge conveyor, an intake conveyor, a frame connected between the conveyors, a pair of brackets received on opposite sides of the frame and a conveyor discharge member supported by the brackets. The conveyor discharge member includes a plate providing a substantially planar surface between the conveyors. The conveyor discharge member dislodges from the bracket when an object enters an area between the discharge conveyor and the conveyor discharge member creating a particular longitudinal force upon the conveyor discharge member.  
         [0010]     In another form of the present invention, a method for reducing jams of an object between first and a second conveying surfaces is provided. The method includes receiving a conveyor discharge member between the first and second conveying surfaces providing a planar surface between the first conveying surface and the second conveying surface and dislodging the conveyor discharge member from between the first and second conveying surfaces in response to a particular longitudinal force applied in an area of the first conveying surface and the conveyor discharge member.  
         [0011]     Therefore, the present invention provides a conveyor system including a conveyor discharge member between first and second conveying surfaces. The conveyor system includes a conveyor discharge member received by a frame, which is connected between the conveying surfaces. The discharge conveyor member provides a generally planar surface between the first and second conveying surfaces and supports a substantial vertical load, such as the weight of a person. When a conveyed object creates a sufficiently strong longitudinal force upon the conveyor discharge member, it is assumed to be a package jam, and the conveyor discharge member dislodges from a set of brackets mounted on the frame to reduce the likelihood of damage. When the conveyor discharge member dislodges from the brackets, the first conveying surface may be halted to prevent any damage to the conveyed objects or conveying surfaces.  
         [0012]     These and other objects, advantages, purposes, and features of the present invention will become apparent upon review of the specification in conjunction with the drawings. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0013]      FIG. 1  is a top perspective view of the breakaway conveyor discharge between first and second conveying surfaces, in accordance with the present invention;  
         [0014]      FIG. 2  is a top perspective view of the conveyor discharge member of  FIG. 1  in an upward angled position;  
         [0015]      FIG. 3  is a top perspective view of the conveyor discharge member of the present invention;  
         [0016]      FIG. 4  is a bottom perspective view of the conveyor discharge member of  FIG. 3 ;  
         [0017]      FIG. 5  is a side elevation of the conveyor discharge member engaged with the bracket in a base position of the present invention;  
         [0018]      FIG. 6  is a side elevation of the bracket and conveyor discharge member of  FIG. 5  in a dislodged position;  
         [0019]      FIG. 7  is the same view as  FIG. 5  of an alternative embodiment;  
         [0020]      FIG. 8  is a side elevation of the bracket and conveyor discharge member of  FIG. 8  in a dislodged position with the retainer broken;  
         [0021]      FIG. 9  is the same view as  FIG. 1  of another alternative embodiment;  
         [0022]      FIG. 10  is the same view as  FIG. 5  of an alternative embodiment; and  
         [0023]      FIG. 11  is a side elevation of the bracket and conveyor discharge member of  FIG. 10  in a dislodged position. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0024]     Referring now to the figures, a conveyor system  10  includes a first conveyor system  12  with a first slat conveying surface  14  and a second conveyor system  16  with a second conveying surface  18 , as best illustrated in  FIGS. 1 and 2 . First conveying surface  14  includes a discharge end  20  and second conveying surfaces includes a charge end  22 . Discharge end  20  and charge end  22  may both have a large radius of curvature due to sprockets or pulleys at each end with a large radius. When adjacent discharge end  20  and charge end  22  are placed in tandem or in series, the ends may form a non-planar gap  24  between conveying surfaces  14 ,  18 . A conveyor discharge member  26  is placed in gap  24  to provide a generally planar surface  28  for smooth transitioning of conveyed objects in a longitudinal direction, A, between conveying surfaces  14 ,  18 , as best illustrated in  FIG. 1 . Conveyor discharge member  26 , which may also be referred to as a breakaway conveyor discharge member, is able to withstand a substantial vertical load or force B ( FIG. 5 ) greater than a particular longitudinal load, C ( FIG. 5 ). Additionally, conveyor discharge member  26  is operable for sliding or moving into a dislodged position ( FIGS. 2 and 6 ) discharging or dislodging or breaking away from gap  24 , as will be discussed further below.  
         [0025]     Conveyor discharge member  26 , as best illustrated in  FIGS. 3 and 4 , includes a plate  27  with substantially planar surface  28 , a support frame  30 , end plates  32  located at each end of the support frame, a first pin  34  and a second pin  36  received on each end plate. Conveyor discharge member  26  is received by a pair of brackets  40  ( FIGS. 5-9 ), which are mounted on a frame  38 . Frame  38  is a structure received between first and second conveyor systems  12 ,  16  ( FIGS. 1 and 2 ). Frame  38  is preferably composed of a metal such as steel, aluminum or any other similar robust material. Frame  38  may be a separate structure or a part of or integrated with the frame or sidewalls of one or both of first and second conveyor systems  12 ,  16 .  
         [0026]     Brackets  40  are received facing each other on opposite internal sides of frame  38 . Bracket  40  receives first and second pins  34 ,  36  to allow conveyor discharge member  26  to be received between first and second conveying surfaces  14 ,  18  in gap  24 . Bracket  40  may be attached to the opposite interval sides of frame  38  with a plate  41  received on the external sides of the frame. Plates  41  may provide additional support when bracket  40  is mounted onto the internal sides of frame  38 . Each bracket  40  includes a generally downstream facing first slot  42  and a generally downstream facing second slot  44  receiving first pin  34  and second pin  36 , respectively. First and second pins  34 ,  36  of conveyor discharge member  26  slide or move in slots  42 ,  44  from a base position ( FIGS. 5 and 7 ) to a dislodged or discharged position ( FIGS. 6 and 8 ). The range of motion or movement or positions of conveyor discharge member  26  will be discussed in further detail below.  
         [0027]     Planar surface  28  is the top surface of plate  27 . Planar surface  28  is substantially planar with a low coefficient of friction to easily transfer or slide objects being conveyed from first conveying surface  14  to second conveying surface  18 . Plate  27  is fastened to support frame  30  with bolts  52  ( FIG. 3 ) or welds. It should be noted that any like mounting means may mount plate  27  onto support frame  30 . Planar surface  28  is preferably a polymeric material, but can be composed of any other similar material with a low coefficient of friction, such as other metals like steel or aluminum. In the illustrative embodiments, planar surface  28  includes a pair of notches  54  to compensate or provide clearance for a plurality of sorter shoes  56  of first conveyor system  12 , which may be a linear sorter conveyor or a positive displacement sorter conveyor with a slat conveying surface like a Siemens RS-200 Conveying System, such as disclosed in commonly assigned U.S. Pat. No. 5,127,150, the disclosure of which is hereby incorporated herein by reference, or any other similar sorter conveyor.  
         [0028]     Support frame  30 , end plates  32 , first pins  34  and second pins  36  form a robust structure providing support for plate  27  as the pins are placed in bracket  40 . Bracket  40  includes a preferably block-like body with first slot  42 , second slot  44  and apertures  66  therethrough. Apertures  66  may receive bolts  68  for mounting bracket  40  onto frame  38 . First slot  42  includes a first base portion  60  and a first opening portion  70 . Second slot  44  includes a second base portion  62  and a second opening portion  72 .  
         [0029]     When first and second pins  34 ,  36  are fully received into first and second base portions  60 ,  62  of first and second slots  42 ,  44 , conveyor discharge member  26  is in the base position, as illustrated in  FIGS. 1 and 5 . In this base position, first and second pins  34 ,  36  on each end plate  32  are seated or engaged or secured in first and second base portions  60 ,  62  of bracket  40  and conveyor discharge member  26  is able to support a substantial vertical load or force B, such as the weight of a person, applied generally perpendicular to planar surface  28  without displacing or bending or deforming by the conveyor discharge member. In this base position, the substantial vertical load or force B may be applied substantially perpendicular to surface  28  and conveyor discharge member  26  will not move or displace from this base position due to first and second base portions  60 ,  62  securing or supporting or holding pins  34 ,  36  in the base position. First and second base portions  60 ,  62  may include a detent, notch, ridge, or slight arc to help support or hold or secure first and second pins  34 ,  36  in the base position. Thus, conveyor discharge member  26  is able to withstand a vertical load B substantially greater than a particular longitudinal load C in the base position since first and second base portions  60 ,  62  of slots  42 ,  44  stabilize and support pins  34 ,  36  of the conveyor discharge member when a substantially vertical load B is applied.  
         [0030]     When generally longitudinal force C is applied generally to conveyor discharge member  26 , such as to a leading edge  78  of planar surface  28 , first pin  34  will be urged or forced out of first base portion  60  and slide or move into first opening portion  70  while second pin  36  is also urged or forced out second base portion  62  and slide or move into second opening portion  72 , thus moving or sliding conveyor discharge member  26  into the dislodged or discharged position while avoiding adjacent conveying systems  12 ,  16  as best illustrated in  FIG. 6 . When the particular longitudinal load C is applied onto conveyor discharge member  26 , first and second base portions  60 ,  62  of slots  42 ,  44  do not offer or provide longitudinal support in the downstream direction of conveying, A, and thus pins  34 ,  36  slide or move in the direction of conveying out of the portions of the slots. First opening portion  70  may include a downward angled portion  71  which urges leading edge  78  of planar surface  28  downward when first pin  34  is urged or forced out of first base portion  60 . Second opening  72  may be angled slightly upward in order to urge leading edge  78  downward as to prevent contact with either first conveying surface  14  or second conveying surface  18 . Longitudinal force C may originate from conveyed objects or from items protruding from such conveyed objects. If generally longitudinal force C is great or continuously applied, conveyor discharge member  26  eventually completely dislodges or discharges or breaks away from brackets  40  and the conveyor discharge member may be caught by at least one tether  80 , which may be connected to frame support  30  and frame  38 . Tether  80  catches conveyor discharge member  26  when it fully discharges, dislodges, or breaks away from brackets  40 . In another form of the present invention, tether  80  may be connected to some form of alarm or sensor to notify a technician or user of the dislodging or discharging or breaking away of conveyor discharge member  26  from brackets  40 .  
         [0031]     Support frame  30 , end plates  32 , first pins  34 , second pin  36  and bracket  40  are preferably composed of a metal, such as steel, aluminum or the like but can be any material like a polymeric composite that is robust enough to withstand a substantial vertical load upon planar surface  28 . End plates  32  are preferably welded onto support frame  30 , but also may be bolted on. First pin  34  and second pin  36  are preferably welded onto end plate  22  but also may be bolted on. First pin  34  and second pin  36  are preferably round, cylindrical or peg-like in shape, to be easily received in and out of slots  42 ,  44  of bracket  40 .  
         [0032]     A set of sensors  82 , as shown in  FIGS. 1 and 2 , may be installed and positioned in or substantially proximate to slots  42 ,  44  of brackets  40  to monitor or sense any displacement of first and second pins  34 ,  36  relative to the first and second slots. Sensors  82  may be any mass sensor or the like that is well known in the art, and may be mounted or received on the external side of frame  38 , as illustrated in  FIGS. 1 and 2 . Sensors  82  would monitor displacement of first and second pins  34 ,  36  to notify users and/or adjust operating parameters for conveyors  12 ,  16 . For example, when conveyor discharge member  26  is in the base position, optional sensors  82  will identify this state and do nothing. If the generally longitudinal force C is applied upon conveyor discharge member  26  to displace first and second pins  34 ,  36  from first and second slots  42 ,  44  to slide or move the conveyor discharge member into the dislodged or discharged position, sensors  82  will identify this condition or state or position and may slow down the speed of first conveyor system  12  or stop it completely. If the generally longitudinal force C is great enough or continuous to completely dislodge, discharge or break away conveyor discharge member  26  from brackets  40 , sensors  82  will identify this condition or state or position and shut down first conveying surface  14  to prevent damage to first and second conveyors  12 ,  16  or the conveyor discharge member. Additionally, optional sensors  82  may notify users of jams or dislodging or discharging or breaking away of conveyor discharge member  26  in order to place the conveyor discharge member back to the base position. It should also be appreciated that sensors  82  may be placed in a multiple of configurations. For example, sensor  82  may be placed in first slot  42 , in second slot  44  or both. Additionally, plurality of sensors  82  may be placed along each slot  42 ,  44  to obtain a more precise location, position or orientation of conveyor discharge member  26 . For example, sensors  82  may be placed in first and second base portions  60 ,  62 , and first and second openings  70 ,  72  to provide a more precise reading of the position or orientation or state or condition of conveyor discharge member  26 .  
         [0033]     In an alternative embodiment of the present invention, a retainer  84  or shear pin or shear device or shear retainer or similar element, which in the illustrative embodiment is a plastic bolt, may be inserted into first slot  42  of bracket  40  to secure first pin  34  in the base position ( FIG. 8 ). Retainer  84  may be a shear pin that will break, as shown in  FIG. 9 , when the generally longitudinal force C exceeds a threshold breaking point of the pin member when applied onto conveyor discharge member  26 . When retainer  84  or equivalent element breaks, conveyor discharge member  26  operates in a similar fashion or manner as described above, by moving into the discharge or dislodge position, if generally longitudinal force C is great enough or continuous. However, retainer  84  will not break if substantial vertical load B is applied onto conveyor discharge member  26 , thus the conveyor discharge member supports vertical load B substantially greater than generally longitudinal load C. It should be noted pin members  84  or equivalent element may also be placed in both or either of first or second slots  42 ,  44  or any combination thereof, while still keeping within the spirit and scope of the present invention.  
         [0034]     In another embodiment of the present invention of  FIG. 9 , substantially planar surface  28  may comprise a plurality of rollers  88  or wheels or balls, or the like, while keeping with the scope and spirit of the present invention. Rollers  80 , wheels or balls would allow conveyed objects to transition between first and second conveying surfaces  14 ,  18  and operate in a similar manner or fashion as planar surface  28  provided above.  
         [0035]     In yet another embodiment of the present invention in  FIGS. 10 and 11 , brackets  40 ′ include a generally downstream facing first slot  42 ′ and a generally downstream facing second slot  44 ′ receiving first pin  34  and second pin  36 , respectively. First and second pins  34 ,  36  of conveyor discharge member  26  slide or move in slots  42 ′,  44 ′ from a base position as illustrated in  FIG. 10 . First slot  42 ′ includes a first base portion  60 ′ and a generally downward angled portion  70 ′. Second slot  44 ′ includes a second base portion  62 ′ and a second opening  72 ′. In the base position, first and second pins  34 ,  36  on each end plate  32  are seated or engaged or secured in first and second base portions  60 ′,  62 ′ of bracket  40 ′. Conveyor discharge member  26  is able to support a substantial vertical load or force applied generally perpendicular to planar surface  28  without displacing or bending or deforming the conveyor discharge member in the base position. When a generally longitudinal force C is applied to conveyor discharge member  26 , first pin  34  will be urged or forced out of first base portion  60 ′ and slide or move into downward angled portion  70 ′ while second pin  36  is also urged or forced out of second base portion  62 ′ to slide or move out of second opening  72 ′, thus moving or sliding conveyor discharge member  26  into the dislodged or discharged position while avoiding adjacent conveying systems  12 ,  16 , as best illustrated in  FIG. 11 . Downward angle portion  70 ′ urges leading edge  78  of surface  28  downward to avoid contact between conveyor discharge member  26  and conveying systems  12 ,  16 .  
         [0036]     In yet another embodiment of the present invention, a pair of brackets may include a first pin and a second pin engaging a first generally upstream facing slot and a second generally upstream facing slot of a conveyor discharge member, while keeping within the spirit and scope of the present invention. The first and second pins of the brackets may slide or move in the slots to dislodge when a generally longitudinal force C is applied to the conveyor discharge member. The slots are generally upstream facing to avoid contact with the adjacent conveying systems  12 ,  16  when the conveyor discharge member dislodges. Additionally, when the first and second pins of the brackets are engaged or secured in the slots of the conveyor discharge member, the conveyor discharge member can withstand a substantial vertical force or load.  
         [0037]     While the preferred embodiment of the present invention is described above, it is contemplated that variations will be developed within the teaching of the present disclosure. Changes and modifications to this specifically described embodiment may be carried out without departing from the principles of the present invention, which is intended to be limited only by the scope of the appended claims as interpreted according to the principles of patent law.