Abstract:
An apparatus for conveying conveyable material. The apparatus includes a plurality of cars joined together by a plurality of spacers. The spacers couple the cars a fixed distance apart to form a shuttle. The shuttle is guided along a track between a first position and a second position. In the first position, the shuttle is aligned with a first group of supports. The shuttle in the first position receives conveyable material from the supports. The shuttle in the second position is aligned with a second group of supports. The shuttle disposes the conveyable material from each of the cars carrying the conveyable material to the second group of supports. A drive means repeatedly drives the shuttle between the first position and the second position. The cars remain the fixed distance apart during the driving between the first position and the second position.

Description:
FIELD 
     The present invention relates to a shuttle for incrementally conveying materials and, more specifically, to a shuttle car conveyor for incrementally transporting conveyable materials downstream along a track. 
     BACKGROUND 
     Flat rolled products in the metals industry are commonly wound into coils. These coils are transported by coil conveying systems such as roller chain conveyors and walking beam conveyors. 
     The roller chain conveyors are comprised of a plurality of individual coil support pallets linked together by chain sections. Wheels mounted on bearings and axles support each pallet. Roll chain conveyors are generally driven by sprockets mounted on a rotating shaft. The rotating shaft is driven by a gear reducer and motor. The roller chain conveyor is guided by custom-machined track which is supported on structural steel. The disadvantages of this design are: 1) there are a lot of parts to maintain since each pallet has rollers, bearings and axles; 2) the chain stretches, which affects the positioning of the downstream coil; 3) the custom-machined track wears out due to the high load of the roller (wheel); 4) the individual components are difficult to repair; 5) the system is costly due to the number of component parts and the need for custom track; and 6) the conveyor speed is limited. 
     Walking beam conveyors are comprised of a multitude of coil support pallets mounted on a beam. The beam is supported on rollers. The conveyor indexes coils between stationary coil support saddles. The conveyor includes an elevating mechanism which lifts the coils up off of stationary saddles. The conveyor is then traversed, to index the coils to adjacent saddles downstream. The conveyor is usually driven by a hydraulic cylinder. The disadvantages of this design are: 1) the distance of traverse of the walking beam is limited by the length of the cylinder stroke, 2) the length of the beam conveyor is limited by manufacturing and shipping constraints, 3) the speed of the conveyor is limited by the operating speed of the drive cylinder, and 4) repairing the walking beam support rollers and elevating mechanisms requires major disassembly of the unit because the rollers and elevating mechanisms are fixed on foundations. 
     Accordingly, the present invention seeks to improve upon the previous apparatuses by providing a shuttle car conveyor comprising a plurality of individual cars. Each individual car of the shuttle conveyor is coupled to an adjacent individual car of the shuttle conveyor. A spacer couples the individual cars to positively space the cars a fixed distance during movement of the shuttle between a first position and a second position. 
     The shuttle car conveyor has several advantages. Connecting the cars to keep the cars a fixed distance apart when the shuttle is driven from the first position to the second position facilitates accurate positioning of the coils by the shuttle car conveyor. The fixed spacing also simplifies automation because the shuttle car conveyor can operate with only a single car having a drive mechanism. 
     Additionally, providing a shuttle car conveyor made up of individual cars simplifies maintenance. The cars can be easily disassembled and repaired as separate modules. Further, providing individual cars allows the shuttle to continue operating even if one of the car&#39;s motors is not functioning. 
     The shuttle car conveyor can be easily adapted to various systems. The shuttle car conveyor can be lengthened by adding car modules or spacers, or by lengthening the spacers. The shuttle car conveyor design allows for the use of standard rails. The option of using either electric motor, hydraulic motor or cable drum drive to power the shuttle allows the shuttle to operate at higher speeds than the chain conveyor system or walking beam conveyor system. 
     SUMMARY 
     The shuttle conveyor system has a plurality of cars. A plurality of spacers couple the plurality of cars a fixed distance apart to form a shuttle. A track provides a pathway along which the shuttle is driven. 
     The system has a plurality of supports. Each support is for supporting conveyable material. The plurality of supports has a first support and a last support. The amount of supports is at least one more in number than the amount of cars forming the shuttle. 
     The shuttle has a first position along the pathway. In the first position, each of the cars forming the shuttle has a predetermined alignment with a different corresponding support. These different corresponding supports form a first group of supports selected from the plurality of supports. 
     The shuttle has a second position along the pathway. In the second position each of the cars forming the shuttle has a predetermined alignment with a different corresponding support. These different corresponding supports form a second group of supports selected from the plurality of supports. The first and second group of supports have at least one support in common. The first group of supports contains the first support, which is exclusive of the second group. The second group of supports contains the last support, which is exclusive of the first group. The second position is downstream along the pathway from the first position. 
     The shuttle car conveyor system has disposing means for disposing the conveyable material from each of the first group of different corresponding supports to each of the cars in the first position and for disposing the conveyable material from each of the cars in the second position to each of the second group of different corresponding supports. 
     A driving means repeatedly drives the shuttle between the first and second positions to convey conveyable material from the first support to the last support. 
     The invention is further characterized in that the supports are saddles, and each of the saddles supports conveyable material over the cars in the first position. 
     The invention is still further characterized in that the plurality of spacers are a plurality of elongated lengths of rigid material. Each length of elongated material has a first end and a second end. Each first end is coupled to a different one of said cars. Each second end is coupled to another different one of said cars. Each first end coupled to said different one of said cars is coupled by a tapered pin; each second end coupled to said another different one of said cars is coupled by a tapered pin. 
     The invention can still be further characterized in that the means for disposing is made up of a plurality of elevating platens. Each platen is coupled to a different one of the plurality of cars. The platens have an elevated position in which each platen passes through a different chasm defined by a different one of the saddles. 
     These and other features, novelties and advantages of the present invention can be understood by reference to the brief description of the drawings, the detailed description and the appended drawings and appended claims. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a side elevation of a four-car shuttle car conveyor system in accordance with the preferred embodiment of the invention. 
     FIG. 2 is a cross-section taken along lines  2 — 2  of FIG. 1 which illustrates a coil supported on an elevating platen. 
     FIG. 3 is also a cross-section taken along lines  2 — 2  of FIG. 1, except FIG. 3 shows the coil supported on a stationary support saddle. 
     FIG. 4 is a cross-section of a tapered connecting pin which joins a car and spacer. 
     FIGS. 5-5 d ,  6 - 6   c ,  7 - 7   c ,  8 , and  9 - 9   d  illustrate the four-car shuttle car conveyor in operation. 
    
    
     DETAILED DESCRIPTION 
     In accordance with the preferred embodiment of the invention shown in FIGS. 1-4, a four-car and five-saddle shuttle car conveyor system  10  is provided. The system has cars  12 ,  12   a ,  12   b ,  12   c ; elevating platens  21 ,  21   a ,  21   b ,  21   c ; spacer trolleys  31 ,  31   a ,  31   b ; coil saddles  42 ,  42   a ,  42   b ,  42   c ,  42   d ; and track  50 . The plurality of cars connected by the spacer trolleys forms a shuttle car conveyor. 
     Each car is generally fabricated of steel plate. Each car has two axles  62  and four wheels  63 . Each car axle  62  is mounted on two pillow block bearings  64 . The wheels are typically rim toughed wheels. As shown in FIG. 3, the wheels are adapted to be disposed on standard rails of steel beam track  50 . The cars shown are driven by electric or hydraulic motors  66 . The electric motor is used to provide direct electric motor driven axles on said plurality of cars or in the case of a hydraulic motor, direct hydraulic motor driven axles on said plurality of cars. There are other methods to drive the shuttle car conveyor. These include: 1) a motor driven cable drum drive mounted either on or off the cars, 2) a rack and pinion arrangement, 3) a hydraulic cylinder, or 4) chains and sprockets. 
     Each elevating platen  21 ,  21   a ,  21   b ,  21   c  is fabricated of heavy steel plate in a v-saddle configuration to center and retain a metal coil on the platen. The platens are mounted on guide rods  73 ,  73   a ,  73   b ,  73   c ,  73   d ,  73   e ,  73   f ,  73   g . Each platen is raised/lowered by a hydraulic cylinder  75 ,  75   a ,  75   b ,  75   c . Alternatively, the elevating platens may also be incorporated into the coil support saddles  42 - 42   d  rather than on the cars. 
     The cars are mechanically linked together by spacers  31 ,  31   a ,  31   b . The spacers shown are long and include a flange joint  80 ,  80   a ,  80   b  to facilitate manufacturing and shipment. Additionally, wheel/axle assemblies  82 ,  82   a ,  82   b ,  82   c ,  82   d ,  82   e  are included for intermediate support of the spacers. The wheel/axle assemblies are supported in any suitable manner such as pillow block bearings. In the preferred embodiment, the spacers  31 ,  31   a ,  31   b  are constructed of rectangular welded structural steel tubing. 
     The spacers are connected to each car by a tapered pin arrangement  86 ,  86   a ,  86   b ,  86   c ,  86   d ,  86   e  as shown in FIG.  4 . The tapered pin section reduces the clearance between the pin and the spacer to minimize play between the cars and spacers. The tapering also facilitates pin removal. As can be seen in FIG. 4, the tapered pin has a tapered portion  186  and a portion which receives a bolt  286 . The tapered portion is opposite the portion which receives the bolt. 
     The conveyor system incrementally conveys metal coils deposited on saddle  42  downstream until each coil reaches saddle  42   d . The shuttle car conveyor incrementally conveys coils downstream by alternating between a first position and a second position. In the first position, the shuttle car conveyor is oriented to always position cars  12 ,  12   a ,  12   b  and  12   c , respectively, at saddles  42 ,  42   a ,  42   b  and  42   c . In the first position, the platens rise and the shuttle car conveyor picks up coils previously deposited on any one of saddles  42 - 42   c . (See FIGS. 5 a ,  5   b ). The shuttle then moves to the second position. 
     In the second position, the shuttle car conveyor is always oriented to position cars  12 ,  12   a ,  12   b  and  12   c  respectively at saddles  42   a ,  42   b ,  42   c  and  42   d . Thus, in the second position the shuttle car conveyor is oriented to position each car one saddle downstream relative to each car&#39;s orientation in position #1. (See FIGS. 5 c ,  5   d ). Therefore, in the second position, the shuttle car conveyor deposits each picked-up coil one saddle downstream from the coil&#39;s previous position. By driving the shuttle between position #1 and position #2, the shuttle can convey a continuous stream of coils from saddle  42  to saddle  42   d . A coil, once conveyed to saddle  42   d , is removed to free saddle  42   d  to accept another conveyed coil. 
     FIGS. 5-9 illustrate the operation in detail. 
     Coil  44  is loaded onto stationary coil support saddle  42  by an overhead crane or coil ram tractor (fork-type tractor) or another shuttle (not shown). The shuttle car conveyor is then driven to position the shuttle in the first position (see FIGS. 5 and 5 a ). Once positioned, the elevating platens of the cars rise. Platen  21  associated with car  12  raises coil  44  off saddle  42  (see FIG. 5 b ). The shuttle car conveyor is then driven to position the shuttle in the second position. Once positioned, the elevating platens of the cars lower. Elevating platen  21  associated with car  12  lowers coil  44  on support saddle  42   a  (see FIGS. 5 c  and  5   d ). The shuttle car conveyor is then driven back to position #1. By this time another coil  44   a  has been deposited on saddle  42  (see FIG.  6 ). The elevating platens on the cars rise. Platen  21  associated with car  12  raises coil  44   a  off support saddle  42 , and platen  21   a  associated with car  12   a  raises coil  44  off support saddle  42   a  (see FIG. 6 a ). The shuttle is then driven to position #2 (see FIG. 66 b ). The elevating platens on the cars lower. Platen  21   a  associated with car  12   a  lowers coil  44  on saddle  42   b  and platen  21  associated with car  12  lowers coil  44   a  on saddle  42   a  (see FIG. 6 c ). The shuttle car conveyor is then driven back to position #1. The cars&#39; platens rise. Platen  21  associated with car  12  picks up newly deposited coil  44   b  from saddle  42 ; platen  21   a  associated with car  12   a  picks up coil  44   a  from saddle  42   a ; platen  21   b  associated with car  12   b  picks up coil  44  from saddle  42   b  (see FIGS. 7 and 7 a ). The shuttle is then driven back to position #2. At position #2, coil  44  is lowered on saddle  42   c ; coil  44   a  is lowered on saddle  42   b ; and coil  44   b  is lowered on saddle  44   a  (FIGS. 7 b  and  7   c ). 
     The incremental conveying of coils downstream is repeated until coil  44  has been conveyed to saddle  42   d , coil  44   a  has been conveyed to saddle  42   c , coil  44   b  has been conveyed to saddle  42   b , and a newly deposited coil  44   c  has been conveyed to saddle  42   a  (see FIG.  8 ). 
     Continuing on, another coil  44   d  is deposited on saddle  42 . The shuttle car conveyor is then driven back to position #1. The platens rise and the coils  44 - 44   d  are raised off their respective saddles (see FIGS. 9 and 9 a ). Prior to the shuttle traversing back to position #2, a crane or perhaps another shuttle car conveyor (not shown) removes coil  44  from saddle  42   d . The removal frees saddle  42   d  to receive coil  44   a . (See FIG. 9 b ). The shuttle car conveyor is then driven to position #2. The shuttle in position #2 deposits its coils: coil  44   a  is deposited on saddle  42   d ; coil  44   b  is deposited on saddle  42   c ; coil  44   c  is deposited on saddle  42   b ; and coil  44   d  is deposited on saddle  42   a  (see FIGS. 9 c  and  9   d ). 
     By driving the shuttle car conveyor between position #1 and position #2, coils deposited on saddle  42  are continuously incrementally conveyed downstream to saddle  42   d . The coils deposited on saddle  42   d  are continuously removed to allow the shuttle car conveyor to continue to convey newly deposited coils downstream. The shuttle car conveyor can simultaneously convey downstream an amount of coils equal to the number of cars making up the shuttle car conveyor. 
     The number of cars in the shuttle, the number of coil support saddles, and the length of the spacers are dependent on cycle time and distance requirements of a particular application. If the distance between the cars is long, wheels are coupled to the spacers for support. 
     The shuttle car conveyor has several advantages. Connecting the cars to keep the cars a fixed distance apart when the shuttle is driven from the first position to the second position facilitates accurate positioning of the coils by the shuttle car conveyor. The fixed spacing also simplifies automation because the shuttle car conveyor can operate with only a single car having a drive mechanism. 
     Additionally, providing a shuttle car conveyor made up of individual cars simplifies maintenance. The cars can be easily disassembled and repaired as separate modules. Further, providing individual cars allows the shuttle to continue operating even if one of the car&#39;s motors is not functioning. 
     The shuttle car conveyor can be easily adapted to various systems. The shuttle car conveyor can be lengthened by adding car modules or spacers, or by lengthening the spacers. The shuttle car conveyor design allows for the use of standard rails. The option of using either electric motor, hydraulic motor or cable drum drive to power the shuttle allows the shuttle to operate at higher speeds than the chain conveyor system or walking beam conveyor system. 
     It is important to note that the present invention has been described with reference to specific examples. It would be apparent to those skilled in the art that a person understanding this invention may conceive of changes or other embodiments or variations which utilize the principles of the invention without departing from the scope of the invention as set forth in the appended claims. The specification and drawings are therefore to be regarded in an illustrative rather than a restrictive sense. Accordingly, it is not intended that the invention be limited except as may be necessary in view of the appended claims.