Abstract:
A system for dividing a flow of objects into two or more lanes of object flow, the system comprising a first conveyor configured to transport a plurality of objects, the conveyor having a transportation plane and plurality of substantially planar regions elevated above and substantially parallel to the transportation plane, the plurality of substantially planar regions each being configured to hold at least one of the plurality of objects being transported; a second conveyor substantially adjacent to the first conveyor; and a guide mounted above the transportation plane and the planar regions of the first conveyor, the guide configured to divert an object positioned on one of the substantially planar regions elevated above the transportation plane onto the second conveyor.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates generally to apparatuses and methods for dividing or diverting incoming objects from one or more conveyor belt production lines into a plurality of subsequent conveyor belt lines. 
       BACKGROUND 
       [0002]    Conveyor belt systems are commonly used within the manufacturing industry to distribute and handle goods. Depending on the specific operation involved, it is sometimes desirable to divide or separate at least a portion of the goods from a first conveyor belt to one or more subsequent conveyor belts. However, it is sometimes difficult to effectively transport goods along multiple channels without interrupting the distribution flow. 
         [0003]    The present invention is intended to overcome or ameliorate the prior art disadvantages discussed above or to provide a useful alternative thereto. 
       SUMMARY OF THE INVENTION 
       [0004]    In accordance with one aspect of the present invention, a system for dividing a flow of objects into two or more lanes of object flow is provided. The system comprises a first conveyor configured to transport a plurality of objects, the conveyor having a transportation plane and a plurality of substantially planar regions elevated above and substantially parallel to the transportation plane, the plurality of substantially planar regions each being configured to hold at least one of the plurality of objects being transported; a second conveyor substantially adjacent to the first conveyor; and a guide mounted above the transportation plane and the planar regions of the first conveyor, the guide configured to divert an object positioned on one of the substantially planar regions elevated above the transportation plane onto the second conveyor. 
         [0005]    In accordance with yet another aspect of the present invention, a method for dividing a flow of objects into two or more lanes of object flow is provided. The method comprises the steps of transporting a plurality of objects along a first transportation path of a first conveyor; diverting an object positioned on a substantially planar region elevated above and substantially parallel to a transportation plane of the first conveyor along a second transportation path; and receiving one or more objects diverted along the second transportation path with a second conveyor. 
         [0006]    In accordance with still another aspect of the present invention, an apparatus for dividing a flow of objects into two or more lanes of object flow is provided. The apparatus comprises a first conveyor configured to transport a plurality of objects, the first conveyor including a plurality of substantially elevated planar regions each being configured to hold at least one of the plurality of objects; a second conveyor substantially adjacent to the first conveyor; and a guide for diverting an object positioned on one of the elevated planar regions of the first conveyor onto the second conveyor. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0007]    The above-mentioned aspects of the present teachings and the manner of obtaining them will become more apparent and the teachings will be better understood by reference to the following description of the embodiments taken in conjunction with the accompanying drawings, wherein: 
           [0008]      FIG. 1  is a perspective view of a conveyor belt system in accordance with the teachings of the present invention; 
           [0009]      FIG. 2  is a top view of the conveyor belt system of  FIG. 1 ; 
           [0010]      FIG. 3  is a side view of the conveyor belt system of  FIG. 1 ; 
           [0011]      FIG. 4  is a front view of the conveyor belt system of  FIG. 1 ; 
           [0012]      FIG. 5  is a perspective view of a multiple lane conveyor belt system in accordance with the teachings of the present invention; 
           [0013]      FIG. 6  is a top view of the multiple lane conveyor belt system of  FIG. 5 ; 
           [0014]      FIG. 7  is a perspective view of another multiple lane conveyor belt system in accordance with the teachings of the present invention; and 
           [0015]      FIG. 8  is a top view of the multiple lane conveyor belt system of  FIG. 7 . 
       
    
    
     DETAILED DESCRIPTION 
       [0016]    The embodiments of the present teachings described below are not intended to be exhaustive or to limit the teachings to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices of the present teachings. 
         [0017]    Referring to  FIG. 1 , a perspective view of a first embodiment of a conveyor belt system  10  in accordance with the teachings of the present invention is shown. According to this aspect of the invention, a first conveyor belt  12  carries a series of goods  14  along direction  16 , while a second conveyor belt  18  is positioned substantially adjacent to the first belt and configured to receive at least a portion of the goods  14  that have been diverted off of the first conveyor belt. To divert or deflect a portion of the goods  14  from the first conveyor belt  12  to the second conveyor belt  18 , a rod or guide bar  20  is positioned across the top surface of transportation plane  22  of the first conveyor belt  12 . As the goods  14  advance along the first conveyor belt  12  in the direction of arrow  16 , some of the goods  14  physically contact the guide bar  20 , and are thereby caused to change course and divert onto the second conveyor belt  18 . 
         [0018]    It should be understood and appreciated that any type of object positionable as a physical barrier and extendable across at least a portion of the conveyor belt can be used as the rod or guide bar  20  for diverting a portion of the goods  14  onto a subsequent conveyor belt in accordance with the present invention. For instance, the rod or guide bar  20  can be an elongated bar that is connected to a frame that is disposed around the conveyor belt assembly  10 . Moreover, it is envisioned that any type of solid material (e.g., wood, metal and/or plastic) can be used to construct the rod or guide bar  20  in accordance with the teachings of the present invention, as long as such material is structurally able to cause any items or goods that impact its surface to change course and divert along an intended transportation path or channel. 
         [0019]    As mentioned above, only a portion of the goods  14  are configured to directly impact the guide bar  20  and thereby be caused to deflect onto the second conveyor belt  18 . The goods  14  that do not directly impact the guide bar  20  maintain their respective position on the first conveyor belt  12 , while the goods impacting the guide bar  20  are encouraged to change direction and advance to a subsequent belt (e.g., second conveyor belt  18 ). To determine whether an individual good  14  will impact the guide bar  20  and deflect onto a second or subsequent belt depends upon whether or not that good is positioned on a raised section  24  of the belt. More particularly, and in accordance with this aspect of the present invention, the first conveyor belt  12  is divided into various sections or regions, some of which are elevated or raised from the top surface  22  of the belt  12 . For instance, and with reference to  FIG. 1 , various raised sections  24  of the first conveyor belt  12  are slightly elevated from the top surface (transportation plane)  22  of the belt. When a good  14  is positioned on a raised section  24  of the belt  12 , the good is configured to impact the guide bar  20  when it reaches the portion of the belt which the guide bar intersects. On the other hand, when a good  14  is positioned on a non-raised section  26  of the belt, the good  14  is configured to pass underneath the guide bar  20 , and thereby not be shifted onto a subsequent belt. The second conveyor belt  18  is configured such that it is positioned at substantially the same elevation as the non-raised sections  26  of the first conveyor belt  12 . 
         [0020]    According to certain specific aspects of the present invention, the raised sections  24  of the first conveyor belt  12  may be in the form of platforms or stages that are raised above the transportation surface  22  of the belt. However, it should be understood and appreciated that any structure or shape having a substantially horizontal or planar surface that is raised above the transportation surface  22  of the belt and configured to hold a good can be used in accordance with the teachings of the present invention. 
         [0021]      FIG. 2  shows a top view of the exemplary embodiment of the invention described above. As can be clearly seen from this view, once a good  14  reaches the position along the course of transportation in which the guide bar  20  intersects the first belt  12 , that good will be diverted or deflected onto the second belt  18  if the good is positioned on a raised section  24 . In other words, the guide bar  20  functions as a physical barrier that will not allow the good  14  to continue along the course of the first belt  12  if that good is positioned at an elevation that is the same or slightly higher than the elevation of the guide bar  20  above the transportation surface  22  of the belt. Because the guide bar  20  is angled in a direction that terminates into the second conveyor belt  18 , when the good  14  physically impacts the guide bar  20 , the good  14  is forced to deflect along the guide bar  20  and into the direction of (and ultimately onto) the second conveyor belt  18 . 
         [0022]      FIG. 3  depicts a side view of the conveyor belt system  10  of  FIG. 1 . As shown in  FIG. 3 , two goods  14   a  are positioned on non-raised sections  26  of the belt  12  and are thereby able to pass underneath the guide bar  20  without being physically shifted or deflected onto the second conveyor belt  18 . In fact, one good (shown as  14   b ) has already passed underneath the guide bar  20  and is still securely positioned on the first conveyor belt  12 . The goods  14   c  located on the raised sections  24  of the first conveyor belt  12 , however, are configured to directly impact the guide bar  20 , and thereby subsequently shift onto the second conveyor belt  18 . 
         [0023]      FIG. 4  shows a front view of the conveyor belt system  10  of  FIG. 1 . According to this exemplary illustration, a good  14   d  (shown in dashed lines) that is positioned on a raised section  24  of the belt  12  contacts the guide bar  20  that is suspended over the belt. Upon impacting the guide bar  20 , the good  14   d  is diverted or shifted onto the second belt  18  along the direction of arrow  30 . The diverted good is shown on the second belt as reference numeral  14   e.    
         [0024]    While the above-described embodiments of the present invention illustrate a two lane conveyor belt system, it should be understood and appreciated that other conveyor belt arrangements having multiple (e.g., more than two) lanes or belts can also be used and still adhere to the scope and teachings of the present invention. As such, the present invention is not intended to be limited herein. 
         [0025]    One such multiple belt arrangement in accordance with the teachings of the present invention is shown in  FIGS. 5 and 6 . More particularly,  FIGS. 5 and 6  illustrate a 3:6 conveyor belt assembly  100 , in which three incoming lanes or belts of goods are individually divided into three additional lanes of goods, for a total of six lanes/belts. For instance, a first conveyor belt  102  carries a series of goods  104  along direction  106  from a first incoming production lane  101 , while a second conveyor belt  108  is positioned substantially adjacent to the first belt  102  and configured to receive at least a portion of the goods  104  if diverted onto. To divert or deflect a portion of the goods  104  from the first conveyor belt  102  to the second conveyor belt  108 , a rod or guide bar  110  is positioned across the top surface or transportation plane  112  of the first conveyor belt  102 . As the goods  104  advance along the first conveyor belt  102  in the direction of arrow  106 , some of the goods  104  physically contact the guide bar  110 , and are thereby caused to change course and divert onto the second conveyor belt  108 . 
         [0026]    As explained above with respect to the embodiment shown in  FIG. 1 , only a portion of the goods  104  are configured to directly impact the guide bar  110  and deflect onto the second conveyor belt  108 . To determine whether an individual good  104  will impact the guide bar  110  and deflect onto a second or subsequent belt depends upon whether or not that good is positioned on a raised section  114  of the belt. When a good  104  is positioned on a raised section  114  of the belt  102 , the good is configured to impact the guide bar  110  when it reaches the portion of the belt to which the guide bar intersects. On the other hand, when a good  104  is positioned on a non-raised section of the belt  116 , the good  104  is configured to pass underneath the guide bar  110 , and thereby not be shifted onto a subsequent belt. 
         [0027]    Adjacent to the first and second conveyor belts ( 102 ,  108 ) are third and fourth conveyor belts ( 120 ,  122 ), which carry a series of goods  124  from a second incoming production lane  103 . These goods  124 , depending on whether positioned on a raised section  126  or a non-raised section  128  of the belt  120 , will either be diverted onto the fourth conveyor belt  122  (i.e., by way of the second guide bar  130 ), or will pass underneath the guide bar  130  without being diverted. 
         [0028]    Adjacent to the third and fourth conveyor belts ( 120 ,  122 ) are fifth and sixth conveyor belts ( 132 ,  134 ), which carry a series of goods  136  from a third incoming production lane  105 . These goods  136  can be diverted from the fifth belt  132  onto the sixth belt  134  by way of the third guide bar  140  if positioned on a raised section  142  of the fifth belt  132 . When positioned on a non-raised section  144  of the fifth belt  132 , the goods  136  are allowed to continue along the belt without being diverted. 
         [0029]    Another multiple belt arrangement in accordance with the teachings of the present invention is shown in  FIGS. 7 and 8 . More particularly,  FIGS. 7 and 8  illustrate a 2:6 conveyor belt assembly  200 , in which each of two incoming lanes or belts of goods are individually divided into three lanes of goods, for a total of six lanes/belts. For instance, a first conveyor belt  202  carries a series of goods  204  along direction  206  from a first production lane  201 , while a second conveyor belt  208  is positioned substantially adjacent to the first belt  202  and configured to receive at least a portion of the goods  204  if diverted onto it. To divert or deflect a portion of the goods  204  from the first conveyor belt  202  to the second conveyor belt  208 , a rod or guide bar  210  is positioned across the top surface or transportation plane  212  of the first and second conveyor belts  202 ,  208 . As the goods  204  advance along the first conveyor belt  202  in the direction of arrow  206 , some of the goods  204  physically contact the guide bar  210 , and are thereby caused to change course and divert onto the second conveyor belt  208 . 
         [0030]    Similarly to the other illustrative embodiments of the present invention described above, only a portion of the goods  204  are configured to directly impact the guide bar  210  and deflect onto the second conveyor belt  208 . To determine whether an individual good  204  will impact the guide bar  210  and deflect onto a second or subsequent belt depends upon whether or not that good is positioned on a raised section  214  of the belt. When a good  204  is positioned on a raised section  214  of the belt  202 , the good is configured to impact the guide bar  210  when it reaches the portion of the belt to which the guide bar intersects. On the other hand, when a good  204  is positioned on a non-raised section  216  of the belt, the good  204  is configured to pass underneath the guide bar  210 , and thereby not be shifted onto a subsequent belt. 
         [0031]    In accordance with this illustrative embodiment of the present invention, both the first and second conveyor belts ( 202 ,  208 ) have both raised and non-raised sections ( 214 ,  216 ). In certain embodiments, the first conveyor belt  202  has two raised sections  214  immediately adjacent to one another and then followed by one non-raised section  216 , while the second conveyor belt  208  has immediately alternating raised and non-raised sections  214 ,  216 . In accordance with this exemplary illustration, when a good  204  on the first conveyor belt  202  is positioned on one of the raised sections, it is possible to configure the system so that the good  204  will either be diverted onto a raised section  214  of the second conveyor belt  208  or alternatively onto a non-raised section  216  of the second conveyor belt. To determine whether an individual good  204  will be diverted from the first conveyor belt  202  onto a raised or non-raised section of the second conveyor belt  204  is impacted by numerous different factors, such as (but not limited to), the respective speeds of the belts, the size and/or length of the raised and non-raised sections of the belts, as well as the shape and size of the goods to be diverted. Those of skill within the art will understand and appreciate that other factors may also be incorporated into the conveyor belt assemblies of the present invention to influence whether the goods are diverted onto raised or non-raised sections. As such, the present invention is not intended to be limited herein. 
         [0032]    Immediately adjacent to the second conveyor belt  208  is a third conveyor belt  230 . In accordance with certain aspects of the present invention, the third conveyor belt  230  is configured such that it is positioned at substantially the same elevation as the non-raised sections  216  of the first and second conveyor belts  202 ,  208 . In accordance with illustrative embodiments in which a good  204  is diverted from the first conveyor belt  202  onto a raised section  214  of the second conveyor belt  208 , that good  204  will then subsequently be diverted from the second conveyor belt  208  onto the third conveyor belt  230 . 
         [0033]    Adjacent to the first, second and third conveyor belts ( 202 ,  208 ,  230 ) are fourth, fifth and sixth conveyor belts ( 232 ,  234 ,  236 ), which carry a series of goods  238  from a second incoming production lane  203 . The fourth conveyor belt  232  carries the series of goods  238  along direction  206 , while the fifth conveyor belt  234  is positioned substantially adjacent to the fourth belt and configured to receive at least a portion of the goods  238  if diverted onto. To divert or deflect a portion of the goods  238  from the fourth conveyor belt  232  to the fifth conveyor belt  234 , a second rod or guide bar  240  is positioned across the top surface or transportation plane  242  of the fourth and fifth conveyor belts  232 ,  234 . As the goods  238  advance along the fourth conveyor belt  232  in the direction of arrow  206 , some of the goods  238  physically contact the guide bar  240 , and are thereby caused to change course and divert onto the fifth conveyor belt  234 . 
         [0034]    Similarly to the other illustrative embodiments of the present invention described above, only a portion of the goods  238  are configured to directly impact the guide bar  240  and deflect onto the fifth conveyor belt  234 . To determine whether an individual good  238  will impact the guide bar  240  and deflect onto a subsequent belt depends upon whether or not that good is positioned on a raised section  244  of the belt. When a good  238  is positioned on a raised section  244  of the belt  232 , the good is configured to impact the guide bar  240  when it reaches the portion of the belt to which the guide bar intersects. On the other hand, when a good  238  is positioned on a non-raised section  246  of the belt, the good  238  is configured to pass underneath the guide bar  240 , and thereby not be shifted onto a subsequent belt. 
         [0035]    In accordance with this illustrative embodiment of the present invention, both the fourth and fifth conveyor belts ( 232 ,  234 ) have both raised and non-raised sections ( 244 ,  246 ). In certain embodiments, the fourth conveyor belt  232  has two raised sections  244  immediately adjacent to one another and then followed by one non-raised section  246 , while the fifth conveyor belt  234  has immediately alternating raised and non-raised sections  244 ,  246 . In accordance with this exemplary illustration, when a good  238  on the fourth conveyor belt  232  is positioned on one of the raised sections, it is possible to configure the system so that the good  238  will either be diverted onto a raised section  244  of the fifth conveyor belt  234  or alternatively onto a non-raised section  246  of the fifth conveyor belt. To determine whether an individual good  238  will be diverted from the fourth conveyor belt  232  onto a raised or non-raised section of the fifth conveyor belt  234  can be impacted by numerous different factors, such as (but not limited to), the respective speeds of the belts, the size and/or length of the raised and non-raised sections of the belts, as well as the shape and size of the goods to be diverted. Those of skill within the art will understand and appreciate that other factors may also be incorporated into the conveyor belt assemblies of the present invention to influence whether the goods are diverted onto raised or non-raised section. As such, the present invention is not intended to be limited herein. 
         [0036]    Immediately adjacent to the fifth conveyor belt  234  is a sixth conveyor belt  236 . In accordance with certain aspects of the present invention, the sixth conveyor belt  236  is configured such that it is positioned at substantially the same elevation as the non-raised sections  246  of the fourth and fifth conveyor belts  232 ,  234 . In accordance with illustrative embodiments in which a good  238  is diverted from the fourth conveyor belt  232  onto a raised section  244  of the fifth conveyor belt  234 , that good will then subsequently be diverted from the fifth conveyor belt  234  onto the sixth conveyor belt  236 . 
         [0037]    While various illustrative embodiments incorporating the principles of the present teachings have been disclosed hereinabove, the present teachings are not limited to the disclosed embodiments. Instead, this application is intended to cover any variations, uses, or adaptations of the present teachings and use its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which these teachings pertain and which fall within the limits of the appended claims.