Abstract:
A diverter is for intended use in connection with a diverter conveyor for diverting articles moving in a conveying direction from a primary path of travel to one of three different optional paths of downstream travel. The diverter includes a plurality of guides, each mounted for relative movement thereto from a first position to a second position. Depending on the position, the diverter is caused to follow one of the several downstream paths of travel. Related aspects include a conveyor incorporating the diverter and methods of use and manufacture.

Description:
TECHNICAL FIELD 
       [0001]    This disclosure relates generally to conveyors and, more particularly, to a conveyor for diverting articles being conveyed. 
       BACKGROUND OF THE INVENTION 
       [0002]    Systems for selectively diverting conveyed articles in a direction transverse to the conveying direction are well known. The typical arrangement includes a conveyor associated with a plurality of diverters (sometimes called “carriers”) for engaging the articles. As the conveyor moves in an endless path, an adjacent guide track engages a guide associated with each diverter. In the usual mode of operation, this engagement causes the diverter and the associated article to move laterally along the conveyor. Using such an arrangement advantageously allows for selective placement of the articles into multiple rows or lanes, as necessary or desired for a downstream operation, or alternatively may simply divert selected articles to a takeaway conveyor for further processing. 
         [0003]    Currently, most diverter systems are adapted for moving articles from a position along the lateral side of the conveyor across the conveying surface to a position closer to the opposite side of the conveyor. However, it is desirable in some applications to provide for diversion from a central position along the conveying surface to either lateral side of the conveyor, or possibly to allow for the continued unaltered conveyance of the diverter in the central position (which may provide a significant reduction in wear as a result of the lack of a need for specific guidance in such position). Accordingly, a need is identified for a diverter conveyor that addresses and overcomes the foregoing limitations, as well as possibly others. 
       SUMMARY OF THE INVENTION 
       [0004]    One aspect of the invention pertains to an apparatus for intended use in connection with a conveyor for conveying articles in a conveying direction along at least three different paths. The apparatus includes a diverter for moving in the conveying direction along an intermediate path of travel. The diverter includes a plurality of movable guides including a first guide mounted for relative movement to a first position corresponding to a first path of diverter travel closer to one side of the conveyor and a second guide mounted for relative movement to a second position corresponding to a second path of diverter travel closer to a second side of the conveyor. A switch includes a first condition for engaging the first guide to cause the diverter to follow the first path, a second condition for engaging the second guide to cause the diverter to follow the second path, or a third condition for allowing the diverter to follow the intermediate path of travel. 
         [0005]    In one embodiment, the switch comprises a first portion adapted for engaging the first guide in the first position and a second portion adapted for engaging the second guide in the second position. An actuator may be provided for moving the first portion of the switch to engage the first guide and the second portion of the switch to engage the second guide. A limiter may also be provided for limiting the stroke of the actuator. The actuator may comprise a first actuator connected to the first portion of the switch and a second actuator connected to the second portion of the switch. 
         [0006]    A first magnetic coupling may be provided for holding the first guide in either the first position or the second position, and a second magnetic coupling for holding the second guide in either the first position or the second position. A reset guide upstream of the switch may be provided for moving the first guide to the second position and the second guide to the first position. A first divider downstream of the switch may be provided for engaging the first guide in the first position and a second divider downstream of the switch may be provided for engaging the second guide in the second position. A dead zone may be provided between the switch and the first or second dividers. 
         [0007]    A method for conveying articles in a conveying direction along a first path of travel or a second path of travel is also disclosed. The method comprises conveying a diverter including a plurality of guides including a first guide mounted for movement to a first position adjacent one side of the diverter corresponding to the first path of travel and a second guide mounted for movement to a second position adjacent another side of the diverter corresponding to the second path of travel. The method further comprises holding each guide in either the first position or the second position by way of a magnetic coupling between the diverter and the guide. The method may further include the step of moving the guide between the first and second positions. 
         [0008]    A further aspect of the disclosure pertains to an apparatus for intended use in connection with a conveyor for conveying articles in a conveying direction. The apparatus comprises at least one diverter for moving in the conveying direction along a central path of travel. The diverter includes a first movable guide mounted for relative movement to a first position corresponding to a first path of diverter travel closer to one side of the conveyor and a second position corresponding to the central path of travel. A switch is provided for engaging the first guide to cause the diverter to follow the first path. 
         [0009]    In one embodiment, the diverter includes a second guide mounted for relative movement to a third position corresponding to a second path of diverter travel closer to one side of the conveyor and a fourth position. The switch may comprise a first portion adapted for engaging the first guide in the first position and a second portion adapted for engaging the second guide in the third position. An actuator may be provided for moving the first portion of the switch to engage the first guide and the second portion of the switch to engage the second guide, and a limiter for limiting the stroke of the actuator. The actuator may comprise a first actuator connected to the first portion of the switch and a second actuator connected to the second portion of the switch. 
         [0010]    A first magnetic coupling may be provided for holding the first guide in either the first position or the second position. A reset guide may be provided upstream of the switch for moving the first guide to the second position. A first divider downstream of the switch may be provided for engaging the first guide in the first position. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]      FIGS. 1 and 1   a  are top and bottom perspective views of a conveyor for use in connection with the diverter forming one of the many inventions described herein; 
           [0012]      FIG. 2  is a perspective view of a diverter including two guides; 
           [0013]      FIGS. 3 and 4  are top and perspective views of a switch, illustrating in particular the guides for traversing a switch; 
           [0014]      FIGS. 5 and 6  are top and perspective views of the switch of  FIG. 3 , illustrating in particular reset guides; 
           [0015]      FIGS. 7-10  are top and perspective views of the switch of  FIG. 3 , illustrating in particular the switch in a first condition; 
           [0016]      FIGS. 11-14  are top and perspective views of the switch of  FIG. 3 , illustrating in particular the switch in a second condition; 
           [0017]      FIGS. 15-18  are top and perspective views of the switch of  FIG. 3 , illustrating in particular the switch guides in a third condition; 
           [0018]      FIGS. 19-21  are perspective views of the actuator illustrating the various positions; and 
           [0019]      FIGS. 22 and 23  illustrate a toggle position rest zone. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0020]    Reference is now made to  FIG. 1 , which illustrates a diverter system  10  for use in diverting articles being conveyed. The system  10  as shown includes a driven conveyor  12  comprised of a first endless conveyor  14  (including a chain; not shown), a second endless conveyor  16  spaced from the first chain, one or more associated diverters  20  for supporting or engaging the article(s) being conveyed (preferably, on its upper or article engaging surface S), and diverter support (in the form of transverse rods  18 ) positioned between the conveyors  14 ,  16 . In the illustrated embodiment, the association with the support rods  18  is such that the diverter  20  is capable of slidably moving relative to the support in a transverse or lateral direction T relative to the conveying or longitudinal direction C along a forward run in response to the influence of an externally applied force in order to divert articles transversely across the conveying surface (such as for forming lanes on a downstream conveyor, or for moving selected articles onto an associated takeaway conveyor (not shown)). The details of an exemplary diverter construction may be found in Applicant&#39;s international patent application PCT/US05/003497, the disclosure of which is incorporated herein by reference, as well as in U.S. Pat. No. 7,690,496, which is also incorporated herein by reference. 
         [0021]    Viewing also  FIG. 2 , each diverter  20  may be associated with a guide assembly  22  for use in causing it to move selectively in the transverse direction T (or not) depending on its association with a corresponding guide structure (as will be discussed in more detail below). This guide assembly  22  may mount to the underside of the diverter  20 , such as by using fasteners, as outlined in the &#39;496 patent. The guide assembly  22  includes a pair of guide bodies  26   a,    26   b,  each associated with a movably mounted guide  28   a,    28   b  positioned in an associated recess or cavity. Each guide  28   a,    28   b  is mounted for movement within the recess or cavity between a first position and a second position, the significance of which will be outlined in the following description. 
         [0022]    In order to maintain the guide  28   a,    28   b  in either the first or second position, and thus determine the path of travel in the conveying direction C, a magnetic coupling may be provided. This magnetic coupling may be formed between the corresponding parts of the bodies  26   a,    26   b  of the diverter  20  and the associated guides  28   a,    28   b.  In the illustrated embodiment, and as perhaps best understood viewing  FIG. 3 , this is accomplished by associated magnets M positioned in the bodies  26   a,    26   b  and forming the guides  28   a,    28   b  of a magnetic material for forming the desired magnetic coupling, and most preferably comprises a ferromagnetic material. However, the opposite arrangement could also be used instead. 
         [0023]    Turning now to  FIGS. 3 and 4 , the details of a switch  30  for switching the position of the guides  28   a,    28   b  is shown. Firstly, it is noted that the switch  30  includes optional spaced body guides  32   a,    32   b,  which are designed to receive and guide the diverters  20  as a result of the engagement with the corresponding guide bodies  26   a,    26   b  (It should be understood that the diverter  20  in  FIG. 4  is showed spaced from the conveyor  12  for purposes of illustration only). Thus, the body guides  32   a,    32   b  may be considered to provide a centering function for the guides  28   a,    28   b  relative to the switch  30 . As can be appreciated from viewing  FIG. 5 , the end of the body guides  32   a,    32   b  may be rounded and thus used for transitioning the diverters  20  from the return to the forward run of the conveyor  12  (see action arrow N). 
         [0024]    The switch  30  also includes reset guides  34   a,    34   b,    34   c,  as shown in  FIGS. 5 and 6 . These guides  34   a - 34   c  engage the guides  28   a,    28   b  and force them to a default position, which in this embodiment corresponds to a central position relative to the lateral sides of the conveyor  12  when the switch  30  is in the home condition. Hence, with reference to  FIGS. 7 and 8 , an upstream actuator  36  in a home position allows the guides  28   a,    28   b  of the diverter  20  (guide  28   a  in the second position, and guide  28   b  in the first position) to pass downstream through the switch unaffected, and results in no diversion activity. In other words, downstream dividers  38   a,    38   b  (see  FIGS. 9 and 10 ) are not engaged and the diverter  20  travels past the switch  30  in the home or intermediate position. 
         [0025]    However, in alternate positions of the actuator  36 , a first portion  36   a  (which is tapered in the conveying direction C) is moved (note position  36   a ′) to cause the guide  28   a  in the first position to divert, as shown in  FIGS. 11 and 12 . As a result of downstream guidance provided by the divider  38   a,  the diverter  20  is caused to move from the home or intermediate position along a path of travel toward a position closer to one lateral side of the conveyor  12 , as shown in  FIGS. 13 and 14  (note arrow L for left). The opposite guide  28   b  remains unaffected. 
         [0026]    Likewise, in another position of the actuator  36 , a second portion  36   b  (also tapered) is moved (note position  36   b ′) to cause the guide  28   b  to divert to a second position, as shown in  FIGS. 15 and 16 . As a result of downstream guidance provided by the divider  38   b,  the diverter  20  is caused to move from the home or intermediate position toward a second path of travel closer to another lateral side of the conveyor  12 , as shown in  FIGS. 17 and 18  (note arrow R for right). The opposite guide  28   a  remains unaffected. 
         [0027]    Details of one possible construction of the actuator  36  are shown in  FIGS. 19-21 . It can be understood that the actuator comprises a pair of linear actuators, such as pressurizable cylinders  40   a,    40   b,  associated with each portion  36   a,    36   b  of the actuator  36 . When both cylinders  40   a,    40   b  are fully extended, as shown in  FIG. 21 , the portions  36   a,    36   b  are brought together and the diverter  12  position remains unchanged, as described in the foregoing discussion. When each cylinder  40   a  or  40   b  is retracted, the corresponding portions  36   a,    36   b  assume a corresponding position for engaging the guide  28   a,    28   b  and causing diversion (compare  FIGS. 19 and 20 ). Floating stroke limiting rods  42  connecting the portions  36   a,    36   b  and with oversized heads prevent the cylinders  40   a,    40   b  from causing actuation to a position in which a crash would occur as the result of simultaneous actuation. 
         [0028]    Turning to  FIGS. 22 and 23 , it is also noted that a zone Z is provided downstream of the actuator  36  for allowing the guides  28   a,    28   b  to assume the proper condition (as the result of the magnetic coupling) prior to being engaged by the dividers  38   a,    38   b.  The particular length of the zone in the conveying direction may be adjusted depending on the speed of operation. 
         [0029]    Finally,  FIGS. 1 and 1   a  illustrate the downstream guidance that may be provided. Specifically, along the forward run, guide rails  44   a,    44   b  cause the movement of the diverters to the desired position, such as along the left or right side of the conveyor  12 . Likewise, guide rails  46   a,    46   b  along the return run cause the diverters  20  to return to the central position. As should be appreciated, the position of the guides  26   a,    26   b  is not relevant for continued operation, since it will be reset prior to entering the switch  30 . 
         [0030]    Numerous advantages flow from practicing the foregoing teachings. Aside from the simplicity, an advantage of the proposed approach is that it avoids the need for moving a diverter from along one lateral side of the conveyor to another. Rather, the diverter can be moved from the central or intermediate position to either side, which will decrease the longitudinal distance required to make the diversion. The central location and the lack of guidance in the intermediate position also eliminate the past problem of constant friction and resulting wear. The particular nature of the actuator  36  also helps to avoid the possibility of collisions and ensure that proper guidance is achieved in a reliable manner, thus allowing for the desired high speed of operation to be achieved in order to answer modern throughput demands. 
         [0031]    With the exceptions described above for forming the magnetic coupling, the diverter  20  and its associated components may be formed of any durable material, with UHMW polyethylene, polypropylene or Acetal being preferred choices because of the high durability, relatively low weight, and low cost of such materials. Using these materials results in a substantially strong structure for contacting the articles, and one not prone to oxidation and rust. However, the diverter  20  and other components may be formed of any material, including metal or other polymers, without limitation. 
         [0032]    The foregoing descriptions of various embodiments of the invention are provided for purposes of illustration, and are not intended to be exhaustive or limiting. Modifications or variations are also possible in light of the above teachings. The embodiments described above were chosen to provide the best application to thereby enable one of ordinary skill in the art to utilize the disclosed inventions in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention.