Abstract:
A guide rail spacer is provided that can be adjusted among a plurality of predetermined fixed positions with respect to the guide rail which it supports. The spacer can also be secured when not in use such that it does not interfere with conveyor line operations while remaining readily available for use.

Description:
RELATED APPLICATION 
     This application is a continuation of application Ser. No. 09/173,661, filed Oct. 15, 1998, now U.S. Pat. No. 6,135,271. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates in general to guide rail spacers for use with guide rail assemblies used in assembly line and conveyor belt systems and, in particular, to an improved means for providing variable adjustment and positioning of a guide rail. 
     2. Description of the Related Art 
     Guide rails are used to direct the travel of articles along a predetermined path of an assembly line or conveyor system. The articles are conveyed in a belt or track during the processing and packaging procedures of a typical manufacturer. Dependable support and adjustment of the guide rails is important to ensure manufacturing efficiency and to prevent the articles from tipping over or falling off the conveyor system. 
     Typically, whenever a different article travels through the conveyor system, the guide rails must be adjusted to accommodate the specifications of that article. This entails adjusting the guide rails to certain vertical and horizontal distances from the conveyor system. Although previous guide rail support posts allowed for this adjustment procedure, they did not allow this procedure to be readily repeatable. That is, each time a different article was conveyed, the vertical and horizontal distance calibrations had to be performed anew. Depending on the complexity of the adjustments, this procedure could require significant amounts of time and cause unnecessary manufacturing downtime. This nonrepeatability problem has been addressed by U.S. Pat. No. 5,819,911 issued to Ledingham. This patent discloses a railing support post that can be adjusted with respect to the guide rail which it supports. 
     A spacer is typically used to adjust among predetermined fixed positions with respect to the guide rail which it supports. However, prior art spacer designs have significant shortcomings. For example, although the prior art spacer designs disclose a two-position spacer, the spacer dangles freely from a lanyard proximal the guide rails, when neither position is used. Although this arrangement allows the spacer to be readily available for use, it can nevertheless inadvertently become tangled with or otherwise interfere with conveyor line operations. 
     A need therefore exists for a guide rail spacer that can be adjusted among a plurality of predetermined fixed positions with respect to a guide rail supported by a guide rail support post. A need also exists for a spacer that can be secured when not in use such that it does not interfere with conveyor line operations while remaining readily available for use. 
     SUMMARY OF THE INVENTION 
     In accordance with the present invention, a guide rail spacer is provided that can be adjusted among a plurality of predetermined fixed positions with respect to the guide rail which it supports. The spacer can also be secured when not in use such that it does not interfere with conveyor line operations while remaining readily available for use. 
     A further advantage of the present invention is that multi-functioning spacers may be mounted along a portion of the guide rail support to provide adjustment of a guide rail among predetermined fixed positions. Individual spacers maintain a plurality of mounting positions which allow one spacer to function as the equivalent of several spacers. The spacer is also constructed so that it does not interfere with conveyor line operations when not is use, but remains readily available for use. The spacer may also include a handle section for easy insertion and removal. 
     In accordance with one aspect of the present invention, the spacer has a body defining a plurality of channels with the plurality of channels including a first channel interposed between a second channel and a third channel. The first channel and second channels sized and configured to accept the tube, and the third channel sized and configured to accept the housing element. 
     Further aspects, features and advantages of the present invention will become apparent from the detailed description of the preferred embodiment that follows. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The above-mentioned and other features of the invention will now be described with reference to the drawings of a preferred embodiment of the present guide rail spacer. The illustrated embodiment of the guide rail spacer is intended to illustrate, but not to limit the invention. The drawings contain the following figures: 
     FIG. 1 is a perspective view of a flexible guide rail support post supporting a pair of guide rails and having a spacer inserted in a first position in accordance with the teachings of the invention; 
     FIG. 2 is a perspective view of the spacer of FIG. 1; 
     FIG. 3A is a side elevation view of the guide rail support post of FIG. 1, illustrating the spacer in a first position; 
     FIG. 3B is a side elevation view of the guide rail support post of FIG. 1, illustrating the spacer in a second position; and 
     FIG. 3C is a side elevation view of the guide rail support post of FIG. 1, illustrating the spacer in a home position. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The present embodiment of the guide rail spacer is disclosed in the context of an exemplary guide rail support post to support one or more guide rails on a conveyor assembly. The principles of the present invention, however, are not limited to use with guide rail support posts or even conveyor assemblies for that matter. Instead, it will be understood by one skilled in the art, in light of the present disclosure, that the guide rail spacer disclosed herein can also be successfully utilized in a variety of other contexts. 
     To assist in the description of the components of the illustrated embodiment, the following coordinate terms are used. A “longitudinal axis” is generally parallel to the ends  48 , 50  of the spacer  30  when mounted on the guide rail support post  10 . A “lateral axis” is normal to the longitudinal axis and is generally parallel to the plane of the supported guide rails  13 , 14 . A “transverse axis” extends normal to both the longitudinal and lateral axes and along the vertical height of the support bar  2 . In addition, as used herein, the “longitudinal direction” refers to a direction substantially parallel to the longitudinal axis; the “transverse direction” refers to a direction substantially parallel to the transverse axis; and the “lateral direction” refers to a direction substantially parallel to the lateral axis. Also, the terms “proximal” and “distal” are used consistently with the description of the exemplary application and in reference the guide rails  13 , 14 , proximal being closer to the guide rails  13 , 14  and distal being farther from the guide rails  13 , 14 . 
     Referring to the drawings, and particularly to FIG. 1, an exemplary guide rail support post  10  is comprised of a support bar  12 , a removable tube  14 , an exterior spring  16 , a housing element  18 , and a clamping means  20 . The cylindrical exterior spring  16  and cylindrical housing element  18  abut each other and encase the cylindrical tube  14  to form a working member. The working member is secured and positioned by the support bar  12 . 
     A handle  22  is affixed to a distal end  24  of the tube  14  and the clamping device  20  is affixed to a proximal end  26  of the tube  14  (best seen by FIGS.  3 A-C). Application of a linear force onto the handle  22  advances the proximal end  26  of the tube  14  beyond the proximal end  28  of the housing element  18  (best seen by FIGS. 3A-C) and compresses the spring  16 . When the linear force is removed, the spring force returns the tube  14  to a resting position. A spacer  30  may then be mounted onto the exposed proximal end  26  of the tube  2  , thereby adjusting the support post  10  in a fixed position. In this manner, one or more spacers  30  may be added or removed to allow adjustment among a variety of fixed positions. A more detailed description of the structure, assembly and operation of the guide rail support post  10  is provided in U.S. Pat. No. 5,819,911 issued to Ledingham and hereby incorporated by reference. 
     Referring to FIG. 2, the support post incorporates a spacer  30  that can be mounted onto the proximal end  26  of the tube  14 . The spacer  30  is constructed in a generally L-shaped design and has a first side  32  and a second side  34 , both sides  32 , 34  extending in the longitudinal and transverse directions. The first side  32  communicates with the second side  34  through an upper bridge  36  and a lower bridge  38 , both bridges  36 , 38  extending in the lateral direction. The upper bridge  38  bounds an upper portion  40  of the spacer  30  and the lower bridge  38  bounds a lower portion  42  of the spacer  30 . The upper and lower portions  40 , 42  of the spacer  30  communicate through a middle portion  44  which is formed therebetween. The spacer  30  also has a proximal end  48  and a distal end  50  that each extend in the transverse direction, the proximal and distal ends  48 , 50  are open or exposed. 
     The upper portion  40  of the spacer  30  has a longitudinal length that is approximately equal to the longitudinal length of the middle portion  44  of the spacer  30 . The lower portion  42  of the spacer  30  has a longitudinal length that is approximately twice the longitudinal length of the longitudinal length of the upper and middle portions  48 , 44 . 
     The lower portion  42  of the spacer  30  has a lateral length that is approximately equal to the lateral length of the middle portion  44  of the spacer  30 . The upper portion  40  of the spacer  30  has a lateral length that is preferably 1.1 to 2 times longer, and more preferably approximately 1.3 to 1.5 times longer, than the lateral length of the lower or middle portions  42 , 44 . 
     The upper portion  40 , lower portion  42  and middle portion  44  of the spacer  30  preferably have transverse lengths that are approximately equal. 
     When so arranged, a first or middle channel  52  is formed between the proximal and distal ends  48 , 50  of the spacer  30 . The middle channel  52  is bounded in the lateral direction by the first and second sides  32 , 34  of the spacer  30 . The middle channel  52  communicates with a lower channel  54  and an upper channel  56  in the transverse direction. The middle channel  52  is sized and configured to accept a portion of the tube  14  but not to accept a portion of the housing element  18 . That is, the tube  14 , which has a smaller radius than the radius of the middle channel  52  can pass through the middle channel  52 , while the housing element  18 , which has a larger radius than the radius of the middle channel  52  cannot pass through the middle channel  52 . 
     A second or lower channel  54  is formed between the proximal and distal ends  48 , 50  of the spacer  30 . The lower channel  54  is bounded in the lateral direction by the first and second sides  32 , 34  of the spacer  30  and is bounded in the transverse direction by the lower bridge  38 , while also communicating with the middle channel  52  in the transverse direction. The lower channel  54  is sized and configured similar to the middle channel  52  such that the lower channel  54  can accept a portion of the tube  14  but not accept a portion of the housing element  18 . That is, the tube  14 , which has a smaller radius than the radius of the lower channel  54  can pass through the lower channel  54 , while the housing element  18 , which has a larger radius than the radius of the lower channel  54 , cannot pass through the lower channel  54 . 
     A third or upper channel  56  is formed between the proximal and distal ends  48 , 50  of the spacer  30 . The upper channel  56  is bounded in the lateral direction by the first and second sides  32 , 34  of the spacer  30  and is bounded in the transverse direction by the upper bridge  36  while also communicating with the middle channel  52  in the transverse direction. The upper channel  56  is sized and configured such that the upper channel  56  can accept both a portion of the tube  14  and a portion of the housing element  18 . That is, the tube  14 , which has a smaller radius than the radius of the upper channel  56  can pass through the upper channel  56 , while the housing element  18 , which also has a smaller radius than the radius of the upper channel  56  can also pass through the upper channel  56 . 
     The exterior and interior of the spacer  30  can be formed in a variety of geometric configurations. The illustrated embodiment shows the exterior of the lower and middle portions  42 , 44  of the spacer  30  as being generally linear and smooth, with the first and second sides  32 , 34  generally parallel in the longitudinal and transverse directions. The exterior of the upper portion  40  has an arcuate curvature, preferably semi-circular, in the transverse direction and is linear in the longitudinal direction. The illustrated embodiment shows the interior dimensions as being generally similar to the exterior dimensions. However, the upper and lower bridges  36 , 38  form arcuate curvatures which respectively form semi-circular segments within the second and third channels  54 , 56 . The illustrated channels  52 , 54 , 56  thus each form a region having a radius and capable of capturing a radial body. The cross-sectional configurations of the channels, however, need not be radial but rather can form a variety of cross-sectional shapes. For example, one or more of the channels can have an interior perimeter with a cross-sectional shape that is square, rectangular, circular, oval, triangular, pentagonal, octagonal and the like. For another example of a modified channel interior, but without limitation, the channels may combine to form a keyway with an aperture defining a home position (detailed below) with the other channels forming a slot extending into the aperture and defining a plurality of positions. As will be recognized, in this configuration, the keyway may advantageously form a bounded region within the body of the spacer  30 . 
     The above-described dimensions of the spacer  30  provide for fixing the proximal end  26  of the tube  14  beyond the proximal end  28  of the housing element  18 , thereby permitting adjustment of the guide rails  13 , 14  to a plurality of positions. Preferably, this fixation comprises mounting the spacer  30  onto the proximal end  26  of the tube  14 . When a linear force F is applied to the handle  22 , the force advances the tube  14  and compresses the spring  16 , the proximal end  26  of the tube  14  is thereby exposed beyond the proximal end  28  of the housing element  18  and capable of receiving a portion of the spacer  30 . When the force F is removed, the spring force returns the tube  14  to a resting position which corresponds to a fixed guide rail position. A plurality of spacers  30  may be mounted on the proximal end  26  of the tube  14  to provide additional varied guide rail positions. The spacer  30  is advantageously pre-placed between the clamp  20  and support  12  before the support  12  is connected to the guide rails  13 , 14  thereby longitudinally capturing the spacer  30  between the assembled clamp  20  and support  12  along the tube  16  and guide element  18 . 
     FIGS. 3A-C illustrate the spacer  30  mounted on either the proximal end  26  of the tube  14  or mounted across the guide element  18 . More specifically, FIG. 3A shows the spacer  30  mounted in a first position on the proximal end  26  of the tube  14 . FIG. 3B shows the spacer  30  mounted in a second position on the proximal end  26  of the tube  14 ; and FIG. 3C shows the spacer mounted in a third position over the circumferentially layered guide element  18  and tube  14 . 
     Referring to FIG. 3A, when linear force F is applied to the handle the proximal end  26  of the tube  14  is exposed beyond the proximal end  26  of the housing element  18  and capable of receiving a portion of the spacer  30 , as described above. When the middle channel  52  of the spacer  30  is transversely aligned around the tube  14  and the tube  14  subsequently released, the size and configuration of the middle channel  52  is such that the middle channel  52  can accept a portion of the tube  14  but cannot not accept a portion of the guide element  18 , as described above. By this arrangement, the proximal end  48  of spacer  30  abuts the clamp  20  and the distal end  50  of the spacer  30  abuts the guide element  18  while a portion of the tube  14  extends within the middle channel  52 . This spacer  30  position corresponds to a first position where the spacer  30  extends the guide rail to a first predetermined length L 1 . 
     Referring to FIG. 3B, when the spacer  30  is oriented similar to the spacer shown in FIG.  3 A and described above, and the lower channel  54  is transversely aligned around the tube  14  and the tube  14  subsequently released, the size and configuration of the lower channel  54  is such that the lower channel  54  can accept a portion of the tube  14  but cannot not accept a portion of the guide element  18 , as described above. By this arrangement, the proximal end  48  of spacer  30  abuts the clamp  20  and the distal end  50  of the spacer  30  abuts the guide element  18  while a portion of the tube  14  extends within the lower channel  54 . This spacer  30  position corresponds to a second position where the spacer  30  extends the guide rail to a second predetermined length L 2 . 
     Referring to FIG. 3C, when the spacer  30  is oriented similar to the spacer  30  shown in FIG.  3 A and described above, and the upper channel  56  is transversely aligned with the tube  14  and the tube  14  subsequently released, the size and configuration of the upper channel  56  is such that the upper channel  56  can accept both a portion of the tube  14  and a portion of the guide element  18 , as described above. By this arrangement, the guide element  18  and tube  14  both pass entirely through the upper channel  56  of the spacer  30 . The proximal ends  26 , 28  of the tube thus both abut the clamp  20 , with a portion of the tube  14  circumferentially layered within a portion of the guide element  18 , which, is within the upper channel  56 . This spacer  30  position corresponds to a third or home position where the spacer  30  extends the guide rail to a third predetermined length that is coextensive with not using the spacer  30 . The spacer  30  can be advantageously rotated 90 degrees to reduce undesired contact with the support post  10  (not shown). 
     The spacer  30  may also incorporate a handle molded into the upper or lower bridge  36 , 38 . This handle allows easy insertion and removal of the spacer  30 . 
     In the preferred embodiment, the tube  14  is approximately eight inches in length with an exterior radius of slightly less than one half inch. Both the exterior spring  16  and housing elements  18  are approximately four inches in length with an interior radius of slightly more than one half inch. The middle channel  52  of the spacer  30  has a longitudinal length of approximately one-half inch and an inner radius that is slightly larger than the outer radius of the tube  14  and slightly smaller than the outer radius of the guide element  18 , a preferably an inner radius of approximately one half inch. The lower channel  50  of the spacer  30  has a longitudinal length of approximately one inch and an inner radius that is slightly larger than the outer radius of the tube  14  and slightly smaller than the outer radius of the guide element  18 , a preferably an inner radius of approximately one half inch. The upper channel  56  of the spacer  30  has a longitudinal length of approximately one-half inch and an inner radius that is slightly larger than the outer radius of the guide element  18 , a preferably a radius of one-half to three-quarters of an inch. 
     The illustrated spacer  30  is constructed in a unibody configuration of a rigid molded plastic. Plastic is preferred for its strength and low cost. However, there is no requirement that the spacer  30  be constructed of a unibody design and can be constructed of other materials such as metals, composites and other suitable materials depending on the particular application of the spacer. 
     The embodiments illustrated and described above are provided merely as examples of the spacer constructed in accordance with the present invention. Other changes and modifications can be made from the embodiments presented herein by those skilled in the art without departure from the spirit and scope of the invention, as defined by the appended claims.