Patent Publication Number: US-2009223779-A1

Title: Conveyor Diverter

Description:
This application claims the benefits of PCT application PCT/U.S.07/67212 filed on Apr. 23, 2007, which claims priority of U.S. provisional application 60/794,340 for CONVEYOR DIVERTER filed on Apr. 24, 2006, which is hereby incorporated for all that is disclosed therein. 
    
    
     BACKGROUND 
     Conveyor systems may include diverging conveyors wherein items being transferred via the conveyor system are required to be moved from one conveyor to another. For example, the conveyor system may include a main conveyor and several side conveyors. The side conveyors may be located adjacent the main conveyor so as to intersect the main conveyor at angles. 
     Items being transported via the main conveyor may need to be moved to a side conveyor. An arm or member swings into the path of the item, which causes the item to be diverted to a side conveyor. The above-described angle is required due to limitations in the speed in which items can be diverted from the main conveyor to side conveyors. For example, if an item is moving at a high velocity and contacts the arm, the item could become damaged. 
     In order to use less space in a conveyor system, the angle between the side conveyor and the main conveyor should be as close to perpendicular as possible. However, as the angle approaches perpendicular, items being conveyed on the main conveyor tend to strike the arm rather than be guided by the arm, which can damage the items. In addition, the items may not get diverted to the side conveyor, which will clog the main conveyor and require maintenance to unclog the main conveyor. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a top plan view of an embodiment of a conveyor system. 
         FIG. 2  is a top perspective view of an embodiment of the diverter of  FIG. 1 . 
         FIG. 3  is a side elevation view of the diverter of  FIG. 2 . 
         FIG. 4  is a top plan view of the diverter of  FIG. 2 . 
         FIG. 5  is a side perspective view of an embodiment of the first end of the arm of  FIG. 2  with a section of the upper chassis removed. 
         FIG. 6  is a view of the first end of the arm of  FIG. 5  with a section of chain removed. 
         FIG. 7  is a partial, top perspective view of an embodiment of the diverter of  FIG. 2 . 
         FIG. 8  is a top perspective view of an embodiment of a diverter that has a curved arm. 
         FIG. 9  is a top plan view of the diverter of  FIG. 8 . 
         FIG. 10  is a top plan view of an embodiment of a conveyor using the diverter of  FIG. 8 . 
         FIG. 11  is a side view of a diverter having a plurality of arms. 
     
    
    
     SUMMARY 
     Conveyor diverters are disclosed herein. One embodiment of a conveyor diverter comprises an arm comprising a first end and a second end. The arm has a first surface extending between a location proximate the first end and a location proximate the second end. The arm is movable between a first position and a second position. A chain is located within the arm. The chain comprises at least one roller assembly, wherein at least a portion of the roller assembly extends beyond the first surface. 
     DETAILED DESCRIPTION 
     A top plan view of an embodiment of a conveyor system  100  is shown in  FIG. 1 . The conveyor system  100  includes a main conveyor  110 , a side conveyor  112 , and a diverter  114 . The main conveyor  110  transports items  120  in a direction  122 . The main conveyor  110  may be, as an example, a belt-type conveyor, wherein the items  120  are moved by way of a moving belt. The side conveyor  112  moves the items  120  in a direction  126 . As described in greater detail below, the diverter  114  serves to move selected items  120  from the main conveyor  110  to the side conveyor  112 . In some embodiments, the conveyor system  100  may have a plurality of side conveyors. However, only the one side conveyor  112  is described herein. 
     For reference purposes, an axis  130  extends perpendicular to the direction  122 , which in the embodiment described in  FIG. 1  is also perpendicular to the main conveyor  110 . An angle θ, exists between the axis  130  and the direction  126 . The diverter  114  described herein reduces the angle θ relative to conventional conveyor systems, which enables more side conveyors to be located adjacent a section of the main conveyor  110 . Therefore, the length of the main conveyor  110  may be reduced relative to conventional conveyor systems. As described below, the diverter  114  also reduces the chance of damage to the items  120  when being diverted to the side conveyor  112  when the angle θ is reduced. 
     The diverter  114  includes an arm  132  that swings between a first position and a second position. The first position is noted by the dashed lines  134 . When the arm  132  is in the first position, the arm  132  does not contact items  120  being transported via the main conveyor  110 . Accordingly, the items  120  are able to travel along the main conveyor  110 . However, when the arm  132  is in the second position as noted by the solid lines of arm  132 , the arm  132  contacts the items  120 . Thus, when the arm  132  is in the second position, the items in the proximity of the arm  132  are diverted on to the side conveyor  112 . 
     It is noted that the diverter  114  must move the items  120  from the main conveyor  110  to the side conveyor  112  without damaging the items. It is also noted that the items  120  may be traveling at a very high speed on the main conveyor  110 , which complicates the transferring the items to the side conveyor  112  without damaging the items  120 . 
     A top perspective view of an embodiment of the diverter  114  is shown in  FIG. 2 . The diverter  114  of  FIG. 2  is configured to be attached to a floor or other stable surface proximate a conveyor. Thus, the diverter  114  includes a platform  144  that mounts to the floor or surface. Other embodiments of the diverter  114  are configured to be attached to the conveyor system  110 ,  FIG. 1 . Attached to the platform  144  is a support  146 , which may be a metal member. In the embodiment of the diverter  114  described herein, both the platform  144  and the support  146  are immovable relative to the conveyor. Attached to the support  146  is a motor platform  148  that serves to support a motor  150 . 
     Also attached to the support  146  is a hinge  154 . The hinge  154  includes an upper portion  156  and a lower portion  158 . A cover  162  covers mechanisms and the like located in and associated with the hinge  154 . The arm  132  is pivotally attached to the lower portion  158  of the hinge  154 , so that the arm  132  may move along an arc  160 . A support bar  164  is pivotally attached to the upper support portion  156  and the arm  132 . The support bar  164  serves to reduce the torque applied on the lower portion  158  by the arm  132 , which enables the lower portion  158  to be smaller. 
     A movement arm  170  is attached between the arm  132  and a mount, which in the embodiment of  FIG. 2  is the motor platform  148 . Associated with the movement arm  170  is a control mechanism  172  that serves to control the movement of the movement arm  170 . The movement arm  170  serves to move the arm  132  to preselected positions and to maintain the arm  132  in these positions as it is being contacted by items  120 ,  FIG. 1 . In some embodiments, the movement arm  170  is a hydraulic device and the control mechanism  172  is a hydraulic control. 
     The arm  132  includes a chassis  173  having an upper chassis portion  174  (sometimes referred to as a first chassis portion) and a lower chassis portion  175  (sometimes referred to as a second chassis portion). Sandwiched between the upper chassis portion  174  and the lower chassis portion  175  is a chain  176 . As described in greater detail below, the chain  176  facilitates the movement of items  120 ,  FIG. 1 , that contact the arm  132 . The chain  176  extends slightly from a front side  177  (also referred to as a first side) of the arm  132  wherein items  120 ,  FIG. 1 , being diverted contact chain  176  proximate the front side  177  of the arm  132 . A back side  178  of the arm  132  has a cover  179  that serves to cover the chain  176 . Some embodiments of the diverter  114  do not include the cover  179 . 
       FIG. 3  is a side elevation view of the diverter  114 .  FIG. 3 , shows the chain  176  sandwiched between the upper chassis portion  174  and the lower chassis portion  175 . As described in greater detail below, the chain  176  facilitates the movement of items  120 ,  FIG. 1 , from the main conveyor  110  to the side conveyor  112 . More specifically, as items  120  contact the chain  176 , the chain  176  moves the items  120  to the side conveyor  112 . As described in greater detail below, the use of the chain  176  reduces the friction between the arm  132  and items being diverted. Therefore, the diversion from the main conveyor  110  to the side conveyor  112  can occur at a higher speed, a reduced angle θ, and with less damage to the items  120 ,  FIG. 1 . 
     A top plan view of the diverter  114  is shown in  FIG. 4  with the movement arm  170  retracted. The arm  132  may move in the direction  184  when the movement arm  170  extends. As shown in  FIG. 4 , the support arm  164  is able to pivot with the arm  132  so as to provide support to the arm  132  during the whole sweep of movement. With reference to  FIG. 1 , the arm  132  as shown in  FIG. 4  is in the first position as noted by the dashed lines  134 . 
     As also shown in  FIG. 4 , the chain  176  extends slightly from the chassis  173 . This extension of the chain  176  causes items being diverted to contact the chain  176  and not the chassis  173 . As described in greater detail below, some embodiments of the chain  176  include rollers that further facilitate the movement of items that contact the arm  132 . In these embodiments, the rollers extend from the chassis  173  so as to contact items being conveyed or otherwise diverted. The chain  176  moves in a direction  185  with reference to the front side  177  of the arm  132 , which is a clock wise direction when viewed from the top plan view of  FIG. 4 . Accordingly, items contacting the arm  132  are forced to move in the direction  185  by the chain  176 . 
     For reference purposes, the arm  132  has a first end  190  that is located opposite the hinge  154  and a second end  192  that is located proximate the hinge  154 , wherein the direction  185  extends from the second end  192  toward to the first end  190 . 
     An exploded perspective view of and embodiment of the first end  190  of the arm  132  is shown in  FIG. 5 . For illustration purposes, the view of  FIG. 5  has a portion of the upper chassis portion  174  removed. The chain  176  include a plurality of upper links  200  and lower links  202 . Both the upper links  200  and lower links  202  include a plurality of outer links  208  and inner links  210  that are pivotally connected to one another by way of shafts  214 . The shafts  214  extend between the upper links  200  and the lower links  202 . A plurality of roller assemblies  220  are located between the upper links  200  and the lower links  202  wherein the shafts  214  extend through the roller assemblies  220 . As described in greater detail below, the roller assemblies  220  rotate or spin as the chain  176  moves. The direction of rotation of the roller assemblies  220  is such that the portion of the roller assemblies that extend beyond the chassis  173  move in the direction  185 . By accelerating the items in the direction  185 , the speed at which the items  120 ,  FIG. 1 , are diverted from the main conveyor  110 ,  FIG. 1 , to the side conveyor  112 ,  FIG. 1  may be increased, with less damage to the items  120 . 
     In the embodiment of the roller assemblies  220  described herein, the roller assemblies  220  include inner rollers  222  and outer rollers  224 . The outer rollers  224  are movable relative to the inner rollers  222 , wherein friction exists between the inner rollers  222  and the outer rollers  224 . When an item first contacts the outer rollers  224 , the frictional force between the inner rollers  222  and the outer rollers  224  due to the force applied by the item is minimal. Accordingly, the outer rollers  224  may spin relative to the inner rollers  222 , which causes the items initially to move in the direction  185  at a slow speed. The force exerted by the items on the outer rollers  224  increases due to the items being forced against the arm  132  by the their movement on the main conveyor  110 ,  FIG. 1 . The increased force applied to the outer rollers  224  increases the frictional force between the inner rollers  222  and the outer rollers  224  increases. The increased friction, in turn, causes less slippage between the inner rollers  222  and the outer rollers  223 . Thus, the items are accelerated to a speed in the direction  185  that is proportional to the speed at which the inner rollers  222  rotate. It is noted that the angular velocity of the outer rollers  224  may exceed the velocity of the chain  176  as described in greater detail below. 
     Attached to the upper links  200  are vertical rollers  230  (sometimes referred to as second rollers) and horizontal rollers  232  (sometimes referred to as first rollers). As shown in  FIG. 5 , the outer links  208  may include brackets  234  that support the vertical rollers  232 . The shafts  214  may pass through the horizontal rollers  232  so as to connect them to the upper links  200 . The vertical rollers  230  and the horizontal rollers  232  serve to stabilize the chain  176  during operation. 
     The embodiment of the arm  132  shown in  FIG. 5  has a platform  240 , wherein the vertical rollers  232  contact the platform  240  and may roll relative to the platform  240 . The horizontal rollers  230  may contact the inner surface of the upper chassis portion  174  and may roll relative to the inner surface. It is noted that similar or identical rollers may be associated with or connected to the lower links  202 . Likewise, the arm  132  may have a platform on which vertical rollers connected to the lower links  202  contact. In addition, vertical rollers associated with the lower links  202  may contact or roll relative to the inner surface of the lower chassis portion  175 . In some embodiments all or some of the rollers are not connected to the lower links  202 . The platform  240  may be substantially perpendicular to the inner surface of the upper chassis  174 . 
     Another view of the first end  190  of the arm  132  is shown in  FIG. 6 . The view of  FIG. 6  has a portion of the chain  176  removed to provide a view of the inner portion of the arm  132 . As shown, the embodiment of the chain  176  of  FIG. 6  has lower horizontal rollers  244  attached to the lower links  202 . 
     As shown by the removed portion of the chain  176 , the embodiment of the arm  132  shown in  FIG. 6  has a rail  250  located therein. The rail  250  has a channel  252  located or formed therein. The channel  252  is sized to receive the outer rollers  224 . The rail  250  has an upper surface  254 , a first outer surface  256 , an inner surface  258 , and a second outer surface  260 . In embodiment of the arm  132  of  FIG. 6 , the inner rollers  222  contact the first outer surface  256  and the second outer surface  260  of the rail  250 . The contact causes the inner rollers  222  to spin as the chain  176  moves. Likewise, the outer rollers  224  also spin and have a greater angular velocity than the inner rollers  222 . Therefore, an item may be conveyed by the chain  176  wherein the velocity of the item is greater than the velocity of the chain  176 . As described above, friction between the inner rollers  222  and the outer rollers  224  can be used to accelerate items at a slower rate than conventional diverters. 
     In some embodiments, the outer rollers  224  may contact the inner surface  258  of the channel  252 . This contact will cause the outer rollers  224  to spin at a rate proportional to the velocity of the chain  176 . 
     A partial view of the diverter  114  at the location of the second end  192  of the arm  132  is shown in  FIG. 7 . The view of  FIG. 7  includes the hinge  154  with the cover  162 ,  FIG. 2 , removed so as to show the mechanisms within the hinge  154 . One mechanism located within the hinge  154  is a gear box  200  that is connected to a drive mechanism  202 . Within the second end  192  of the arm  132  is a sprocket or the like attached to the drive mechanism  202 . The sprocket engages the chain  176 . As shown, the drive mechanism  202  passes through a section of the lower portion  158  of the hinge  154 . The gear box  200  is a right angle device wherein the motor  150  rotates a horizontal shaft. Based on the rotation, the gear box  200  rotates the vertical drive mechanism  202 , which rotates the above-described sprocket. The rotation of the sprocket causes the chain  176  to move. 
     As shown in  FIG. 7 , the arm  132  may swing about the hinge  158 . Regardless of the location of the arm  132 , the drive mechanism  202  will always be able to rotate and cause the sprocket to rotate. Therefore, the chain  176  is able to be moved regardless of the position of the arm  132 . 
     The use of the chain  176 ,  FIGS. 5 and 6 , with the roller assemblies  220  enables the diverter  114 ,  FIG. 1 , to quickly move items  120  from the main conveyor  110  to the side conveyor  112  without damaging the items  120 . Thus, the angle θ may be reduced and more side conveyors may be located adjacent a second of the main conveyor  110 . 
     Another embodiment of a diverter  300  is shown in  FIG. 8  and has a curved arm  304  rather than the straight arm  132 ,  FIG. 2 .  FIG. 9  is a top plan view of the diverter  300 . Other than the curved arm  304 , the diverter  300  is substantially similar to the diverter  114  of  FIG. 2 . In the embodiment of the diverter  300  of  FIG. 9 , the curved arm  304  has a radius R. It is noted that the radius R may be varied depending on the application of the diverter  220 . It is noted that the entire length of the curved arm  304  does not need to be curved. Rather, a portion may be straight and another portion may be curved. In another embodiment, only the front side of the arm  304  is curved. Thus, the chain travels along the curve. 
     With additional reference to  FIGS. 5 and 6 , the configuration of the upper chassis portion  174  and the lower chassis portion  175  serve to contain the chain  176  from exiting the front side  177  of the arm  132 ,  304 . For example, the vertical rollers  230  contact the inner surfaces fo the upper chassis portion  174  and the lower chassis portion  175 . The contact serves to maintain the chain  176  within the arm  132 ,  304 . With this configuration, the arm  132 ,  304  may be operated with the curve. In addition, the arm  132 ,  304  need not be operated with the chain  176  moving about a horizontal plane. Rather, the arm  132 ,  304  can operate with the chain  176  moving about a slant, such as an incline or decline. 
     A portion of an embodiment of a conveyor  310  that includes the diverter  300  is shown in  FIG. 10 . As with the conveyor  100  of  FIG. 1 , the conveyor  310  includes a main conveyor  314  and a side conveyor  316 . The diverter  310  serves to divert items  120  from the main conveyor  314  to the side conveyor  316 . When the curved arm  304  is in a first position as noted by the dashed lines, the items continue on the main conveyor  314 . When the curved arm  304  is in the second position as noted by the solid lines, the items  120  contact the curved arm  304  and are diverted to the side conveyor  316 . 
     The side conveyor  316  intersects the main conveyor  314  at an angle φ. The curved arm  304  enables the items  120  to be diverted substantially perpendicular to the main conveyor  314 . Therefore, the angle φ is able to be much less than the angle θ of the conveyor  100 ,  FIG. 1 . Thus, a greater number of side conveyors may be associated with a section of the main conveyor using the diverter  300  than would be using a diverter having a straight arm. 
     Having described some embodiments of the diverters  114 ,  300 , other embodiments will now be described. With reference to  FIGS. 3 and 8 , in some embodiments, the diverters  114 ,  300  include a plurality of arms  132 ,  304 . For example, the diverters  114 ,  300  may include a plurality of hinges, wherein an arm is pivotally connected to each hinge in a substantially similar manner as the arms  132 ,  304  are connected. 
     An example of such an embodiment is shown in  FIG. 11 , which is a side view of a diverter  400  having a plurality of arms  404 . The plurality of arms  404  are referred to individually as the first arm  406 , the second arm  408 , the third arm  410 , and the fourth arm  412 . All the arms  404  are substantially identical to each other, thus, the following description of the first arm  406  is applicable to all the arms  404 . 
     The first arm  406  is substantially identical to the above described arm  132 ,  304 . Accordingly, the arms  404  may be straight or curved as described above. The first arm  406  has a first surface  420  that contacts items moving via the first conveyor  110 . A chain  176  is located proximate the first surface  420  and extend through the first surface  420 . The chain  176  is substantially identical to the chain  176  described above. 
     A support member  424  extends through or attaches to all the arms  404 . The support member  424  serves as an pivot point for the arms  404 . In addition, the support member  404  may have a shaft or the like located therein that serves to rotate the chains  176  in each of the arms  404 . The support member is substantially similar to the hinge  154  described above. 
     A support arm  428  is attached to the first arm  406 . The support arm  428  is substantially similar to the support arm  164  described above and serves to support the weight of the arms  404  while allowing the arms  404  to pivot. A plurality of supports  430 ,  432 ,  434  connect arms  404  to one another so that the support arm  428  carries the weight of all the arms  404 . More specifically, a first support  430  is connected between the first arm  406  and the second arm  408 , a second support  432  is connected between the second arm  408  and the third arm  410 , and a third support is connected between the third arm  410  and the fourth arm  412 . By connecting the arms  404 , their weight is carried by the support arm  428  and they pivot in unison. 
     The plurality of arms  404  used in the diverter  400  increases the area in which items contact the arms  404 , which enables the diverter  400  to divert larger items. In some embodiments, all the arms  404  are controlled by a single controller wherein the single controller causes all the arms  404  to move in unison as describe above. 
     In other embodiments, a plurality of controllers are used to move the arms  404  independent of one another. In such an embodiment, the arms  430 ,  432 ,  434  are not used. In some embodiments as described above, a single motor is used to move the chains  176  of all the arms  404 . In other embodiments, a plurality of motors are used to move the plurality of chains  176 . 
     The arms  132 ,  304  have been described herein using a single chain  176 . In some embodiments, the arms  132 ,  304  may have a plurality of chains  176  wherein the chains  176  are stacked on each other. The use of a plurality of chains enables a greater contact with items being conveyed. 
     Having described the diverters  114 ,  300 ,  400 , their operation will now be described. The following description will be based on the diverter  114  and its relation to the conveyor  100 ,  FIG. 1 . It is noted that the operation of the diverters  300 ,  400  are substantially similar to the operation of the diverter  114 . The diverter  114  serves to divert select items  120  from the main conveyor  110  to the side conveyor  112 . When an item  120  is to be diverted, the arm  132  moves from the first position to the second position where it is able to contact the moving item. 
     With additional reference to  FIG. 6 , the moving items  120  that are to be diverted contact the outer rollers  224  on the chain  176 . Because of the friction between the inner rollers  222  and the outer rollers  224 , the items  120  are not instantly subjected to the velocity of the moving chain  176 . Rather, the items  120  being diverted exert an increasing force on the outer rollers  224  as they are moved in the direction  122  by the main conveyor  110 . The increasing force increases the frictional force between the inner rollers  222  and the outer rollers  224 . The increased frictional force causes the outer rollers  224  to rotate with, rather than slide relative to, the inner rollers  222 . Thus, the velocities of the items  120  being conveyed, by way of their contact with the outer rollers  224 , increase. The items  120  are then rapidly conveyed to the side conveyor  112 . This movement enables the conveyor system  100  to use a smaller angle θ than conventional conveyor systems. 
     The chain is maintained in the chassis by way of the rollers  230 ,  232 ,  244 , and horizontal rollers located adjacent the inner surface of the lower chassis portion  175 . As set forth above, the vertical rollers  232  serve to maintain the height of the chain  176  within the chassis  173 . The horizontal rollers  230 ,  244  serve to keep the chain  176  from extending beyond the chassis  173 . They also serve to reduce the friction between the chain  176  and the chassis  173 . This function becomes more noticeable with regard to the curved arm  304 ,  FIG. 9 . Tension on the chain  176  in a curved arm will likely force the chain  176  against the inner surface of the upper and lower chassis portions  174 ,  175 . Thus, the outer rollers  224  will not extend beyond a preselected distance from the chassis  173  when they are used within the curved arm  304 . 
     It is noted that the outer rollers  224  are exposed on the first end  190  of the arm  132 . This exposure facilitates the movement of the items all the way to the first end  190  of the arm. Thus, the items do not encounter a portion of the arm  132  that does not have a moving chain, which would cause the items to slow. 
     The conveyor system  100  has been described as being operated on a horizontal plane. However, the configuration of the chain  176  within the arms  132 ,  304 ,  404  enables the conveyor system  100  to be operated at an angle. For example, the main conveyor  110  and the side conveyors  112  may be inclined or declined. Accordingly, the arms  132 ,  304 ,  404  may move parallel to the inclined or declined plane because the chain  176  is retained within the arms  132 ,  304 ,  404  and will not fall out of the arms  132 ,  304 ,  404  if they are not maintained horizontal.