Patent Publication Number: US-6216848-B1

Title: Vacuum table conveying apparatus and associated methods

Description:
FIELD OF THE INVENTION 
     The invention relates to the field of article handling and, more particularly, to the field of handling articles for transporting or conveying during various industrial processing. 
     BACKGROUND OF THE INVENTION 
     Over the years, various article, e.g., mail, feeding, handling, sorting, and transporting systems have been developed for feeding, handling, sorting, and transporting pieces of mail. Within the field of article handle, one source of bottleneck and other handling problems has been the transporting of the articles along a surface. For example, know article conveying systems often have unstable platforms and may have an arcuate sectional profile whereby medial portions of a conveyor belt are often arcuate. This unstable platform and arcuate profile, however, can make printing on a surface of an article, e.g., a mail item, paper, or cardboard material, difficult. The results can be a distortion in the surface or ink as the ink from a printer is being applied. This, in turn, can cause irregularities within the printed image, poor image quality, and poor image resolution. Accordingly, there is a need for a more stable conveyor system which allows articles to be handled and transported effectively and allows printing on the surface of the article with minimal irregularities, high quality, and high resolution in the printed image. 
     SUMMARY OF THE INVENTION 
     In view of the foregoing background, the present invention advantageously provides a vacuum table conveying apparatus and associated methods which provide a stable conveying platform for articles mounted thereon. The present invention also advantageously provides a vacuum table conveying apparatus having a substantially flat belt conveying surface so that printer heads can easily be positioned closely adjacent the flat surface to thereby enhance image quality and resolution of images printed on surfaces of articles being conveyed therealong. The present invention additionally provides a vacuum table conveying apparatus and associated methods which has a high volume of air under a low vacuum pressure to enhance the holding power and the uniformity of the conveying of articles positioned thereon. The present invention further advantageously provides a vacuum table conveying apparatus and associated methods which allows air to move with the articles positioned thereon at substantially the same speed and which has a vacuum chamber substantially impervious to leaks. 
     More particularly, the present invention provides a vacuum table conveying apparatus which preferably includes a frame, a vacuum chamber positioned to extend along an upper portion of the frame, vacuum forming means positioned in fluid communication with the vacuum chamber to apply a low vacuum with a high volume of air to the vacuum chamber, and at least one vacuum belt overlying the vacuum chamber. The at least one vacuum belt preferably has a plurality of openings extending through upper and lower surfaces thereof so that vacuum from the vacuum chamber extends through the plurality of openings and applies to articles mounted on the upper surface of the at least one vacuum belt. 
     The vacuum forming means, for example, is preferably provided by a vacuum source which has a plurality of fans positioned in fluid communication with the vacuum chamber for applying a low vacuum with a high volume of air to the vacuum chamber. The apparatus also preferably has a plurality of spaced-apart rollers mounted to the frame, and the at least one vacuum belt is preferably mounted to and extending between the plurality of spaced-apart rollers and overlying the vacuum chamber. The apparatus additionally preferably has at least one drive connected to the frame for driving the plurality of rollers to thereby drive the at least one vacuum belt mounted thereon and convey articles mounted on the at least one vacuum belt in a predetermined direction of travel. 
     For enhanced stability of the table platform, e.g., belt and upper portions of the frame, each of the plurality of spaced-apart rollers preferably includes a roller channel formed in an outer surface of the roller. The at least one vacuum belt, in turn, preferably includes a belt stability protrusion extending outwardly from a medial portion of a lower surface of the at least one vacuum belt and positioned within each of the roller channels to thereby provide enhanced stability in the at least one vacuum belt when being driven by the plurality of rollers. 
     A vacuum table conveyor belt is additionally provided according to the present invention and preferably is formed by a combination of a first low friction web material layer, a second plastic material layer overlying the first low friction web material, and a belt stability protrusion connected to and extending outwardly from a medial portion of the first low friction web material layer. The belt stability protrusion is preferably positioned to abuttingly contact a drive roller and preferably has peripheries having a vertical sectional view thereof which define a substantially frusto-conical shape or another substantially V-shape. 
     The present invention also includes a method of conveying articles. The method preferably includes providing a low vacuum and high volume air source in fluid communication with a vacuum chamber, positioning at least one conveyor belt having a plurality of openings extending therethrough to overlie the vacuum chamber and in fluid communication with the vacuum source, and positioning a plurality of articles on the at least one conveying belt to be held in position by the vacuum applied through the plurality of openings from the vacuum chamber. 
     The present invention further provides a method of printing on conveyed articles. This method preferably includes providing a low vacuum and high volume air source in fluid communication with a vacuum chamber, positioning at least one substantially flat conveyor belt having a plurality of openings extending therethrough to overlie the vacuum chamber and in fluid communication therewith, positioning a plurality of articles on the at least one conveying belt to be held in position by the vacuum applied through the plurality of openings from the vacuum chamber, driving the at least one conveying belt in a predetermined direction, sensing the presence of articles positioned on the at least once conveyor belt, and positioning a head of a printer closely adjacent an upper surface of the substantially flat conveyor belt. 
     The combination of additional table platform stability, the enhanced vacuum which provides a uniform vacuum force and a strong holding force, and the substantially flat belt surface allow the vacuum table conveying apparatus to greatly enhance performance and handling quality of items such as mail, paper, books, or other material being transported therealong. The apparatus, for example, can advantageously be used for high speed transport and printing applications such as labels or other indicia on mail items. In such applications, high resolution ink jet requires an extremely stable platform, both in vertical and horizontal planes, as well as a constant speed. The paper or mail items, in turn, need to move on a substantially flat surface and very close to the ink jet printer head. If the surface is not substantially flat, then the particles or drops of ink being emitted from the ink jet head tend to be elliptical in formation and cause poor resolution or other quality problems. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Some of the features, advantages, and benefits of the present invention having been stated, others will become apparent as the description proceeds when taken in conjunction with the accompanying drawings in which: 
     FIG. 1 is a perspective environmental view of a vacuum table conveying apparatus having a printer head and an article sensor mounted thereto according to the present invention; 
     FIG. 2 is a sectional view of a vacuum table conveying apparatus taken along line  2 — 2  of FIG. 1 according to the present invention; 
     FIG. 3 is a perspective view of a vacuum table conveying apparatus according to the present invention; 
     FIG. 4 is a sectional view of a vacuum table conveying apparatus taken along line  4 — 4  of FIG. 3 according to the present invention; 
     FIG. 5 is a fragmentary side elevational view of a vacuum table conveying apparatus according to the present invention; 
     FIG. 6 is a fragmentary perspective view of a vacuum table belt mounted to a roller of a vacuum table conveying apparatus according to the present invention; and 
     FIG. 7 is a fragmentary top view of a vacuum table conveying apparatus according to the present invention. 
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout, and prime and double prime notations are used to indicate similar elements in alternative embodiments. 
     FIGS. 1-6 illustrate a vacuum table conveying apparatus  10  and associated methods according to the present invention. The apparatus  10  preferably includes a frame  12  and a vacuum chamber  20  positioned to extend along an upper portion of the frame  12 . The frame  12  preferably includes at least two portions. A first portion  13  has a plurality of frame legs  15  and defines a main frame for providing structural support from a support surface, e.g., a floor. A second portion  16 , i.e., upper portion, has a generally T-shape (see FIGS. 1,  3 , and  7 ) and defines a gate for installing other portions of the apparatus  10  onto the frame  12 , e.g., belts and/or rollers as described further herein below. The frame  12  is preferably extremely rigid and relatively light weight. 
     The vacuum table conveying apparatus  10  also has vacuum forming means, e.g., preferably provided by a vacuum source  30 , positioned in fluid communication with, e.g., air flow, the vacuum chamber  20  to apply a low vacuum with a high volume of air to the vacuum chamber  20 . The vacuum source  30  preferably is provided by a plurality of fans  32 ,  34 ,  36 , e.g., three fans rotating counter-clockwise to form or create suction-type air flow, positioned in fluid communication with the vacuum chamber  20  for applying the low vacuum with a high volume of air, e.g., about  700  cubic feet of air flow per minute, to the vacuum chamber as understood by those skilled in the art. This low vacuum and high volume of air generates a strong adherence of article, e.g., paper or mail items, to the conveyor belts  42 ,  44  and a substantial increase in indifference to air leaks. The fans  32 ,  34 ,  36  are preferably positioned within fan mount openings extending along a lower portion or bottom of the vacuum chamber  20 . The vacuum chamber  20  in combination with the fans  32 ,  34 ,  36  allows the vacuum force to be spread substantially uniformly throughout the upper surface of the chamber  20  and through openings  41  in the conveyor belts  42 ,  44 . Additionally, as understood by those skilled in the art, notches or sawtooth cuts can be formed in the fan blades to decrease noise. 
     At least one vacuum conveyor belt  42 , and more preferably at least two or a pair  42 ,  44  as illustrated, overlies the vacuum chamber  20 . The belts  42 ,  44 , in essence, form at least major portions of a top to the vacuum chamber  20 . The pair of spaced-apart vacuum belts  42 ,  44  are each mounted to a plurality of spaced-apart rollers  52 ,  54 ,  56  and extend substantially parallel to each other in the same plane. Each of the vacuum conveyor belts  42 ,  44  preferably has a plurality of openings  41  extending through upper and lower surfaces thereof so that substantially uniform vacuum or vacuum force from the vacuum chamber  20  extends through the plurality of openings  41  and applies to articles, e.g., mail, mounted on the upper surface of the belt  42 ,  44 . 
     As perhaps best illustrated in FIGS. 4-7, the plurality of spaced-apart rollers  52 ,  54 ,  56  are each preferably mounted to the frame  12 , and the vacuum conveyor belts  42 ,  44  are each preferably mounted to and extending between the plurality of spaced-apart rollers and each overlie the vacuum chamber  20 . A framed grid  25  is positioned within the vacuum chamber  20  between the plurality of fans  32 ,  34 ,  36  and the vacuum belts  42 ,  44  and is connected to the frame  12  to thereby provide additional underlying support to the belts  42 ,  44 . The grid  25  advantageously can include adjustable or threaded cross-members which allow the tightening, adjusting, mounting, or other supporting operations to the grid  25  and the belts. When appropriate tension is within the belts  42 ,  44 , the belts are preferably slightly spaced-apart from or separated from the grid  25 . When operating, however, the vacuum from the vacuum source  30  pulls the belts into slight or supporting contact with the grid  25 . Accordingly, the upper surfaces of the grid  25  are preferably low friction surfaces so that the belts during operation more easily slide across the surfaces. 
     The plurality of spaced-apart rollers  52 ,  54 ,  56  preferably include at least one roller  56  positioned to underlie the vacuum chamber  20 , positioned at a lower elevation than at least two other rollers  52 ,  54  of the plurality of spaced-apart rollers  52 ,  54 ,  56 , and being slidably connected to the frame  12  for adjusting tension within the vacuum conveyor belts  42 ,  44  (see FIGS. 1,  3 , and  5 ). The at least one roller  56  at the lower elevation is preferably adjusted by loosening threaded fasteners  58 , slidably positioning the roller  56  into a position where the tension of the belt or belts  42 ,  44  are at a desired location, and then re-tightening the threaded fasteners  58 . The positioning of this roller  56  also advantageously provides a triangular path for the belts  42 ,  44  which allows plenty of room for the vacuum chamber  20  and the fans  32 ,  34 ,  36 . 
     The vacuum table conveying apparatus  10  additionally preferably has at least one drive  60  connected to the frame  12  for driving the plurality of rollers  52 ,  54 ,  56  to thereby drive the belts  42 ,  44  mounted thereon and convey articles mounted on the belts  42 ,  44  in a predetermined direction of travel (i.e., see direction arrow of FIG.  1 ). The drive  60  preferably includes at least one motor, e.g., preferably including a drive shaft and a drive mechanism, e.g., a cam, a chain, or arm(s), for driving the rollers  52 ,  54 ,  56  as understood by those skilled in the art. 
     As perhaps best illustrated in FIGS.  4  and  6 - 7 , for enhanced table platform stability, each of the plurality of spaced-apart rollers  52 ,  54 ,  56  preferably includes a roller channel  55  formed in a medial portion of an outer surface of the roller. Each of the vacuum belts  42 ,  44 , in turn, preferably includes a belt stability protrusion  45  extending outwardly from a medial portion of a lower surface of the vacuum conveyor belt  42 ,  44  and positioned within each of the roller channels  55  to thereby provide enhanced stability in the vacuum conveyor belt  42 ,  44  when being driven by the plurality of rollers  52 ,  54 ,  56 . 
     In contrast to conventional vacuum tables, which use several narrow belts, the apparatus  10  preferably has two relatively wide belts  42 ,  44  to enhance the ability to provide a substantially flat surface. Narrow belts also provide only a single row of openings. These wide belts  42 ,  44  of the present invention have a pattern of a plurality of openings  41  in both directions. 
     As perhaps best illustrated in FIG. 4, the vacuum table conveyor belt  42 ,  44  is preferably formed by a combination of a first low friction web material layer  46 , a second plastic material layer  47  overlying the first low friction web material, and a belt stability protrusion  45  connected to and extending outwardly from a medial portion of the first low friction web material layer  46 . This first layer  46  is also preferably formed of a plastic material and is preferably bonded or formed together such as with an adhesive or welded, e.g., heat or RF welded, to the second layer  47 . The belt stability protrusion  45  is preferably positioned to abuttingly contact a drive roller, e.g., preferably each of rollers  52 ,  54 ,  56 , and preferably has peripheries having a vertical sectional view thereof which define a substantially frusto-conical shape or another substantially V-shape (see FIG.  4 ). The first and second layers  46 ,  47  also each include a plurality of coaxially aligned openings  41  extending therethrough which allow the vacuum from the plurality of fans  32 ,  34 ,  36  to draw and hold articles onto the belts  42 ,  44 . 
     Also, the frame  12  of the vacuum table conveying apparatus also advantageously has an elongate frame member  18  positioned in the spaced-apart region between the pair of spaced-apart vacuum belts. The elongate frame member  18  is preferably formed of metal and preferably extends substantially the lengthwise extent of each of the upper conveying surfaces of the pair of spaced-apart vacuum belts  42 ,  44 . The frame  12  preferably also has other supporting elongate members  17 ,  19  which support the peripheries of the belts. In essence, in total, if only one belt is needed, then two elongate support members can be used. If three belts are needed, then four elongate support members can be used. The elongate support members are preferably one more than the needed or desired belts so as to provide peripheral support for the belt(s). 
     Although not require, if printing or other operations are desired to be performed in conjunction with the use of the apparatus  10 , then sensors or other detectors can advantageously be used with the apparatus for sensing or detecting the articles on the apparatus  10 . In the example or embodiment shown for example, at least one sensor  70 , e.g., a photocell or photodetector, is mounted adjacent the frame  12  for sensing the presence of articles positioned on the vacuum belts  42 ,  44 . The elongate frame member  18 , in turn, additionally preferably has a reflective upper surface to enhance sensing of the articles, e.g., black, white, or other various colors, when positioned on the pair of spaced-apart conveying belts  42 ,  44 . A printer head  80 , e.g., an inkjet printer head, can also be associated with or mounted to the frame  12  and is positioned closely adjacent the upper surface of the vacuum conveyor belts  42 ,  44  for printing high resolution indicia on a surface of an article positioned on the belts  42 ,  44  responsive to the sensing of the presence of articles on the belts  42 ,  44 . The sensor  70  preferably provides electrical signals to a controller (not shown), e.g., a microprocessor or micro-controller, as understood by those skilled in the art. The controller then communicates with or sends command signals to the printer for activation of the printer head. The controller can also be used to control the drive speed of the drive motor for the rollers  52 ,  54 ,  56 . The apparatus  10 , for example, can advantageously be used for high speed transport and printing applications such as labels or other indicia on paper or mail items. For example, the belt speed can advantageously be adjusted from about  80  feet per minute to about  750  feet per minute. Although this is not to be construed as a limit on speed capabilities of the apparatus  10 , this does provide a wide range of speed capabilities for various types of printer heads. It should be understood by those skilled in the art that the apparatus  10  has higher speed capabilities as well. 
     As shown in FIGS. 1-7, the present invention also includes a method of conveying articles. The method preferably includes providing a low vacuum and high volume air source  30  in fluid communication with a vacuum chamber  20 , positioning at least one conveyor belt  42 ,  44  having a plurality of openings  41  extending therethrough to overlie the vacuum chamber  20  and in fluid communication with the vacuum source  30 , and positioning a plurality of articles on the at least one conveying belt  42 ,  44  to be held in position by the vacuum applied through the plurality of openings  41  from the vacuum chamber  20 . 
     This method can also advantageously include driving the at least one conveying belt  42 ,  44  in a predetermined direction, adjusting the tension in the at least one conveyor belt  42 ,  44  prior to the step of driving the at least one conveyor belt  42 ,  44 , and stabilizing the at least one conveyor belt  42 ,  44  to prevent slidable motion of the at least one conveyor belt  42 ,  44  in at least two planes, e.g., X, Y, and Z directions (see FIG.  6 ). The stabilizing step preferably includes providing a plurality of spaced-apart rollers  52 ,  54 ,  56  each having a channel  55  extending through a medial portion thereof, and the at least one conveyor belt  42 ,  44  preferably includes a belt stability protrusion  45  extending outwardly from a lower surface thereof and positioned within the channel  55  of each of the plurality of rollers  52 ,  54 ,  56  to thereby stabilize the belt and inhibit slidable motion of the belt in three planes, e.g., as illustrated by the X, Y, and Z directional arrows of FIG.  6 . 
     As perhaps best shown in FIGS. 1-2 and  6 - 7 , the present invention further provides a method of printing on conveyed articles. This method preferably includes providing a low vacuum and high volume air source  30  in fluid communication with a vacuum chamber  20 , positioning at least one substantially flat conveyor belt  42 ,  44  having a plurality of openings  41  extending therethrough to overlie the vacuum chamber  20  and in fluid communication therewith, positioning a plurality of articles on the at least one conveying belt to be held in position by the vacuum applied through the plurality of openings  41  from the vacuum chamber  20 , driving the at least one conveying belt  42 ,  44  in a predetermined direction, sensing the presence of articles positioned on the at least once conveyor belt  42 ,  44 , and positioning a head  80  of a printer closely adjacent an upper surface of the substantially flat conveyor belt  42 ,  44 . 
     This method can further advantageously include conveying the plurality of articles between the printer head  80  and the upper surface of the conveyor belt  42 ,  44  and printing indicia on each of the plurality of articles conveyed therebetween responsive to the sense presence of an article. This method still can further include stabilizing the at least one conveyor belt  42 ,  44  to prevent slidable motion of the at least one conveyor belt in at least two planes. The stabilizing step preferably includes providing a plurality of spaced-apart rollers  52 ,  54 ,  56  each having a channel  55  extending through a medial portion thereof, and the at least one conveyor belt  42 ,  44  preferably includes a belt stability protrusion  45  extending outwardly from a lower surface thereof and positioned within the channel  55  of each of the plurality of rollers  52 ,  54 ,  56  to thereby stabilize the belt  42 ,  44  and inhibit, e.g., prevent, slidable motion of the belt  42 ,  44  in three planes. Tension in the at least one conveyor belt  42 ,  44  can also advantageously be adjusted prior to the driving step according to the methods of the present invention (see FIGS.  3  and  5 ). 
     Many modifications and other embodiments of the invention will come to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed, and that modifications and embodiments are intended to be included within the scope of the appended claims.