Patent Publication Number: US-RE48600-E

Title: Belt conveyor wing pulley

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
     This application is a reissue continuation of application Ser. No. 14/493,500, filed Sep. 23, 2014, which is a continuation reissue of application Ser. No. 13/068,153, filed May 3, 2011, which is an application for reissue of U.S. Pat. No. 7,527,142, now RE45,145. 
     NOTICE OF RELATED APPLICATIONS  
     Notice: More than one reissue application has been filed for the reissue of U.S. Pat. No. 7,527,142. The additional reissue applications are: application Ser. No. 13/068,153, filed May 3, 2011, which issued as U.S. Pat. No. RE45,145 on Sep. 23, 2014; application Ser. No. 14/493,500, filed Sep. 23, 2014, which is a continuation reissue application of application Ser. No. 13/068,153; and application Ser. No. 15/979,879, filed May 15, 2018, which is a continuation of application Ser. No. 14/493,500. 
    
    
     BACKGROUND 
     The present invention is directed to belt conveyor pulleys and in particular to wing-type pulleys. Wing pulleys are known for supporting an endless belt of a conveyor at the feed end of the conveyor, where material such as sand, gravel, or the like is deposited on the conveyor belt. Wing pulleys comprise separate radially spaced plates emanating from a central hub that define separate contact surfaces on the pulley. The contact surfaces of a wing pulley beat the underside of the conveyor belt to remove debris and direct it as well as any other material away from the pulley to prevent wear and/or damage to the conveyor belt. There is a need to improve the effectiveness of a wing pulley in expelling debris from the belt. 
     SUMMARY 
     A wing pulley for a belt conveyor having a first end and a second end comprises a pair of spaced cylindrical hubs and a plurality of wings spaced about the hubs. Each wing of the plurality of wings has an upper edge for contacting a conveyor belt and includes a planar first wing portion having an outer end at the first end of the wing pulley. The first wing portion extends at least partway between the first end of the wing pulley and the second end of the wing pulley. A planar second wing portion has an outer end at the second end of the wing pulley. The second wing portion extends at least partway between the second end of the wing pulley and the first end of the wing pulley. Each wing of the plurality of wings is connected to a metal plate. The metal plate is spaced apart from the upper edges of said wings and extends between adjacent wings. The metal plate is at least partially supported by the hubs. The metal plate in combination with said adjacent wings defines a space to receive material below the conveyor belt. The space is unobstructed at the first and second ends of the wing pulley. Rotation of the wing pulley results in material in the space between adjacent wings being directed laterally toward the respective first and second ends of the wing pulley and discharged laterally away from the respective first and second ends of the wing pulley. The first and second wing portions define a non-zero angle therebetween. Each of the first and second wing portions are oriented at an angle C defined by the respective outer ends of the first and second wing portions relative to a respective radial of the hub. Each outer end of the first and second wing portions has a lower edge positioned on the respective radial. 
     The present invention is directed to a wing pulley for a belt conveyor. The pulley has a length for supporting a conveyor belt along its width. The pulley comprises spaced first and second hubs aligned along a common axis. Each of the first and second hubs has a circumferential surface. Radially spaced about and connected to the circumferential surfaces of the first and second hubs are a plurality of wings. Each wing of the plurality of wings is configured to define a contact surface radially spaced from the first and second hubs for contacting the conveyor belt. The contact surface of a first wing of the plurality of wings is configured to overlap with the contact surface of a second wing of the plurality of wings along the length of the pulley such that the width of the conveyor belt is supported by the first and second wings. A gusset is connected between a first surface of each wing and a second surface of an adjacent wing. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a first embodiment of a wing pulley of the present invention. 
         FIG. 2  is a front plan view of a wing plate of the wing pulley of  FIG. 1 . 
         FIG. 3  is an end view of a hub and one wing of the wing pulley of  FIG. 1 . 
         FIG. 4  is a rear perspective view of the hung and wing of  FIG. 3 . 
         FIG. 5  is an end elevational view of the wing pulley of  FIG. 1 . 
         FIG. 6  is a diagrammatic perspective view of the wing pulley of  FIG. 1  engaging a conveyor belt. 
         FIG. 7  is a perspective view of a second embodiment of a wing pulley of the present invention. 
         FIG. 8  is a perspective view of the right end of the wing pulley of  FIG. 7 . 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  is a perspective view of a first embodiment of a wing pulley  10  of the present invention. Wing pulley  10  includes a pair of spaced hubs  12  having a common center axis A and a plurality of wings  14  that are generally equally radially spaced about hubs  12  and secured thereto. In one exemplary embodiment, each wing  14  is formed at an angle such that wing  14  includes first and second wing portions  14 A and  14 B. In one preferred embodiment, wing portions  14 A and  14 B define an angle B of about 137 degrees. In one embodiment, each wing  14  includes a contact surface  20  defined by a round metal bar secured along an upper edge of wing  14 , which engages and supports a conveyor belt. Wing portions  14 A,  14 B define a wing apex  16  at an approximate midpoint of wing  14  relative to wing ends  18 . Relative to the direction of rotation of wing pulley  10 , apex  16  is oriented forward of an imaginary line I that extends between ends  18  along the contact surface  20  and is generally parallel with the center axis A of wing pulley  10 . Connected between adjacent wings  14  are metal gussets  19 , which extend from hubs  12  to apex  16 . Gussets  19  are secured to wings  14  and hubs  12  by welding. Hubs  12  have a central opening for receiving a bushing and shaft for rotationally mounting wing pulley  10  at the feed end of a conveyor. 
       FIG. 2  is a front plan view of a wing plate  22  which forms each wing  14  of wing pulley  10 . Wing plate  22  includes a lower edge  24  and an upper edge  26 , which extend between opposing ends  18 . The lower edge  24  and the upper edge  26  define a height H of wing plate  22 . In one embodiment, lower edge  24  is configured with a notch  28  adjacent to ends  18  for connection of wing plate  22  to each hub  12 . Upper edge  26  defines the length L of wing plate  22 , which is greater than the length of lower edge  24 . Upper edge  26  travels in an arc from midpoint M of wing plate  22  to each end  18 , such that wing plate  22  has bi-lateral symmetry relative to midpoint M. The radius of curvature of upper edge  26  is selected to define a radius R of wing  14  as measured from axis A ( FIG. 1 ) that is generally the same at all points along the length L of upper edge  26  and contact surface  20  (not shown). The radius of curvature of upper edge  26  will vary according to the particular length and radius selected for wing pulley  10  and may be calculated using any suitable mechanical design software. Wing plate  22  is formed by cutting a plate of steel having a thickness of between about 3/16 inch to about 5/16 inch, such as with a plasma cutter. In one embodiment, wing plate  22  has a length of about 40.50 inches and a midpoint of about 20.25 inches. 
       FIG. 3  is an end view of hub  12  and one wing  14  representative of the orientation of each wing  14  relative to hub  12 . As shown in  FIG. 3 , in one embodiment, lower edge  24  of wing portion  14 A is positioned on a radial B of axis A of hub  12 A at end  18  of wing  14 . Wing portion  14 B is similarly positioned relative to the opposite hub. Each wing  14  is set at an angle C such that each wing portion  14 A,  14 B lies in a plane that is between about 0 degrees and 30 degrees forward of radial B in the direction of intended rotation of wing pulley  10 , as indicated by arrow D. In one preferred embodiment, each wing portion  14 A,  14 B is set at an angle of about 30 degrees relative to radial B. As further shown in  FIG. 3 , attached to upper edge  26  of wing plate  22  is a metal contact bar  30 , which in the embodiment shown has a generally circular cross section. In one exemplary embodiment, contact bar  30  has a diameter of about 0.984 inches. Other shapes and dimensions of contact bar  30  may be employed with the present invention. 
       FIG. 4  is a rear perspective view of the hub and wing shown in  FIG. 3 . As shown in  FIG. 4 , each hub  12 A,  12 B is provided with a stepped circumferential outer surface  32 , with the inward facing portions of hubs  12 A,  12 B having a slightly smaller outer diameter than the adjacent outward facing portion of hubs  12 A,  12 B. The notch  28  of each wing portion  14 A,  14 B includes a lower edge which lies at an angle relative to lower edge  24  of wing plate  22 . The angle of the lower edge of notch  28  is selected to maximize the lower edge contact of wing plate  22  with the outer surface  32  of hubs  12 A,  12 B. Wing plate  22  is connected to hubs  12 A,  12 B by welding along the lower edge of notch  28  on opposite sides of wing plate  22 . 
     Adjacent wings  14  are connected together via gussets  19 , which are shown in phantom in  FIG. 4 . Each gusset  19  is comprised of two elongated metal plates  19 A,  19 B that extend from hubs  12  to apex  16  and is configured to contact the facing surfaces of adjacent wing plates. Each end  34  of gusset plates  19 A,  19 B are secured to the hub outer surface  32  by welding. Plates  19 A,  19 B are secured to one wing plate  22  along edge  36  by welding, while the adjacent wing plate (not shown) is secured to edge  38  by welding. Plates  19 A and  19 B are also welded together at the interface of the two plates at the apex  16 . Plates  19 A,  19 B extend from the lower edge of notch  28  and hubs  12  at an angle toward the upper edge  26  of wing plate  22 , which results in each gusset  19  having a radius at the apex  16  of wing  14  relative to hub axes A that is greater than the radius of ends  34  of gusset  19 . Gussets  19  thus slope away from the midpoint of wings  14  to the hubs  12 , which aids in the ability of wing pulley  10  to direct debris in a direction towards hubs  12 . 
       FIG. 5  is an end view of wing pulley  10  of  FIG. 1 . As shown in  FIG. 5 , in one embodiment, wing pulley  10  is comprised of ten generally equally radially spaced wings  14 , each of which is mounted to hubs  12  in the manner previously described. Collectively, the metal contact bars  30  define a generally cylindrical contact surface of wing pulley  10  for supporting a conveyor belt. As shown in  FIG. 5 , the contact bar  30  of each wing  14  substantially overlaps the contact bar  30  of an adjacent wing  14 . As a result, a conveyor belt is able to be substantially supported along the length of wing pulley  10  by at least two wings  14 . The overlap of contact bars  30  of adjacent wings  14  provides a smooth transition for belt contact from one contact bar to the next adjacent contact bar, which minimizes the amount of vibration transmitted to the conveyor belt and decreases the rate of wear on the belt. 
       FIG. 6  is a diagrammatic perspective view of wing pulley  10  shown engaging a conveyor belt  40  at the feed end of a conveyor. The upper belt surface  42  is shown traveling away from wing pulley  10 , while the lower belt surface  44  is shown traveling toward wing pulley  10 , with wing pulley  10  rotating counterclockwise. Material deposited on the upper belt surface  42  invariably results in some material migrating to the lower belt surface  44  facing wing pulley  10 . Material  46  that falls on the lower belt surface  44  is carried to wing pulley  10  until it engages wings  14 . The angular shape of wings  14  relative to apex  16  and the rotation of wing pulley  10  result in the material  46  being quickly and efficiently directed laterally toward ends  18  of wings  14  and away from wing pulley  10 . The V-shaped configuration of wings  14  further aid in keeping belt  40  centered on wing pulley  10 . 
       FIG. 7  is a front perspective view of a second embodiment of the present invention.  FIG. 7  shows a wing pulley  50  having eight generally equally radially spaced wings  52 , each of which is formed in a V-shape substantially as described relative to wings  14  of the first embodiment ( FIG. 1 ). Each wing  52  is secured to hubs  54  by welding in the manner previously described. Also adjacent wings  52  are connected to gussets  56  by welding in the manner previously described. Wing pulley  50  differs from wing pulley  10  in that contact bars  58  are formed from metal bars  58 A,  58 B having a rectangular cross-sectional shape. Metal bars  58 A,  58 B have mitered ends that abut one another and are welded together to conform to the angle of wings  52 . As a result of wing pulley  50  having eight wings, there is less overlap between the contact bars  58  of adjacent wings  52 , yet wings  52  provide sufficient belt support. As shown in  FIG. 8 , which is an end perspective view of one wing  52  mounted to hubs  54 , each wing  52  is oriented on a radial R′ in a plane that is substantially parallel to radial R′. Unlike wings  14  of wing pulley  10 , the lower edge  56  of wings  52  of wing pulley  50  lack a notch at the ends  58  of wings  52 . 
     The V-shaped wing configuration of the wing pulley of the present invention deflects material away from the wing pulley and conveyor belt more efficiently and effectively than standard wing pulleys. As a result, material is less apt to get wedged between adjacent wings and the conveyor belt and belt damage is minimized. The V-shaped wing configuration also results in wing overlap along the length of the wing pulley to permit a conveyor belt to be supported by multiple wings along the belt width and ease the transition of belt contact from one wing to the next. This in turn minimizes vibration to the belt, extends belt life and reduces the amount of noise generated from the wings contacting the belt. 
     Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and/or equivalent implementations may be substituted for the specific embodiments shown and described without departing from the scope of the present invention. This application is intended to cover any adaptations or variations of the specific embodiments discussed herein. Therefore, it is intended that this invention be limited only by the claims and the equivalents thereof.