Patent Abstract:
An article transfer member including a resiliently mounted guide for aligning articles being transferred onto an outfeed conveyor from an infeed conveyor. The resiliently mounted guide includes an arcuate guide plate that is spring biased so as to flex responsive to variations in the dimensions of the packages being transferred normally as a result of a damaged package and maintaining the packages in alignment on the outfeed conveyor.

Full Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to a guide for controlling the transfer of articles between oppositely running conveyors. 
     There are many arrangements wherein oppositely running conveyors disposed side by side and generally parallel are used for transporting articles. A common such use is in conveying accumulator systems utilized between an upstream delivery station and a downstream receiving station to accumulate or store articles when the capacity of the downstream receiving station is either shut down or run at a speed wherein it cannot handle the number of articles being fed by the upstream delivery station. Such accumulator systems are well known to those skilled in the art. One particular accumulator is disclosed in U.S. Pat. No. 4,018,325. An additional prior art accumulator system is disclosed in U.S. Pat. No. 4,513,858. With such accumulator systems, and in any other system wherein articles are transferred from one conveyor running in one direction onto another conveyor running in an opposite direction, a device must be provided for controlling the transfer of the articles from one conveyor onto the other. 
     The present invention relates particularly to an article guide for a transport member or device utilized for controlling the transfer of articles from a first conveyor running in a first direction onto a second conveyor running in a second opposite direction. 
     OBJECTS AND SUMMARY OF THE INVENTION 
     It is therefore a principal object of the present invention to provide an improved article guide for an apparatus for controlling the flow of articles, particularly the flow of articles from a first conveyor driven in a first direction onto a second conveyor driven in a second direction. 
     An additional object of the invention is to provide a resilient article guide for maintaining articles of different dimensions in alignment as they are transferred between oppositely running conveyors. 
     Still another object of the invention is to provide a resilient article guide for use with an apparatus for transferring articles between oppositely running conveyors while minimizing binding of articles as they are being transferred. 
     Yet still another object of the present invention is to provide an improved article transport member for use on conventional conveyors. 
     Additional objects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention. 
     The present invention has particular application in conveyor accumulator systems wherein oppositely running and parallel conveyors are used to accumulate and store articles between an upstream receiving station and a downstream delivery station. One such accumulator system is disclosed and described in co-pending U.S. patent application Ser. No. 09/235,888 entitled “Apparatus for Controlling the Flow of Articles.” The present invention is an improvement to co-pending U.S. patent application Ser. No. 09/456,957 entitled “Apparatus for Controlling the Flow of Articles”. 
     Although conveyors are a feature of the present invention, conventional conveyors are well known to those skilled in the art and need not be described herein in great detail. The features of the conveyors necessary for an understanding of the invention will be sufficiently described. 
     In accordance with the objects and purposes of the invention, an apparatus is provided for controlling the flow of articles. This apparatus includes a first conveyor driven in a first direction to convey articles thereon in the first direction. A second conveyor is driven in a second opposite direction to convey articles thereon in the opposite direction. As mentioned above, the first and second conveyors may be used in a conventional accumulator system. The conveyors extend generally side by side and parallel with a constant space defined between the inside edges thereof. 
     A movable transport member is disposed generally across and movable along the space defined between the conveyors. The transport member has a drive member that is drivingly engaged simultaneously by the first and second conveyors so that the drive member continuously rotates as either of the first or second conveyors moves. The transport member will move linearly between the conveyors so long as a speed differential exists between the conveyors. In other words, if both conveyors are moving linearly in opposite directions but at the same speed, the transport member remains stationary relative to the conveyors but will rotate. If the conveyors are moving in opposite directions but at different speeds, the transfer member will rotate and also move linearly in the direction of the faster conveyor. 
     In a preferred embodiment, the drive member comprises a toothed wheel that is simultaneously engaged by drive lugs on each of the conveyors. 
     The transport member also includes an article transfer member. This article transfer member is operably disposed transversely relative to the conveyors to contact and transfer articles from the first conveyor to the second conveyor along a transfer path. 
     In one preferred embodiment of the invention, the article transfer member further includes an endless drive belt that is disposed along the transfer path so as to contact and move articles therealong. This drive belt may run in an endless path between the drive member and article transfer member. The drive belt is drivingly engaged by the drive member, for example by a belt drive wheel that is operably connected to or driven by the drive member. 
     In a preferred embodiment, the major components of the movable transport member are mounted or carried on pivotally mounted support members or plates. For example, the article transfer member is preferably mounted on a rear support plate and the drive member is mounted on a front support plate. These front and rear support plates are pivotal relative to each other at a common pivot point. The article transfer member may further include a dead plate that is disposed so as to extend between the conveyors along the transfer path. The articles moved between the conveyors are moved over this dead plate. The dead plate is carried by a support that is also pivotally mounted at the common pivot point but at a different height or level. 
     The supports or plates for the drive member, article transfer member, and dead plate are pivotally mounted relative to each other to provide for relative movement between the components as the transport member moves through curves defined by the conveyors. It is preferred to precisely control the relative movement between the components so that the flow of articles between the conveyors is not interrupted and is maintained at a relatively constant rate through the conveyor curves. In this manner, in a preferred embodiment, the front and rear support plates and dead plate support are engaged or connected by a gear mechanism so that pivotal movement of either of the front or rear support plates is transferred to the other of the respective front and rear support plates and to the dead plate support as the transport member moves along the conveyor curves. This gear mechanism preferably has a different gear ratio between the front and rear support plates as compared to the dead plate support. The gear ratio for the horseshoe guide support is selected to ensure that the horseshoe guide remains substantially perpendicular to the conveyors as the transport member moves along the conveyor curves. 
     It should be appreciated that any manner of gear mechanism may be utilized to properly gear the support plates together. In one preferred embodiment, the gear mechanism is mounted to the front support plate and comprises a first gear engaged with the rear support plate and a second gear engaged with the dead plate support. The different gears define the different gear ratios. 
     In one embodiment of the invention, the article transfer member includes an idler wheel. The transfer path for the articles is defined between the drive belt and a circumferential portion of the idler wheel. The articles may move along the idler wheel as they are transferred between the conveyors. The idle wheel may thus be formed of a relatively low friction producing material so as not to impede the operation of the drive belt that engages and moves the articles. 
     The article transfer member may also include a rigid guide member. This guide member generally defines the transfer path between the conveyors. The drive belt may be supported by and movable along this guide member. The guide member is carried by a support member that is engaged by at least one of the front, rear, and dead plate supports. The guide member support also includes oppositely extending guide arms that are movable in guide ways defined in the first and second conveyors. Thus, it should be understood that the guide member support will also pivot as the transport member moves through the conveyor curves. 
     In one preferred embodiment of the invention, a belt tensioning device is carried by the drive member. This belt tensioning device may have various configurations and, in one embodiment, includes belt guides around which the drive belt runs. These belt guides are pivotally mounted relative to each other and interconnected by a tension device, such as a spring or similar device. The belt tension is adjusted by adjusting the position of the spring relative to the belt guide. The belt tensioning device moves with the guide member so that belt tension is relatively constant at all times. 
     It is further preferred to include a rigid linkage member interconnected between at least one of the belt guides and the rigid guide member carried by the article transfer member. This rigid linkage member ensures that pivotal movement of the guide member is imparted to the belt guide as the transport member moves through the conveyor curves so that the pivotal movement of the guide member will cause the belt guides to change position accordingly to compensate for the change in position between the guide member and drive member. The guide member prevents advancing or retarding of the belt when entering or exiting curves. This causes the belt to move at a constant speed relative to the conveyor movement, which is necessary to maintain constant spacing of the packages being accumulated on the conveyor. In this manner, a relatively constant article conveying speed for the drive belt is maintained through the conveyor curve. 
     The present invention pertains to a resilient article guide for maintaining articles of different dimensions in alignment as they are transferred between the oppositely running conveyors. Sometimes the dimensions of the articles vary due to damaged packaging, etc. even when only a single desired dimension article is being transported from one conveyor to another by the article transport member. In order to maintain these articles, such as juice boxes, in alignment as they are moved from the transport member onto the adjacent conveyor, a resiliently biased article guide is used with the transport member. It includes an arcuate plate that can be moved out readily from the transport member by enlarged packages without causing binding of the packages as they exit the transport member. 
     The invention will be described below in greater detail by reference to embodiments disclosed in the attached figures. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of an accumulator system on which an improved article guide of FIG. 7 can be used incorporating the present invention; 
     FIG. 2 is a perspective view of components of the transport member without the article guide of the present invention; 
     FIG. 3 is an operational view of the transport member of FIG. 2; 
     FIG. 4 is a partial cut-away underside view of an embodiment of the transport member; 
     FIG. 5 is a detailed view of the gear mechanism according to the invention; 
     FIG. 6 is a detailed component view of an embodiment of the transport member according to the invention; 
     FIG. 7 is a perspective view of a transport member equipped with a resilient guide constructed in accordance with the present invention; and 
     FIG. 8 is a perspective view of a mounting bracket for the resilient guide. 
    
    
     DETAILED DESCRIPTION 
     Reference will now be made in detail to the presently preferred embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not meant as a limitation of the invention. For example, the features illustrated or described as part of one embodiment may be utilized on another embodiment to yield still a further embodiment. It is intended that the present invention include such modifications and variations. 
     An apparatus, generally  10 , according to the invention for controlling the flow of articles is illustrated generally in FIG.  1 . Apparatus  10  includes a first conveyor  12  that moves in a first direction and a second conveyor  14  that moves in a second opposite direction. The first and second conveyors  12 , 14  are arranged in a side-by-side parallel relationship such that a constant space or gap  16  is defined between the inside edges of the conveyors. Conveyors  12 ,  14  may be formed as any conventional conveyor, including conventional link-type conveyors, belt conveyors, and the like. 
     The present invention is not limited to any particular conveying system and has application in any system wherein articles are to be moved from a first conveyor onto a second conveyor. As mentioned above, a conventional system incorporating such oppositely moving and parallel conveyors is an accumulator system, generally shown in FIG. 1, used for accumulating and storing articles between an upstream receiving station and a downstream delivery station. A detailed description of an accumulator system is provided in co-pending U.S. patent application Ser. No. 09/235,888 entitled “Apparatus for Controlling the Flow of Articles.” The &#39;888 application is incorporated herein in its entirety for all purposes. 
     Conveyors  12 ,  14  may be formed of individual interconnected segments or links  18 , as is well understood by those skilled in the art. Conveyors  12 ,  14  define an upper conveying surface, generally  20 , upon which articles are placed to be conveyed by the conveyors. The underside of the conveyors  12 ,  14  is provided with spaced apart drive dogs (not illustrated). These drive dogs are conventionally engaged by a drive motor  26  (FIG. 1) or other mechanism for moving the conveyor in the conveying direction. This drive arrangement is well understood by those skilled in the art and need not be explained in great detail herein. Referring particularly to FIG. 3, the conveyors also include spaced apart drive lugs  22  also on the underside of the conveyors. These drive lugs  22  are engaged by a drive wheel of the drive member according to the invention, as discussed in greater detail below. 
     Conveyors  12 ,  14  are supported by any manner of frame structure generally illustrated as  24  in FIG.  1 . Frame structure  24  preferably includes or defines longitudinally extending guide channel defined between the opposite facing edges that define space  16 . These guide channels are engaged by arm members of a component of the article transfer member, as described in greater detail below. In an alternative embodiment not illustrated in the figures, such guide channels could also be defined in the oppositely facing edges of the conveyor links  18 . 
     Apparatus  10  according to the invention also includes a movable transport member, generally  30 . The following description relating to transport member  30  will be made in reference to FIGS. 2-6 in general, and particularly FIG.  6 . It should be appreciated that FIG. 6 is a detailed component view of one preferred embodiment of transport member  30  and that certain components illustrated in FIG. 6 are not shown in the other figures for sake of clarity and explanation. 
     Transport member  30  is disposed so as to extend generally across space  16  between the conveyors, as generally illustrated in FIG.  1 . Transport member  30  defines a transfer path for the articles, generally  74 , from first conveyor  12  to second conveyor  14 . In the preferred embodiment illustrated, transport member  30  includes a drive member, generally  44 , and an article transfer member, generally  64 . 
     Article transfer member  64  includes a member disposed transverse to the conveyor so as to contact and transfer articles from first conveyor  12  to second conveyor  14 . In the embodiment illustrated, a drive belt  66  cooperating with an idler wheel or pair of wheels  70  is utilized in this regard. Drive path  74  is defined between drive belts  66  and a portion of the circumference of idler wheel  70 . Articles conveyed on first conveyor  12  are frictionally engaged by drive belt  66  and moved across a dead plate  32  disposed across space  16 . The articles are conveyed between idler wheel  70  and drive belt  66 , as particularly illustrated in FIG.  1 . Dead plate  32  will be described in greater detail below. 
     Drive belt  66  is an endless drive belt and runs in its path between drive member  44  and article transfer member  64 . Drive belt  66  is driven by the drive member, for example by a drive wheel  48  driven by the drive member, as described in greater detail below. 
     Article transfer member  64  may include a rear support member, such as a plate member  68 . Plate member  68  is pivotally mounted relative to a common pivot point  98 . A bearing  100  is provided at pivot point  98  for this purpose. Rear support plate  68  carries axle  72  on which the idler wheel or pair of wheels  70  is mounted. Rear support plate  68  also includes gear teeth  86  defined on an opposite edge thereof, as particularly illustrated in FIGS. 5 and 6. 
     Transport member  30  also includes a drive member, generally  44 . In the embodiment illustrated in the figures, drive member  44  includes a front support member or plate  46 . Front support plate  46  is also pivotally mounted at common pivot point  98  by way of bearing  100  and a bearing layer  102 . Front support plate  46  and rear support plate  68  are geared together by a gear mechanism, generally  104 . Gear mechanism  104  may take on any manner of linkage or gearing arrangement and, in the illustrated embodiment, includes a gear member  106  that is mounted to front support plate  46  at location  109  by way of mounting device  108 . Referring particularly to FIG. 5, gear member  106  is stationarily mounted and includes a first gear  105  and a second gear  107 . Gears  105  and  107  have different diameters and thus comprise different gear ratios. Gear  107  engages with gear teeth  86  defined on rear support  68 . 
     As mentioned above, a dead plate  32  is disposed across space  16  between the conveyors. The articles move onto and across dead plate  32  as they are transferred from one conveyor to the other. In the embodiment illustrated, dead plate  32  is comprised of a base member  34  having a friction reducing layer of material  36  attached thereto. Dead plate  32  is mounted to a dead plate support, such as plate member  38 , that is also pivotally mounted to common pivot point  98  by way of bearing  100 . An additional bearing layer  102  is disposed between dead plate support  38  and front support plate  46 , as particularly illustrated in FIG.  6 . Dead plate support  38  includes mounts  42  for mounting dead plate  32  thereon. As seen particularly in FIGS. 5 and 6, dead plate support  38  also includes gear teeth  40  defined on an edge thereof. Gear teeth  40  are engaged by second gear  107  of gear member  106 . In this manner, pivotal movement of either of the front and rear support plates is transferred to the dead plate support as transport member  30  moves along curves defined by conveyors  12 ,  14 . The size, and thus gear ratio, of gear  107  and  105  of gear member  106  are selected so that pivotal movement of front support plate  46  and rear support plate  68  is imparted or transferred to dead plate support  38  at a stepped down ratio so that dead plate  32  is maintained essentially perpendicular between conveyors  12 ,  14  as transport member  30  moves through the curve. This is an important consideration since the relative length of transfer path  74  between the conveyors should be maintained constant regardless of the position of transport member  30  relative to a straight or curved section of the conveyors. This is necessary so as to maintain a relatively constant article conveying rate as transport member  30  moves along the conveyors. 
     Referring particularly to FIGS. 4 and 6, front support plate  46  includes an axle  52  mounted thereon. A drive wheel  48  is mounted on axle  52  and includes a plurality of teeth  50  defined on the circumference thereof. Teeth  50  engage with drive lugs  22  defined on the underside of conveyors  12 ,  14 , as particularly illustrated in FIG.  3 . Thus, it should be understood that so long as either of conveyors  12  or  14  is moving, drive wheel  48  will be caused to rotate. If conveyors  12 ,  14  are moving at the same linear speed, drive wheel  48  will rotate but remain linearly stationary. If a speed differential exists between conveyors  12 ,  14  drive wheel  48  will also move linearly in the direction of the faster moving of the conveyors. Thus, if conveyors  12 ,  14  are moving at the same linear speed, articles will be transferred from conveyor  12  to conveyor  14  at the same relative linear position. However, if the speed of the conveyors changes due to a change in the upstream or downstream supply/delivery stations, then transport member  30  will also move between the conveyors as it continues to transfer articles from conveyor  12  to conveyor  14 . 
     A belt drive wheel  62  is also mounted on axle  52 . Belt drive wheel  62  is rotationally driven by drive wheel  48  through a gear arrangement, such as a planetary gear arrangement  54 . Referring particularly to FIGS. 4 and 6, planetary gear arrangement  54  includes a ring gear  60  mounted to stationary plate  46 . Planet gears  58  are disposed between ring gear  60  and sun gear  56  and rotate on shafts mounted to drive wheel  48 . Drive belt  66  is disposed in tension around a portion of the circumference of belt drive wheel  62 , and is thus driven in its endless path by belt drive wheel  62 . 
     A belt tensioning device, generally  110 , is also preferably provided on drive member  44 . Belt tensioning device  110  is provided so as to variably adjust the tension of drive belt  66 . In the embodiment illustrated, belt tensioning device  110  includes belt guides  112  around which belt  66  runs. Belt guides  112  are mounted on supports  114  that are pivotally mounted relative to each other. In the embodiment illustrated in FIG. 6, a pivotal mounting block  116  is provided for this purpose. Supports  114  may also be pivotally mounted on axle  52 , as generally illustrated in FIG.  3 . Any number of devices or mechanisms may be utilized for pivotally interconnecting supports  114 . A tensioning device, such as a spring  118 , is interconnected between supports  114 . Referring particularly to FIGS. 3 and 6, spring  118  is mounted between supports  114  by way of positioning holes  120 . Thus, the tension of the device can be adjusted by changing mounting holes  120  to increase or decrease the tension on belt  66 . 
     In the preferred embodiment illustrated in the figures, article transfer member  64  also includes a relatively rigid guide member  76 . Guide member  76  may have a generally horseshoe-shape as illustrated in the figures, and generally defines the curved transfer path  74 . Drive belt  66  runs along and is supported by guide member  76  by, for example, rollers  80 . Guide member  76  has a longer side arm  84 , as generally illustrated in FIGS. 3 and 4 that defines the receiving or entry point of articles through transfer path  74  and, thus, extends drive belt  66  well into the conveying path of the articles, as particularly seen in FIGS. 1 and 3. 
     Guide member  76  is supported by a guide member support, such as plate  78  particularly illustrated in FIG.  6 . Guide member  76  is mounted to support plate  78  by any conventional means, including bolt mounts  82 . Support plate  78  is pivotally mounted on axle  72  and includes oppositely extending arms  88  having bearing members  90  mounted thereon. Arms  88  and bearing members  90  ride in guide channels or grooves defined in support structure  24  of the conveyors, as mentioned above. The channels (not illustrated) in the support structure may comprise relatively simple C-shaped or V-shaped channels in which arms  88  with bearings  90  are disposed. The opposite end of guide member support plate  78  has a slot  96  defined therein. A pin (not illustrated) extending from a bearing block  94  extends through slot  96  and limits the pivotal movement of guide member support plate  78 . Bearing block  94  is mounted to front support member or plate  46 . Guide member support  78  is also engaged with at least one of the front support member  46 , rear support member  68 , or dead plate support  38 . In the embodiment illustrated particularly in FIG. 6, a hole  102  is provided in front support member  68 . A pin (not illustrated) extending upwardly from dead plate support  38  extends through hole  102  and into a receiving hole (not visible) in guide member support  78 . Thus, pivotal movement of article transfer member  64  caused by arms  88  engaging in curved sections of conveyors  12 ,  14  is transferred to rear support member  68  and dead plate support  38 . 
     A relatively rigid linkage member  122  may also be provided to interconnect guide member  76  and belt tensioning device  110 . For example, linkage  122  may be mounted directly to guide member  76  or guide member support  78  at one end and directly to one of the supports  114  for belt guides  112  at the other end. Linkage member  122  is provided so that relative movement between guide member  76  and drive member  44  is imparted directly to tensioning device  110  to cause a change in belt position as transport member  30  moves through a curve in the conveyors. This change in belt position compensates for what would otherwise be a change in the effective running length of drive belt  66  caused by the pivotal movement between drive member  44  and article transfer member  64  which would result in a detrimental change in the conveying rate of the articles. 
     As shown in FIGS. 7 and 8, there is provided a resilient guide generally designated by the reference character  200  that is provided to receive the articles being transferred from the infeed conveyor to the outfeed conveyor by the transfer member  64  and maintain them in alignment. Sometimes the articles being transferred will vary in dimensions as a result of the packages being mishandled or damaged and will tend to turn sideways as they are released from between the idler wheel  70  and belt onto the outfeed conveyor  14 . In order to ensure that the articles, regardless of variations in their dimensions, are in alignment and properly oriented as they exit from between the idler wheel  70  and the belt  66 , a spring biased guide plate  202  is positioned to receive the articles from the belt  66  and direct them onto the outfeed conveyor  14 . If an article is oriented improperly, the pressure from a spring  204  pushing against an arcuate guide plate  206  into engagement with the article properly realigns the article. The guide plate  206  has an inwardly extending flange  208  that projects over the upper surface of the belt  66 . The other end of the guide plate  210  terminates downstream of the rigid members  76  and  76   a  forming the rigid guide member. 
     The arcuate shaped guide plate  206  is supported by outwardly extending arms  212  and a base member  214 . The outwardly extending arms  212  terminate in a vertically extending wall  216 . The wall  216  is secured to an L-shaped adjustable flange  218  by means of a bolt  220  which extends through a hole provided in the flange  218  and a hole provided in the plate  216 . A spring  221  is placed on the bolt  220  and is secured thereto by means of a washer  222  and a nut  224 . The biasing force applied by the spring can be adjusted by rotating the nut  224 . The lower end  226  of the L-shaped flange  218  has an elongated slot  228  provided therein. A bolt  230  extends through a hole provided in the rigid member  76   a  and is secured thereto by means of a nut  232 . As a result of the elongated slot  226  being provided in the horizontal flange of the bracket  218 , the position of the arcuate plate  206  can be varied for accommodating different size articles being transferred by the article transfer member. In other words, the distance between the arcuate plate  206  and the idler wheel  70  can be varied by loosening the bolt  230  securing the bracket  218  and readjusting its position. 
     Accordingly, if an article that is being transferred by the transfer member tends to be rotated as it leaves the idler wheel  70  and belt  66 , the arcuate surface of the resilient guide member  206  will realign the article so that as the articles are moved onto the outfeed conveyor  14  they are aligned properly with each other regardless of whether the dimensions of the articles vary. If one article has a larger width than the other, it will force the guide plate back slightly. 
     It should be appreciated by those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope and spirit of the invention. For example, the particular structural members described herein can take on any manner of shape or configuration. In addition, the relative pivotal movements between the components can be supported by any manner of structure and gearing arrangement. It is intended that the present invention include such modifications and variations as come within the scope of the appended claims and their equivalents.

Technology Classification (CPC): 1