Patent Abstract:
A diverter is for intended use in connection with a diverter conveyor for diverting articles moving in a conveying direction from a first path of travel to a second path of travel. The diverter includes a guide mounted for relative movement thereto from a first position adjacent one side of the diverter corresponding to the first path of travel to a second position adjacent another side of the diverter corresponding to the second path of travel. A magnetic coupling is formed between the diverter and the guide for maintaining the guide in either the first position or the second position. A selector may be provided as part of a switch for switching the guide between the first and second positions. Related aspects include a conveyor incorporating the diverter and methods of use and manufacture.

Full Description:
TECHNICAL FIELD 
   The present invention relates generally to conveyors and, more particularly, to a conveyor for diverting articles being conveyed. 
   BACKGROUND OF THE INVENTION 
   Systems for selectively diverting conveyed articles in a direction transverse to the conveying direction are well known. The typical arrangement includes a conveyor associated with a plurality of diverters (sometimes called “carriers”) for engaging the articles. As the conveyor moves in an endless path, an adjacent guide track engages a guide associated with each diverter. In the usual mode of operation, this engagement causes the diverter and the associated article to move laterally along the conveyor. Using such an arrangement advantageously allows for selective placement of the articles into multiple rows or lanes, as necessary or desired for a downstream operation, or alternatively may simply divert selected articles to a takeaway conveyor for further processing. 
   During high speed operation, a fixed guide associated with each diverter is used to transition from a main portion to an auxiliary portion (branch or spur) of the guide track for effecting the desired diversion. Typically, the switching is done by either mechanically moving the guide track or else using a magnet at the intersection to cause the diverter to follow the alternate path associated with the diversion of the article. At high speeds, both manners of switching are considered unreliable, and also must occur at the location of the intersection between the main and auxiliary portions in order to be effective. In the event the diverter is not properly switched, not only is the article not diverted in the desired manner, but a catastrophic failure may also result, requiring downtime to make the necessary repair. This downtime not only increases the maintenance expense, but also the expense associated with a concomitant loss in production while completing the appropriate repair operation. 
   Accordingly, a need is identified for a high speed diverter system that addresses and overcomes the foregoing limitations. 
   SUMMARY OF THE INVENTION 
   An apparatus is for intended use in connection with a diverter conveyor for conveying articles in a conveying direction along a first path of travel or a second path of travel. The apparatus comprises a diverter for moving along in the conveying direction, the diverter including an article engaging surface and a guide mounted to the diverter for relative movement thereto from a first position adjacent one side of the diverter corresponding to the first path of travel to a second position adjacent another side of the diverter corresponding to the second path of travel. A magnetic coupling is formed between the diverter and the guide for maintaining the guide in either the first position or the second position. 
   Preferably, the guide is pivotally mounted to the diverter for movement between the first and second positions. The guide may comprise a ferromagnetic material and the diverter may further comprise first and second magnets corresponding to the first and second positions of the guide, or vice versa. The guide preferably also depends from the diverter in a direction generally opposite the article engaging surface. 
   Another aspect of the disclosure relates to an apparatus for conveying articles moving in a conveying direction along a first path of travel or a second path of travel. The apparatus comprises an endless conveyor and a diverter conveyed by the endless conveyor. The diverter includes an article engaging surface and a guide mounted to the diverter for relative movement thereto from a first position adjacent one side of the diverter corresponding to the first path of travel to a second position adjacent another side of the diverter corresponding to the second path of travel. A magnetic coupling is formed between the guide and the diverter for maintaining the guide in either the first position or the second position. 
   Preferably, the endless conveyor comprises a plurality of supports for supporting the diverter for movement in the transverse direction, as well as a pair of spaced endless chains for supporting the plurality of supports. A selector is also provided for moving the guide between the first and second positions, along with a first guide track corresponding to the first path of travel and an intersecting second guide track corresponding to the second path of travel. 
   Yet another aspect is an apparatus for conveying articles moving in a conveying direction along a first path of travel or a second path of travel. The apparatus comprises a diverter including an article engaging surface and a guide mounted to the diverter for relative movement thereto from a first position adjacent one side of the diverter corresponding to the first path of travel and a second position adjacent another side of the diverter corresponding to the second path of travel. A switch comprising a first guide track corresponding to the first path of travel, a second, intersecting guide track corresponding to the second path of travel, the first and second guide tracks arranged for engaging the guide of the diverter, and a selector for selecting the first or second position of the guide. The selector is positioned upstream of the intersection between the first and second guide tracks. 
   Preferably, a magnetic coupling is provided for holding the guide in either the first position or the second position. Furthermore, a structure defining the intersection of the first and second guide tracks includes an apex is preferably offset from a midpoint between the first and second positions of the guide. The selector may be positioned upstream of an outfeed guide positioned upstream of the intersection of the first and second guide tracks. 
   Still a further aspect of the disclosure is a method for conveying articles in a conveying direction along a first path of travel or a second path of travel. The method comprises conveying a diverter including a guide mounted for movement between a first position adjacent one side of the diverter corresponding to the first path of travel to a second position adjacent another side of the diverter corresponding to the second path of travel. The method further comprises holding the guide in either the first position or the second position by way of a magnetic coupling between the diverter and the guide. The method may still further comprise the step of moving the guide between the first and second positions. 
   Yet a further aspect of the disclosure is a method of manufacturing a diverter for conveying articles in a conveying direction along a first path of travel or a second path of travel. The method comprises mounting a guide to the diverter for movement relative to the diverter from a first position adjacent one side of the diverter corresponding to the first path of travel to a second position adjacent another side of the diverter corresponding to the second path of travel. The method further comprises forming a magnetic coupling between the diverter and the guide for maintaining the guide in the first or second position during conveyance. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of a conveyor for use in connection with the diverter forming one of the many inventions described herein; 
       FIG. 1   a  is a partially cutaway, partially cross-sectional perspective view of one end of the conveyor of  FIG. 1 ; 
       FIG. 1   b  is a partially cutaway, partially cross-sectional side view of one end of the conveyor of  FIG. 1 ; 
       FIG. 2  is a perspective view of the guide for use with the diverter; 
       FIG. 3  is an exploded view of the diverter including the guide of  FIG. 2 ; 
       FIG. 4  is a top plan view of the diverter and an associated switch; 
       FIG. 4   a  is a perspective view of an alternate embodiment of the switch; 
       FIGS. 5   a  and  5   b  are top plan views illustrating various modes of operation of the diverter in association with the switch; 
       FIG. 6  is a partially cutaway, partially cross-sectional perspective view of an alternate embodiment of the diverter; and 
       FIG. 6   a  is a cutaway end view of the diverter of  FIG. 6 . 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Reference is now made to  FIGS. 1 ,  1   a  and  1   b , which illustrate a diverter system  10  forming one aspect of the present invention. The system  10  as shown includes a driven conveyor  12  comprised of a first endless conveyor  14  (including a chain; not shown), a second endless conveyor  16  spaced from the first chain, one or more associated diverters  20  for supporting or engaging the article(s) being conveyed (preferably, on its upper or article engaging surface  20   a ), and diverter support (in the form of transverse rods  18 ; note cross-sectional depiction in  FIG. 1   a ) positioned between the conveyors  14 ,  16 . In the illustrated embodiment, the association with the support rods  118  is such that the diverter  20  is capable of slidably moving relative to the support in a transverse or lateral direction T relative to the conveying or longitudinal direction C along a forward run in response to the influence of an externally applied force in order to divert articles transversely across the conveying surface (such as for forming lanes on a downstream conveyor, or for moving selected articles onto an associated takeaway conveyor (not shown)). The details of an exemplary diverter conveyor may be found in Applicant&#39;s international patent application PCT/US05/003497, the disclosure of which is incorporated herein by reference. 
   Turning to  FIG. 1   b , as well as  FIGS. 2-3 , each diverter  20  includes a guide assembly  22  for use in causing it to move selectively in the transverse direction T depending on its association with a corresponding guide structure (as will be discussed in more detail below). This guide assembly  22  preferably mounts to the underside of the diverter  20 , such as by using fasteners  24 , and includes a body  26  supporting a movably mounted guide  28  in an associated recess or cavity  26   a . Specifically, the guide  28  in the illustrated embodiment connects to a support  30 , which in turn is mounted for pivoting movement from a first position adjacent one side of the body  26  to a second position adjacent another, preferably opposite side of the body. More specifically, the body  26  carries a pin  32  in a generally vertical orientation for receiving the support  30  such that it can pivot to or fro in a horizontal plane. Suitable means for capturing the support  30  in place on the pin  32  without inhibiting the movement of the associated guide  28  between the relative positions may also be included, such as one or more bushings  35 . 
   In order to maintain the guide  28  in either the first or second position, and thus determine the path of travel in the conveying direction C, a magnetic coupling is provided. Preferably, this magnetic coupling is formed between the body  26  and the guide support  30 . In the illustrated embodiment, this is accomplished by associating magnets  34  with the body  26 , such as in recessed pockets  26   b ,  26   c  corresponding to the first and second positions. Preferably, the magnets  34  are disk-shaped, oriented with one pole facing the support  30 , and formed of a strong permanent magnetic material, such as that comprising Neodymium. The support  30  may then be formed of a magnetic material for forming the desired magnetic coupling, and most preferably comprises a ferromagnetic material. Alternatively, it should be appreciated that the body  26  could be formed of a ferromagnetic material, while the support  30  carries one or more magnets for forming the coupling in order to maintain the guide  28  in the first or second position. In any case, the relative positioning is preferably such that the magnetic coupling holds the guide  28  in the first or second position. The coupling should be sufficiently strong that an intermediate position cannot be maintained, but not so strong that interference is created that would urge the guide to the opposite position as the sole result of magnetic attraction. 
   Turning now to  FIGS. 4 and 5   a - 5   b , one manner of using the diverter  20  of  FIGS. 2-3  in connection with the conveyor  12  is shown and will be described. The conveyor  12  is associated with first and second guide tracks  36 ,  38  that correspond to the first and second positions of the guide  28 . The guide tracks  36 ,  38  intersect at a point, upstream of which is mounted a switch  40  positioned generally below the diverter  20  for use in selectively positioning the guide  28 . Most preferably, the switch  40  is positioned as close as possible to the point in the endless path where the diverter  20  arrives at the forward or upper run from the return or lower run of the conveyor  12 . 
   In the illustrated embodiment, the switch  40  comprises a selector, such as a pusher  42 , associated with an actuator  44 , such as a linear actuator for moving the pusher to and fro in the transverse direction. However, the selector could also take the form of means for applying an attractive or repulsive force for moving the guide  28  between the respective positions, such as may be supplied by one or more selectively actuated electromagnets M forming part of the switch  40  (see  FIG. 4   a ). Infeed and outfeed guides  46 ,  48  may also be provided on opposite sides of the selector to ensure the guide  28  is guided in the proper manner as the transition is made into and out of the switch  40 . 
   Referring now to  FIG. 5   a , operation of the system  10  including the conveyor  12  with the diverter  20  with the guide assembly  22  is shown. In this embodiment, the guide  28  is initially maintained in the first position corresponding to the first guide track  36  while the conveyors  14 ,  16  move the diverter  20  along in the conveying direction. If it is determined that the diverter  20  should divert an associated article (not shown) or otherwise move in a direction transverse to the conveying direction C, the switch  40  is actuated (such as based on an output signal from a sensor S mounted adjacent the conveying surface, such as a photoeye). As a result of actuation, the selector (pusher  42  in the illustrated embodiment) moves the guide  28  through an arc in a horizontal plane (as the result of the pivotal mounting of the associated support  30 ) and from the first position to the second position. The applied energy is such that the magnetic coupling holding the guide  28  in the first position is broken or overcome (such as by decoupling the support  30  from the associated magnet  34 ), and then reestablished as the result of the repositioning of the guide to the second position (such as by the support  30  coupling with the other magnet  34 ). Consequently, when the guide  28  reaches the intersection as the result of the continued movement of the diverter  20  in association with the endless conveyors  14 ,  16 , it associates with the second guide track  38  and the diverter  20  is diverted as a result. The guide  28  thereafter remains mechanically captured in this guide track  38 , and is thus prevented from returning to the first position or returning to the first guide track  36 . A downstream guide member  50  ensures that the depending guide  28  follows the desired path to effect the movement of the diverter  20 , and may thus be arranged at any selected angle and length, depending on the desired application. 
     FIG. 5   b  illustrates the situation where the guide  28  enters the switch  40  toggled to the second position corresponding to the second guide track  38 . If diversion of the article is desired, then no action is of course necessary. However, if it is desired to toggle the guide  28  back to the first position associated with the first guide track  26 , the selector may be used to accomplish this, either by actuation at or before the diverter  20  is in the proper position such that the selector (pusher  42  in the embodiment shown) engages and urges it to move.  FIG. 5   b  shows the pusher  42  serving as the selector positioned to cause the guide  28  to move to the first position such that it is captured by and follows the corresponding guide track  36 , including downstream of the switch  40 . 
   As should be appreciated, the initial position of the diverter  20  shown in  FIG. 5   b  corresponds to the path followed by the first guide track  36 , even though the guide  28  approaches in the second position. This initial positioning may be result from a corresponding return guide member  52  or like structure along a return run of the conveyor  12  (see  FIG. 1 ). This position of the diverter  20  may also be achieved without changing the position of the guide  28 , as indicated in  FIG. 5   b.    
   Numerous advantages flow from practicing the foregoing teachings. Aside from the simplicity, an advantage of the proposed approach is that it avoids the need for mechanical gates, fixed magnets, or the like positioned precisely at the intersection between the guide tracks. Rather, the decision to divert is made upstream of the intersection, which helps to ensure that it is done in the proper manner and potentially avoids catastrophic failures that may be caused by a mechanical failure. This is further aided by the use of the outfeed guide  48  of the switch  40 , which helps to ensure that the guide  28  has time to reach the desired position and form the magnetic coupling if switched ahead of the intersection. Throughput may thus be increased without sacrificing reliability or adding considerable cost and complexity. 
     FIG. 4  shows a divider  58  at the intersection between the diverging guide tracks  36 ,  38  as having an apex substantially aligned the midpoint or center of the path of travel of the guide  28  relative to the diverter assembly  22  in the transverse direction. If the guide  28  were to somehow inadvertently assume a position intermediate the first and second positions, a collision might occur with the apex of this divider  58 , which of course is undesirable. Hence, it is also contemplated that the apex should be offset from this centered position, thereby helping to assure that a collision is avoided and the guide  28  is urged into the corresponding guide track  36 ,  38 . 
     FIGS. 6 and 6   a  illustrate an alternate embodiment of the guide assembly  22  associated with a diverter  20 . As with the embodiment described above, the guide assembly  22  is mounted to underside of the diverter  20 , such as by using fasteners  24 , and includes a body  26  supporting a movably mounted guide  28 . The guide  28  is again connected to a support  30  that is pivotally attached for movement from a first position adjacent one side of the body  26  to a second position adjacent another, preferably opposite side of the body, and may include one or more bushings  35 . However, the body  26  carries a pin  32  in a generally horizontal orientation for receiving the support  30 . Preferably, this support  30  is fabricated at least partly of a ferromagnetic material, and the magnets  34  are positioned above it on either side of the body  26  (but again it should be appreciated that the body could be formed of a ferromagnetic material, while the support carries any magnets for forming the coupling in order to maintain the guide in the first or second position). As a consequence of this alternate approach, a lower profile arrangement is provided, with the guide  28  forming a pendulum for swinging to and fro through an arc in a vertical plane at it moves between the relative positions. 
   With the exceptions described above for forming the magnetic coupling, the diverter  20  and its associated components may be formed of any durable material, with UHMW polyethylene, polypropylene or Acetal being preferred choices because of the high durability, relatively low weight, and low cost of such materials. Using these materials results in a substantially strong structure for contacting the articles, and one not prone to oxidation and rust. However, the diverter  20  and other components may be formed of any material, including metal or other polymers, without limitation. 
   The foregoing descriptions of various embodiments of the invention are provided for purposes of illustration, and are not intended to be exhaustive or limiting. Modifications or variations are also possible in light of the above teachings. For instance, it is possible to mount the guide  28  for relative sliding movement between the first and second positions. It is also possible to include additional switches and branches associated with more than the two guide tracks shown. More than one guide assembly  22  could also be associated with each diverter  20  for encountering associated switches spaced apart in the transverse direction T, the conveying direction C, or both. The embodiments described above were chosen to provide the best application to thereby enable one of ordinary skill in the alt to utilize the disclosed inventions in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention.

Technology Classification (CPC): 1